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Intellisys Adaptive Pressure Controllers
User Manual
45 pgs1.05 Mb4

Nor-Cal Intellisys Adaptive Pressure Controllers User Manual

Tel: 800-824-4166
or 530-842-4457
Fax: 530-842-9130
www.n-c.com
1967 So. Oregon
Yreka, CA 96097 USA
Nor-Cal Products, Inc.
Adaptive Pressure Controllers
APC-OP-LIT 1/12
100-Series
for Geared Drive Throttling Butterfly Valves and Universal Valve Drives
200-Series
for Direct Drive Throttling Butterfly Valves
300-Series
for Geared Drive Sealing Butterfly Valves
700-Series
for Throttling SoftShut Gate Valves
800-Series
for Throttling Pendulum Valves
IQA and IQD Series
for All Throttling Valves
IntellIsys AdAptIve pressure Controllers
Table of Contents
1.0
............Introduction ..............................................................................................................................................
2.0
............Device Specification ..................................................................................................................................
............Unpacking and Installation ........................................................................................................................
3.0
3.1
....... A/C Powered Touch-Panel Controllers Interface ........................................................................................
3.2
....... A/C Powered Buried Box Controllers Interface ...........................................................................................
3.3
....... DC Powered Controllers with Serial I/O Interface .......................................................................................
3.4
....... DC Powered Controllers with Serial and Analog/TTL I/O Interface ............................................................
3.5
....... DC Powered Contollers with Serial and DeviceNet I/O Interface ..............................................................
3.6
....... DC Powered IQA Controlled Valve with Serial and Analog/TTL I/O Interface ............................................
3.7
....... DC Powered IQD Controlled Valve with Serial and DeviceNet I/O Interface ...............................................
4.0
............Theory of Operation ................................................................................................................................
5.0
............APC Controller Module Interfaces ...........................................................................................................
6.0 ..............
7.0
............Analog/TTL Interface ...............................................................................................................................
8.0
............DeviceNet Interface .................................................................................................................................
8.1
8.2
9.0
............DeviceNet Device Profile ..........................................................................................................................
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
10.0
10.1
10.2
10.3
10.4
10.5
11.0
12.0 Appendix I Appendix II - Warranty and Intellectual Property Coverage
RS-232 Serial Interface and Commands ..................................................................................................
....... Overview and Setup ................................................................................................................................
....... Establishing a DeviceNet connection .......................................................................................................
....... Identity Object ........................................................................................................................................
....... Message Router Object ...........................................................................................................................
....... DeviceNet Object ....................................................................................................................................
....... Assembly Object .....................................................................................................................................
....... I/O Assembly Instances ............................................................................................................................
....... Connection Object..................................................................................................................................
....... Discrete Input Point Object ......................................................................................................................
....... S-Device Supervisor Object ......................................................................................................................
....... S-Analog Sensor Object ..........................................................................................................................
...... S-Analog Actuator Object .......................................................................................................................
......S-Single Stage Controller Object .............................................................................................................
......Selection Object ......................................................................................................................................
..........LCD Front Panel Interface ...........................................................................................................................................................................
...... Commonly Used Function Buttons ..........................................................................................................34
..... Basic Operation.......................................................................................................................................34
.....Configure Setpoints ................................................................................................................................36
.....Utility Menu ............................................................................................................................................38
.....Configure Display Units
..........Battery Back-Up ......................................................................................................................................
..........Product Support......................................................................................................................................
- Spare Parts and Ordering Information ..................................................................................................
10 11 12 13 14 15 16 19 22 22 24 26 27 27 27 28 28 28 28 29 30 31 31 32 33
........................................................................................................................................ 40
41 42 44
.............................................................................................
45
4 5 6 7 8 9
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IntellIsys AdAptIve pressure Controllers
List of Tables
2.1
......APC Controller General Equipment Specifications ...........
2.2
.....APC Controller Analog TTL I/O ........................................
2.3
......APC Controller RS-232 Serial I/O .....................................
2.4
......APC Controller Performance ...........................................
2.5
......APC Controller Reliability ................................................
3.1.1
... (J3&J4) “APC-X50-A” Gauge Connector ........................
3.1.2
... (J1) “APC-X50-A” A/C Power Connector ........................
3.1.3
... (J5) “APC-X50-A” Valve Connector ................................
3.1.4
..(J2) “APC-X50-A” RS-232 Serial Port ..............................
3.1.5
... (SW1) “APC-X50-A” Dip Switch Settings for
3.1.6
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.3.1
3.3.2
3.3.3
3.3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.5.1
3.5.2
3.5.3
3.5.4
3.6.1
3.6.2
3.6.3
3.6.4
3.7.1
3.7.2
3.7.3
6.1
6.2
6.3
8.1
8.2
8.3
8.4
8.5
9.1.1
9.1.2
Serial Communications ...................................................7
... (J6) “APC-X50-A” Analog / TTL Connector .....................
... (J3&J4) “APC-X00-A” Gauge Connector ........................
... (J1) “APC-X00-A” A/C Power Connector ........................
... (J5) “APC-X00-A” Valve Connector ................................
..(J2) “APC-X00-A” RS-232 Serial Port ..............................
..(SW1) “APC-X00-A” Dip Switch Settings for
Serial Communications ...................................................
..(J6) “APC-X00-A” Analog / TTL Connector .....................
... (J1) “APC-800L-A-S01” Gauge Connector .....................
... (J2) “APC-800L-A-S01” Power Connector ......................
... (J3) “APC-800L-A-S01” Valve Connector ........................
... (J4) “APC-800L-A-S01” I/O Connector...........................
... (J4) “APC-X00L-A” Analog / TTL Connector ..................
... (SW1) “APC-X00L-A” Dip Switches ..............................
... (J1) “APC-X00L-A” Valve Connector .............................
... (J3) “APC-X00L-A” Auxiliary Connector .......................
... (J2) “APC-X00L-A” Gauge Connector ..........................
... (J1) “APC-X00L-D” DeviceNet Network Connector.......
... (J2) “APC-X00L-D” Auxiliary Connector .......................
... (J3) “APC-X00L-D” Gauge Connector ..........................
... (J3) “APC-X00L-D” Valve Connector .............................
... (SW1) “IQA” Dip Switches ............................................
... (J3) “IQA” Auxiliary Connector .....................................
... (J2) “IQA” Gauge Connector ........................................
... (J4) “IQA” Analog / TTL Connector ...............................
... (J1) “IQD” DeviceNet Network Connector ....................
... (J2) “IQD” Auxiliary Connector .....................................
... (J3) “IQD” Gauge Connector ........................................
......RS-232 Serial Commands .............................................
......RS-232 Serial Requests and Responses ..........................
......Values for xx for use with Dual Range Mode ..................
......DeviceNet Module LED Status .......................................
......DeviceNet Network LED Status ......................................
......DeviceNet Explicit Messaging ........................................
......Output Assembly Formats .............................................
......Input Assembly Formats ................................................
... Identity Object Attributes ..............................................
... Nor-Cal Product Types ...................................................
5
9.3.1
... DeviceNet Object Attributes ..........................................
5
9.4.1
... Assembly Object Attributes ...........................................
5
9.5.1
... Input Assembly Instances ..............................................
5
9.5.2
... Output Assembly Instances ...........................................
5
9.6.1
... Connection Object Attributes .......................................
7
9.7.1
... Discrete Input Point Object Attribute; Instance ID 1........
7
9.7.2
... Discrete Input Point Object Attribute; Instance ID 2........
7
9.8.1
... S-Device Supervisor Object Attributes ...........................
7
9.8.2
... S-Device Supervisor Object Exception Status Bit Map.....
9.8.3
... Device Status Attribute Value ........................................
9.9.1
... S-Analog Sensor Instances ............................................
7
9.9.2
... S-Analog Sensor Object Attributes ................................
8
9.10.1
8
9.10.2
8
9.11.1
8
9.11.2
8
9.12.1
8
9.12.2 9 9 9 9
10
List of Figures
10 10
4.1
......Typical installation and configuration of a buried box
10 10
4.2
......Typical installation and configuration of an
11 11
8.1
......IQD DeviceNet connector pin assignment .....................
11
8.2
......DeviceNet baud rate selection switch ............................
11
8.3
......DeviceNet address switches ..........................................
12
8.4
......Typical DeviceNet Hardware Installation ........................
12
9.1
......Object Model for the Process Control Valve Device ........
12
9.2
......Object State Transition Diagram ....................................
12
10.1
....LCD Front Panel Interface ..............................................
13
10.2
....Configure Setpoints ......................................................
13
10.3
....Utility Menu ..................................................................
13
12.1
....Possible Failure Modes and Recommended Actions.......
16
12.2
....Valid Status LED Combinations .....................................
16 18 22 22 24 25 25 27 27
Information in this manual is subject to change without notice.
.S-Analog Actuator Object Attributes .............................
.S-Analog Actuator Exception Status Bitmap ..................
.S-Single Stage Controller Object Attributes ...................
.S-Single Stage Controller Object Subclass Attributes;
Instance 1 .....................................................................
.Selection Object Attributes; Instance 1 ..........................
.Selection Object Attributes; Instance 2 ..........................
Intellisys Downstream Pressure Control system .............
IQ Pressure Control valve ...............................................
Contact Nor-Cal Products
Intellisys Customer Support
at 800-824-4166 ext. 186
or visit our website
at www.n-c.com
APC-OP-LIT 1/12
27 28 28 28 28 28 28 29 29 29 30 30 31 31 31
31 32 32
14
14 22 22 22 23 26 29 33 36 38 42 43
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3
IntellIsys AdAptIve pressure Controllers
1.0 - Introduction
Thank you for purchasing a new Intellisys™ adaptive downstream pressure controller (APC) from Nor-Cal Products. Before installing and operating the product, please read this manual thoroughly as it contains critical hook-up and operating tips. If you encounter any problems, or if you have any questions, please contact our Intellisys Customer Service Support at 800-824-4166, ext. 186 or visit our web site at www.n-c.com.
Nor-Cal Products’ APCs are designed for downstream pressure control over a wide range of vacuum control applications. The APC is a self-contained unit that incorporates all control electronics and associated pressure control software. APCs are available in different models. Line voltage and low voltage buried box versions connect to the valve via a valve cable. IQA and IQD controllers are already mounted on the valve. Any APC, regardless of type, accepts the inputs from one or two pressure gauges as well as communications to the host controller, thus making it the heart of a pressure control loop.
Limited local operation is possible on some models via the on valve open/close switches. Other models offer full programmability and operation via a front panel display and interface. Local status lights also help the operator during operation, maintenance or troubleshooting. Remote operation or monitoring can be effected either through the serial RS-232, Analog/TTL and in some cases the DeviceNet communication interfaces.
Important Personnel Safety and Product Protection Information
Throughout this manual, information that is of particular importance to the installation, the safety of oper­ating personnel and the protection of equipment are highlighted by the following three symbols. The WARNING symbol is also used on the equipment wherever necessary.
NOTE: Calls attention to helpful tips about proper
installation, maintenance or use of the controller.
CAUTION: Highlights areas of concern that, if overlooked, could
result in damage to the controller or surrounding equipment.
WARNING : Alerts the installation, operating or maintenance
personnel of hazardous aspects of the controller, which, if ignored could result in serious personal injury or death.
APC-OP-LIT 1/12
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IntellIsys AdAptIve pressure Controllers
2.0 - Device Specification
The following tables summarize specifications essential to the installation and hook-up of the APC-Series product. Please note that the information herein is lim­ited to the APC controller. For valve installation instructions and guidelines, please refer to the appropriate Valve Operating Manual.
TABLE 2.1 – APC CONTROLLER GENERAL EQUIPMENT SPECIFICATIONS
FEATURE SPECIFICATION
Dimensions Please refer to the diagram specific to sections 3.1 to 3.5
Weight, in lbs (kg)
Rated Input Voltage
Rated Frequency A/C Powered models only: 50-60 Hz
Rated Current
Rated Input Protection
Rated Output Power (for gauge excitation)
Protection Class I Degree of Protection
(IP) Laser Class 1 (LED’s)
Certifications/EU Directives
Maximum Altitude 6562 ft (2000 m) Allowable Ambient
Operating Temperature
Allowable Ambient Humidity
Installation Clearance
IQA and IQD models: N/A, included in valve weight Low voltage models: 2.0 (0.9) A/C powered models: 3.5 (1.6)
Low voltage models: 24 VDC ±10%, differential A/C powered models: 100 to 240 VAC
Low voltage models: 3.0 A @ 24 VDC max,
1.0A @ 24 VDC average A/C powered models: 1.0A typ @ 115 VAC 3A max
Low voltage models: 35 volts max, reverse- and internal current resettable fuse
A/C powered models: 300 VA slow blow fuse Low voltage models: ± 15 VDC @ 700 mA
A/C powered models: ± 15 VDC @ 800 mA, 2X
X0
CE Standard for Process Equipment including EMC Directive 89/336/EC for D/C powered models. Low Voltage Directive 2006/95/EC to EN 61010-1:2001 for A/C powered models
32ºF to 113ºF (0ºC to 45ºC)
0 to 95% non-condensing
3” (75 mm) on all perforated sides. A minimum of 3½” (90 mm) is needed to allow for connectors. If access and line of sight is required for LED’s and switches a minimum of 6” (150mm) is required on those sides.
TABLE 2.2 – APC CONTROLLER ANALOG TTL I/O
FEATURE SPECIFICATION
Analog (Gauge) Input
Analog Output 0 to 10V differential @ 35 mA, short circuit protected
TTL Input
TTL Output Open collector, optically isolated, 25V @ 10 mA max
FEATURE SPECIFICATION
Communications Settings
Connections
Communications Protocol See Section 6.0 in this manual
End of line delimiter
FEATURE
Valve speed (open to closed)
Control range
Accuracy
Repeatability 0.12% of reading 0.12% of reading
FEATURE BUTTERFLY VALVES PENDULUM VALVE
Electronics MTBF
Warranty 1 year 1 year
0 to 10V differential
Diode protected at –0.4 VDC, compatible with open collector relay closure or standard logic signals, 25V max. Maximum low input voltage is 0.6V and minimum sink current is 1 mA. Minimum high input voltage is 2.5V, or open.
TABLE 2.3 – APC CONTROLLER RS-232 SERIAL I/O
Factory configured at 9600 baud, 1 stop bit, no parity, 8-bit character
Rxd Data, Txd data and Common. No handshake connections.
Carriage return (ASCII 0x0D) or Line Feed (ASCII 0x0A) or carriage return then line feed in that order
TABLE 2.4 – APC CONTROLLER PERFORMANCE
BUTTERFLY VALVES
125 to 250 msec, depending on valve size
0.5% to 100% of gauge
0.25% of reading 5mV min
TABLE 2.5 – APC CONTROLLER RELIABILITY
>10,000 hours >10,000 hours
GATE & PENDULUM VALVES
2 to 5 sec, depending on valve size
0.5% to 100% of gauge
0.25% of reading 5mV min
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APC-OP-LIT 1/12
5
IntellIsys AdAptIve pressure Controllers
3.0 - Unpacking and Installation
Inspect the shipping box before unpacking. Any damage should be reported to Nor-Cal Products or directly to the transportation carrier. Carefully remove the product from the box and visually inspect it for damage. If return of the product to Nor-Cal Products should become necessary, please contact Intellisys Customer Service to obtain a Return Materials Authorization (RMA) Number.
NOTE: Do not discard the packing materials until the product has been inspected to your satisfaction.
Pre-Installation Functionality Check
Nor-Cal Products carefully ensures that every product shipped is in perfect working condition. However, it is still a good idea to quickly check the functionality of the unit prior to installation into the vacuum system. To do so, connect the APC controller to the valve and then to an appropriate power source. The valve will complete a 30-second initialization sequence during which the valve plate will cycle back-and-forth a few times while the OPEN/CLOSE LEDs blink in an alternating pattern. The valve will eventually stop in the open position. Further verification of the system can be done by toggling the “OPEN / CLOSE” switch (if available) on the controller front panel. If the valve does not operate as described please contact Nor-Cal technical support.
other objects away from the valve opening and associated moving parts.
Installation
To allow for proper ventilation, make sure that at least 3 inches of unobstructed space is available adjacent to all perforated sides of the APC controller. Then, complete all cable connections as required referring to the figures and pin assignment tables in Sections 3.1 – 3.3 of this manual. A list of pre-manufactured cable assemblies available from Nor-Cal Products can be found in Appendix I.
WARNING : The valve plate movement presents a pinching hazard. Please keep fingers, hands or
CAUTION: The +15V and –15V power pins of the APC’s gauge connector are power sources
that are intended to power the system pressure gauge(s). It can supply a maximum of 700 mA. Do not use for any other purpose and do not connect to the tool main 15V supply as the two supplies would interfere with each other.
CAUTION: For all low voltage controller models, the Power V+ and Power V- pins of the DeviceNet or Analog/TTL connector are directly linked to the Power V+ and Power V- pins of the Auxiliary Connector. Make sure to only use one or the other.
NOTE: Low voltage controller models do not have a power on/off switch. Consider installing an external power on/off switch between the DC power supply and the controller to allow for de-energizing the unit without having to disconnect the cable.
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IntellIsys AdAptIve pressure Controllers
3.1 - A/C Powered Touch-Panel Controller Interface
Refer to the following diagrams and tables when connecting to an A/C powered APC Touch Panel Controller including models APC-150-A, APC-250-A, APC-350-A, APC- 750-A and APC-850-A.
TABLE 3.1.1 - (J3 & J4) “APC-X50-A” GAUGE
CONNECTOR DB-9 RECEPTACLE
(IDENTICAL PINOUTS)
SIGNAL
PIN
ASSIGNMENT
1 Signal input from gauge 2 N/C
3 N/C
4 +15VDC output to gauge 5 -15VDC output to gauge 6 N/C 7 N/C
Signal common from
8
gauge Power common
9
output to gauge
TABLE 3.1.2- (J1) “APC-X50-A” A/C
POWER CONNECTOR
PIN FUNCTION
1 Neutral 2 Ground
3 Line in 100 to 240 VAC
2
1 3
TABLE 3.1.3 - (J5)
“APC-X50-A” VALVE
CONNECTOR,
DB-15 RECEPTACLE
SIGNAL
PIN
ASSIGNMENT
A” RS-232 SERIAL PORT, DB-9
1 Drive A+ 2 Drive A­3 Drive B­4 Drive B+ 5 Sense B­6 Sense B+ 7 Sense A­8 Sense A+
9 Reserved 10 Reserved 11 Reserved 12 Reserved 13 Reserved 14 Reserved 15 Reserved
NOTE: Function \names\ with a
backward slash indicate active low input or output signals
3.50
Power
On/Off
Switch
ON
ON
POWER
POWER
OFF
OFF
O
O
3.50
TABLE 3.1.4 - (J2) “APC-X50-
RECEPTACLE
SIGNAL
PIN
ASSIGNMENT
1 RS485 (B)
RS-232 TX (data from
2
APC to host) RS-232 RX (data from
3
host to APC) 4 N/C 5 Signal Common 6 N/C 7 N/C 8 N/C 9 RS485 (A)
8.50
POWER
POWERPOWER
FAULT
FAULTFAULT
CONTROL
CONTROLCONTROL
OPEN
OPENOPEN
CLOSED
CLOSEDCLOSED
Intellisys
ADAPTIVE PRESSURE CONTROLLER
POWER
!
!!
POWER
100-240V~
100-240V~ 50-60 Hz
50-60 Hz
VALVEVALVE
I
I
GAUGE 1GAUGE 1
GAUGE 2GAUGE 2
8.00
TTL/ANALOG I/O
TTL/ANALOG I/O
SW1SW1
SERIALSERIAL
TABLES 3.1.5 - (SW1) “APC-X50-A” DIP SWITCH
SETTINGS FOR SERIAL COMMUNICATIONS
BAUD RATE SWITCH 1 SWITCH 2
19200 OFF (up) OFF (up)
9600 ON (down) OFF (up) 4800 OFF (up) ON (down) 1200 ON (down) ON (down)
PARITY SWITCH 3 SWITCH 4
None OFF (up) Either ON or OFF
Odd ON (down) OFF (up)
Even ON (down) ON (down)
STOP BITS* SWITCH 5
1 OFF (up) 2 ON (down)
* If parity is enabled (either odd or even) then only 1 stop bit is used and SW1 position 5 will be ignored
OTHER
SWITCH 6SWITCH 7SWITCH
FUNCTIONS
ON (down)
Enable RS-485
OFF (up) RS-232
Analog S.P.
0-5 VDC
Analog S.P.
0-10 VDC
TM
Reserved
Reserved
(J6) “APC-X50-A”ANALOG / TTL
CONNECTOR, DB-37 RECEPTACLE
PIN FUNCTION
10 \Analog Div 10 Select In\ 11 \Analog SP Control Select In\ 12 Digital GND / RS232 Common 13 TTL Out Common 14 N/C 15 N/C 16 N/C 17 N/C 18 Analog Valve Out (0-5 VDC) 19 \Valve Open Out\ 20 N/C 21 N/C 22 N/C 23 \Valve Closed Out\ 24 Fault Out 25 \Zero Gauge Select In\ 26 See NOTE below 27 \Open Valve In\ 28 PLO #2 Status 29 PLO #1 Status 30 N/C 31 N/C 32 N/C 33 Analog SP+ In 34 Analog SP- In 35 Analog GND 36 Analog CDG Out
37 Analog Valve Out
350- series controllers, pin 26 is defined as \Hold Valve Select In\
850- series controllers,
8
pin 26 is defined as \Valve Initialization Enable In\
TABLE 3.1.6 -
1 N/C 2 N/C 3 N/C 4 Digital GND / RS232 Common 5 \CDG2 Select In\ 6 \Position Control Select In\ 7 N/C 8 \Close Valve In\ 9 \Control Active Out\
NOTE: For 150-, 250- &
NOTE: For 750- &
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7
VALVEVALVE
POWER
TTL/ANALOG I/O
TTL/ANALOG I/O
GAUGE 1GAUGE 1
SW1SW1
!!
100-240V~ 50-60 Hz
SERIALSERIAL
GAUGE 2GAUGE 2
6.50
2.75
IntellIsys AdAptIve pressure Controllers
3.2 - A/C Powered Buried Box Controllers Interface
Refer to the following diagrams and tables when connecting to an A/C powered APC Buried Box Controller including models APC-100-A, APC-200-A, APC-300-A, APC- 700-A and APC-800-A.
TABLE 3.2.1 - (J3 & J4) “APC-X00-A” GAUGE
CONNECTOR DB-9 RECEPTACLE
(IDENTICAL PINOUTS)
SIGNAL
PIN
ASSIGNMENT
1 Signal input from gauge 2 N/C
3 N/C
4 +15VDC output to gauge 5 -15VDC output to gauge 6 N/C 7 N/C
Signal common from
8
gauge Power common
9
output to gauge
TABLE 3.2.2 - (J1) “APC-X00-A” A/C
POWER CONNECTOR
PIN FUNCTION
1 Neutral 2 Ground
3 Line in 100 to 240 VAC
2
1 3
TABLE 3.2.3 - (J5)
“APC-X00-A” VALVE
CONNECTOR,
DB-15 RECEPTACLE
SIGNAL
PIN
ASSIGNMENT
1 Drive A+ 2 Drive A­3 Drive B­4 Drive B+ 5 Sense B­6 Sense B+ 7 Sense A­8 Sense A+
9 Reserved 10 Reserved 11 Reserved 12 Reserved 13 Reserved 14 Reserved 15 Reserved
NOTE: Function \names\ with a
backward slash indicate active low input or output signals
Power
On/Off
Switch
TABLE 3.2.4 - (J2) “APC-X00-A” RS-
232 SERIAL PORT, DB-9 RECEPTACLE
SIGNAL
PIN
ASSIGNMENT
1 RS485 (B)
RS-232 TX (data from
2
APC to host) RS-232 RX (data from
3
host to APC) 4 N/C 5 Signal Common 6 N/C 7 N/C 8 N/C 9 RS485 (A)
Status LEDs
Valve Open/Close Switch Momentary
TABLES 3.2.5 - (SW1) “APC-X00-A” DIP SWITCH
SETTINGS FOR SERIAL COMMUNICATIONS
BAUD RATE SWITCH 1 SWITCH 2
19200 OFF (up) OFF (up)
9600 ON (down) OFF (up) 4800 OFF (up) ON (down) 1200 ON (down) ON (down)
PARITY SWITCH 3 SWITCH 4
None OFF (up) Either ON or OFF
Odd ON (down) OFF (up)
Even ON (down) ON (down)
STOP BITS* SWITCH 5
1 OFF (up) 2 ON (down)
* If parity is enabled (either odd or even) then only 1 stop bit is used and SW1 position 5 will be ignored
OTHER
FUNCTIONS
ON (down)
OFF (up) RS-232
SWITCH 6SWITCH 7SWITCH
8
Enable RS-485
Analog S.P.
0-5 VDC
Analog S.P.
0-10 VDC
Reserved
Reserved
(J6) “APC-X00-A”ANALOG / TTL
CONNECTOR, DB-37 RECEPTACLE
PIN FUNCTION
10 \Analog Div 10 Select In\ 11 \Analog SP Control Select In\ 12 Digital GND / RS232 Common 13 TTL Out Common 14 N/C 15 N/C 16 N/C 17 N/C 18 Analog Valve Out (0-5 VDC) 19 \Valve Open Out\ 20 N/C 21 N/C 22 N/C 23 \Valve Closed Out\ 24 Fault Out 25 \Zero Gauge Select In\ 26 See NOTE below 27 \Open Valve In\ 28 PLO #2 Status 29 PLO #1 Status 30 N/C 31 N/C 32 N/C 33 Analog SP+ In 34 Analog SP- In 35 Analog GND 36 Analog CDG Out
37 Analog Valve Out
300- series controllers, pin 26 is defined as \Hold Valve Select In\
800- series controllers, pin 26 is defined as \Valve Initialization Enable In\
TABLE 3.2.6 -
1 N/C 2 N/C 3 N/C 4 Digital GND / RS232 Common 5 \CDG2 Select In\ 6 \Position Control Select In\ 7 N/C 8 \Close Valve In\ 9 \Control Active Out\
NOTE: For 100-, 200- &
NOTE: For 700- &
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IntellIsys AdAptIve pressure Controllers
3.3 - DC Powered Controllers with Serial I/O Interface
Refer to the following diagram and tables when connecting to a DC powered APC controller including model APC-800L-A-S01.
TABLE 3.3.1 - (J1)
“APC-800L-A-S01”
GAUGE CONNECTOR,
DB-15 RECEPTACLE
PIN FUNCTION
1
Chassis GND
2
Chassis GND
3
N/C
4
Signal common from gauge 2
5
Signal input from gauge 2
6
N/C
7
Signal common from gauge 1
8
Signal input from gauge 1
9
+15V supply to gauge
10
+15V supply to gauge
11
Power Supply Common
12
Power Supply Common
13
N/C
14
-15V supply to gauge
15
-15V supply to gauge
(J2) “APC-800L-A-S01” POWER
TABLE 3.3.2 -
CONNECTOR, DB-9 PLUG
PIN FUNCTION
1
Chassis GND
2
Power RTN
3 Power RTN
Power +24V IN
4 5
Power +24V IN
6
N/C
7
N/C
8
N/C
9
N/C
Status
LED
POWER
Status LEDs
4.15
TABLE 3.3.3 -
(J4) “APC-800L-A-S01” VALVE
CONNECTOR, DB-15 PLUG
SIGNAL
PIN
ASSIGNMENT
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
I/O
Drive A+
Drive A-
Drive B­Drive B+ Sense B-
Sense B+
Sense A-
Sense A+
Reserved Reserved Reserved Reserved Reserved Reserved Reserved
TABLE 3.3.4 -
(J3) “APC-800L-A-S01” I/O
CONNECTOR,
DB-15 RECEPTACLE
PIN FUNCTION
1
Chassis GND RS-232 TX (data from
2
APC to host), or 485A RS-232 RX (data from
3
host to APC), or 485B
4
N/C
5
N/C
6
N/C
7
Digital GND
8
N/C
9
N/C
10
N/C
11
N/C
12
Valve Closed input
13
Digital GND
14
\Valve Closed Output\
15
TTL Output Common
5.12
2.49
5.95
APC-OP-LIT 1/12
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IntellIsys AdAptIve pressure Controllers
Status LEDs
3.4 – DC Powered Controllers with Serial and Analog/TTL I/O Interface
Refer to the following diagram and tables when connecting to a DC powered APC controller including models APC-100L-A, APC-200L-A, APC-300L-A, APC-700L-A and APC-800L-A.
TABLE 3.4.2 - (SW1) “APC-X00L-A” DIP SWITCHES
SWITCH 1 SWITCH 2 SWITCH 3 SWITCH 4
TABLE 3.4.1 – (J4) “APC-X00L-A”
ANALOG / TTL CONNECTOR,
DB-25 RECEPTACLE
PIN FUNCTION
1
Chassis GND RS-232TX (data from IQ
2
to host) RS-232RX (data from
3
host to IQ)
4
Analog CDG Out
5
Analog GND
6
Analog Valve Out
7
Digital GND \Analog SP Control
8
Select In\
9
Analog SP+ In
10
Analog SP- In
11
Power RTN
12
Power 24V in
13
\CDG2 Select In\
14
See NOTE below \Position Control Select
15
In\
16
N/C
17
Analog GND
18
\Close Valve In\
19
\Open Valve In\
20
Fault Out
21
N/C
22
\Valve Open Out\
23
\Valve Closed Out\
24
TTL Out Common
25
Chassis GND
NOTE: For 100L-A, 200L-A
and 300L-A series controllers, pin
14 is defined as \Hold Valve Select In\
OFF (up)
ON (down)
9600 baud 8 bit, no parity 1 stop bit
19200 baud
Status
LEDs
TABLE 3.4.4 - (J3) “APC-X00L-A”
AUXILIARY CONNECTOR,
DB-15 RECEPTACLE
PIN FUNCTION
1
Not used RS-232 TX (data from IQ
2
to host) RS-232 RX (data from
3
host to IQ)
4
Digital GND
5
Power RTN
6
Not used
7
Power +24V in
8
Not used
9
Analog CDG Out
10
Analog Valve Out
11
Analog GND
12
TTL Out Common
13
\Valve Open Out\
14
\Valve Closed Out\
15
Chassis GND
7 bit, even parity
(1 stop bit only)
4.78
5.74
2 stop bits
PIN FUNCTION
1 2 3 4 5 6 7 8 9
0-10 V Analog
in
0 to 5V
Analog in
2.51
5.69
TABLE 3.4.5 - (J2) “APC-X00L-A”
GAUGE CONNECTOR,
DB-9 RECEPTACLE
Signal input from gauge 1 +15 V supply to gauge
-15 V supply to gauge Not used Signal input from gauge 2 Signal common from gauge 2 Not used Signal common from gauge 1 Power supply common
TABLE 3.4.3 - (J1) “APC-X00L-A”
VALVE CONNECTOR,
DB-15 RECEPTACLE
PIN
1 Drive A+ 2 Drive A­3 Drive B­4 Drive B+ 5 Sense B­6 Sense B+ 7 Sense A­8 Sense A+
9 Reserved 10 Reserved 11 Reserved 12 Reserved 13 Reserved
14 Reserved
15 Reserved
SIGNAL
ASSIGNMENT
NOTE: For 700L-A and 800L-A
series controllers, pin 14 is defined as \Valve Initialization Enable In\
1010
APC-OP-LIT 1/12
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IntellIsys AdAptIve pressure Controllers
2.51
5.74
5.69
4.78
Indicating LEDs
1
4
3
2
5
3.5 - DC Powered Controllers with Serial and DeviceNet I/O Interface
Refer to the following diagrams and tables when connecting to an D/C powered APC controller including models APC-100L-D, APC-200L-D, APC-300L-D, APC-700L-D and APC-800L-D.
TABLE 3.5.1 –
(J1) “APC-X00L-D”
DEVICENET NETWORK
CONNECTOR
PIN FUNCTION
1
Drain
2
Power In +
3
Power In -
4
CAN H
5
CAN L
TABLE 3.5.2 – (J2) “APC-X00L-D”
AUXILIARY CONNECTOR,
DB-15 RECEPTACLE
PIN FUNCTION
1
Not used RS-232 TX (data from IQ to
2
host)/485 (A) RS-232 RX (data from host to
3
IQ)/485 (B)
4
Digital GND
5
Power RTN
6
Not used
7
Power +24V in
8
Not used
9
Analog CDG Out
10
Analog Valve Out
11
Analog GND
12
TTL Out Common
13
\Valve Open Out\
14
\Valve Closed Out\
15
Chassis GND
TABLE 3.5.3 – (J3) “APC-X00L-D”
GAUGE CONNECTOR,
DB-9 RECEPTACLE
PIN # FUNCTION
1
Signal input from gauge 1
2
+15 V supply to gauge
3
-15 V supply to gauge
4
Not used
5
Signal input from gauge 2
6
Signal common from gauge 2
7
Not used
8
Signal common from gauge 1
9
Power supply common
TABLE 3.5.4 - (J4) “APC-X00L-D”
VALVE CONNECTOR,
DB-15 RECEPTACLE
PIN
1 Drive A+ 2 Drive A­3 Drive B­4 Drive B+ 5 Sense B­6 Sense B+ 7 Sense A­8 Sense A+
9 Reserved 10 Reserved 11 Reserved 12 Reserved 13 Reserved
14 Reserved
15 Reserved
SIGNAL
ASSIGNMENT
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APC-OP-LIT 1/12
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IntellIsys AdAptIve pressure Controllers
3.6 – DC Powered IQA Controlled Valve with Serial and Analog/TTL I/O Interface
Refer to the following diagram and tables when connecting to an IQA controller including models TBV-IQA, TSS-IQA and TPV-IQA.
OFF (up)
ON (down)
TABLE 3.6.2 – (J3) “IQA”
AUXILIARY CONNECTOR,
DB-15 RECEPTACLE
PIN FUNCTION
1
Not used
2
RS-232 TX (data from IQ to host)
3
RS-232 RX (data from host to IQ)
4
Digital GND
5
Power RTN-
6
Not used
7
Power +24V in
8
Not used
9
Analog CDG Out
10
Analog Valve Out
11
Analog GND
12
TTL Out Common
13
\Valve Open Out\
14
\Valve Closed Out\
15
Chassis GND
TABLE 3.6.1 – (SW1) “IQA” DIP SWITCHES, DB-25 RECEPTACLE
SWITCH 1 SWITCH 2 SWITCH 3 SWITCH 4
9600 baud 8 bit, no parity 1 stop bit 0 to 10 V Analog In
19200 baud
7 bit, even parity
(1 stop bit only)
POWER
Indicating
LEDs
CTRL
FAULT
SW1
2 stop bits 0 to 5 V Analog In
Valve Open/Close
membrane switches
ANALOG/TTL
AUXILIARY
TM
GAUGE
TABLE 3.6.3 – (J2)
“IQA” GAUGE CONNECTOR,
DB-9 RECEPTACLE
PIN # FUNCTION
1
Signal input from gauge 1
2
+15 V supply to gauge
3
-15 V supply to gauge
4
Not used
5
Signal input from gauge 2
6
Signal common from gauge 2
7
N/C
8
Signal common from gauge 1
9
Power supply common
TABLE 3.6.4 – (J4) “IQA”
ANALOG/TTL CONNECTOR,
DB-25 RECEPTACLE
PIN FUNCTION
1
Chassis GND
2
RS-232TX (data from IQ to host)
3
RS-232RX (data from host to IQ)
4
Analog CDG Out
5
Analog GND
6
Analog Valve Out
7
Digital GND
8
\Analog SP Control Select In\
9
Analog SP+ In
10
Analog SP- In
11
Power RTN
12
Power +24V in
13
\CDG2 Select In\
14
See NOTE below
15
\Position Control Select In\
16
N/C
17
Analog GND
18
\Close Valve In\
19
\Open Valve In\
20
Fault Out
21
N/C
22
\Valve Open Out\
23
\Valve Closed Out\
24
TTL Out Common
25
Chassis GND
NOTE: When IQA is installed on a
TBV valve, pin 14 is defined as \Hold Valve Select In\
NOTE: When IQA is installed on a
TPV or TSS valve, pin 14 is defined as \Valve Initialization Enable In\
1212
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IntellIsys AdAptIve pressure Controllers
1
4
3
2
5
3.7 - DC Powered IQD Controlled Valve with Serial and DeviceNet I/O Interface
Refer to the following diagram and tables when connecting to an IQD controller including models TBV-IQD, TSS-IQD and TPV-IQD.
TABLE 3.7.1 –
(J1) “IQD” DEVICENET
NETWORK CONNECTOR
PIN FUNCTION
1
Drain
2
Power In +
3
Power In -
4
CAN H
5
CAN L
Indicating LEDs
AUXILIARY
TM
Valve Open/Close membrane switches
GAUGE
TABLE 3.7.2 – (J2) “IQD”
AUXILIARY CONNECTOR,
DB-15 RECEPTACLE
PIN FUNCTION
1
Not used RS-232 TX (data from IQ to
2
host)/485 (A) RS-232 RX (data from host to
3
IQ)/485 (B)
4
Digital GND
5
Power RTN
6
Not used
7
Power +24V in
8
Not used
9
Analog CDG1 Out
10
Analog Valve Out
11
Analog GND
12
TTL Out Common
13
\Valve Open Out\
14
\Valve Closed Out\
15
Chassis GND
TABLE 3.7.3 – (J3) “IQD”
GAUGE CONNECTOR,
DB-9 RECEPTACLE
PIN # FUNCTION
1
Signal input from gauge 1
2
+15 V supply to gauge
3
-15 V supply to gauge
4
Not used
5
Signal input from gauge 2
6
Signal common from gauge 2
7
Not used
8
Signal common from gauge 1
9
Power supply common
APC-OP-LIT 1/12
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IntellIsys AdAptIve pressure Controllers
4.0 - Theory of Operation
All APC controllers are designed for downstream pressure control (see Fig 4.1 and 4.2). As such, it is one of four important components in a pressure control system. The other three essential components include a host system computer, a throttle valve and one or two vacuum gauges, such as a Capacitance Diaphragm Gauge (CDG). Most manufacturers’ vacuum gauges can be used to provide the vacuum measurement signal, provided they have a voltage output proportional to pressure.
AC or DC power supply
APC Controller
Host system with
RS232/485 or DeviceNet
communications
FIGURE 4.1 – TYPICAL INSTALLATION AND CONFIGURATION OF A BURIED BOX INTELLISYS DOWNSTREAM PRESSURE CONTROL SYSTEM
Vacuum gauge(s)
Vacuum Chamber
Pump
Nor-Cal throttle valve
Initialization Sequence
When first powered up, the APC controller will run the valve through an initialization sequence that lasts for approximately 30 seconds. The primary purpose for this operation is for the controller to determine the fully open and closed points, as well as for certain motor and position calibration steps to occur. While the initialization sequence is active, the amber FAULT light will be illuminated and the OPEN/CLOSE LEDs will blink in an alternating fashion. Once the initialization sequence is complete, the valve will move to the fully open position and the green OPEN LED will illuminate.
NOTE: The controllers for TPV pendulum valves and TSS
gate valves contain a valve initialization safety lock function. This safety lock will prevent valve initialization to occur until given a “clear-to-proceed” command. The RS-232 serial command for this is JC. Alternatively, the \Valve Initialization Enable In\ TTL pin can be pulled low to initiate this sequence.
CAUTION: Never attempt to initialize a throttle valve with
differential pressure across the sealing gate. Make sure the pressure on both sides is equalized. Damage to pumps and other equipment can occur otherwise.
Vacuum gauge(s)
DC power supply
Host system with
RS232/485 or DeviceNet
communications
FIGURE 4.2 – TYPICAL INSTALLATION AND CONFIGURATION OF AN IQ PRESSURE CONTROL VALVE
Vacuum Chamber
Pump
Nor-Cal IQ-series Valve
Normal Operation
After the initialization sequence is complete normal operation of the valve is possible. There are two primary modes of operation, a) position control mode and b) pressure control mode.
In position control mode, the valve will move to any position in its range based on a position set-point command from the host. The valve will remain in that position until instructed to do otherwise. Position control mode can be useful in certain cases where pre-determined amount of baffling or throttling is necessary.
Pressure control mode, on the other hand, is used whenever control to a
specific system pressure level is desired. The host provides the set-point value to the controller which, in turn, moves the valve to achieve that set point as quickly as possible. During pressure control mode, external perturbations such as flow changes and plasma events will automatically be compensated for by the controller so that the pressure set-point is maintained. The set point value can be changed by the host at any time.
Tuning
The APC controller contains an Adaptive Pressure Control Algorithm that has been designed to work over a wide range of flow and pressure combina­tions. The APC controller therefore does not have a “learn mode” and there is no need for the user to set PID parameters. In some instances, however, vacuum system design may affect the closed loop pressure control time constants. As a result, pressure control performance may at times be affected. If satisfactory pressure control cannot be achieved with the Adaptive Pressure Control Algorithm, please contact Nor-Cal Products’ Intellisys Customer Support.
1414
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