MKS nPC PCA0 User manual

1003195-001
Revision A, 3/08
Instruction Manual
Ninety Industrial Way
Wilmington
MA 01887
Main: 978.284.4000
Fax: [phone]
www.mksinst.com
MKS Type πPCTM
PCA & P99A
Digital Pressure Controller
Instruction Manual

WARRANTY
Type πPCTM Equipment
MKS Instruments, Inc. (MKS) warrants that for one year from the date of shipment the
equipment described above (the “equipment”) manufactured by MKS shall be free from
defects in materials and workmanship and will correctly perform all date-related
operations, including without limitation accepting data entry, sequencing, sorting,
comparing, and reporting, regardless of the date the operation is performed or the date
involved in the operation, provided that, if the equipment exchanges data or is otherwise
used with equipment, software, or other products of others, such products of others
themselves correctly perform all date-related operations and store and transmit dates and
date-related data in a format compatible with MKS equipment. THIS WARRANTY IS
MKS’ SOLE WARRANTY CONCERNING DATE-RELATED OPERATIONS.
For the period commencing with the date of shipment of this equipment and ending one
year later, MKS will, at its option, either repair or replace any part which is defective in
materials or workmanship or with respect to the date-related operations warranty without
charge to the purchaser. The foregoing shall constitute the exclusive and sole remedy of
the purchaser for any breach by MKS of this warranty.
The purchaser, before returning any equipment covered by this warranty, which is
asserted to be defective by the purchaser, shall make specific written arrangements with
respect to the responsibility for shipping the equipment and handling any other incidental
charges with the MKS sales representative or distributor from which the equipment was
purchased or, in the case of a direct purchase from MKS, with the MKS home office in
Wilmington, Massachusetts, USA.
This warranty does not apply to any equipment which has not been installed and used in
accordance with the specifications recommended by MKS for the proper and normal use
of the equipment. MKS shall not be liable under any circumstances for indirect, special,
consequential, or incidental damages in connection with, or arising out of, the sale,
performance, or use of the equipment covered by this warranty.
MKS recommends that all MKS pressure and flow products be calibrated periodically
(typically every 6 to 12 months) to ensure accurate readings. When a product is returned
to MKS for this periodic re-calibration it is considered normal preventative maintenance
not covered by any warranty.
THIS WARRANTY IS IN LIEU OF ALL OTHER RELEVANT WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTY OF
MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE, AND ANY WARRANTY AGAINST INFRINGEMENT OF ANY
PATENT.
3-08 1003195-001

1003195-001
Rev A, 3/08
MKS Type πPCTM
PCA & P99A
Digital Pressure Controller
Instruction Manual

Copyright © 2006 by MKS Instruments, Inc.
All rights reserved. No part of this work may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopying and recording, or by any information storage or retrieval
system, except as may be expressly permitted in writing by MKS Instruments, Inc.
Printed in the United States of America
Baratron®and Mass-Flo®are registered trademarks of MKS Instruments, Inc., Andover, MA
DeviceNet™ is a trademark of Open DeviceNet Vendor Association, Inc., Coral Springs, FL
Swagelok®and VCR®are registered trademarks of Swagelok Marketing Company, Solon, OH
Elgiloy®is a registered trademark of Elgiloy Company.
Inconel®and Incoloy®are registered trademarks of Inco Alloys International, Inc, Huntington, WV.
Protected under the following U. S. Patents: No. 5,461,913, 6,810,308, 7,000,465, or International Patents and
Patents pending.

Table of Contents
i
Table of Contents
List of Figures................................................................................................................................................... iii
List of Tables......................................................................................................................................................v
List of References............................................................................................................................................ vii
Pressure Transducer Safety Information ........................................................................................................1
Symbols Used in This Instruction Manual ....................................................................................................................1
Symbols Found on the Unit...........................................................................................................................................1
Safety Procedures and Precautions................................................................................................................................1
Sicherheitshinweise für den Druckmeßumformer..........................................................................................3
In dieser Betriebsanleitung vorkommende Symbole .....................................................................................................3
Erklärung der am Gerät angebrachten Symbole............................................................................................................3
Sicherheitsvorschriften und Vorsichtsmaßnahmen .......................................................................................................3
Informations relatives à la sécurité concernant le transducteur de pression...............................................5
Symboles utilisés dans ce manuel d'utilisation..............................................................................................................5
Symboles figurant sur l'unité.........................................................................................................................................5
Mesures de sécurité et précautions ................................................................................................................................5
Medidas de seguridad del transductor de presión..........................................................................................7
Símbolos usados en este manual de instrucciones.........................................................................................................7
Símbolos hallados en la unidad .....................................................................................................................................7
Procedimientos y precauciones de seguridad ................................................................................................................7
Chapter One: General Information ................................................................................................................9
Introduction ...................................................................................................................................................................9
How This Manual is Organized...................................................................................................................................11
Customer Support........................................................................................................................................................12
Chapter Two: Installation and Configuration .............................................................................................13
Unpacking the πPC......................................................................................................................................................13
Product Location and Requirements............................................................................................................................14
Dimensions..................................................................................................................................................................15
Device Information (Labels, Display, Communication, Mounting, Leak Integrity)....................................................22
Installation and Startup Procedure...............................................................................................................................27
Chapter Three: Ethernet Interface Setup and Configuration....................................................................31
Step 1: Install the Java™ Plugin (for single IP address) .............................................................................................31
Step 2: Setup Network for Communication Through Ethernet ...................................................................................32
Chapter Four: Embedded Web-Based GUI and Diagnostics.....................................................................41
Logging On To Your πPC...........................................................................................................................................41
Monitor Mode..............................................................................................................................................................41
Setup Mode..................................................................................................................................................................46
Chapter Five: Overview .................................................................................................................................57
General Information ....................................................................................................................................................57
How the πPC Pressure Controller Works....................................................................................................................59
Tuning the πPC Pressure Controller............................................................................................................................ 61

Table of Contents
ii
Operation of the πPC PC99 Model with Gases other than Nitrogen (Multi Gas)........................................................67
Versions of the πPC (Electrical Interface Related, i.e. Pinouts, cables, etc.) ..............................................................68
Interface Cables for Analog I/O ..................................................................................................................................71
Overview of the Analog πPC Operation......................................................................................................................73
Overview of πPC DeviceNet Digital Operation ..........................................................................................................75
DeviceNet Protocol......................................................................................................................................................76
Overview of πPC RS-485 Digital Operation...............................................................................................................77
RS-485 Protocol ..........................................................................................................................................................77
Chapter Six: Maintenance.............................................................................................................................79
General Information ....................................................................................................................................................79
Zero Adjustment..........................................................................................................................................................79
Chapter Seven: Troubleshooting ..................................................................................................................85
Troubleshooting Chart.................................................................................................................................................85
Appendix A: Product Specifications for the PC90 Model ..........................................................................91
Physical Specifications................................................................................................................................................91
Performance Specifications .........................................................................................................................................91
Environmental Specifications......................................................................................................................................92
Mechanical Specifications..........................................................................................................................................92
Electrical Specifications .............................................................................................................................................92
Appendix B: Model Code Explanation for the PC90 Model ......................................................................95
Model Code Description..............................................................................................................................................95
Appendix C: Product Specifications for the PC99 Model ..........................................................................99
Physical Specifications................................................................................................................................................99
Performance Specifications .........................................................................................................................................99
Environmental Specifications....................................................................................................................................100
Mechanical Specifications........................................................................................................................................100
Electrical Specifications ...........................................................................................................................................101
Appendix D: Model Code Explanation for the PC99 Model....................................................................105
Model Code Description............................................................................................................................................105
Appendix E: Valve Orifice Selection ..........................................................................................................109
General Information ..................................................................................................................................................109
How to Verify the Orifice Selection..........................................................................................................................110

List of Figures
iii
List of Figures
Figure 1: 4-VCR Front View – DeviceNet .......................................................................................................15
Figure 2: 4-VCR Front View – 9-Pin D RS-485...............................................................................................16
Figure 3: 4-VCR Front View – 15-Pin D Analog.............................................................................................16
Figure 4: 4-VCR Left and Right Side Views – DeviceNet...............................................................................17
Figure 5: 4-VCR Left and Right Side Views – 9-Pin D RS-485 ......................................................................17
Figure 6: 4-VCR Left and Right Side Views – 15-Pin D Analog.....................................................................18
Figure 7: 4-VCR Top View (15-Pin D Analog Shown) ...................................................................................18
Figure 8: 4-VCR Bottom View.........................................................................................................................18
Figure 9: C or W Seal Front View – DeviceNet ...............................................................................................19
Figure 10: C or W Seal Front View – 9-Pin D RS-485 .....................................................................................19
Figure 11: C or W Seal Front View – 15-Pin D Analog....................................................................................20
Figure 12: C or W Seal Left and Right Views – DeviceNet..............................................................................20
Figure 13: C or W Seal Left and Right Side Views – 9-Pin D RS-485 .............................................................21
Figure 14: C or W Seal Left and Right Side Views – 15-Pin D Analog............................................................21
Figure 15: C and W Seal Top View (DeviceNet Shown) ..................................................................................21
Figure 16: C and W Seal Bottom View .............................................................................................................22
Figure 17: Labels for the πPC (PC99 and PC90)...............................................................................................22
Figure 18: Push Button Display Readouts .........................................................................................................23
Figure 19: Embedded GUI, Device Page in Monitor Mode (DeviceNet PC90 shown) ....................................42
Figure 20: Embedded GUI, Device Page in Monitor Mode (DeviceNet PC99 shown) ....................................42
Figure 21: Embedded GUI, Plot Page in Monitor Mode (PC90 shown) ...........................................................44
Figure 22: Embedded GUI, Diagnostics Page (PC99 shown) ...........................................................................45
Figure 23: Embedded GUI, Configuration Page in Monitor Mode (DeviceNet πPC shown) ...........................46
Figure 24: Embedded GUI, Device Page in Setup Mode (DeviceNet PC90 shown) ........................................47
Figure 25: Embedded GUI, Device Page in Setup Mode (DeviceNet PC99 shown) ........................................48
Figure 26a: Embedded GUI, Multi Gas, Creating A New Gas Instance (PC99 only).......................................48
Figure 25b: Embedded GUI, Multi Range, Changing the Full Scale Flow Range (PC99 only) .......................49
Figure 27: Embedded GUI, Plot Page in Setup Mode (DeviceNet PC90 shown) .............................................50
Figure 28: Embedded GUI, Plot Page in Setup Mode (Analog)........................................................................50
Figure 29: Embedded GUI, Configuration Page in Setup Mode (DeviceNet PC99 shown) .............................51
Figure 30: Embedded GUI, Configuration Page in Setup Mode (Analog PC99 shown)...................................51
Figure 31: Embedded GUI, Optional PC Page in Setup Mode (Analog πPC Only) .........................................53
Figure 32: Embedded GUI, Plot Page with Enabled Optional Input (Analog PC99 Shown)............................54
Figure 33: Embedded GUI, DNet Settings Page in Setup Mode (PC99 shown) ...............................................55
Figure 34: πPC Controller in Downstream Control Position (PC90 or PC99) ..................................................59
Figure 35: πPC Controller in Upstream Control Position (PC90 only) .............................................................60
Figure 36: Effects of the Proportional Control ..................................................................................................61
Figure 37: Effects of the Integral Control..........................................................................................................62
Figure 38: Controller Response with Initial Kp and Ki term values..................................................................64

List of Figures
iv
Figure 39: Controller Response with New Kp and Ki term values ...................................................................65
Figure 40: Controller Response with New Kp and Ki term values ...................................................................66
Figure 41: DeviceNet Connector Pin Diagram.................................................................................................. 70
Figure 42: Orifice Selection Graph ................................................................................................................. 111

List of Tables
v
List of Tables
Table 1: Definition of Symbols Found on the Unit.............................................................................................1
Tabelle 2: Bedeutung der am Gerät angebrachten Symbole...............................................................................3
Tableau 3: Définition des symboles sur l'unité ...................................................................................................5
Tabla 4: Definición de los símbolos hallados en la unidad.................................................................................7
Table 5: DeviceNet Network Status LED Indicators........................................................................................24
Table 6: RS-485 Module Status LED Indicators ..............................................................................................25
Table 7: Pinout, PC90 Model, 15 Pin Analog I/O ............................................................................................68
Table 8: Pinout, PC99 Model, 15 Pin Analog I/O ............................................................................................69
Table 9: Pinout, πPC, RS-485, 9 Pin Digital I/O..............................................................................................70
Table 10: DeviceNet Connector Pinout ............................................................................................................70
Table 11: Interface Cables ................................................................................................................................71
Table 12: Highest Pressures Suggested for Proper Zero Adjustment ...............................................................81
Table 13: Troubleshooting Chart......................................................................................................................85
Table 14: Valve Orifice Size...........................................................................................................................109
Table 15: Valve Orifice Index Number ..........................................................................................................110

List of Tables
vi
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