Halma ALICAT SCIENTIFIC PC User manual

OPERATING MANUAL
FOR PRESSURE
CONTROLLERS
Models PC · PCS · PC3 · PC3S · PCR · IVC · EXTSEN

2 Introduction
Thank you for purchasing your pressure controller.
If you have any questions, or if something is not working as expected,
please contact us. We are eager to help you in any way possible.
Contact Information
Alicat Scientific World Headquarters
7641 N Business Park Dr., Tucson, AZ 85743 USA
[e-mail] • alicat.com • [phone]
India
[e-mail]
Halma India Pvt. Ltd.
Plot NO. A-147, Road No. 24,
Next to Spraytech Circle
opp. Metropolitan Company,
Wagle Industrial Estate
Thane-West
Mahārāshtra 400 604
[phone]
China & SE Asia
[e-mail]
alicat.com.cn
2nd Floor, Block 63, No. 421,
Hong Cao Rd,
Shanghai 200233
PRC
[phone] ext. 801
Europe
[email protected]om
Geograaf 24
6921 EW Duiven
The Netherlands
+31 (0) 26 203.1651
Recalibrate your pressure controller every year.
Annual calibration is required to ensure the continued certainty of readings,
and to extend the Limited Lifetime Warranty (page 48). Fill out the
Service Request Form at alicat.com/service,or contact us directly when
it is time to send in your device for recalibration.
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
Rev.  • 2020.10.13 • PRESSURE CONTROLLER operating manual

PRESSURE CONTROLLER operating manual 3
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 6).
• Ability to control gases and liquids to accommodate for a wide
range of pressure control applications, when properly configured.
• Data logging to your PC over a serial data connection to capture all
pressure data, for logging and analysis purposes (see page 32).
Please take the time to find and read the information for your specific
device. This manual covers the following Alicat Scientific instruments:
• PC-Series absolute, gauge, and dierential pressure controllers
• PC3-Series external-sensing pressure controllers
• IVC-Series integrated vacuum controllers
This includes devices configured with corrosion-resistant materials
(PCS, PC3S), devices with a remote-sensing line (PC3, PC3S), a remote
sensor (EXTSEN), “hammerhead” dual valve configurations (PCH, PCR,
PCRH), pneumatic valves (PCP), and most combinations of these options.
This also includes devices labeled as approved for CSA Class 1 Div 2 and
ATEX Class 1 Zone 2 hazardous environments. See page 47 for Special
Conditions regarding the use of CSA/ATEX labeled devices.
Recalibration
Your pressure controller is a precision device, and an annual calibration
is strongly recommended.
A yearly recalibration has several benefits:
• It ensures that your unit is functioning according to specification.
• Contamination may cause the instrument to measure improperly.
Recalibration ensures the instrument is clean and free of debris.
• Recalibration maintains your LIFETIME WARRANTY (see page 48).
Sending your unit in for recalibration is quick, easy, and inexpensive.
Please keep the original box to return your Alicat instrument for recali-
bration. For more information regarding recalibration, see page 40.

4 Table of Contents
Contents
Introduction 3
Recalibration 3
Getting Started 6
The Pressure Controller Display 7
Status Messages 7
Mounting 8
Process Ports 8
Filters 8
Operating Pressure 8
Connecting Plumbing to Your Pressure Controller 9
Applications 10
Valve Orientation 10
Special Configurations 11
Dierential Pressure 11
Integrated Vacuum Controllers (IVC) 12
Remote-Sensing Controller 13
Using Alicat Pressure Instruments with Fluids 13
Power and Signal Connections 14
RS-232 or RS-485 Digital Signals 15
Engineering Units 16
Option: Color TFT Display 17
Navigation & Customization 18
Main Menu 18
Taring 18
Control Menus 19
Changing the Setpoint 21
Establishing Setpoint Limits 22
Setpoint Ramping 23
Adjusting the Closed Loop Controller 25
Troubleshooting valve performance with PID tuning 27
Device Information 28
Basic Configuration Menu 29
Engineering Units 29
Advanced Setup 30
Display Setup 30
Sensor Setup 31
Configuring Serial Communications 32

PRESSURE CONTROLLER operating manual 5
Contents
Serial Communication 33
Establishing Communication 33
Polling Mode 34
Streaming Mode 34
Taring 35
Collecting Pressure Data 35
Commanding a New Setpoint 36
Sending Setpoints as Floating Point Numbers 36
Sending Setpoints as Integers 36
Quick Command Guide 37
Troubleshooting 38
Maintenance 41
Cleaning 41
Recalibration 41
Engineering Units 42
Pinouts 43
8-Pin Mini-DIN (Default) 43
Locking Industrial Connector Pinout 44
9-pin D-Sub Connector Pinouts 45
M12 Connector Pinouts 46
15-Pin D-Sub Connector Pinouts 47
Additional Information for CSA and ATEX Approved Devices 48
Limited Lifetime Warranty 49

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.
+0.0000
MENU
PSIG SETPT
+0.0000
Ga Press
PSIG
+0.0000
I/O Port
(shape varies)
DC
In
Light
Switch
Controls
Valve
Display
Flow
Body OutletInlet Process
Connections
Mounting
Holes
Flow Direction

PRESSURE CONTROLLER operating manual 7
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 o.
Live data is measured 1000 times per second, and is typically displayed
10 times per second on the device’s LCD screen.
Device engineering units are used by the controller in its serial commu-
nications and calculations. These can optionally be dierent from the
button engineering units, which are the units being displayed. These
can be individually configurable using the front display (page 28).
Chooses the pressure
engineering units (page 28).
TARE PRESS tares the pressure
reading on the device. Ensure
the device is exposed to
atmospheric pressure when
this is performed. Tares are
not available on absolute
pressure () devices.
SETPT sets the pressure
control setpoint (page 20).
MENU enters the menu
system (page 17).
The button under the Alicat
logo toggles the backlight
(see page 29 for more
display options).
Status Messages
ADC Analog-digital converter error
EXH Exhaust mode active
HLD Valve hold active
LCK Front display is locked
POV Pressure over range of device

8 Getting Started
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). If another orientation is desired, please contact Alicat.
Process Ports
Your pressure controller has been shipped with plastic plugs fitted into its
ports. To lessen the chance of contaminating the stream, do not remove
these plugs until you are ready to install the device.
Standard pressure controllers have female inlet and outlet ports. Welded
VCR® and other specialty fittings may have male connections.
• For connections without face seal fittings, use thread-sealing
Teflon tape to prevent leakage, but do not wrap the first two
threads. This will help prevent tape getting into the stream.
• No tape is needed for face seal fittings.
• When changing fittings, carefully clean the port threads.
! Warning: Do not use pipe dopes or sealants on the process
connections, as these compounds can cause permanent
damage to the controller should they get into the stream.
Filters
We recommend in-line sintered filters to prevent large particulates from
entering the pressure controller, even though they may increase pressure
drop. Suggested maximum particulate sizes are as follows:
PC/PCP/PCH/PC3: 20 microns PCR/PCR3: 40 microns
Operating Pressure
Controllable Pressure Burst Pressure,
≤500 PSI devices*
Burst Pressure,
>500 PSI devices*
102.4% of full scale pressure 300% of full scale pressure 150% of full scale pressure
*Exceeding burst pressure will permanently damage the internal pressure sensor.
Connecting Plumbing
Your pressure controller can regulate positive pressure and/or vacuum,
depending on configuration. Connect the controller so that flow travels
as indicated by the arrow, usually left to right, from the front of the device.
Maximum controllable pressure
is 102.4% of full scale pressure.
The burst pressure is 3× full scale
pressure on standard pressure
controllers, and 1.5× full scale
pressure for high-pressure
devices (> 500 PSI). Exceeding
the burst pressure of the device
will permanently damage the
internal pressure sensor.

PRESSURE CONTROLLER operating manual 9
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. This config-
uration follows our standard pressure control algorithm (valve opens to
increase pressure, closes to decrease pressure). For example:
Gas Supply Pressure Regulator Pressure Controller Process Flow Exit Port
Up-Stream Valve
Back Pressure Control Application,
Downstream Valve (upstream pressure control)
A pressure controller with a downstream valve configuration will result in
the sensor exposed to the upstream pressure. Due to this, the controller
will be regulating the upstream pressure, and this configuration is known as
a back pressure controller. This configuration follows our inverse pressure
control algorithm (valve closes to increase pressure, opens to decrease
pressure). For example:
Note: Back pressure controlers include “DS,” for downstream valve, in their part codes.
Changing the Valve Orientation
The valve position on your Alicat pressure controller can be switched in the
field. In addition to the valve switch, the controller must be configured for
either forward pressure control (default control) or back pressure control
(inverse control). If you need to switch from forward to back control, a video
and explanation can be found at alicat.com/valve-direction-change.
Gas Supply Pressure Regulator Pressure ControllerProcess Flow Exit Port
Down-Stream Valve

10 Getting Started
Special Configurations
PC-Series pressure controllers are occasionally ordered with special
configurations to work in specialized ways:
Dierential 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
pressure is measured from. The
upstream port is for the higher
of the two pressures, and the
downstream port is for the lower
pressure. In these devices, the
flow path through the device is
not connected to either leg of
the dierential pressure sensor. A 15 PSI pressure controller with
differential pressure detector ports in
front, and a DB9 serial data connection.
Gas
Supply
Alicat
Controller Process Port
Flow
Process
P2
P1 Sensor (no flow)
P2 Sensor (no flow)
P

PRESSURE CONTROLLER operating manual 11
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. The pressure
sensor is isolated from the flow path
in this configuration.
Using Alicat Pressure Instruments with Fluids
All of these pressure devices may be used with chemically-compatible
liquids, but a few warnings must be taken into account:
1. Water is about 50 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  of water (or similar fluid).
2. The factory PID tuning terms are established using air. It may be
necessary to adjust the PID tuning parameters if you will be using
a controller with liquid. Find more information at alicat.com/PID, or
contact us (page 2) to help you through this tuning process.
▲Caution: Please check with Alicat before using
your pressure controller with liquids unless
specifically ordered for this purpose.
A 100 PSI gauge pressure controller with
a remote sensor port (in front), and an
8-pin mini-DIN serial data connection.
Gas
Supply
Alicat PC3
Controller
Flow
Pressure Sensor Line (no flow)
Pressure-Controlled
Process
Process

12 Getting Started
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:
• 10, 100, and 1000 TorrA
• Dual sensor package
which integrates a 1000
Torr and 10 Torr sensor
for increased turndown
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 often come with ⁄″-20 SAE
ports by default, but they can be ordered with welded VCR®, compression,
or VCO®fittings if required. Process port sizes may change depending
on the valve on your device.
A 10-torr integrated vacuum controller with
its specialized vacuum sensor in the back.

PRESSURE CONTROLLER operating manual 13
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.
4–20 mA analog outputs require at least 15 Vdc and 290 mA.
 Note: Large valve controllers (PCR models) require a
24–30 Vdc power supply with a 2.1 mm female positive-
center plug capable of supplying at least 750 mA.
Standard 8-Pin Mini-DIN Pinout
For 6-pin locking industrial connector, M12, DB9, and DB15 pinouts, see
page 42 or visit alicat.com/pinouts.
Pin Cable Color Function
Black Not connected
Optional: 4–20 mA primary output signal
Brown
Static 5.12 Vdc
Optional: Secondary analog output
(4–20 mA, 0–5 Vdc, 1–5 Vdc, 0–10 Vdc) or basic alarm
Red Serial RS-232RX input signal
Optional: RS-485 A
Orange Analog setpoint input
Yellow Serial RS-232TX output signal
Optional: RS-485 B
Green 0–5 Vdc
Optional: 1–5 Vdc or 0–10 Vdc) output signal
Blue Power in (as described above in the checked notes)
Purple Ground (common for power, digital communications,
analog signals, and alarms)
▲Caution: Do not connect power to pins 1 through 6. Permanent
damage can occur. Pin 2 (5.12 Vdc Output) is often mistaken
for the standard 0–5 Vdc analog output signal. Pin 2 is
normally a constant 5.12 Vdc that reflects system bus voltage.

14 Getting Started
RS-232 or RS-485 Digital Signals
DB9 to 8-Pin Mini-DIN Connection for RS-232 or RS-485 Signals
9-Pin Serial Connection 8-Pin Mini-DIN Connection
Pin Function Pin 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. See page 32 for details on serial communication and
how to use the data connection to issue commands.
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. Communication protocols that eliminate analog outputs include
DeviceNet, EtherCAT, EtherNet/IP, Modbus TCP/IP, and PROFIBUS.
Secondary Analog Output Signal
You may specify an optional second analog output at the time of order.
This output may be 0–5 V, 1-5 V, 0–10 V, or 4–20 mA and can represent
any measured parameter. Since 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.
5
23
DB9 Male
8-Pin
Mini-DIN
Female

PRESSURE CONTROLLER operating manual 15
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 
(gauge),  (absolute), or  (dierential). Low pressure controllers
may include default units of inHOG, inHOD, or torrA.
Device engineering units are the units of measurement used for calcu-
lation and sent through a serial data connection. Optionally, these may
be different from the displayed button engineering units.
Selecting Engineering Units
If a parameter is already highlighted in the center of the screen, pressing
that measurement’s button again will bring up a menu to modify either
the button engineering units or the device engineering units.
If the device and button engineering units are the same (below
left), the menu will oer to change button engineering units or device
engineering units. Device engineering units can also be set in the Basic
Configuration Menu (page 28).
If device and button engineering units differ (below right), the menu
will oer to change button engineering units ( Set button eng units ), or to
match button units to device engineering units (Show device eng units).
This will show if the front display
units (button engineering units)
are the same as the serial data
units (device engineering units).
This will show if the front display
units (button engineering units)
are different than the serial data
units (device engineering units).

16 Getting Started
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.
• YELLOW: Menu items that are
ready to be selected appear
in yellow. This color replaces
the >symbol in selections
on monochrome display.
 Press the Alicat logo button to turn o the color
display backlight, located below the row of three
buttons under the screen. The pressure controller
remains in operation while the backlight is o.
LCD Contrast
LCD contrast is ranged from 0–11 on color displays, with 11 indicating the
greatest contrast. See page 29 for information about display options.
Specifications for Instruments with Color Displays
Color displays will require an additional 40 mA when using a 24 Vdc
power supply. All other specifications from your device’s specification
sheet remain in eect.

PRESSURE CONTROLLER operating manual 17
Navigation &
Customization
Main Menu
The Main Menu system is accessed by
pressing the MENU button from the Main
Display (page 7).
• CONTROL (page 18), ABOUT
(page 27), TARES (below), BASIC
CONFIG (page 28), and ADV SETUP
(page 29) enter their menus.
• MAIN (page 7) exits
to the main display.
Taring
Taring ensures accurate measurements
by giving the device a zero reference.
Auto-tare automatically tares when a
zero setpoint is set for a short time, but
auto-tare is not recommended for
pressure controllers in most situations.
How to Manually Tare
1. Ensure that there is no flow,
and that pressure is zero.
2. MENU →TARE →TARE PRESS, or
via serial command (page 34).
Gauge pressure tares must be
done with the controller open
to atmospheric pressure.
When to Tare
• After significant changes in pressure
• After dropping or bumping the pressure controller
• After installing the controller in a dierent orientation
Main Menu
Tare Menu

18 Navigation and Customization
Control Menus
The CONTROL and 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).
• SETPT displays the current
setpoint. Press to command
a new setpoint or clear the
existing one. Setpoints are
not editable via the front panel if the source is analog.
• BACK returns to the Main Menu selection (previous page).
• ADV CONTROL moves to the Advanced Control menu (below).
• MAIN exits to the Main Display (page 7).
Menu →Control → Advanced Control
• SETPT SOURCE selects setpoint
input from either serial data and
the front panel, or analog sources.
• LOOP SETUP selects the type of
closed loop control and adjusts
PID settings (page 24).
• BACK returns to the Control
Menu (above).
• CONTROL OPTS sets options
for setpoint ramping and
limits for pressure control
(starting page 19).
• MAIN exits to the Main
Display (page 7).
Control Menu
Advanced Control Menu

PRESSURE CONTROLLER operating manual 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).
• DEAD BAND Sets the size of the
control deadband (below).
• BACK Returns to the Advanced
Control Menu (page 18).
• SETPT LIMITS Sets upper and
lower setpoint limits (page 21).
• MAIN Exits to the Main
Display (page 7).
Control Deadband
Menu →Control → Advanced Control →
Control Options →Dead Band
The control deadband on the pressure
controller allows the user to select
upper and lower bounds around the
setpoint. The controller will not adjust
its valve position if the measured
pressure is within these bounds. In this
example, the controller will not adjust
its valve position if the measured pres-
sure is within 5  of the setpoint.
Control Options Menu
Control Deadband Menu

20 Navigation and Customization
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). To cancel a setpoint, press CLEAR, or give
it a zero setpoint.
Changing Between Setpoint Sources
Menu →Control → Advanced Control →Setpoint Source
Pressure controllers accept setpoints from the front panel, a serial data
connection, or an analog signal.
• When the source is set to Serial/
Front Panel, the controller
will accept input from either
the front panel, or an RS-232/
RS-485 connection. Neither
source is a subordinate of
the other, so the controller
will accept the most recent
command from either source.
• When the source is set to Analog,
the controller will ignore serial
setpoint commands and will
prevent input from the front
panel. Available analog inputs
include: 0–5 Vdc, 1–5 Vdc,
0–10 Vdc, and 4–20 mA.
Adjusting the setpoint with the optional IPC
(Integrated Potentiometer Control)
If your controller has been ordered with a potentiometer control knob
(IPC), then the setpoint source must be set to Analog for the controller to
accept setpoint commands from the IPC.
! When using a serial setpoint signal with a controller that has an
IPC, leave the IPC knob at the midpoint when it is not in use.
Setpoint Source Menu