Aalborg DPC User manual

OPERATING MANUAL
Aalborg®DPC
Digital Mass Flow Controllers
Technical Data Sheet No. TD-DPC-0F Date of Issue: October 2020

Aalborg® is a registered trademark of Aalborg® Instruments & Controls.
NOTE: Aalborg® reserves the right to change designs and dimensions at its sole
Discretion at any time without notice. For certied dimensions please contact Aalborg®.

TABLE OF CONTENTS
1. Unpacking the DPC Mass Flow Controller.......................................
1.1 Inspect Package for External Damage....................................................
1.2 Unpack the Mass Flow Controller..........................................................
1.3 Returning Merchandise for Repair.........................................................
2. INSTALLATION........................................................................
2.1 Safety Instructions.................................................................................
2.2 Primary Gas Connections..........................................................................
2.3 Pressure Requirements.........................................................................
2.3.1 DPC 07/17/37/47/57/67/77 Pressure Requirements.......................
2.3.2 DPC04/14 "BREEZE" low differential pressure models......................
2.4 Mounting.................................................................................................
3. ELECTRICAL CONNECTIONS.......................................................
3.1 Power Supply Connections.....................................................................
3.2 Analog Set Point Input Signals Connections..........................................
3.3 Analog Output Signals Connections......................................................
3.4 Digital Communication Interface Connections.......................................
4. PRINCIPLE OF OPERATION........................................................
5. SPECIFICATIONS...................................................................
5.1 CE Compliance.......................................................................................
5.2 DPC Accessories...................................................................................
6. OPERATING INSTRUCTIONS......................................................
6.1 Preparation and Power Up.....................................................................
6.2 Swamping Condition...............................................................................
6.3 Instrument Process Information (PI) Screens........................................
6.4 Local User Interface Menu Structure......................................................
6.4.1 Parameter Entry................................................................................
6.4.2 Submenu “Change PP Password”...................................................
6.4.3 Instrument Set Point and Valve Control...........................................
6.4.4 Submenu "Control PID Parameters".................................................
6.4.5 Submenu “Device Information”........................................................
6.4.6 Submenu “Units of Measure”...........................................................
6.4.7 Submenu “User-Defined Units”........................................................
6.4.8 Submenu “Select Gas”....................................................................
6.4.9 Submenu “User-Defined Mixture”...................................................
6.4.10 Submenu “Gas Flow Alarm”...........................................................
6.4.11 Submenu “Gas Pressure Alarm”...................................................
6.4.12 Submenu “Gas Temperature Alarm”...............................................
6.4.13 Totalizers Settings..........................................................................
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6.4.14 Submenu “Pulse Output”.............................................................
6.4.15 General Settings..........................................................................
6.4.15.1 Valve Parameters......................................................................
6.4.15.2 STP/NTP Conditions..................................................................
6.4.15.3 Display and Process Information (PI) Screens..........................
6.4.15.4 Submenu “Communication Port Settings”................................
6.4.15.5 Submenu “Modbus Interface” (optional)...............................
6.4.15.6 Relay Assignment..................................................................
6.4.15.7 Analog Output Configuration..................................................
6.4.15.8 Analog Input Configuration....................................................
6.4.15.9 Status LED Settings................................................................
6.4.15.10 Signal Conditioner Settings.................................................
6.4.15.11 Program Set Point................................................................
6.4.16 Sensor Zero Calibration.................................................................
6.4.16.1 DP Sensor Zero Calibration..................................................
6.4.16.2 Start AP Auto Tare..................................................................
6.4.17 Submenu “Alarms and Diagnostic”..............................................
6.4.17.1 Alarm Event Register..............................................................
6.4.17.2 Diagnostic Events Register.....................................................
6.4.17.3 Sensors ADC Reading (read only)..........................................
6.4.17.4 Temperature Sensors Diagnostic (read only)..........................
6.4.17.5 Analog Output & PO Queue Diagnostic (read only)...............
6.4.17.6 Solenoid Valve Parameters Diagnostic (read only)................
6.4.17.7 Reference Voltage & DSP Calculation Diagnostic .................
6.5 Multi-Functional Push-Button Operation...............................................
7. MAINTENANCE.......................................................................
7.1 General...............................................................................................
7.2 Cleaning.............................................................................................
8. RECALIBRATION...................................................................
9. RS485/RS232 SOFTWARE INTERFACE COMMANDS.........................
9.1 General............................................................................................
9.2 Commands Structure......................................................................
10. TROUBLESHOOTING................................................................
10.1 CommonConditions.............................................................................
10.2 Troubleshooting Guide........................................................................
10.3 Technical Assistance..........................................................................
Appendix I: Component Diagram.....................................................................
Appendix II: Dimensional Drawings.................................................................
Appendix III: Warranty.......................................................................................
Appendix IV: Index of Figures...........................................................................
Appendix V: Index of Tables.............................................................................
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1
1. UNPACKING THE DPC MASS FLOW METER
1.1 Inspect Package for External Damage
Your DPC Mass Flow Controller was carefully packed in a sturdy cardboard carton, with
anti-static cushioning materials to withstand shipping shock. Upon receipt, inspect the
package for possible external damage. If the unopened package is damaged, contact the
shipping company immediately to make a report.
1.2 Unpack the Mass Flow Meter
Open the carton carefully from the top and inspect for any sign of concealed shipping dam-
age. In addition to contacting the shipping carrier please forward a copy of any damage
report to your distributor or Aalborg®directly.
When unpacking the instrument please make sure that you have all the items indicated on
the Packing List. Please report any shortages promptly.
1.3 Returning Merchandise for Repair
Please contact the customer service representative of your distributor or Aalborg®if you
purchased your Mass Flow Meter directly, and request a Return Authorization Number
(RAN). Equipment returned without an RAN will not be accepted. Aalborg®reserves the
right to charge a fee to the customer for equipment returned under warranty claims if the
instruments are tested to be free from warrantied defects. Shipping charges are borne by the
customer. Meters returned “collect” will not be accepted!
It is mandatory that any equipment returned for service be purged of any hazardous con-
tents including, but not limited to, toxic, infectious, corrosive or radioactive material.
No work shall be performed on a returned product unless the customer submits a fully
executed and signed SAFETY CERTIFICATE. Contact the Service Manager at your distribu-
tor or at Aalborg to obtain this form prior to returning the product.
2. INSTALLATION
2.1 Safety Instructions
Aalborg®warranties and all other responsibilities by direct or implied
are voided if users fail to follow all instructions and procedures
described in this manual.
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LIFE SUPPORT APPLICATIONS: The DPC is not designed for use in life
support applications where malfunctioning of the device may cause
personal injury. Customers using or selling this device for use in such
applications do so at their own risk and agree to be fully responsible for
any damages resulting from improper use or sale.
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2

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CAUTION Some of the IC devices used in the DPC are static-sensitive and
may be damaged by improper handling. When adjusting or servicing the
device, use of a grounded wrist strap is recommended to prevent inadvertent
damage to the integral solid-state circuitry.
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2.2 Primary Gas Connections
The DFC Mass Flow Controller will not operate with liquids. Only clean, non corrosive
gases may be introduced into the instrument. If gases are contaminated, they must be
filtered to prevent the introduction of impediments to the sensor.
For more information, contact your distributor or Aalborg®.
Prior to connecting gas lines, inspect all parts of the piping system, including ferrules and
other fittings, for dust or other contaminants. Do not use pipe grease or sealant on process
connections as they can contaminate narrow laminar flow elements that may cause perma-
nent damage to the instrument.
When connecting the gas system to be controlled, be sure to observe the direction of gas flow
as indicated by the arrow on the front of the instrument.
Insert tubing into the compression fittings until the ends of the properly sized tubing sit flush
against the shoulders of the fittings. Compression fittings are to be tightened 1¼ turns
according to the manufacturer's instructions. Avoid overtightening which may seriously
damage the compression fitting.
2.3 Pressure Requirements
2.3.1 DPC 07/17/37/47/57/67/77 Pressure Requirements
Maximum operating line (common mode) pressure for DPC07/17/37/47/57/67/77 series
flow controllers is 120 PSIG (8.3 Bar). For controllers with downstream valve configuration
if the installation line pressure is more than 120 PSIG (8.3 Bar), a pressure regulator must
be installed upstream of the flow controller to bring pressure down to 120 PSIG (8.3 Bar).
CAUTION: DPC meters should not be used for monitoring oxygen gas unless
specifically cleaned and prepared for such application.
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CAUTION: For DPC07/17/37/47/57/67/77 flow controllers, the maximum
common mode pressure in the instrument must not exceed 120 PSIG
(8.3 bar).Applying pressure above 120 PSIG (8.3 bar) will cause permanent
damage to the differential pressure sensor.
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CAUTION: Do not apply upstream – downstream differential pressure
exceeding 12 PSID to DPC07/17/37/47/57/67/77 models of flow controllers
when valve is in OPEN mode. Exposure to higher differential pressures may
cause permanent damage to the product.
For DPC07/17/37/47/57/67/77 controllers normally high common mode
pressure (within 120 PSIG) will not damage the differential pressure
sensor, but pressure transients (momentary pressure variations) on
upstream or downstream ports can result in permanent
sensor damage to the product.
For DPC07/17/37/47/57/67/77 controllers avoid instantaneous
application of high differential pressure by switching solenoid valve
to OPEN mode while differential pressure across upstream and down
stream of the controller is more than 12 PSID.
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2.3.2 DPC04/14 "BREEZE" low differential pressure
models pressure requirements
Maximum operating line (common mode) pressure for Breeze (low differential pressure)
DPC04/14 models of flow controllers is 50 PSIG (3.44 Bar). For controllers with downstream
valve configuration if the installation line pressure is more than 50 PSIG (3.44 Bar), a pres-
sure regulator must be installed upstream of the flow controller to bring pressure down to
50 PSIG (3.44 Bar).
CAUTION: For Breeze DPC 04/14 series models the maximum common mode
pressure in the instrument must not exceed 50 PSIG (3.44 bar). Applying
pressure above 50 PSIG (3.44 bar) will cause permanent damage to the
differential pressure sensor.
For Breeze DPC04/14 models do not apply upstream – downstream differential
pressure exceeding 9.75 PSID when valve is in OPEN mode. Exposure to
higher differential pressures may cause permanent damage to the product.
For Breeze DPC04/14 models normally high common mode pressure (within
50 PSIG) will not damage the differential pressure sensor, but pressure
transients (momentary pressure variations) on upstream or downstream ports
can result in permanent sensor damage to the product.
For Breeze DPC04/14 models avoid instantaneous application of high
differential pressure by switching solenoid valve to OPEN mode while
differential pressure across upstream and downstream of the controller is
more than 9.75 PSID.
The user shall install the instrument only in process lines that meet the DPC
controller’s pressure and temperature ratings. A margin of safety should be
provided if spikes and surges exist in the process. Proper pressure relief
valves and burst plates should be installed in high pressure applications.
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CAUTION: To avoid obstructions and contamination in the sensor tube and the
narrow flow channels in the laminar flow element, the user should install the
instrument in process lines that have clean gases. Upstream particulate
filters with maximum particulate size 20µ are recommended for all
applications.
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2.4 Mounting
DPC04/07/14/17/37/47/57/66/77 series Mass Flow Controllers have mounting holes with
6-32 thread (8-32 thread for DPC 57/67/77) on the bottom of the instrument body for
mounting to flat panels. See APPENDIX II for exact dimensions.
The DPC Mass Flow Controller can be mounted in any position. It is not required to maintain
straight runs of pipe upstream or downstream of the instrument. It is preferable to install
the controller in a stable environment, free of frequent and sudden temperature changes,
high moisture, and drafts.
DPC controller ports are equipped with 10-32 female thread (DPC04/07), 1/8" NPT female
thread (DPC14/17/37), 1/4" NPT female thread (DPC47), 1/2" NPT female thread (DPC57)
and 3/4" NPT female thread (DPC67/77).
3. Electrical Connections
DPC instrument is equipped with an 8 pin-MiniDIN power, analog/relay output, interface con-
nector. Table I explains the pin designations. See Figure 3 for a Pin Diagram.
PIN FUNCTION NOTE
1Solid State SPST Relay NO
(normally open) contact #1 Do not exceed SSR
maximum voltage 48 AC peak/DC and
maximum load current 400 mA.
2Solid State SPST Relay NO
(normally open) contact #2
3Analog Set Point Input (+)
(0-5Vdc, 0-10Vdc, 4-20mA)
Input Impedance: 100K (0-5, 0-10 Vdc)
250 Ohm (4-20 mA)
4Analog (0-5Vdc,0-10Vdc,4-20 mA)
Input/Output reference (-)
Common (return) for pins 3 and 6 (0-5Vdc
or 0-10 Vdc or 4-20 mA)
5 Not Assigned. Do Not Connect! Factory use only. Do Not Connect any
signals to this pin!
6Analog (0-5Vdc, 0-10Vdc or 4-20
mA) Output (+)
Output. Do not apply external voltage or
any current source. Be sure to observe
recommended load impedance.
7 Power supply, positive (+)
Power input 12 – 26 Vdc.
(DPC04/07/14/17/37/47) or 24-26Vdc
(DPC57/67/77).
8 Power supply, common (-) Power input common.
TABLE I: 8-PIN DESIGNATIONS AND NOTES

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Figure 3: DPC 8-pin mini-din connector configuration
CAUTION: 4-20 mA analog output requires at least 14 Vdc power.
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CAUTION: Generally, "Mini-DIN" Connector numbering patterns are
standardized. There are, however, some connectors with nonconforming
patterns, so the numbering sequence on your mating connector may or may
not coincide with that shown in our pin configuration above. It is imperative
that you match the appropriate wires in accordance with the correct sequence
regardless of the particular numbers displayed on the mating connector.
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3.1 Power Supply Connections
The AC to DC power supply requirements for DPC04/07/14/17/37/47 controllers are 12 to
26 Vdc, with maximum load current at least 350 mA (unipolar power supply), and maximum
ripple below 150 mV P-P. The AC to DC power supply requirements for DPC57/67/77
controllers are 24 to 26 Vdc, with maximum load current at least 650 mA (unipolar power
supply), and maximum ripple below 150 mV P-P.
Power can be applied to the DPC controller either through the power jack or the 8-pin Mini-
DIN connector (see Figure 1).
CAUTION: Never apply power simultaneously from both connectors, as this
may damage the instrument.
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DC Power (+) --------------- pin 7 of the 8-pin Mini-DIN connector
DC Power (-) --------------- pin 8 of the 8-pin Mini-DIN connector
CAUTION: Never apply power voltage above 26Vdc. Doing so may damage the
DPC and/or cause faulty operation.
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