Halma ALICAT SCIENTIFIC PC Operating Manual
Pressure controllers
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Summary of Contents for Halma ALICAT SCIENTIFIC PC
- Page 1 OPERATING MANUAL FOR PRESSURE CONTROLLERS Models PC · PCS · PC3 · PC3S · PCR · IVC · EXTSEN...
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Page 2: Introduction
• +1 888-290-6060 India China & SE Asia Europe india@alicat.com info-cn@alicat.com europe@alicat.com Halma India Pvt. Ltd. alicat.com.cn Geograaf 24 Plot NO. A-147, Road No. 24, 2nd Floor, Block 63, No. 421, 6921 EW Duiven Next to Spraytech Circle Hong Cao Rd, The Netherlands opp. -
Page 3: Recalibration
Introduction Your new pressure controller has a variety of innovative features: • 1000 readings per second ensures high resolution data. • Backlit display with adjustable contrast is easy to read in direct sunlight. In dimly lit areas, press the bottom-center logo to turn on the backlight (see page •... -
Page 4: Table Of Contents
Contents Introduction Recalibration Getting Started The Pressure Controller Display Status Messages Mounting Process Ports Filters Operating Pressure Connecting Plumbing to Your Pressure Controller Applications Valve Orientation Special Configurations Differential Pressure Integrated Vacuum Controllers (IVC) Remote-Sensing Controller Using Alicat Pressure Instruments with Fluids Power and Signal Connections RS-232 or RS-485 Digital Signals Engineering Units... - Page 5 Serial Communication Establishing Communication Polling Mode Streaming Mode Taring Collecting Pressure Data Commanding a New Setpoint Sending Setpoints as Floating Point Numbers Sending Setpoints as Integers Quick Command Guide Troubleshooting Maintenance Cleaning Recalibration Engineering Units Pinouts 8-Pin Mini-DIN (Default) Locking Industrial Connector Pinout 9-pin D-Sub Connector Pinouts M12 Connector Pinouts 15-Pin D-Sub Connector Pinouts...
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Page 6: Getting Started
Getting Started Getting to Know Your Pressure Controller Connectors and Buttons The drawings below represent a typical configuration of a pressure controller. Your device’s appearance and connections may differ. I/O Port (shape varies) Controls PSIG SETPT +0.0000 +0.0000 Display PSIG +0.0000 Valve Ga Press... -
Page 7: Status Messages
The Pressure Controller Display The figure below identifies the various features of the main pressure controller display. Press the button behind the Alicat logo to toggle the backlight on and off. Live data is measured 1000 times per second, and is typically displayed 10 times per second on the device’s LCD screen. -
Page 8: Mounting
Mounting All pressure controllers have mounting holes under the base for convenient attachment to flat panels. No straight runs of pipe are required upstream or downstream. Standard controllers are position insensitive and can be mounted in any orientation. ▲ Caution: Pressure controllers that use large Rolamite valves (PCR, PCR3, PCRS) should be mounted with their valve oriented vertically (right-side up). -
Page 9: Applications
Applications Valve Orientation Your pressure controller will control process pressure to whatever side the pressure sensor is exposed to. Pressure Control Application, Upstream Valve (downstream pressure control) With the valve located on the upstream side, the sensor will be exposed downstream, therefore it will control pressure downstream. -
Page 10: Special Configurations
Special Configurations PC-Series pressure controllers are occasionally ordered with special configurations to work in specialized ways: Differential Pressure PC-PSID Series pressure devices monitor and control the differ- ential pressure between two points in the system. These devices have two ports located on the front face of the unit for connection to two points in the system where the differential... -
Page 11: Integrated Vacuum Controllers (Ivc)
Remote-Sensing Controller PC3 -Series models sense and control the pressure at some point in the system outside the pressure controller itself. All PC-Series control- lers can be ordered with an addi- tional NPT port on the front, which is connected directly to the pressure sensor in the device. -
Page 12: Remote-Sensing Controller
Integrated Vacuum Controllers (IVC) IVCs are similar to our PC-Series absolute pressure controllers in functionality and in the navigation menu available on the screen. IVC devices are used in applications where precise control of vacuum is required, and are available with the following sensor packages: •... -
Page 13: Power And Signal Connections
Power and Signal Connections Power can be supplied to your controller through either the power jack or the multi-pin connector on top of your device, depending on configuration. ✓ Note: Controller power jacks require a 12–30 Vdc power supply with a 2.1 mm female positive-center plug capable of supplying at least 250 mA, with an additional 40 mA for a color display. -
Page 14: Rs-232 Or Rs-485 Digital Signals
RS-232 or RS-485 Digital Signals DB9 to 8-Pin Mini-DIN Connection for RS-232 or RS-485 Signals 8-Pin Mini-DIN Female DB9 Male 9-Pin Serial Connection 8-Pin Mini-DIN Connection Function Function Ground Ground Transmit Receive Receive Transmit To use the RS-232 or RS-485 digital signal, connect the Output Signal (Pin 5), the Input Signal (Pin 3), and Ground (Pin 8) to your serial port as shown below. -
Page 15: Engineering Units
Engineering Units The device’s units of measurement are handled in two ways: Button engineering units are the units of measurement on the front display. For the standard pressure controller, the default units are PSIG (gauge), PSIA (absolute), or PSID (differential). Low pressure controllers may include default units of inH₂OG, inH₂OD, or torrA. -
Page 16: Option: Color Tft Display
Option: Color TFT Display Multi-Color Display Indicators • GREEN: Parameter labels and adjustments associated with the button directly above or below the label are presented in green. • WHITE: Parameters operating under normal conditions. • RED: Parameters with values exceeding 128% of the device’s specifications. -
Page 17: Navigation & Customization
Navigation & Customization Main Menu The Main Menu system is accessed by MENU pressing the button from the Main Display (page • CONTROL (page 18), ABOUT (page 27), TARES (below), BASIC CONFIG (page 28), and ADV SETUP (page 29) enter their menus. •... -
Page 18: Control Menus
Control Menus CONTROL ADV CONTROL menus allow you to command new setpoints, change the setpoint control loop, and adjust proportional, integral, and derivative (PID) control settings, among other options. → Menu Control SETPT RAMP • activates and sets the speed of setpoint ramping (page 22). - Page 19 Control Options The control options menu allows the user to enable ramping in either direction, establish a control deadband, or create setpoint limits. → → → Menu Control Advanced Control Control Options RAMP ENABLE • Defines the conditions when setpoint ramping will be active (page 22).
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Page 20: Changing The Setpoint
Changing the Setpoint A setpoint is the amount of pressure the controller will attempt to match by opening or closing its valve. Press the SETPT button on the Main Display (page 7) or Control Menu → MENU CONTROL , previous page) to choose a new setpoint. The setpoint selection screen indicates the engineering units and maximum allowable setpoint (e.g., PSIG 10.00 Max... -
Page 21: Establishing Setpoint Limits
Establishing Setpoint Limits The Setpoint Limits Menu configures upper and lower limits (within the device’s overall capabilities) for selecting a pressure control setpoint. • When using the front panel, if you try to command a new setpoint that is outside of the upper and lower limits, the display notifies you that the requested setpoint is out of range. -
Page 22: Setpoint Ramping
Setpoint Ramping Setpoint ramping determines how quickly your pressure controller will reach the requested pressure setpoint. In practice, this might be used to prevent sudden bursts of pressure or flow from hitting delicate instruments when starting up a process. To activate setpoint ramping, set a maximum ramp rate and configure when to enable the ramping function. - Page 23 Enabling Setpoint Ramping Overrides → → → → Menu Control Advanced Control Control Options → Ramp Enable More Options MORE OPTS button lets you configure overrides for the ramping function for two independent scenarios: • POWER ON toggles whether the device should use the ramping setting that was last in use when it was turned off, when...
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Page 24: Adjusting The Closed Loop Controller
Adjusting the Closed Loop Controller Your pressure controller uses an electronic closed loop algorithm to determine how to actuate its valve in order to achieve the commanded setpoint. We have tuned these settings for your specific operating condi- tions, but changes to your process sometimes require on-site adjustments to maintain optimal control performance. - Page 25 Tuning the PD/PDF control algorithm The controller’s default control algorithm (PD) employs pseudo-derivative feedback (PDF) control, which uses two editable variables: • The larger the D gain, the slower the controller will correct errors between the commanded setpoint and the measured process value. This is equivalent to the P variable in common PDF controllers.
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Page 26: Troubleshooting Valve Performance With Pid Tuning
Troubleshooting valve performance with PID tuning The following issues can often be resolved by adjusting the PID gain values for your pressure controller. Fast oscillation around the setpoint • PD: Reduce the P gain in decrements of 10% • PD²I: Increase the P gain in increments of 10%, and then adjust the I gain to fine-tune. -
Page 27: Device Information
Device Information → Menu About • DEVICE INFO displays serial number, firmware, and calibration information. DEVICE STATE • shows information for troubleshooting (see below). • MFG INFO displays manufacturer contact information. • BACK returns to the Main Menu (page 17). About Menu MAIN •... -
Page 28: Basic Configuration Menu
Basic Configuration Menu Engineering Units There are two types of engineering units: • Button Engineering Units: Changes the units on the front display only. • Device Engineering Units: Changes the units on the front display and serial data frame. 1: Basic Configuration Menu 2: Parameters in Device Units Menu 3: Available Pressure Engineering Units 4: Confirming Device Engineering Units... -
Page 29: Advanced Setup
Advanced Setup → Menu Advanced Setup • SENSOR SETUP (page 30), COMM SETUP (page 31), DISP SETUP (below) enter their respective menus. BACK • returns to the top-level Main Menu (page 17). • MAIN exits to the Main Display (page Advanced Setup Menu Display Setup →... -
Page 30: Sensor Setup
Sensor Setup → → Menu Advanced Setup Sensor Setup • DISPLAY AS ZERO (zero band) defines a pressure under which values are displayed as zero, and displays the current setting. The maximum zero band is 6.38%. NUM OF DIGITS • sets the number of digits of pressure readings to display on-screen and in the serial... -
Page 31: Configuring Serial Communications
Configuring Serial Communications → → Menu Advanced Setup Comm Setup Unit ID The unit ID is the identifier that a computer uses to distinguish a controller from other devices when it is connected to a network. Using the unit ID letters A–Z , you can connect up to 26 devices to a computer at the same time via a single... -
Page 32: Serial Communication
Serial Communication Connecting your device to a computer allows you to log the data that it generates. The pressure controller communicates digitally through its communications connector and cable using a real or virtual COM port on your computer. This section of the manual shows you how to operate the flow controller using ASCII commands. -
Page 33: Polling Mode
✓ Note: In what follows, indicates an ASCII carriage return (decimal 13, hexadecimal D). For many devices, this is the same as hitting the Enter key. Serial commands are not case-sensitive. Polling Mode Your controller is shipped in polling mode with a unit ID of , unless requested otherwise. -
Page 34: Taring
Taring Be sure to tare your pressure controller before collecting data. If auto-tare is enabled, provide a zero setpoint until auto-tare activates, usually after a few seconds, depending on the device’s full-scale pressure. The controller can also be tared from the front panel. See page Serial commands can be used to manually tare the device: Taring pressure aligns the internal gauge pressure sensor with the current... -
Page 35: Commanding A New Setpoint
Commanding a New Setpoint Before attempting to send setpoints to your pressure controller serially, confirm that its setpoint source is set to Serial/Front Panel by selecting → → → MENU CONTROL ADV CONTROL SETPT SOURCE There are two ways to command a new setpoint over a serial connection, as described below. -
Page 36: Quick Command Guide
Quick Command Guide ✓ Note: Serial commands are not case-sensitive. In these examples, the unit ID of the controller is [current unit ID]@=[desired unit ID] Change unit ID: Tare pressure: ap Poll the live data frame: a Begin streaming data: a@=@... -
Page 37: Troubleshooting
Troubleshooting If you run into trouble with your device’s installation or operation, please get in touch with us (see page 2). You’ll also find help on our website alicat.com and in the pages that follow. General Use Issue: My controller does not turn on or has trouble staying on. Action: Check power and ground connections. - Page 38 Pressure Readings Issue: My controller won’t reach its setpoint. Action: You must ensure that there is enough supply pressure to reach the setpoint. If increasing the pressure doesn’t help, check to see if there is a clog. Teflon tape can get stuck in the flow channel and block flow (see page 8).
- Page 39 Serial Communications Issue: My computer can’t communicate with the controller. Action: 1. Make sure the baud rate and other serial settings such as the COM port number are the same as your controller (see page 31). 2. Check the pressure controller unit’s serial ID (also on page 31).
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Page 40: Maintenance
Maintenance Cleaning This device requires minimal maintenance. If necessary, the outside of the device can be cleaned with a soft, dry cloth. Avoid excess moisture or solvents. The primary cause of damage and/or long-term inaccuracy in these devices is contamination and/or corrosion damage. Gases and liquids should be filtered for particulates or biological materials that may grow in the device. -
Page 41: Engineering Units
Engineering Units Pressure Units Absolute Gauge Differential Notes pascal hPaA hPaG hPaD hectopascal kPaA kPaG kPaD kilopascal MPaA MPaG MPaD megapascal mbarA mbarG mbarD millibar barA barG barD g/cm2A g/cm2G g/cm2D gram force per square centimeter kg/cmA kg/cmG kg/cmD kilogram force per square centimeter PSIA PSIG PSID... -
Page 42: Pinouts
Pinouts Check the calibration data sheet and pinout for your device. page 32 for additional important information about connecting your device to a computer for serial commands. Individual pinouts available at alicat.com/pinout. 8-Pin Mini-DIN (Default) Female Connector: Device Male Connector: Cable Pin Cable Color Function Not Connected... -
Page 43: Locking Industrial Connector Pinout
Locking Industrial Connector Pinout Male Connector: Cable Female Connector: Device Function Power In (+) RS-232TX / RS-485 B RS-232RX / RS-485 A Analog Setpoint Input Ground (common for power, communications, and signals) Analog Out (voltage or current as ordered) ✓ Note: The availability of different output signals depend on the options ordered. -
Page 44: 9-Pin D-Sub Connector Pinouts
9-pin D-Sub Connector Pinouts Female Connector Male Connector Common 9-pin D-Sub Pinouts DB9 (Female) DB9A / DB9M (Male) DB9K DB9R DB9T DB9U Current Out TX or B TX or B RX or A Analog Out 2 Analog Out Analog Out Analog Out Analog Out RX or A... -
Page 45: M12 Connector Pinouts
M12 Connector Pinouts Common M12 Pinouts Pin M12 M12MD 0–5 Vdc Output Signal Not Connected Optional: 1–5 or 0–10 Vdc Optional: 4–20 mA primary output signal Static 5.12 Vdc Optional: Secondary analog output Power In (4–20 mA, 0–5 Vdc, 1–5 Vdc, 0–10 Vdc) or basic alarm Serial RS-232 RX signal Serial RS-232 RX Signal... -
Page 46: 15-Pin D-Sub Connector Pinouts
15-Pin D-Sub Connector Pinouts Female Connector: Cable Male Connector: Device Common 15-pin D-Sub Pinouts DB15 DB15A DB15B DB15H DB15K DB15O DB15S Ground Ground Ground Ground Ground Analog Out Analog Out Analog Out RX or A Analog Out Analog Out Ground Analog In Ground Analog Out... -
Page 47: Additional Information For Csa And Atex Approved Devices
Additional Information for CSA and ATEX Approved Devices II 3 G Ex ec IIC T4 Gc Sira 19ATEX4045X Class I, Division 2, Group A, B, C and D, T4 24 Vdc, 0.800A maximum • T −40°C to +60°C Ex ec IIC T4 Gc Class 1, Zone 2 AEx ec IIC T4 Gc CSA 08CA2009485X CSA and ATEX approved devices are equipped with a 6-pin locking industrial connector, but may be ordered... -
Page 48: Limited Lifetime Warranty
Limited Lifetime Warranty Notice: Alicat Scientific, Inc. reserves the right to make any changes and improvements to the products described in this manual at any time and without notice. This manual is copyrighted. This document may not, in whole or in part, be copied, reproduced, translated, or converted to any electronic medium or machine readable form, for commercial purposes, without prior written consent from the copyright holder. - Page 49 PRESSURE CONTROLLER operating manual...
- Page 50 Main Menu Accessible from MENU on the Main Display • Control (page • Setpoint ramping • Setpoint setting • Advanced Control • Setpoint source • Loop setup • Control options • About (page • Device information • Manufacturer information • Device state •...