Luxel Radak Power Controller II Series User manual

Radak Radak Power Controller II Series
Manual Rev 3.0
Covers controllers after SN 5034(II) and 1033 (II+)

PO Box 1879, 60 Salt Spring Drive
Friday Harbor, WA. 98250
www.luxel.com
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Power Controller II / II+

PO Box 1879, 60 Salt Spring Drive
Friday Harbor, WA. 98250
www.luxel.com
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Power Controller II / II+
Table of Contents
Introduction...................................................................................................................................... 1
Warranty....................................................................................................................................... 2
Specifications............................................................................................................................... 3
Operation.................................................................................................................................. 3
Electrical................................................................................................................................... 3
Mechanical ............................................................................................................................... 3
Feature Comparison Chart.............................................................................................................. 4
General Description......................................................................................................................... 5
Installation........................................................................................................................................ 6
Mechanical Installation................................................................................................................. 6
Electrical Connections ................................................................................................................. 6
Power input.................................................................................................................................... 7
Remote I/O............................................................................................................................... 9
Operation....................................................................................................................................... 13
Overview.................................................................................................................................... 13
Primary button functions:........................................................................................................ 14
Basic Controller Operation..................................................................................................... 14
Controller Displays ................................................................................................................. 15
Access Levels ........................................................................................................................ 15
RADAK Power Controller configuration....................................................................................... 19
Accessing the configuration level........................................................................................... 19
Instrument Configuration........................................................................................................ 20
Disabling manual operation.................................................................................................... 20
Enabling gain scheduling ....................................................................................................... 20
Process Value Configuration.................................................................................................. 20
High temperature limit ............................................................................................................ 21
Programmer Configuration..................................................................................................... 22
Limiting output power ............................................................................................................. 23
Setpoint Limits........................................................................................................................ 24
Programming.............................................................................................................................. 24
Program Behavior .................................................................................................................. 24
Sample Program .................................................................................................................... 25
Running Programs ................................................................................................................. 27
Stopping Programs................................................................................................................. 27
Modifying Program Parameters.............................................................................................. 27
Tuning..................................................................................................................................... 28
General notes on tuning......................................................................................................... 28
Controller high cutback setting............................................................................................... 28
Gain scheduling...................................................................................................................... 29
Auto tune................................................................................................................................ 29
Adaptive tune ......................................................................................................................... 29
Automation with the RADAK II+ power controller........................................................................ 30
I/O Points:............................................................................................................................... 30
Configuration:......................................................................................................................... 30
Example Control Schemes: ....................................................................................................... 31
Goal........................................................................................................................................ 31
Equipment .............................................................................................................................. 31
Assumptions........................................................................................................................... 31
RADAK Power Controller II+ ......................................................................................................... 35
Deposition Controller..................................................................................................................... 35
Maintenance.................................................................................................................................. 36
Troubleshooting............................................................................................................................. 37
Symptom ..................................................................................................................................... 37

PO Box 1879, 60 Salt Spring Drive
Friday Harbor, WA. 98250
www.luxel.com
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Power Controller II / II+
Possible causes............................................................................................................................. 37
Correction.................................................................................................................................... 37
Appendix I.................................................................................................................................. 38
Appendix II................................................................................................................................. 38

Page 1
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PO Box 1879, 60 Salt Spring Dr.
Friday Harbor, WA. 98250
www.luxel.com
Power Controller II / II+
Introduction
Thank you for choosing a RADAK Power Controller II. We hope that you will find it simple to
operate while offering advanced control options. Although specifically designed and optimized for
controlling one of Luxel’s line of RADAK evaporation furnaces, your RADAK Power Controller II is
also well-suited for many other power control applications, such as lamps, filament heaters, etc.
Instructions for connecting your RADAK Power Controller II to these auxiliary devices is included
in an appendix.
*Caution! Installation must be carried out by qualified personnel. Failure to install or
operate this power controller in the manner described in this manual could result in injury
of the operator and/or failure of the controller to meet its stated specifications.
*Caution! Always unplug the power cord from the rear panel before removing any of the
cabinet covers or components. Line voltage is present on exposed connectors and
components inside the cabinet, and is capable of causing injury or death.
This manual is organized in a way that you should find convenient to look up the specific
information you need quickly and easily. Chapter 1 provides a general overview of the design of
the power controller. Chapter 2 describes the installation procedures necessary to safely place
the power controller into operation. Operation of the power controller is covered in Chapter 3.
The layout of this chapter is by task grouping (organized by specific results to be achieved), so
that you can quickly find out how to accomplish a specific goal. It is also useful to read over this
chapter to acquire a feel for the general method of configuring, programming, and operating this
power controller in its different operating modes. Chapter 4 covers maintenance of the power
controller. Troubleshooting follows in Chapter 5, which includes wiring diagrams and
replacement parts specifications.
Appendix I is included to assist those who desire to connect their power controller to devices
other than RADAK evaporation furnaces. It covers the information necessary to assess the load
for its suitable control, configure the power controller for a different sensor feedback, and tune the
controller for the load’s response.
Warning
*Caution! Installation must be carried out by qualified personnel. Failure to install or
operate this power controller in the manner described in this manual could result in injury
of the operator and/or failure of the controller to meet its stated specifications.
*Caution! Always unplug the power cord from the rear panel before removing any of the
cabinet covers or components. Line voltage is present on exposed connectors and
components inside the cabinet, and is capable of causing injury or death.

Page 2
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Fax: [phone]
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PO Box 1879, 60 Salt Spring Dr.
Friday Harbor, WA. 98250
www.luxel.com
Power Controller II / II+
Warranty
Your RADAK Power Controller II is warranted to be free of defects due to materials or
workmanship for 1 (one) year from date of purchase. This warranty excludes damage caused by
improper installation and intentional or inadvertent misuse (e.g. operating into an unsuitable load).
In the event of a warranty claim, Luxel Corporation reserves the right to either repair or replace
the unit at our discretion.

Page 3
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PO Box 1879, 60 Salt Spring Dr.
Friday Harbor, WA. 98250
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Power Controller II / II+
Specifications
Operation
Temperature range:................................ 0 to 1500 °C (type C), 0 to 1200 °C (type K)
Temperature resolution: ......................... 0.1 °C (0 to 999.9 °C)
1 °C (1000 to 1500 °C)
Temperature units:.................................. °C, °F, K (selectable)
PID constants: ........................................ 2 sets
Environment:........................................... 0 to 55 °C operating ambient, 10 to 70 °C storage
5 to 95 % relative humidity, non condensing. Not suitable
for use at elevations greater than 2000 m, or in explosive
or corrosive atmospheres
Electrical
Input power:............................................ 115 Vac/60 Hz 12 A max
Fuses:..................................................... System –10 A fast blow; Controller –2 A fast blow
Thermocouples:...................................... Type C (0 to 1500 °C), or type K (0 to 1200 °C)
Furnace outputs:..................................... 0 to 40 Vac, at 0 to 30 A
Mechanical
Enclosure:............................................... 8.43 W x 5.25 H x 15.07 L (inches, excluding handles)

Page 4
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PO Box 1879, 60 Salt Spring Dr.
Friday Harbor, WA. 98250
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Power Controller II / II+
Feature Comparison Chart
Model:
II
II+
General
Incorporates Eurotherm Model #
2404
2404
RS 232 Communications
x
x
Auto-Tune algorithm
x
x
Output Channels
1
1
Programmer
Stored Programs
1
4
Program Segments
8
16
Stored programs can be linked
x
I/O
Analog inputs
1 PV
1 PV,
external
Software-selectable input source
x
x
All common thermocouple types
x
x
Custom linearization profile
x
x
All standard RTDs, pyrometers
x
x
Voltage, current inputs
x
x
User calibration
x
x
External control inputs
x
x
Digital I/O
2 input
3 input
Relay outputs
1 SPDT
2 SPST, 1
SPDT
Control schemes
PID
PID, external
PC Interface
Eurotherm iTools software for
configuration and control
x
x

Page 5
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PO Box 1879, 60 Salt Spring Dr.
Friday Harbor, WA. 98250
www.luxel.com
Power Controller II / II+
CHAPTER 1
General Description
The RADAK Power Controller II is constructed of three primary components, carefully selected to
work together and provide complete functionality. These components consist of a temperature
controller, a phase angle firing SCR, and an output transformer. The remaining components
inside the power controller enclosure support the operation of and add functionality to the primary
components. These components include switches, relays, connectors, and an auxiliary power
supply.
The temperature controller is a Eurotherm model 2404. This unit, described thoroughly in the
included Eurotherm user manual, accepts a thermocouple signal as a feedback input and
computes an output level which will achieve the desired setpoint value. The control scheme used
by the temperature controller is a PID (Proportional, Integral, Derivative) algorithm, widely used
for general control applications. By adjusting the three terms, P, I, and D, along with output
scaling and power cutback to reduce overshoot, the algorithm can be tuned for any temperature
range and device response to provide a rapid rise to the setpoint temperature with little overshoot
and quick temperature stabilization. In addition, the model II controller allows programming a
time/temperature profile, so that the temperature can be made to follow a sequence of step
changes, linear slopes, and dwell periods.
After computing an appropriate output level, the temperature controller sends a signal to the
phase angle firing SCR to regulate the line voltage being applied to the transformer. Phase angle
firing is used to provide a consistent and steady furnace temperature. An alternative to phase
angle firing, zero-crossing SCRs are much less expensive, but produce small oscillations of the
furnace temperature at steady state. This is due to the low thermal mass, and hence quick
response, of the RADAK evaporation furnace line.
The third important component is the isolation transformer. The transformer is installed on the
output of the SCR and serves two functions. First, the transformer scales the output voltage from
0-120 Vac (or 0-240 Vac) to 0-40 Vac. In addition, the transformer serves to isolate the furnace
(or other resistive load) from the power controller. This reduces the chance of ionic conduction
occurring in the source, which will appear as a short circuit.

Page 6
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PO Box 1879, 60 Salt Spring Dr.
Friday Harbor, WA. 98250
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Power Controller II / II+
CHAPTER 2
Installation
This chapter describes the installation procedures for connecting a RADAK Power Controller II to
a vacuum system containing a RADAK evaporation furnace. For connection to other devices, it is
recommended that you read this chapter first, as it contains complete installation instructions.
Also read Appendix I, which contains some general guidelines for controlling other devices.
*Caution! Installation must be carried out by qualified personnel. Failure to install or
operate this power controller in the manner described in this manual could result in injury
of the operator and/or failure of the controller to meet its stated specifications.
*Caution! Always unplug the power cord from the rear panel before removing any of the
cabinet covers or components. Line voltage is present on exposed connectors and
components inside the cabinet, and is capable of causing injury or death.
Mechanical Installation
The RADAK Power Controller II series instruments are provided in a bench top configuration.
Rack mounting hardware is available to enable the power controller to be mounted in a standard
19 inch instrument rack. This hardware consists of steel angle brackets with bolt-on handles and
mounting screws.
To mount a single cabinet into an instrument rack, a rack mount adaptor is available or it will be
necessary to fabricate a metal support plate to secure the inboard side of the cabinet. This
consists of a simple 5¼ inch by 9¼ inch strip of metal (0.125 inch thick aluminum will work well)
containing holes to bolt to the power controller mounting bracket on one side and the instrument
rack on the other.
Two RADAK Power Controller II series instruments can be mounted side-by-side using only 5¼
vertical inches of rack space.
Electrical Connections
The following figure shows the rear panel of the RADAK Power Controller II.