Apex Digital PC User manual

OPERATING MANUAL
FOR PRESSURE CONTROLLERS
Models PC · PCS · PC3 · IVC

2 Introduction
Introduction
Your pressure controller has many innovative features:
•
1000 readings per second guarantees high resolution data,
page 11.
• Backlit display with adjustable contrast is easy to read even
in direct sunlight. In dimly lit areas, press the bottom button to
turn on the backlight, page 19.
•
Ability to control gases and liquids to accommodate a wide
range of pressure control applications.
•
Connection to a computer for control and data logging to
capture all pressure data for logging and analysis, page 20.
This manual covers the following instruments:
• Absolute, gauge, and dierential pressure controllers
•
Anti-corrosive absolute, gauge, and differential pressure
controllers
• Remote-sensing pressure controllers
• Integrated vacuum controllers
• external sensor pressure controllers
For support or questions regarding the use or operation of
this device, please contact support using the information on
page 16.
Serial #:
Next Calibration:
This device comes with a NIST-
traceable calibration certificate.
This device conforms to the European
Union’s Restriction of Use of Hazardous
Substances in Electrical and Electronic
Equipment (RoHS) Directive 2011/65/EU.
This device complies with the requirements
of the Low Voltage Directive 2014/35/EU
and the EMC Directive 2014/30/EU and
carries the CE Marking accordingly.
This device complies with the
requirements of the European Union’s
Waste Electrical & Electronic Equipment
(WEEE) Directive 2002/96/EC
DOC-MANUAL-PC-G Rev 0 • 2021.08.19

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4 Table of Contents
Contents
Introduction 3
Quick Start Guide 5
Getting Started 6
Getting to Know Your Pressure Controller 6
The Pressure Controller Display 6
Status Messages 6
Mounting 6
Filters 6
Device Ports 7
Connecting Your Pressure Controller 7
Forward (Downstream) Pressure Control 8
Back Pressure Control 8
Dierential Pressure Control 8
Remote-Sensing Controller 9
Integrated Vacuum Controllers (IVC) 9
Using Pressure Instruments with Liquids 9
Power and Signal Connections 10
Analog Signals 10
Displaying Live Data 11
Main Display 11
Taring Your Pressure Controller 11
Option: Color TFT Display 11
Control 12
Changing the Setpoint 12
Adjusting Setpoint with an IPC 12
Setpoint Setup 12
Using Autotare 12
Changing Between Setpoint Sources 12
Managing Setpoint with an Idle Modbus Connection 12
Managing Setpoint on Power-Up 12
Establishing Setpoint Limits 13
Control Loop 13
Changing the Controlled Variable 13
Adjusting the PD/PDF or PD²I Control Algorithms 13
Tuning the PD²I Control Algorithm 14
Troubleshooting Valve Performance with PID Tuning 14
Using a Control Deadband for Pressure Control 14
Setpoint Ramping 15
Setting the Ramp Rate 15
Ramping Options 15
Displaying Valve Drive Percentage 15
Device Information 16
Setup 17
Sensor Setup 17
Choosing Engineering Units 17
Pressure Averaging 17
Zero Band 17
Configuring Serial Communications 18
Unit ID 18
Modbus RTU Configuration 18
Baud Rate 18
Display Setup 19
Main Screen Options 19
Screen Lighting 19
Display Rotation 19
Advanced Setup 19
Serial Communication 20
Modbus RTU Communication 20
Establishing Communication 20
Communication Programs 20
Configuring PuTTy 20
Polling Mode 20
Streaming Mode 21
Taring 21
Collecting Data 21
Commanding a New Setpoint 22
Sending Setpoints as Floating Point Numbers 22
Quick Command Guide 22
Troubleshooting 23
General Use 23
Pressure Readings 23
Serial Communications 24
Maintenance 24
Cleaning 24
Recalibration 24
Reference Information 25
Engineering Units 25
Pinouts 26
8-Pin Mini-DIN (Default) 26
Locking Industrial Connector Pinout 26
9-Pin D-Sub Connector Pinouts 27
15-Pin D-Sub Connector Pinouts 27
M12 Connector Pinouts 28

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Quick Start Guide
Setup
• Connect your pressure controller. Ensure
that flow will pass through your device in the
same direction as the arrow on the flow body
(usually left to right).
•
Choose your engineering units. You can
choose the measurement units by selecting
MAIN MENU → SETUP → Sensor → Engineering
Units (page 17).
Operation: Pressure Verification
Monitor live pressure readings. Readings are
updated and displayed on your device in real
time (page 11).
Connectors and Buttons
The drawing to the right represents a typical
configuration of a standard pressure controller.
Your pressure controller’s appearance and
connections may differ (page 16).
Backlight
The monochrome display comes equipped with
a backlight. To toggle the backlight power,
press the bottom button on the front of your
device.
For optional color TFT displays, pressing this
button will turn o the display to conserve power.
See page 11.
Maintenance and Care
• Pressure controllers do not require cleaning
when flowing clean, dry gases (page 24).
• Calibrate your device annually. To schedule
a calibration, please contact support
(page 16).
This is a typical gauge
pressure configuration.
This is a typical differential
pressure configuration.

6 Getting Started
Getting Started
Getting to Know Your Pressure Controller
The Pressure Controller Display
The figure below identifies the various features of the main pressure controller display.
Highlights pressure in the center of the display.
Tares the pressure (typically unavailable for abso-
lute pressure devices) (page 11).
Opens a menu to set the pressure control setpoint (page 12).
Enters the main menu system (page 11).
Toggles the backlight (more display options are on page 19).
✓ Note: Buttons 4 and 5 have no functions on the main display for pressure devices.
Status Messages
Status messages are shown to the right of the main readout number. In the example to
the right the LCK message indicates that the front display is locked.
ADC Analog-digital converter error
LCK Front display is locked
POV Pressure over range of device
Mounting
Pressure controllers do not require straight runs of pipe upstream or downstream. Most
pressure controllers can be mounted in any position, including upside-down. Corrosive-re-
sistant pressure controllers use media-isolated sensors that must be tared after changing
their orientation.
▲
Caution: Pressure controllers that use large Rolamite valves (PCR, PCR3, PCRS) should
be mounted with their valve oriented vertically (right-side up). Please contact support
for other orientations.
Filters
When pressure drop is not a concern, use in-line sintered filters to prevent large particulates
from entering the pressure controller. Suggested maximum particulate sizes are as follows:
• 20 microns for PC, PCP, PCH, PC3
• 40 microns for PCR, PCR3
The main display. Note bottom
button (7), which toggles the
device backlight.
The main menu with valve position
information, and a LCK status.

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Device Ports
Your pressure controller has been shipped with plastic plugs fitted into its ports. To decrease
the chance of contaminating the flow stream, do not remove these plugs until you are ready
to install the device.
Standard pressure controllers have female inlet and outlet ports. VCR® and other specialty
fittings may have male connections.
•
If you are using a fitting that does not have a face seal, use thread-sealing Teflon tape to
prevent leakage around the port threads, but do not wrap the first two threads. This
will minimize the possibility of getting tape into the flow stream.
• Face seal fittings do not need Teflon tape applied to the threads.
!
Warning: It is not recommended to use pipe dopes or sealants on the process connections
as these compounds can cause permanent damage to the controller should they get
into the flow stream.
Connecting Your Pressure Controller
Connect the controller so that the flow travels in the same direction as the flow arrow, usually
from left to right from the front of the device
! Warning: Using the pressure controller above the maximum specified common mode
or burst pressure will result in permanent damage to the internal pressure sensors.
Range Burst Pressure
Maximum Allowed Common Mode
Pressure (Differential Pressure Only)
0.07-100 PSI 3x full scale 200  (750  for anti-corrosive models)
500 PSI 1.5x full scale 750 
1000-3000 PSI 1.5x full scale N/A
A male VCR®-compatible
connection.
A default NPT female connection.
A male VCO®-compatible
connection.

8 Getting Started
Applications
Forward (Downstream) Pressure Control
When the valve is located on the upstream side (direct control), the sensor will control
pressure downstream. This configuration follows our standard pressure control algorithm.
Note: the valve opens to increase pressure, and closes to decrease pressure.
Example:
Gas Supply Pressure Regulator Pressure Controller Process Flow Exit Port
Upstream Valve
Back Pressure Control
When the valve is located on the downstream side (inverse control), the sensor will control
pressure upstream. This configuration is referred to as a back pressure controller. This
configuration follows our inverse pressure control algorithm. Note: the valve closes to
increase pressure, and opens to decrease pressure.
Example:
Gas Supply Pressure Regulator Pressure ControllerProcess Flow Exit Port
Downstream Valve
✓
Note: Back pressure controllers include “DS,” for downstream valve, in their part codes.
Changing the Valve Orientation
The valve position on your pressure controller can be switched in the field. The controller
must also be configured for either forward pressure control (direct control) or back pressure
control (inverse control). If you need to switch from forward to back pressure control, contact
support (page 16).
Dierential Pressure Control
Dierential pressure controllers have two ports for connecting to the points in the system
where the dierential pressure is to be measured. The upstream port is for the higher
pressure, and the downstream port is for the lower pressure. In these devices, the dierential
pressure ports have no flow, and are not connected to the flow path.

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Remote-Sensing Controller
PC3-Series models sense and control the pressure at some point in the system outside of
the pressure controller itself. All PC-Series controllers can be ordered with an additional
NPT port on the front, which is connected directly to the pressure sensor in the device. The
pressure sensor is isolated from the flow path in this configuration.
Integrated Vacuum Controllers (IVC)
IVCs are similar to the PC-Series absolute pressure controllers in functionality and in the
navigation menus available on the screen. IVC devices are used in applications where
precise control of vacuum is required, and are available with 10 TorrA, 100 TorrA, 1000 TorrA,
and combined 1000 & 10 Torr sensors.
Integration of the vacuum sensor, control valve, and PID algorithm in a single device eliminates
the need for an external vacuum sensor and throttle valve in your system. These devices
have /-20 SAE ports, or optional VCR®-compatible, compression, and VCO®-compatible
fittings. Process port sizes may change depending on the valve on your device.
Using Pressure Instruments with Liquids
Many pressure devices may be used with chemically-compatible liquids, but a few warnings
must be taken into account:
•
Water is more than 55 times more viscous than air. This is important when sizing a pressure
controller, as this significant increase in viscosity requires a larger valve to reach expected
flow rates. For example, a PC-Series pressure controller sized to flow up to 20  of
air will be limited to roughly 0.5 LPM of water (or similar fluid).
•
The factory PID tuning is done using air. It may be necessary to adjust the PID tuning
parameters when using a controller with liquid. Find more information, contact support
(page 16) to help you through this tuning process.
▲
Caution: Please check with customer support before using your pressure controller with
liquids unless specifically ordered for this purpose.
Gas
Supply
PC3 Controller
Flow
Pressure Sensor Line (no flow)
Process
Gas Supply
IVC
Optional Remote Sensor (on IVC3 models)
Process
Exhaust
Vacuum Pump

10 Getting Started
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.
✓ Note: Power requirements vary based on analog configuration and valve type. Please
reference the associated specification sheet for power requirements.
Standard 8-Pin Mini-DIN Pinout
Pin Function
Not Connected Optional: 4–20 mA primary output signal
Static 5.12 Vdc by default. Optional: secondary analog output
(4–20 mA, 0–5 Vdc, 1–5 Vdc, 0–10 Vdc) or basic alarm
Serial RS-232 RX / RS-485(−) Input Signal (receive)
Analog Setpoint Input
Serial RS-232 TX / RS-485(+) Output Signal (send)
0–5 Vdc Optional: 1–5 Vdc or 0–10 Vdc output signal
Power In (as described above)
Ground (common for power, digital communications, analog signals and alarms)
The above pinout is applicable to all devices with the Mini-DIN connector. The availability of dierent output
signals depends on the options ordered. Optional configurations are noted on the unit’s calibration sheet.
▲Caution: Do not connect power to pins 1 through 6, as permanent damage can occur.
It is common to mistake pin 2 (5.12 Vdc Output) as the standard 0–5 Vdc analog output
signal. Pin 2 is normally a constant 5.12 Vdc.
More pinout configuration options begin on page 26.
Analog Signals
Primary Analog Output Signal
Most devices include a primary analog output signal, which is linear over its entire range.
For ranges that start at 0 Vdc, a zero-pressure condition is indicated at approximately 0.010
Vdc. Full scale pressure is indicated by the top of the range: 5 Vdc for 0–5 Vdc, 20 mA for
4–20 mA signals, and so on.
Option: Secondary Analog Output Signal
The default 8-pin Mini-DIN connector places the secondary analog output on pin 2 for both
voltage and current signals. As pressure is the only measured parameter in the pressure
series, this secondary analog output can be used as a comparison to the primary analog
output.
Option: 4–20 mA Current Output Signal
Controllers with a primary or secondary output signal of 4–20 mA current require 15–30
Vdc power.
▲
Caution: Do not connect 4–20 mA devices to “loop powered” systems, as this will damage
portions of the circuitry beyond repair and void the warranty. If you must interface with
existing loop powered systems, always use a signal isolator and a separate power supply.
A pressure controller with the
standard 8-pin Mini-DIN serial
connector.
Male Connector: Cable
Female Connector: Device
1
4
5
68
7
3
2 1
4
5
6
87
3
2