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. 1967 So. Oregon Yreka, CA 96097 USA Tel: 800-824-4166 or 530-842-4457 Fax: 530-842-9130 www.n-c.
Intellisys Adaptive Pressure Controllers Table of Contents 1.0............. Introduction...............................................................................................................................................4 2.0............. Device Specification...................................................................................................................................5 3.0............. Unpacking and Installation..................................................................
Intellisys Adaptive Pressure Controllers List of Tables 2.1....... APC Controller General Equipment Specifications............5 2.2 ...... APC Controller Analog TTL I/O.........................................5 2.3....... APC Controller RS-232 Serial I/O......................................5 2.4....... APC Controller Performance............................................5 2.5....... APC Controller Reliability.................................................5 3.1.1.... (J3&J4) “APC-X50-A” Gauge Connector..
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.
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 Table 2.
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.
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, APC750-A and APC-850-A. Table 3.1.1 - (J3 & J4) “APC-X50-A” Gauge Connector DB-9 Receptacle (identical pinouts) Pin Pin Signal Assignment 3.
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, APC700-A and APC-800-A. Table 3.2.
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 Table 3.3.
Intellisys Adaptive Pressure Controllers 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 OFF (up) Table 3.4.
Intellisys Adaptive Pressure Controllers 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 Indicating LEDs 4.78 2.51 3 4 5 1 2 Table 3.5.
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 3.6.4 – (J4) “IQA” Analog/TTL Connector, DB-25 Receptacle Table 3.6.1 – (SW1) “IQA” Dip Switches, DB-25 Receptacle OFF (up) ON (down) 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 Table 3.6.
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 Network Connector Pin Valve Open/Close membrane switches Indicating LEDs Function 1 Drain 2 Power In + 3 Power In - 4 CAN H 5 CAN L AUXILIARY GAUGE 3 4 TM 5 1 2 Table 3.7.
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).
Intellisys Adaptive Pressure Controllers 5.0 - APC Controller Module Interfaces APC controllers have several interfaces available for communications and connectivity to peripheral devices, depending on model. These are described by function below. Please also refer to Figures 3.1 – 3.5 and their associated Tables for the specific connectors and their pin assignments.
Intellisys Adaptive Pressure Controllers 6.0 - RS-232 Serial Interface and Commands Interface basics All APC controllers support RS-232 serial communications available though one or more interface ports. A full description of the communications protocol and a listing of all active serial commands follows in this section. But first, a three-wire connection needs to be completed to provide the communications lines, with Rxd (data from the APC), Txd (data to the APC) as well as signal common on.
Intellisys Adaptive Pressure Controllers 6.0 - RS-232 Serial Interface and Commands (continued) Modifying the Setpoint The APC controller normally has five programmable set point selectable to be either pressure control or valve position control. Before using the set point to control either pressure or valve position, the set point value must be programmed. This is done by the following command: S1xx.xx where xx.xx is a number from 0.00 to 100.00. One or no decimal places may also be used i.e. x.x or x.
Intellisys Adaptive Pressure Controllers 6.0 - RS-232 Serial Interface and Commands (continued) Activating Dual Pressure Sensor Configuration Reading the Pressure Sensor Configuration When two pressure gauges are attached to the APC controller, the controller can operate in three distinct modes of operation. The full scale setting of the CDG’s can only be accessed through the serial port.
Intellisys Adaptive Pressure Controllers 7.0 - Analog / TTL Interface This section details the Analog/TTL interface. Each function is listed in alphabetical order for easy identification. NOTE: Not every function is available on all controller models – please refer to the connector and pin information in Section 3. Analog CDG Out The signal from the CDG input can be monitored on this pin. It should be referenced to Analog Ground.
Intellisys Adaptive Pressure Controllers 7.0 - Analog / TTL Interface (continued) \Position Control Select In\ Position Control Select is an ACTIVE LOW TTL input that should be referenced to Digital Ground. Pulling this pin low will cause the APC controller to use the analog set-point value as a position command, provided that \Analog Set Point Control Select\ is also pulled low. Leaving it high will by default cause the controller to perform pressure control.
Intellisys Adaptive Pressure Controllers 7.0 - Analog / TTL Interface (continued) User Examples Dual Gauge Operation Below are examples of the most common modes of operation. Please contact Nor-Cal Products technical support for other types of uses. For applications where there is a wide range of control pressures, the use of two differently ranged gauges may be advantageous.
Intellisys Adaptive Pressure Controllers 8.0 - DeviceNet Interface 8.1. Overview and setup DeviceNet is a network communication protocol that provides a cost-effective solution to low-level device networking for semiconductor equipment tools with power and signal in the same cable. Process data and other information such as configuration parameters can be communicated for up to 64 nodes per network at data rate up to 500K baud.
Intellisys Adaptive Pressure Controllers Required Hardware: A DeviceNet network is composed of a host controller, a bus and one or more slave devices. The master node or host controller is commonly composed of a computer equipped with a DeviceNet interface card. The bus is made of cable connectors and junctions generally arranged in trunkline-dropline configuration as shown in Figure 8.4. Interface and bus system part numbers are given as indication only.
Intellisys Adaptive Pressure Controllers 8.2 - Establishing a DeviceNet connection This section describes how to communicate and control the IQD using the DeviceNet port. DeviceNet has two basic message types: Explicit and I/O messaging. Explicit Messaging: Explicit messages are used to read or write an individual piece of information in the device. They are mainly used for initial configuration.
Intellisys Adaptive Pressure Controllers How to read system pressure and valve position: • • • • • • • Select the service code 0E (get attribute) Select class ID 31 (select the s-analog sensor object) Select instance ID 1 (process input CDG1) Select attribute ID 6 (value attribute) The device will respond with data bytes 00 00 meaning that the measured pressure is 0 Select instance ID 3 (valve position) Select attribute ID 6 (value attribute)The device will respond with data bytes FF 7F meaning that the v
Intellisys Adaptive Pressure Controllers 9.0 - DeviceNet Device Profile Figure 9.
Intellisys Adaptive Pressure Controllers 9.1 - Identity Object Class ID 1 hex Instance ID 1 • Vendor ID: Assigned number to Nor-Cal Products Inc. is 612 • Device type: The value of 1Dhex is used for process control valve (cf. specification volume II, page 3-153) • Product code: Nor-Cal Products attributes a specific product code as a function of the valve size or type, Listed to the right in Table 9.12 is the list of current product codes: Table 9.1.
Intellisys Adaptive Pressure Controllers 9.4 - Assembly Object Class ID 4 hex Instance ID (see static assembly Table 9.5.1 and 9.5.2) Table 9.4.1 – Assembly Object Attributes Attribute ID hex Access Code Name Format Value 3 0E (get) 10 (set) Data ARRAY Static assembly Get or set service selectively supported as a function of the selected instance in the connection object. 9.5 - I/O Assembly Instances Table 9.5.1 - Input Assembly Instances Table 9.5.
Intellisys Adaptive Pressure Controllers 9.8 - S - Device Supervisor Object Class ID 30 hex Instance ID 1 Table 9.8.2 – S-Device Supervisor Object Exception Status Bit Map Table 9.8.1 – S-Device Supervisor Object Attributes Attribute IDhex Access Code Bit function Name Format Value 3 0E (get) Device Type Short string “PCV” (ROM) 0 Alarm device common 4 0E (get) SEMI rev.
Intellisys Adaptive Pressure Controllers 9.9 - S-Analog Sensor Object Class ID 31 hex • The process input value is a signed 16-bit integer encoded with least significant byte first and scaled according to 6000hex = 100% of full scale sensor reading 0000hex = 0 • The process input signal acquisition range is currently limited to the bracket [–1.5% to 101.5%].
Intellisys Adaptive Pressure Controllers 9.10 - S-Analog Actuator Object Class ID 32 hex Instance ID 1 Table 9.10.1 – S-Analog Actuator Object Attributes Attribute ID hex Access Code Name Format 5 10 (set) Override UINT 6 0E (get) Value INT 7 0E (get) Status BYTE Value Override for the valve 0 = closed; 7FFFh=open Table 9.10.
Intellisys Adaptive Pressure Controllers 9.12 - Selection Object Class ID 2E hex Instance ID 1 (setpoint) • Attribute 5 determines the selection between pressure control or valve control (1 for pressure control, 2 for position control), default is 1 after reset. • A change on attribute 5 only becomes effective once a new setpoint is sent (attribute 9) Table 9.12.
Intellisys Adaptive Pressure Controllers 10.0 - LCD Front Panel Interface Controller models with a part number in the form APC-x50-A have a touch screen LCD front panel interface, in addition to a Serial and Analog/TTL port. On these models, the functionality of the Serial and Analog/TTL interfaces is identical to that previously described in sections 6.0 and 7.0 of the APC-OP Manual. This section is dedicated to describing the use and operation of the front panel touch screen.
Intellisys Adaptive Pressure Controllers 10.1 Commonly Used Function Buttons Navigating through the various menus of the front panel LCD interface, the user will find that some functions and associated buttons are used in more than one place. This includes the SAVE, SET VALUE, BACK SPACE, CLEAR, BACK and EXIT functions. The SAVE function is generally found on set-up type screens. This button must be pressed before exiting to another page allowing the set-up information to be stored in NVRAM.
Intellisys Adaptive Pressure Controllers 10.2 Basic Operation (continued) The MAIN MENU page simply serves as a central node used in navigation to the various sub menu pages.
Intellisys Adaptive Pressure Controllers 10.3 CONFIGURE SETPOINTS CONFIGURE SETPOINTS is the first sub-menu directly accessible from the MAIN MENU screen. Figure 10.2 shows a navigation tree detailing this part of the function software. MAIN MENU Figure 10.2 – CONFIGURE SETPOINTS Navigation Tree More similar ones for SET GAIN, SET PHASE and SET The SELECT SETPOINT page allows the user to choose which set-point is to have its parameters manipulated.
Intellisys Adaptive Pressure Controllers 10.3 CONFIGURE SETPOINTS (continued) The SELECT ATTRIBUTE page for each setpoint allows the user to pick which attribute(s) to program. Pressing SETPOINT will bring up a number pad screen via which a numerical value can be given to the setpoint.
Intellisys Adaptive Pressure Controllers 10.4 UTILITY MENU The UTILITY MENU is another sub-menu directly accessible from the MAIN MENU screen. Figure 10.3 shows a navigation tree detailing this part of the function software. MAIN MENU more... Figure 10.3 – UTILITY MENU Navigation Tree APC-OP-LIT 1/12 38 Visit our Web Site www.n-c.
Intellisys Adaptive Pressure Controllers 10.4 UTILITY MENU (continued) The UTILITY MENU page simply serves as the means to reach the five functions contained under this category, including INITIALIZE VALVE, RESET CONTROLLER, DIAGNOSTIC INFORMATION, REMOTE MODE and DISPLAY UTILITIES. Pressing the INITIALIZE VALVE button on the UTILITY MENU page brings up the CONFIRM VALVE INITIALIZATION dialogue screen.
Intellisys Adaptive Pressure Controllers 10.5 CONFIGURE DISPLAY UNITS The ability to CONFIGURE DISPLAY UNITS is directly accessible form the MAIN MENU. This screen allows the user to change engineering units for both pressure and valve position. Also, this page is used to set the full scale range of each gauge used. Please make sure to press the SAVE button prior to exiting back to the MAIN MENU.
Intellisys Adaptive Pressure Controllers 11.0 - Battery Back-Up Some APC models are available with a power safe battery back-up option. When installed, this feature will drive the valve closed in the event of a power interruption to the APC controller. This is more commonly of interest when throttling gate- or pendulum valves are used, because these valves typically also serve as the vacuum line isolation valve.
Intellisys Adaptive Pressure Controllers 12.0 - Product Support WARNING: When working with or troubleshooting Nor-Cal APC products extreme care must be taken to avoid putting bodily parts in or near the valve gate mechanism or other moving parts. These may move suddenly and unexpectedly, and many of them are driven with sufficient force so as to cause significant harm and possibly even dismemberment.
Intellisys Adaptive Pressure Controllers Table 12.2 – Valid Status LED Combinations Table 12.2 Key O G FG R FR A = = = = = = LED Off Green Flashing Green Red Flashing Red Amber Mod Net Ctrl Fault OPEN/ CLOSE O O O O O/O All LEDs off. IQD is not receiving power, or internal software is corrupt. G G G A G/G All LEDs on. This is valid for about 1 second after power-up for initial check-up sequence. G O O O O/O Mod, only, is illuminated (green) during initialization sequence.
Intellisys Adaptive Pressure Controllers APPENDIX I – Spare Parts and Ordering Information To make the completion of an Intellisys downstream pressure control system easy, Nor-Cal Products offers a comprehensive selection of cables and related accessories. These include signal and communications cables, power cords, power supplies as well as spare parts.
Intellisys Adaptive Pressure Controllers Appendix II - Limited Warranty and Intellectual Property Coverage Products manufactured by Nor-Cal Products, Inc. (hereinafter referred to as “Nor-Cal”) are warranted against defects in material and workmanship for a period of twelve (12) months from the date of shipment from Nor-Cal to the buyer. Any modification to the product by the buyer or their agent voids this warranty.
