Nor-Cal Intellisys Adaptive Pressure Controllers User Manual

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

Nor-Cal Products, Inc.	Tel: [phone]
1967 So. Oregon	or 530-842-4457
Yreka, CA 96097 USA	Fax: [phone]
	www.n-c.com

Intellisys Adaptive Pressure Controllers

Table of Contents
1.0.............	Introduction..............................................................................................................................................	4
2.0.............	Device Specification...................................................................................................................................	5
3.0.............	Unpacking and Installation........................................................................................................................	6
3.1........	A/C Powered Touch-Panel Controllers Interface.........................................................................................	7
3.2........	A/C Powered Buried Box Controllers Interface...........................................................................................	8
3.3........	DC Powered Controllers with Serial I/O Interface........................................................................................	9
3.4........	DC Powered Controllers with Serial and Analog/TTL I/O Interface............................................................	10
3.5........	DC Powered Contollers with Serial and DeviceNet I/O Interface...............................................................	11
3.6........	DC Powered IQA Controlled Valve with Serial and Analog/TTL I/O Interface.............................................	12
3.7........	DC Powered IQD Controlled Valve with Serial and DeviceNet I/O Interface...............................................	13
4.0.............	Theory of Operation................................................................................................................................	14
5.0.............	APC Controller Module Interfaces...........................................................................................................	15
6.0...............	RS-232 Serial Interface and Commands...................................................................................................	16
7.0.............	Analog/TTL Interface...............................................................................................................................	19
8.0.............	DeviceNet Interface.................................................................................................................................	22
8.1........	Overview and Setup................................................................................................................................	22
8.2........	Establishing a DeviceNet connection........................................................................................................	24
9.0.............	DeviceNet Device Profile..........................................................................................................................	26
9.1........	Identity Object.........................................................................................................................................	27
9.2........	Message Router Object...........................................................................................................................	27
9.3........	DeviceNet Object.....................................................................................................................................	27
9.4........	Assembly Object......................................................................................................................................	28
9.5........	I/O Assembly Instances............................................................................................................................	28
9.6........	Connection Object..................................................................................................................................	28
9.7........	Discrete Input Point Object......................................................................................................................	28
9.8........	S-Device Supervisor Object......................................................................................................................	29
9.9........	S-Analog Sensor Object...........................................................................................................................	30
9.10......	S-Analog Actuator Object........................................................................................................................	31
9.11.......	S-Single Stage Controller Object..............................................................................................................	31
9.12.......	Selection Object......................................................................................................................................	32
10.0...........	LCD Front Panel Interface...........................................................................................................................................................................	33
10.1......	Commonly Used Function Buttons..........................................................................................................	34
10.2......	Basic Operation.......................................................................................................................................	34
10.3......	Configure Setpoints................................................................................................................................	36
10.4......	Utility Menu............................................................................................................................................	38
10.5......	Configure Display Units.........................................................................................................................................	40
11.0...........	Battery Back-Up......................................................................................................................................	41
12.0...........	Product Support......................................................................................................................................	42
Appendix I - Spare Parts and Ordering Information...................................................................................................		44
Appendix II - Warranty and Intellectual Property Coverage .............................................................................................		45

APC-OP-LIT 1/12

2	Visit our Web Site www.n-c.com

Intellisys Adaptive Pressure Controllers

List of Tables

2.1.......	APC Controller General Equipment Specifications...........		5	9.3.1....	DeviceNet Object Attributes..........................................			27
2.2 ......	APC Controller Analog TTL I/O.........................................		5	9.4.1....	Assembly Object Attributes...........................................			28
2.3.......	APC Controller RS-232 Serial I/O......................................		5	9.5.1....	Input Assembly Instances...............................................			28
2.4.......	APC Controller Performance............................................		5	9.5.2....	Output Assembly Instances............................................			28
2.5.......	APC Controller Reliability.................................................		5	9.6.1....	Connection Object Attributes........................................			28
3.1.1....	(J3&J4) “APC-X50-A” Gauge Connector.........................		7	9.7.1....	Discrete Input Point Object Attribute; Instance ID 1........			28
3.1.2....	(J1)	“APC-X50-A” A/C Power Connector........................	7	9.7.2....	Discrete Input Point Object Attribute; Instance ID 2........			28
3.1.3....	(J5)	“APC-X50-A” Valve Connector.................................	7	9.8.1....	S-Device Supervisor Object Attributes............................			29
3.1.4 ...	(J2)	“APC-X50-A” RS-232 Serial Port ..............................	7	9.8.2....	S-Device Supervisor Object Exception Status Bit Map.....			29
3.1.5....	(SW1) “APC-X50-A” Dip Switch Settings for			9.8.3....	Device Status Attribute Value.........................................			29
	Serial Communications...................................................		7	9.9.1....	S-Analog Sensor Instances.............................................			30
3.1.6....	(J6)	“APC-X50-A” Analog / TTL Connector......................	7	9.9.2....	S-Analog Sensor Object Attributes.................................			30
3.2.1....	(J3&J4) “APC-X00-A” Gauge Connector.........................		8	9.10.1..	S-Analog Actuator Object Attributes.............................			31
3.2.2....	(J1)	“APC-X00-A” A/C Power Connector........................	8	9.10.2..	S-Analog Actuator Exception Status Bitmap..................			31
3.2.3....	(J5)	“APC-X00-A” Valve Connector.................................	8	9.11.1..	S-Single Stage Controller Object Attributes....................			31
3.2.4 ...	(J2)	“APC-X00-A” RS-232 Serial Port...............................	8	9.11.2..	S-Single Stage Controller Object Subclass Attributes;
3.2.5 ...	(SW1) “APC-X00-A” Dip Switch Settings for				Instance 1......................................................................			31
	Serial Communications...................................................		8	9.12.1..	Selection Object Attributes; Instance 1...........................			32
3.2.6 ...	(J6)	“APC-X00-A” Analog / TTL Connector......................	8	9.12.2..	Selection Object Attributes; Instance 2...........................			32
3.3.1....	(J1)	“APC-800L-A-S01” Gauge Connector......................	9
3.3.2....	(J2)	“APC-800L-A-S01” Power Connector......................	9
3.3.3....	(J3)	“APC-800L-A-S01” Valve Connector........................	9
3.3.4....	(J4)	“APC-800L-A-S01” I/O Connector...........................	9
3.4.1....	(J4)	“APC-X00L-A” Analog / TTL Connector..................	10	List of Figures
3.4.2....	(SW1) “APC-X00L-A” Dip Switches...............................		10
3.4.3....	(J1)	“APC-X00L-A” Valve Connector.............................	10	4.1.......	Typical installation and configuration of a buried box
3.4.4....	(J3)	“APC-X00L-A” Auxiliary Connector........................	10		Intellisys Downstream Pressure Control system..............			14
3.4.5....	(J2)	“APC-X00L-A” Gauge Connector...........................	10	4.2.......	Typical installation and configuration of an
3.5.1....	(J1)	“APC-X00L-D” DeviceNet Network Connector.......	11		IQ Pressure Control valve...............................................			14
3.5.2....	(J2)	“APC-X00L-D” Auxiliary Connector........................	11	8.1.......	IQD DeviceNet connector pin assignment......................			22
3.5.3....	(J3)	“APC-X00L-D” Gauge Connector...........................	11	8.2.......	DeviceNet baud rate selection switch.............................			22
3.5.4....	(J3)	“APC-X00L-D” Valve Connector.............................	11	8.3.......	DeviceNet address switches...........................................			22
3.6.1....	(SW1) “IQA” Dip Switches.............................................		12	8.4.......	Typical DeviceNet Hardware Installation.........................			23
3.6.2....	(J3)	“IQA” Auxiliary Connector......................................	12	9.1.......	Object Model for the Process Control Valve Device.........			26
3.6.3....	(J2)	“IQA” Gauge Connector.........................................	12	9.2.......	Object State Transition Diagram.....................................			29
3.6.4....	(J4)	“IQA” Analog / TTL Connector................................	12	10.1.....	LCD Front Panel Interface..............................................			33
3.7.1....	(J1)	“IQD” DeviceNet Network Connector.....................	13	10.2.....	Configure Setpoints......................................................			36
3.7.2....	(J2)	“IQD” Auxiliary Connector......................................	13	10.3.....	Utility Menu...................................................................			38
3.7.3....	(J3)	“IQD” Gauge Connector.........................................	13	12.1.....	Possible Failure Modes and Recommended Actions.......			42
6.1.......	RS-232 Serial Commands..............................................		16	12.2.....	Valid Status LED Combinations......................................			43
6.2.......	RS-232 Serial Requests and Responses...........................		16
6.3	Values for xx for use with Dual Range Mode		18
						Contact Nor-Cal Products
8.1.......	DeviceNet Module LED Status........................................		22
8.2.......	DeviceNet Network LED Status......................................		22			Intellisys Customer Support
8.3	DeviceNet Explicit Messaging		24			at 800-824-4166 ext. 186
						or visit our website
8.4	Output Assembly Formats		25
						at www.n-c.com
8.5.......	Input Assembly Formats................................................		25
....9.1.1	...............................................Identity Object Attributes		27	Information in this manual is subject to change without notice.
9.1.2....	Nor-Cal Product Types....................................................		27
							APC-OP-LIT 1/12
Call toll free 800-824-4166 or 530-842-4457 • FAX [phone]								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

4	Visit our Web Site www.n-c.com

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
		IQA and IQD models: N/A, included in valve weight
	Weight, in lbs (kg)	Low voltage models:	2.0 (0.9)
		A/C powered models:	3.5 (1.6)
	Rated Input Voltage	Low voltage models: 24 VDC ±10%, differential
		A/C powered models: 100 to 240 VAC
	Rated Frequency	A/C Powered models only: 50-60 Hz
		Low voltage models: 3.0 A @ 24 VDC max,
	Rated Current		1.0A @ 24 VDC average
		A/C powered models: 1.0A typ @ 115 VAC 3A max
	Rated Input	Low voltage models: 35 volts max, reverse-
			and internal current resettable fuse
	Protection
		A/C powered models: 300 VA slow blow fuse
	Rated Output Power	Low voltage models:	± 15 VDC @ 700 mA
	(for gauge excitation)	A/C powered models: ± 15 VDC @ 800 mA, 2X
	Protection Class	I
	Degree of Protection	X0
	(IP)
	Laser Class	1 (LED’s)
	Certifications/EU	CE Standard for Process Equipment including EMC Directive
		89/336/EC for D/C powered models. Low Voltage Directive
	Directives
		2006/95/EC to EN 61010-1:2001 for A/C powered models
	Maximum Altitude	6562 ft (2000 m)
	Allowable Ambient
	Operating	32ºF to 113ºF (0ºC to 45ºC)
	Temperature
	Allowable Ambient	0 to 95% non-condensing
	Humidity
		3” (75 mm) on all perforated sides. A minimum of 3½”
	Installation Clearance	(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)		0 to 10V differential
	Input
	Analog Output		0 to 10V differential @ 35 mA, short circuit protected
			Diode protected at –0.4 VDC, compatible with open collector
	TTL Input		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.
	TTL Output		Open collector, optically isolated, 25V @ 10 mA max
	TablE 2.3 – APC CoNTROLLER RS-232 SeRIAL I/O
	Feature			SpeciFIcation
	Communications Settings			Factory configured at 9600 baud, 1 stop bit,
				no parity, 8-bit character
	Connections			Rxd Data, Txd data and Common.
				No handshake connections.
	Communications Protocol			See Section 6.0 in this manual
	End of line delimiter			Carriage return (ASCII 0x0D) or Line Feed (ASCII
				0x0A) or carriage return then line feed in that order
		TablE 2.4 – APC CoNTROLLER PeRFORmaNCE
	Feature		Butterfly		Gate & Pendulum valves
			valves
	Valve speed		125 to 250 msec,		2 to 5 sec, depending on valve size
	(open to closed)		depending on valve size
	Control range		0.5% to 100% of		0.5% to 100% of gauge
			gauge
	Accuracy		0.25% of reading 5mV		0.25% of reading 5mV min
			min
	Repeatability		0.12% of reading		0.12% of reading
		TablE 2.5 – APC CoNTROLLER ReLIAbiLITy
	Feature		Butterfly valves			Pendulum valve
	Electronics		>10,000 hours			>10,000 hours
	MTBF
	Warranty		1 year			1 year

	APC-OP-LIT 1/12
Call toll free 800-824-4166 or 530-842-4457 • FAX [phone]	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.

WARNING: The valve plate movement presents a pinching hazard. Please keep fingers, hands or 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.

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.

APC-OP-LIT 1/12

6	Visit our Web Site www.n-c.com

Intellisys Adaptive Pressure Controllers

3.1 - A/C Powered Touch-Panel Controller Interface

RefertothefollowingdiagramsandtableswhenconnectingtoanA/CpoweredAPCTouchPanelControllerincludingmodels APC-150-A,APC-250-A,APC-350-A,APC-

750-AandAPC-850-A.

TablE 3.1.1 - (J3 & J4)

TablE 3.1.6 -

8.50

(J6) “APC-X50-A”AnALOG / TTL

“APC-X50-A” GaUGE

CoNNECTOR, DB-37 ReCEPTACLE

CoNNECTOR DB-9 ReCEPTACLE

Pin

Function

(iDENTICAL pINOUTS)

SiGnal

POWER

1

N/C

2

N/C

Pin

AsSIGnment

FAULT

1 Signal input from gauge

3.50

CONTROL

3

N/C

2

N/C

OPEN

4

Digital GND / RS232 Common

3

N/C

CLOSED

5

\CDG2 Select In\

IntellisysTM

4 +15VDC output to gauge

6

\Position Control Select In\

ADAPTIVE PRESSURE CONTROLLER

5 -15VDC output to gauge

Power

7

N/C

6

N/C

8

\Close Valve In\

On/Off

9

\Control Active Out\

7

N/C

Switch

8

Signal common from

POWER

10

\Analog Div 10 Select In\

gauge

ON I

11

\Analog SP Control Select In\

GAUGE 1

SW1

Power common

POWER

12

Digital GND / RS232 Common

9

OFF O

output to gauge

13

TTL Out Common

100-240V~

3.50

! 50-60 Hz

GAUGE 2

SERIAL

14

N/C

TablE 3.1.2- (J1) “APC-X50-A” A/C

VALVE

TTL/ANALOG I/O

15

N/C

PoWER CoNNECTOR

16

N/C

Pin

Function

17

N/C

1

Neutral

8.00

18

Analog Valve Out (0-5 VDC)

2

Ground

19

\Valve Open Out\

3

Line in 100 to 240 VAC

20

N/C

2

21

N/C

22

N/C

1

3

23

\Valve Closed Out\

24

Fault Out

TablE 3.1.3 - (J5)

25

\Zero Gauge Select In\

26

See NOTE below

“APC-X50-A” VaLVE

27

\Open Valve In\

CoNNECTOR,

TablES 3.1.5 - (SW1) “APC-X50-A” DiP SwITCh

DB-15 ReCEPTACLE

28

PLO #2 Status

SeTTINGS fOR SeRIAL CommuNICATIONS

SiGnal

29

PLO #1 Status

Pin

TablE 3.1.4 - (J2) “APC-X50-

Baud RAte

Switch 1

Switch 2

AsSIGnment

A” RS-232 SeRIAL PoRT, DB-9

30

N/C

19200

OFF (up)

OFF (up)

1

Drive A+

ReCEPTACLE

31

N/C

2

Drive A-

9600

ON (down)

OFF (up)

Pin

SiGnal

32

N/C

3

Drive B-

AsSIGnment

4800

OFF (up)

ON (down)

33

Analog SP+ In

4

Drive B+

1

RS485 (B)

1200

ON (down)

ON (down)

34

Analog SPIn

5

Sense B-

RS-232 TX (data from

2

Parity

Switch 3

Switch 4

35

Analog GND

6

Sense B+

APC to host)

None

OFF (up)

Either ON or OFF

36

Analog CDG Out

RS-232 RX (data from

7

Sense A-

3

Odd

ON (down)

OFF (up)

host to APC)

37

Analog Valve Out

8

Sense A+

4

N/C

Even

ON (down)

ON (down)

9

Reserved

NOTE: For 150-, 250- &

5

Signal Common

10

Reserved

6

N/C

Stop Bits*

Switch 5

350- series controllers,

11

Reserved

1

OFF (up)

pin 26 is defined as

7

N/C

12

Reserved

2

ON (down)

\Hold Valve Select In\

8

N/C

13

Reserved

* If parity is enabled (either odd or even) then only 1 stop bit is used

NOTE: For 750- &

9

RS485 (A)

14

Reserved

and SW1 position 5 will be ignored

850- series controllers,

Other

Switch

Switch

Switch

15

Reserved

pin 26 is defined as

Functions

6

7

8

\Valve Initialization

NOTE: Function \names\ with a

Enable

Analog S.P.

ON (down)

Reserved

Enable In\

backward slash indicate active low

RS-485

0-5 VDC

Analog S.P.

input or output signals

OFF (up)

RS-232

Reserved

0-10 VDC

APC-OP-LIT 1/12

Call toll free 800-824-4166 or 530-842-4457 • FAX [phone]	7

Intellisys Adaptive Pressure Controllers

3.2 - A/C Powered Buried Box Controllers Interface

RefertothefollowingdiagramsandtableswhenconnectingtoanA/CpoweredAPCBuriedBoxControllerincludingmodelsAPC-100-A,APC-200-A,APC-300-A,APC-

700-AandAPC-800-A.

TablE 3.2.1 - (J3 & J4)

“APC-X00-A” GaUGE

CoNNECTOR DB-9 ReCEPTACLE

(iDENTICAL pINOUTS)

SiGnal

Pin AsSIGnment

1Signal input from gauge

2N/C

3N/C

4+15VDC output to gauge

5-15VDC output to gauge

6N/C

7N/C

8Signal common from gauge

9Power common output to gauge

TablE 3.2.2 - (J1) “APC-X00-A” A/C

PoWER CoNNECTOR

Pin Function

1Neutral

2Ground

3Line in 100 to 240 VAC

2

1 3

		Status LEDs
	Power	Valve
		Open/Close
	On/Off
		Switch
	Switch
		Momentary

		POWER	GAUGE 1
				SW1
2.75		100-240V~	GAUGE 2	SERIAL
	!
		50-60 Hz
		VALVE		TTL/ANALOG I/O

6.50

TablE 3.2.3 - (J5)

“APC-X00-A” VaLVE

CoNNECTOR,

DB-15 ReCEPTACLE

Pin SiGnalAsSIGnment

1Drive A+

2Drive A-

3Drive B-

4Drive B+

5Sense B-

6Sense B+

7Sense A-

8Sense A+

9Reserved 10 Reserved 11 Reserved 12 Reserved 13 Reserved 14 Reserved 15 Reserved

TablE 3.2.4 - (J2) “APC-X00-A” RS-

232 SeRIAL PoRT, DB-9 ReCEPTACLE

Pin SiGnal

AsSIGnment

1RS485 (B)

2RS-232 TX (data from APC to host)

3RS-232 RX (data from host to APC)

4N/C

5Signal Common

6N/C

7N/C

8N/C

9RS485 (A)

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	Switch	Switch	Switch
		Functions	6	7	8
	NOTE: Function \names\ with a	ON (down)	Enable	Analog S.P.	Reserved
	backward slash indicate active low		RS-485	0-5 VDC
				Analog S.P.
	input or output signals	OFF (up)	RS-232		Reserved
				0-10 VDC

TablE 3.2.6 -

(J6) “APC-X00-A”AnALOG / TTL

CoNNECTOR, DB-37 ReCEPTACLE

Pin Function

1N/C

2N/C

3N/C

4Digital GND / RS232 Common

5\CDG2 Select In\

6\Position Control Select In\

7N/C

8\Close Valve In\

9\Control Active Out\

10\Analog Div 10 Select In\

11\Analog SP Control Select In\

12Digital GND / RS232 Common

13TTL Out Common

14N/C

15N/C

16N/C

17N/C

18Analog Valve Out (0-5 VDC)

19\Valve Open Out\

20N/C

21N/C

22N/C

23\Valve Closed Out\

24Fault Out

25\Zero Gauge Select In\

26See NOTE below

27\Open Valve In\

28PLO #2 Status

29PLO #1 Status

30N/C

31N/C

32N/C

33Analog SP+ In

34Analog SPIn

35Analog GND

36Analog CDG Out

37Analog Valve Out

NOTE: For 100-, 200- &

300- series controllers, pin 26 is defined as \Hold Valve Select In\

NOTE: For 700- &

800- series controllers, pin 26 is defined as \Valve Initialization Enable In\

APC-OP-LIT 1/12

8	Visit our Web Site www.n-c.com

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

1Chassis GND

2Chassis GND

3N/C

4Signal common from gauge 2

5Signal input from gauge 2

6N/C

7Signal common from gauge 1

8Signal input from gauge 1

9+15V supply to gauge

10+15V supply to gauge

11Power Supply Common

12Power Supply Common

13N/C

14-15V supply to gauge

15-15V supply to gauge

		TablE 3.3.2 -		TablE 3.3.3 -
	(J2) “APC-800L-A-S01” PoWER		(J4) “APC-800L-A-S01” VaLVE
	CoNNECTOR, DB-9 PLUG		CoNNECTOR, DB-15 PlUG
	Pin	Function		SiGnal
	1	Chassis GND	Pin	AsSIGnment
			1	Drive A+
	2	Power RTN
			2	Drive A-
	3	Power RTN
			3	Drive B-
	4	Power +24V IN
			4	Drive B+
	5	Power +24V IN
			5	Sense B-
	6	N/C
			6	Sense B+
	7	N/C
			7	Sense A-
	8	N/C
			8	Sense A+
	9	N/C
			9	Reserved
			10	Reserved
			11	Reserved
			12	Reserved
			13	Reserved
			14	Reserved
			15	Reserved
		Status LEDs
		4.15
	Status
	LED	POWER	I/O
				2.49
		5.12		5.95

TablE 3.3.4 -

(J3) “APC-800L-A-S01” I/O

CoNNECTOR,

DB-15 ReCEPTACLE

Pin Function

1Chassis GND

2RS-232 TX (data from APC to host), or 485A

3RS-232 RX (data from host to APC), or 485B

4N/C

5N/C

6N/C

7Digital GND

8N/C

9N/C

10N/C

11N/C

12Valve Closed input

13Digital GND

14\Valve Closed Output\

15TTL Output Common

	APC-OP-LIT 1/12
Call toll free 800-824-4166 or 530-842-4457 • FAX [phone]	9

Intellisys Adaptive Pressure Controllers

3.4 – DC Powered Controllers with Serial and Analog/TTL I/O Interface

Refer to the following diagram including models APC-100L-A

and tables when connecting to a DC powered APC controller , APC-200L-A, APC-300L-A, APC-700L-A and APC-800L-A.

TablE 3.4.1 – (J4) “APC-X00L-A”

AnALOG / TTL CoNNECTOR,

DB-25 ReCEPTACLE

Pin Function

1Chassis GND

2RS-232TX (data from IQ to host)

3RS-232RX (data from host to IQ)

4Analog CDG Out

5Analog GND

6Analog Valve Out

7Digital GND

8\Analog SP Control Select In\

9Analog SP+ In

10Analog SPIn

11Power RTN

12Power 24V in

13\CDG2 Select In\

14See NOTE below

15\Position Control Select In\

16N/C

17Analog GND

18\Close Valve In\

19\Open Valve In\

20Fault Out

21N/C

22\Valve Open Out\

23\Valve Closed Out\

24TTL Out Common

25Chassis GND

NOTE: For100L-A,200L-A and300L-Aseriescontrollers, pin

14 is defined as\HoldValve Select In\

TablE 3.4.2 - (SW1) “APC-X00L-A” DiP SwITCheS

Switch 1

Switch 2

Switch 3

Switch 4

OFF (up)

9600 baud

8 bit, no parity

1 stop bit

0-10 V Analog

TablE 3.4.3 - (J1) “APC-X00L-A”

in

VaLVE CoNNECTOR,

7 bit, even parity

0 to 5V

ON (down)

19200 baud

2 stop bits

DB-15 ReCEPTACLE

(1 stop bit only)

Analog in

Pin

SiGnal

AsSIGnment

Status LEDs

4.78

1

Drive A+

2

Drive A-

Status

3

Drive B-

4

Drive B+

LEDs

5

Sense B-

2.51

6

Sense B+

7

Sense A-

8

Sense A+

9

Reserved

5.69

5.74

10

Reserved

11

Reserved

12

Reserved

13

Reserved

TablE 3.4.4 - (J3) “APC-X00L-A”

14

Reserved

AuXILIARy CoNNECTOR,

15

Reserved

DB-15 ReCEPTACLE

TablE 3.4.5 - (J2) “APC-X00L-A”

Pin

Function

GaUGE CoNNECTOR,

DB-9 ReCEPTACLE

1

Not used

Pin

Function

2

RS-232 TX

(data from IQ

1

Signal input from gauge 1

to host)

3

RS-232 RX

(data from

2

+15 V supply to gauge

host to IQ)

3

-15 V supply to gauge

4

Digital GND

4

Not used

5

Power RTN

5

Signal input from gauge 2

6

Not used

6

Signal common from gauge 2

7

Power +24V in

7

Not used

8

Not used

8

Signal common from gauge 1

9

Analog CDG Out

9

Power supply common

10Analog Valve Out

11Analog GND

12TTL Out Common

13\Valve Open Out\

14\Valve Closed Out\

15Chassis GND

NOTE: For 700L-Aand 800L-A

series controllers, pin 14 is

defined as \Valve Initialization

Enable In\

APC-OP-LIT 1/12

10	Visit our Web Site www.n-c.com

Intellisys Adaptive Pressure Controllers

3.5 - DC Powered Controllers with Serial and DeviceNet I/O Interface

RefertothefollowingdiagramsandtableswhenconnectingtoanD/CpoweredAPCcontrollerincludingmodelsAPC-100L-D,APC-200L-D,APC-300L-D,APC-700L-Dand

APC-800L-D.

TablE 3.5.1 –
(J1) “APC-x00L-D”
DeVICENeT NeTWORk		Indicating LEDs
CoNNECTOR
Pin	Function	4.78
1	Drain
2	Power In +
3	Power In -
4	CAN H		2.51
5	CAN L
4	3
5
1	2	5.74	5.69

TablE 3.5.2 – (J2) “APC-x00L-D”

AuXILIARy CoNNECTOR,

DB-15 ReCEPTACLE

Pin Function

1Not used

2RS-232 TX (data from IQ to host)/485 (A)

3RS-232 RX (data from host to IQ)/485 (B)

4Digital GND

5Power RTN

6Not used

7Power +24V in

8Not used

9Analog CDG Out

10Analog Valve Out

11Analog GND

12TTL Out Common

13\Valve Open Out\

14\Valve Closed Out\

15Chassis GND

TablE 3.5.3 – (J3) “APC-x00L-D”

GaUGE CoNNECTOR,

DB-9 ReCEPTACLE

Pin # Function

1Signal input from gauge 1

2+15 V supply to gauge

3-15 V supply to gauge

4Not used

5Signal input from gauge 2

6Signal common from gauge 2

7Not used

8Signal common from gauge 1

9Power supply common

TablE 3.5.4 - (J4) “APC-x00L-D”

VaLVE CoNNECTOR,

DB-15 ReCEPTACLE

Pin SiGnal

AsSIGnment

1Drive A+

2Drive A-

3Drive B-

4Drive B+

5Sense B-

6Sense B+

7Sense A-

8Sense A+

9Reserved

10Reserved

11Reserved

12Reserved

13Reserved

14Reserved

15Reserved

	APC-OP-LIT 1/12
Call toll free 800-824-4166 or 530-842-4457 • FAX [phone]	11

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.

TablE 3.6.1 – (SW1) “IQA” DiP SwITCheS, DB-25 ReCEPTACLE

	Switch 1	Switch 2			Switch 3		Switch 4
OFF (up)	9600 baud	8 bit, no parity			1 stop bit		0 to 10 V Analog In
ON (down)	19200 baud	7 bit, even parity			2 stop bits		0 to 5 V Analog In
		(1 stop bit only)
		Indicating					Valve Open/Close
TablE 3.6.2 – (J3) “IQA”		LEDs				membrane switches
AuXILIARy CoNNECTOR,
DB-15 ReCEPTACLE

Pin Function

1Not used

2RS-232 TX (data from IQ to host)

3RS-232 RX (data from host to IQ)

4Digital GND

5Power RTN-

6Not used

7Power +24V in

8Not used

9Analog CDG Out

10Analog Valve Out

11Analog GND

12TTL Out Common

13\Valve Open Out\

14\Valve Closed Out\

15Chassis GND

POWER

ANALOG/TTL

CTRL

FAULT

AUXILIARY	GAUGE
SW1
TM

TablE 3.6.3 – (J2)

“IQA” GaUGE CoNNECTOR,

DB-9 ReCEPTACLE

Pin # Function

1Signal input from gauge 1

2+15 V supply to gauge

3-15 V supply to gauge

4Not used

5Signal input from gauge 2

6Signal common from gauge 2

7N/C

8Signal common from gauge 1

9Power supply common

TablE 3.6.4 – (J4) “IQA”

AnALOG/TTL CoNNECTOR,

DB-25 ReCEPTACLE

Pin Function

1Chassis GND

2RS-232TX (data from IQ to host)

3RS-232RX (data from host to IQ)

4Analog CDG Out

5Analog GND

6Analog Valve Out

7Digital GND

8\Analog SP Control Select In\

9Analog SP+ In

10Analog SPIn

11Power RTN

12Power +24V in

13\CDG2 Select In\

14See NOTE below

15\Position Control Select In\

16N/C

17Analog GND

18\Close Valve In\

19\Open Valve In\

20Fault Out

21N/C

22\Valve Open Out\

23\Valve Closed Out\

24TTL Out Common

25Chassis 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\

APC-OP-LIT 1/12

12	Visit our Web Site www.n-c.com

Intellisys Adaptive Pressure Controllers

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		Indicating LEDs	Valve Open/Close
	NeTWORk CoNNECTOR
				membrane switches
	Pin	Function
	1	Drain
	2	Power In +
	3	Power In -
	4	CAN H
	5	CAN L	AUXILIARY	GAUGE
	4	3
			TM
	5
	1	2

TablE 3.7.2 – (J2) “IQD”

AuXILIARy CoNNECTOR,

DB-15 ReCEPTACLE

Pin Function

1Not used

2RS-232 TX (data from IQ to host)/485 (A)

3RS-232 RX (data from host to IQ)/485 (B)

4Digital GND

5Power RTN

6Not used

7Power +24V in

8Not used

9Analog CDG1 Out

10Analog Valve Out

11Analog GND

12TTL Out Common

13\Valve Open Out\

14\Valve Closed Out\

15Chassis GND

TablE 3.7.3 – (J3) “IQD”

GaUGE CoNNECTOR,

DB-9 ReCEPTACLE

Pin # Function

1Signal input from gauge 1

2+15 V supply to gauge

3-15 V supply to gauge

4Not used

5Signal input from gauge 2

6Signal common from gauge 2

7Not used

8Signal common from gauge 1

9Power supply common

	APC-OP-LIT 1/12
Call toll free 800-824-4166 or 530-842-4457 • FAX [phone]	13

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.

Vacuum

AC or DC power supply

gauge(s)

Vacuum Chamber

Nor-Cal

APC Controller

throttle

valve

Host system with

RS232/485 or DeviceNet

Pump

communications

FiGURE 4.1 – TypICAL iNSTALLATION aND cONFIGURATION oF a buRIED boX InTELLISys dOWNSTREAm pRESSURE cONTROL sysTEm

Vacuum
gauge(s)	Vacuum Chamber

									Nor-Cal
DC power supply									IQ-series
									Valve
Host system with
RS232/485 or DeviceNet							Pump
communications

FiGURE 4.2 – TypICAL iNSTALLATION aND cONFIGURATION OF aN IQ pRESSURE cONTROL 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.

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.

APC-OP-LIT 1/12

14	Visit our Web Site www.n-c.com