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Controller II / II+ Manual

1. LH Use 4 or v to select the segment type StEP Press O to autole Onm continue L aj Id zoj Use 4 or v to set the segment Cor on target temperature 200 Press O to continue The display will show the next segment number Use A or v to select the program segment to be SP2 REM a Leer jet edited i e press v to cycle back to man O Boa the previous segment to correct an oJ tel Si Is error To modify the new segment press O to continue 2404 Use 4 or to select the segment type rmP t Press O to continue tYPE Use 4 or v to set the target temperature 1500 Press O to rmP t continue LS REM Use 4 or v to set the duration of the ramp segment 15 Press O ile ei to continue NOTE ramp units will be displayed briefly in the lower D IT Is display min 24041 OPI OP2 The display should now show segment 3 Press O to continue Use 4 or v to select dwEll Press O to continue dur Use 4 or v to set the duration of the dwell 20 Press O to Ee continue AO Onan b zx Is PO Box 1879 515 Tucker Ave age 25 Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller lI Il The displav should now show segment 4 Press O to continue Use 4
2. Controller Controller NO Output NC Input Alarm Stop c Input 1 Reset on open NO SCR Output Select l c In Progres NO Output Input Event1 c Start Input 2 Wait NC Input 3 Output Standby c Shutdown Figure 1 System control wiring 1 Deposition sequence Operator initiates process by pressing the Run Hold button on the power controller front panel 3 Power controller program segment one raises source temperature to 400 C over 20 minutes 4 Power controller program segment two maintains the source at 400 C for 2 minutes to condition source Power controller program segment three dwells at 400 C and activates output event 1 Output event 1 signals the deposition controller to start the deposition and places the power controller in a wait state holding the program in the segment three dwell 7 The deposition controller enters its in progress state closing the in progress output relay 8 With the in progress relay NO output event 1 relay NO and alarm relay NC contacts closed the SCR select relay is energized transferring furnace control to the deposition controller 9 The deposition controller enters the shutter delay state adjusting furnace power as required to stabilize rate at 10A sec wee eee eee a ee ee ee PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www lux
3. St si B 7 E PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller lI Il Full Access Level pg 16 selecting Edit instead of FULL Press D as required to reach the Pid list Press O as required to reach the G SP screen Use 4 or w to select ALre to make the gain setpoint alterable in the operator level Press O to continue Once you ve completed the desired alterations wait 45 seconds and the controller will automaticallv return to the operator level EE se y PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller lI Il RADAK Power Controller configuration The Eurotherm 2404 has an exhaustive list of parameters that govern the overall behavior of the controller The following section details some of the more fundamental parameters their usage behavior default settings and how to change them Great care should be taken when modifving parameters in the configuration level WARNING Configuration is protected by a password and should only be carried out by a qualified person authorized to do so Incorrect configuration could result in damage to the process being controlled and or personal injurv It is the responsibilitv of the person commissioning the process to ensure that the configuration
4. Gel anna Nan ent its 23 el tele cClulo e e BEE 23 Program NET e TEE 23 sample lte Tei EE 24 RUNnNIng Be et EE 26 Stoppini Beete Lu 26 Modifying Program Parameters us 26 TUNG EE 27 General not s On TUNING oa a a ha bean ne an EES 27 Controller high cutback setting 27 Gain SCNhEQdUIINg Mana i a i p EES ea an an 28 AUTO TUNG bina a i a aman lens et ton 28 Adaptive t n id iii ai a teste rie nes aan gaada 28 Automation with the RADAK IL power controller 29 VO Points a rare ea ege EES bandana aan 29 CONTIGUTAT ON ME 29 Example Control Schemes iii 30 GOA Aa anna hai Ba beast ren aa 30 EQUIPMENT iku ama nenen Nana an 30 ASSUMPTIONS i ia beat ahmad ha tee liner lettre akun ana 30 RADAK Power Controller Il Woman 34 Deposition Controller AA 34 Maintenance Lian e ane a aa Isa ia aa an ete 35 Troubleshooting Ra ban na aa naas bata aa EN Na REA 36 ATA ega enam an dE nu an nana 36 Possible CAUSES ian ie b ER ENAK RaR Nana a ae Nana 36 CORPO CT OM POMPA PA 36 PO Box 1879 515 Tucker Ave Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il Appendix Appendix ll PO Box 1879 515 Tucker Ave Phone 360 378 4137 Fridav Harbor WA 98250 Fax 360 378 4266 www luxel com Email radakOluxel com LUXEL Power Controller lI Il Introduction Thank you for choosing a RADAK Power Controller Il We hope that you will find
5. Il To use these capabilities the temperature controller must be configured with the intended function of each relav Once configured the relav will complete the circuit between the NO and common lead when anv of the events it is assigned occurs Example Control Schemes Goal R Condition the source to 400 C deposit 200A of material at 10A sec ramp source back to ambient temperature Equipment A vacuum chamber equipped with a RADAK furnace Suitable source shutter Crystal deposition rate monitor Deposition controller with input and output capabilities ie XTC with I O expansion board XTC 2 or similar device RADAK Il power controller Assumptions e All equipment is installed and operating properly e Both the RADAK Il and the deposition controller have been calibrated and operating with appropriate PID s tooling factors etc e The crystal is positioned in the system such that deposition rate is monitored with the source shutter open or closed e The deposition controller is wired to control the source shutter e The deposition controller is configured for shutter delay controller establishes proper stable rate prior to opening the shutter As mentioned above each digital input and each relay output must be configured with an associated event s ee OOO ooo Paes eee eee PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak
6. Many other types of loads can be successfully controlled using the Power Controller II One reason for this versatility is the ability to easily reconfigure the input type in the field This is explained in detail in the accompanying Eurotherm manual As an example of its use suppose we wanted to drive a light source to a specific intensity using the power controller After verifying the compatability of the load for the power controller we could connect a photodetector to the thermocouple input socket on the rear panel The temperature controller will need to be informed of the nature of the signal being delivered to it by configuring the input type as volt for voltage level input mV for millivolt level input or mA for milliamp level input These three input types however assume a linear response of the output level to the measured value in our example case light intensity It is quite common for sensors to exhibit a nonlinear relationship For these cases special versions of the above three input types are available The SrV and SrA input types denote square root volts and square root milliamps respectively Finally mVC VC and MAC allow a custom 8 point linearization profile for millivolt volt and milliamp range inputs respectively Consult the Eurotherm manual for more details Note that it is perfectly acceptable to input volt millivolt and milliamp signals through either K or C thermocoupl
7. Power Controller s PID can result in potentially damaging temperature extremes Manual mode may be disabled as explained in the Disabling manual operation section on page 19 A Aa PO Box 1879 515 Tucker Ave age 1 Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il Program Mode Perhaps the most convenient method of operation is the program mode Stored programs specifving setpoints ramps and dwells mav be used to control the operation of the RADAK Power Controller Il Controller Displavs The Eurotherm 2404 controller parameters are grouped in lists run list programmer list setpoint list etc Access levels are used to determine the lists and parameters available to the Bv default the RADAK Power Controller starts in the HOME displav of the HOME list of the Operator access level This allows access to parameters required for basic controller operation while limiting access to the more advanced controller parameters Home List Additional informational displavs are available from the controllers HOME display NOTE You can return to this display at any time by simultaneously pressing the O and D buttons Pressing O once will briefly display temperature units C F If no further action is taken the unit then returns to the HOME display Pressing U twice shows the output power auto mode or power setpoint manual mode in percent This is
8. a read only value in auto mode the controller must be in manual mode to directly control power output Press D and O together to return directly to the HOME display or cycle through the remaining displays using the O button Manual Auto This display is only available in full access mode Press A or v to select Man or Auto Heater current Controller output in Amps Not used Customer defined ID number Use 4 or v to select the unit ID number This number can be used to programmatically identify the controller in remote operations Press O to return to the HOME display Up to twelve additional controller parameters may be promoted to the home display list see Edit pg 16 Access Levels The Eurotherm 2404 controller uses access levels to group the system variables available to the operator There are four levels of access Operator Full Configuration Edit PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller lI Il Operator Access Level This is the default operating access level This level allows quick access to parameters relevant to controller operation such as creating and running programs running the controller auto tune and adjusting PID settings All procedures discussed in the previous sections assume the controller is in the operator access level Additional parameters can be made available
9. furnace This cable size is specified to handle the maximum safe output current of the power controller even though in normal operation the current flow will be considerabiv less ltis very important to consider the resistance and current when connecting the power controller to a device other than a RADAK evaporation furnace Please refer to Appendix for details of these calculations One end of the output cable is supplied with a mating plug to the rear panel receptacle the other end is supplied unprepared The unprepared cable end should be connected to the feedthrough by whatever means are appropriate for the feedthrough Be careful however to connect it in such a way that the full current load will not overheat the connection Le use a large enough connector for the current and make sure the crimp or solder joint is properly made a eee PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller lI Il The recommended feedthrough style is a pair of 1 4 inch solid copper rods penetrating the vacuum svstem The output cable can then be connected to the rods using copper clamping connectors secured to the feedthrough rods with heavv crimp rings providing the attachment point of the cable conductors to the copper rods This is the connection method provided by the optional installation kit Remote I O Many aspects of the operation o
10. it simple to operate while offering advanced control options Although specificallv designed and optimized for controlling one of Luxel s line of RADAK evaporation furnaces vour RADAK Power Controller Il is also well suited for manv other power control applications such as lamps filament heaters etc Instructions for connecting your RADAK Power Controller Il to these auxiliarv 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 wav that vou should find convenient to look up the specific information vou need quickiv and easilv Chapter 1 provides a general overview of the design of the power controller Chapter 2 describes the installation procedures necessarv to safelv place the power controller into operation Operation of the power controller is covered in Chapter 3 The lavout of this chapter is bv task grouping organized bv specific results to be achieved so that you can quickly find out how to accomplish a specific goal It is
11. or v to select rmP t Press O to continue Use 4 or v to set the target temperature to 200 Press O to continue Use 4 or v to set the duration of the ramp segment 10 Press O to continue The displav should now show segment 5 Press O to continue Use 4 or v to select End Press O to continue Use 4 or v to select rSEt Press O to continue Once the end segment is programmed the controller returns to the ER PROGRAM LIST screen atolo e Press O as required to scroll through the remaining menu items or Bl ol i 4 press O and 13 simultaneously to return directly to the home display Running Programs On multi program models first select the program to be run 2404 Lo op From the home display press D as required to reach the run list Press O to continue Use 4 or v to select the program to be run 1 Press O to continue At this point the program can be run by setting the program status Gel ho to run with the 4 or w keys or by using the RUN HOLD button 2 J SI IS Once the program has been selected if required the program can be run with the RUN HOLD button Press the RUN HOLD button once to run the program Subsequently pressing the RUN HOLD button will toggle between program run and hold Stopping Programs Press the RUN HOLD button until both the run and hold lights are off about two seconds
12. power controller s load and may not limit the process temperature Setpoint Limits The RADAK power controllers maximum allowed process value is determined by setting the high range limit in the controllers configuration see High temperature limit pg 20 The process value setpoint may be further restricted by setting the setpoint high low and rate limits NOTE the high setpoint limit can not exceed the high range limit 2404 Com Jos Press D as required to reach the Setpoint list SP Press U as required to reach the setpoint high limit screen SP H Use 4 or v to adjust the setpoint high limit Press O to continue Low setpoint limit SP L and Setpoint rate limit SPrr are also set in this list MANTO mo Press D and U simultaneously to return to the home display or press O l l D as required to cycle to other lists Programming Stored programs specifying setpoints ramps and dwells may be used to control the operation of the RADAK Power Controller II This section describes the structure of RADAK Power Controller s programs and a program s components A step by step example of entering and running a sample program is also provided Program Behavior The first section of the program defines parameters affecting the overall behavior of the program Holdback Strategy When a running program is controlling a RADAK evaporation source the process value may lag behind or ove
13. the potential for damage the configuration level is guarded by a second password Use 4 or vw to select the password digit 2 Once the correct password has been entered there is a two second delay after which the lower readout will change to PASS Fr Press O to continue auto RUN Go oo b I L Instrument Configuration 2404 Press D until the inSt ConF header is Lo oe displayed Press O to continue Disabling manual operation Press U as required to reach the m A screen Use 4 or v to select EnAb to enable manual operation or diSA to disable manual operation Press D to proceed to other sections or D and OJ simultaneously to jump directly to the Exit Use 4 or w to select YES to reboot the controller NOTE this step is required once the configuration level is entered Enabling gain scheduling Press O as required to reach the GSch screen Use 4 or v to Loe select YES to enable gain scheduling or no to disable gain GSch scheduling For more information on gain scheduling see Gain scheduling pg 28 YES Press D to proceed to other sections or D and J simultaneously to CS CR o jump directly to the Exit Use 4 or v to select YES to reboot the AUO o OMA controller NOTE this step is required once the configuration level D VI Is is entered 24041 Process Value Configuration Press D until the PU ConF he
14. to the temperature controller and low voltage power supplv protects these components from an overcurrent situation The correct replacement fuse is 4 x 20 mm 2 Amp 250 Volt fast blow It is important that replacement fuses match these specifications exactly so that the system and operator are adequately protected Warning installing a fuse bearing a different rating from the specified fuse rating can result in damage to the power controller wiring and anv attached device or cause a fire RS 232 This DB9 connector is an industrv standard for serial communications with a personal computer Two wire communications with a grounded common following the RS 232 electrical standard are supported by the temperature controller All functions and settings of the controller are accessible through this link The connection with a personal computer can be made using a straight through cable terminated on one end with a DB9 male connector with the other end as appropriate to the computer Thermocouple The thermocouple provides feedback from the furnace or other attached device as to its current temperature which is the value of primarv interest The temperature controller uses the error between the desired setpoint and measured temperatures to compute a new output power level to apply to the heater coil It is thus important to install the thermocouple cable correctiv so that the measured value accuratelv represents the furnace crucible tempera
15. 78 4266 www luxel com Email radak luxel com Primary button functions A or v raise or lower the parameter that is currently in focus by default the temperature setpoint D scroll through the different parameter lists O cycle through the various parameters in a given list man auto toggle the controller between manual mode and auto mode In manual mode the arrow keys serve to raise or lower the output power directly rather than using the built in PID control am REM algorithm In auto mode the arrow keys allow changing the AUTO ex temperature setpoint which the PID algorithm attempts to follow G a T a run hold toggles between running and pausing the current program Holding this button in for several seconds resets a running program Basic Controller Operation Switch on the power to the controller The controller runs through a self test sequence for approximately three seconds and then displays the measured temperature or process value in the upper readout and the target value or process setpoint in the lower readout This is called the home display You can return to this display at any time by simultaneously pressing the U and D buttons Automatic mode Output is automatically adjusted to maintain the process value Manual mode Output power is controlled directly by the operator Program mode Output power and process setpoint are automatical
16. Box 1879 515 Tucker Ave Friday Harbor Wa 98280 ven Jee com Page 38
17. Green Input 3 The digital inputs may be assigned to trigger various events but come pre configured for program select The following illustrates the use of remote program select Selection is initiated by making electrical contact between the common 0 Program Activation wiring 1 All open 2 Black 0 White 2 3 Black 0 White 2 Red 1 4 Black 0 4 Green 3 Functions for I O cable 4 digital input Wire Marking Wire Color Function 0 Black Common a ee eee PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il 1 Red Input 1 2 Green Input 2 The digital inputs can be used to initiate various events in the temperature controller such as starting and stopping programs selecting a specific program to run or selecting a different PID set to use A full list of these possible uses can be found in the accompanving Eurotherm 2404 manual To use this capabilitv the temperature controller must be configured with the intended function of each input Then connecting the numbered input wire with the common wire causes the programmed function to occur or become active Removing the connection causes the normallv open or default function to occur Note that more than one input wire can be simultaneously connected to the commo
18. LUXEL J Radak Power Controller II Series Manual Rev2 2 LUXEL Power Controller II Il PO Box 1879 515 Tucker Ave Phone 360 378 4137 Fridav Harbor WA 98250 Fax 360 378 4266 www luxel com Email radakOluxel com Tato du CO na oa 1 Specification iii ini ii ua eee iti Bele Galstad iden Ghee 3 Operation iii lam nh aan un lan nana Naa 3 EJE trical ss team maa an cents date he bag enam adek 3 MeChaANICAl Len tenan aan ln aa eh ata na ea aa IN ana maan 3 Feature Comparison Chait bentak tanaman hama pt lan area 4 General Description aini em a tn Eed etat nn enter nue 5 IMS tA At ON EE 6 Mechanical Installation sea hose kanan alat af ka ana kapa nian eau 6 Electrical Connections Loco rizzi ki aa ste pe a aa pp ane an ema ati 6 Lee TE 7 Operatii EE 12 Of il A E E E E 12 Primary button T NCTIONS EE 13 Basic Controller Operation seen tea erfa benne fees aah te tatanan 13 Controller DisplaVs i ian kienet ba a pali fra ad bad Gad fa rfi seed anyenedbdacesaadavesegiiduapensadensaas 14 A ess LEE simon aman i enteng Naa na 14 RADAK Power Controller configuration 18 Accessing the configuration level 18 Instrument Configuration is 19 Disabling manual operation sisi 19 Enabling gain scheduling sisi 19 Process Value Configuration si 19 High temperature Wm 20 Programmer Configuration sise 21 Limiting output power usines 22 Setpoint MAIS iss sr e dass dd Rte und kn Binus ana ba ana
19. To use these capabilities the temperature controller must be configured with the intended function of each input Once configured the digital inputs are activated by connecting their respective input lines to the digital UO common lead Relay Output The relay outputs can be used to signal various events in the temperature controller such as temperature alarms program end sensor break load failure or programmed event The RADAK Il has one alarm relay and two programmable relays Both the alarm relay and the programmable relavs have the same functions however the alarm relav provides both a normallv open NO and normally closed NC contact where the programmable relays have only one contact which can be configured as NO or NC Each of the three relavs mav be configured to signal anv combination of the following events Alarm 1 active YES no Programmer event output 1 to 8 active YES no Alarm 2 active YES no Load failure alarm VES no Alarm 3 active YES no Tuning in progress VES no Alarm 4 active YES no New Alarm has occurred VES no Controller in manual mode VES no End of setpoint rate limit or end of program VES no Sensor break VES no Voltage output open circuit or mA output open circuit VES no Process Value out of range VES no A ws AG PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11
20. achieved bv beginning the auto tune process with the furnace already warm 100C this will eliminate the sluggish initial response from a cold filament NOTE Running auto tune on a low temperature process with the controller s output high limit at 100 can result in a massive potentially damaging process temperature overshoot If after running auto tune a low temperature process lt 500 C seems inordinatelv sluggish you may wish to manually reduce the Integral time setting in the PID list Adaptive tuning may also be used to further refine the PID around the target process value The RADAK Power Controller Il PID parameters are set for Pb 15 C ti 30sec td 15sec Hcb 20 C prior to shipping Controller high cutback setting The high cutback is typically used as part of the controllers tuning algorithm to prevent process value undershoot during cool down However the RADAK Power Controller II high cutback Hcb is also used to prevent controller overshoot during certain conditions The controllers PID uses the difference between the process value and the process setpoint and the rate of change of this difference to determine the proper power output required to maintain the process value at the process setpoint This scheme works very well to control normal process transients however a large increase in setpoint below the process value may be miss interpreted by the controller as a rapid cooling To halt this apparent cool
21. ack Lcb setpoint change with increasing power backwards and correct Rise to setpoint PID parameters need Reference Appendix III 4 2 temperature excessively adjusted through 4 6 tuning slow Cannot connect using Cable miswired Check for straight through RS 232 Wrong comm protocol connection Verify communications protocol El Bisynch Modbus PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il Appendix l Connecting the RADAK Power Controller Il to devices other than Luxel s line of RADAK evaporation furnaces requires performing a few simple calculations to verifv compatabilitv The primarv concern when connecting to other devices is that the power requirements of the device do not exceed the output capabilitv of the power controller This is easilv verified at least initiallv bv applving Ohm s Law The output voltage for 100 power level is 40 volts If this is applied to a Ye Q device resistance the resulting current load will be 80 Amperes I V R The power level from the controller would be P V I or 3200 VA Considering that the maximum output power rating of the output transformer is 600 VA this would not normallv be an acceptable device to operate from it Note however that if the device contains a heated wire filament as the RADAK furnace does that the previous example mav indeed be a suitable m
22. ader is displayed Press O to continue OPI OP2 Display units Press O to reach the unit display Use 4 or v to select C for Celsius F for Fahrenheit k for Kelvin or none for no units PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 1 Decimal Places Press to continue to the dEc P screen Use 4 or v to select the number of decimal places to be displayed If nonE is selcted no units will be displayed nnnn shows no decimal places nnn n shows one decimal place and nn nn shows two decimal places It should be noted that the controller has only four units available for temperature displav therefore selecting nnn n will limit the displav to a maximum of 999 9 and nn nn will limit the display to 99 995 24041 NOTE The high range limit and setpoint limits should alwavs be AUTO 9 ON verified after changing the decimal places displayed as doing so LU Is may change previously set values Press D to proceed to other sections or Li and O simultaneously to jump directly to the Exit Use 4 or v to select YES to reboot the controller NOTE this step is required once the configuration level is entered High temperature limit Press O as required continuing to the rnG h screen Use 4 or v to as set the h
23. 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 l 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 A REG PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller lI Il Warrantv Vour RADAK Power Controller Il is warranted to be free of defects due to materials or wor
24. and the person operating the power controller with the most efficient means of obtaining instructions for a specific operation or setting It begins bv providing general instructions on the three operating modes described above front panel operation RS 232 communications and digital control This is followed bv a section addressing controller setup designating functions to be attached to specific inputs and outputs and setting valid ranges and limits Finallv a section is directed at the operator and covers profile programming and other operator functions Overview There are six front panel buttons on the Eurotherm 2404 temperature controller Bv pressing these buttons in the proper sequence all of the controller functions can be accessed all parameters can be accessed and changed and anv allowable temperature profile can be programmed The six buttons are distinguished by symbols molded into them or printed near them and have specific functions associated with each The displav consists of two lines of numbers The upper larger number shows by default the current measured temperature as read bv the thermocouple The lower smaller number displavs the current setpoint value Note that these displavs represent manv other values during configuration and programming with the current meaning of a displav frequentiv indicated bv a mnemonic www PO Box 1879 515 Tucker Ave age 1 Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 3
25. atch to the power controller Remember that the resistance of a tungsten wire increases dramatically with temperature If the filament is thin enough to get sufficientiv hot in a relativelv short time then the 3200 VA load on the power controller will drop quickly into the acceptable load level range In fact this scenario is exactly what happens with the RADAK furnace It draws a transient high load then immediately drops If the resistance of a device you wish to control using the Rapak Power Controller Il is low enough that the above calculation indicates a high initial load it is verv important to determine whether or not the load resistance will increase quickly Thus either additional information will need to be obtained from the manufacturer of the device or a direct measurement of the curent draw will need to be made with the device operating at a terminal voltage of 40 Vac Another method to allow a seemingiv unsuitable load to be operated using the RADAK Power Controller Il is to set a limit on the output level commanded by the temperature controller This variable OP described more fullv in Chapter 3 specifies the maximum percentage of output voltage to allow Thus in the above example to limit the output level to 600 VA through a 2 Q load you would need to specify OP 43 In this case maximum output would be 0 43 40 V 17 2 V and I 17 2 0 5 34 4 Amperes This gives P V l 592 VA which is within the limits of the controller
26. ation with the RADAK II power controller LO Points Inputs 5 Programmable Digital inputs Dedicated digital inputs External SCR control select 1 SCR Control signal BNC 1 External SCR control select Output Relavs 2A 264Vac max 1 Dedicated Alarm SPDT 2 Programmable SPST RS232 serial communications 1 DB9 serial adapter Configuration Digital Input The digital inputs can be used to initiate various events in the temperature controller such as starting and stopping programs selecting a specific program to run or selecting a different PID set to use Each of the five digital inputs mav be configured to activate one of the following events Manual mode select Simulate pressing of the up button Remote setpoint select Simulate pressing of the down button Setpoint 2 select Simulate pressing of the cvcle button PID set 2 select Simulate pressing of the page button Integral hold Skip to End of Current Segment without changing the setpoint One shot self tune enable Program holdback enabled Adaptive tune enable Setpoint Rate Limit Enable Acknowledge alarms Program waits at the end of the current segment Select Full access level Program Run closed Reset open Kevlock Program Reset closed Run open Run program Reset program Hold program Process Value Select Closed PV1 Open PV2 Run program closed Hold open Advance to End of Segment and to target Setpoint Standby ALL control outputs turned OFF
27. e rear panel receptacles It is not however acceptable to input another thermocouple type through an incompatible receptacle It is likely that doing so will introduce appreciable errors in the measured temperature value Receptacles are available for all common thermocouple types as are extension grade thermocouple wire These can thus be substituted so that an accurate temperature measurement can be maintained A SA eee PO Box 1879 515 Tucker Ave age 3 Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Furnace Model Ramp Rate C min Power Output Limit Tuned PID Range C Gain Scheduler Setpoint Proportional Band Set 1 Integral Time Set 1 Derivative Time Set 1 Manual Reset Set 1 Cutback High Set 1 Cutback Low Set 1 Power Controller II Il Radak I 50 30 500 1500 Appendix II Radak II 50 75 500 1500 n a 30 im 1s 500ms 0 50 50 Radak III 40 100 500 1500 OLED 50 20 200 600 OLED H 40 35 200 600 OLED III 30 100 200 600 tGeneral purpose PID parameters will allow effective control of an empty furnace with minimal or no overshoot within the tuned PID range They should be considered a starting point only Luxel recommends using the auto tune feature to achieve best results for specific processes see controller manual Phone 360 374 4137 Fax 360 378 4265 Email radak luxel com PO
28. el com Email radak luxel com LUXEL Power Controller lI Il U 1 10 The deposition controller enters the deposit state and opens the shutter varving furnace power as necessary to maintain deposition rate at 10A sec 11 At 200A the deposition controller enters the end of process state closes the source shutter and opens the normally closed shutdown relay 12 With the shutdown relav s NC contact open the power controllers input 3 is activated causing a standbv event 13 The standbv event clears all digital outputs except alarms on the power controller Clearing the event 1 output de energizes the SCR relay transferring furnace control back to the power controller Clearing the event 1 output also releases the controller from its wait state resuming program operation 14 The power controller reduces the furnace temperature setpoint to 0 over 20 minutes 15 Deposition is complete wee een eee Eo ae SA ae PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 1 3 Ea io os 3 ki 400 Furnace Temperature 25 C FE Output Alarm G n c Output o Eventi KR O n D 2 Input 1 a Reset R i x Input 2 4 G Wait S D Input 3 a Standbv 4 Input SCR 1 n bar Inp
29. f the Rapak Power Controller Il can be initiated controlled or monitored remotelv through the use of the Remote I O cable Alarm Changeover Relav Outputs Functions for I O cable 1 alarm changeover relay Wire Marking Wire Color Function 0 Black Common 1 Red Relay NO 2 Green Relay NC The alarm changeover relay can be configured to become active upon the temperature controller sensing certain events such as the process value furnace temperature exceeding a preset bound This function is especially useful when operating the power controller in rate control mode The temperature controller can continue to monitor furnace temperature and activate the relay if the temperature rises too high as would happen the source charge were depleted and the deposition controller called for a higher output power in an attempt to bring the deposition rate back into spec The alarm relay would thus be a signal to the deposition controller to shut down the process and alert an operator This relay is a changeover relay meaning it has both normally closed NC and normally open NO contacts When inactive there is continuity between NC and common and not between NO and common When active there is continuity between NO and common and not between NC and common Digital Inputs Functions for I O cable 2 digital input Wire Marking Wire Color Function 0 Black Common 1 Red Input 1 2 White Input 2 3
30. from a hardware or marine supplies store Make sure to test any cleaners on a small portion of the face before application to the entire controller A EE PO Box 1879 515 Tucker Ave age 39 Phone 360 378 4137 Fridav Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il CHAPTER 5 Troubleshooting Your RADAK power controller has been carefully designed and constructed for years of trouble free operation However since there is still the possibility of a problem arising this chapter provides you with the information necessary to find out what s wrong and to deal with it Symptom Does not turn on No input voltage Verify input voltage Should measure 0 0 Should measure 0 Q fuse Display shows flashing Sensor break Check tc system with ohmmeter S br Disconnected Unplug cable from controller and thermocouple measure resistance between Improper tc connection in contacts on cable Should vacuum system measure lt 1 Q If higher check Broken furnace feedthrough and furnace thermocouple connections No output power Switched to wrong furnace Change channel selector switch Switched to wrong SCR Change SCR control switch source Check output system with Open output circuit ohmmeter should measure 0 5 Q If higher check feedthrough and furnace connections Large temperature Low cutback needs adjusted Reference Appendix III 4 5 low overshoot after small cutb
31. igh temperature limit This will set the maximum process setpoint or hard limit that can be called from the front panel or by a program Further restrictions soft limit can be placed by adjusting the output limits and setpoint limits see Limiting output power pg 22 and Setpoint Limits pg 23 respectively NOTE RADAK high temperature limit should not exceed arig e 1200 C for furnaces equipped with K type nue thermocouples or 1500 C for furnaces equipped with C type thermocouples Press D to proceed to other sections or D and J simultaneously to jump directly to the Exit Use 4 or v to select YES to reboot the controller NOTE this step is required once the configuration level is entered EP T o PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il Programmer Configuration Press D until the PROG CONF header is displayed Press G to continue Holdback strategv This setting in the controller configuration determines if one tvpe of holdback applies to a whole program ProG or if the holdback can be specified for each program segment SEG Use 4 or v to select the holdback strategy ProG Press O to continue Power fail strategy The power fail strategy setting determines how the controller recovers from a loss of power while a program is run
32. in or Hour of anv dwells specified in the program Program Cycling CYC n Specifies the number of times the program is to be executed The program may be run from 1 999 times or cont for continuous cycling Program Segments The active process controlling portion of the program consists of segments There are five different segment types Up to 8 segments can be specified within a given program The following is a list of the segment types and their defining parameters rmP r Ramp to a new setpoint at a set rate Hb Segment holdback tvpe oniv if programmer is configured for segment holdback tGt Segment target temperature rAtE Temperature ramp rate rmP t Ramp to a new setpoint in a set time Hb Segment holdback tvpe oniv if programmer is configured for segment holdback tGt Segment target temperature dur Time to reach temperature dwEll Maintain the current setpoint for a specified time Hb Segment holdback type only if programmer is configured for segment holdback dur Duration of dwell StEP Step to a new setpoint Hb Segment holdback type only if programmer is configured for segment holdback tGt Segment target temperature End Last segment of the program End t End type dwEll Program continues at the last septoint indefinitely rSEt Ends the program returns control to the operator at the last setpoint SOP Ends the program setting the controllers output power to that specified Sample Program This section detail
33. in this level through the Edit level below In addition to the HOME list six additional lists are available in the operator access level Run list Program list Auto tune list PID list Information list Access list Each list is accessed sequentially by pressing D Pressing O accesses the parameters in each list Parameters in turn may be modified with the 4 and w keys You can return to the home display at any time by simultaneously pressing the G and D buttons Parameters pertinent to operating the RADAK Power Controller II will be discussed in the following sections WESSEN TEE LR PO Box 1879 515 Tucker Ave age 15 Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 1 Il Full Access Level All parameters relevant to the controller s current configuration are accessible The full access level allows use of all features and operations available in the operator level and also provides access to additional parameters The additional parameters include adaptive tuning see Gain scheduling pg 28 output control set point limits below and displav mode configurations The following steps are required to access the RADAK Power controller s full access level Press D until you reach the access list header ACCS Press O to continue 2404 Use 4 or v to select the pass code digit 1 Press O to continue Use 4 or v to select FuLL to enter the selec
34. ing the controller reacts by applying power even though the process value may be well above the process setpoint For example A program has been run with the ending segment dwelling at 740 C The operator wishes to reduce process temperature to 710 C The program is terminated normally by holding the run hold button Once the program is terminated the controller resets the process setpoint to zero The operator then increases the process setpoint to 710 C The controller sees the sudden massive decrease between the process value and the process setpoint and even though the process value is well above the new setpoint applies full power to halt the change The resulting overshoot depends on the controller maximum output PID settings and process being controlled but may be on the order of several hundred degrees The RADAK Power Controller II s high cutback is set to 20 C prior to shipping thus the controller will take no corrective action as long as the process value is more than 20 C above the process setpoint It should be noted that some overshoot may still occur if the process setpoint is increased to within 20 C of the process value If the operator above had set the process value to 730 C instead of 710 C with Hcb set to 20 C the controller would still have reacted by applying power but the correction would have been halted once the process value exceeded the setpoint by 20 C greatly curtailing the overshoot a gt TT y PO B
35. is correct The configuration parameters are grouped in lists For a complete list of parameters available see Eurotherm 2404 manual pages 6 4 through 6 6 In this section the following parameters will be covered Instrument Configuration Disabling manual operation Enabling gain scheduling Process Value Configuration Displav units Decimal places High temperature limit Programmer Configuration Holdback strategv Power fail recoverv strategv Servo strategv Pogram svnchronization availabilitv not used Accessing the configuration level There are two methods of entering the configuration level depending on the controller s status 2404 If the controller is off holding the 4 and e buttons simultaneously while turning the unit on will take you directly to the CONF password display Proceed to Instrument Configuration below If the unit is operating the following steps are required to access the configuration level Press D until you reach the access list header ACCS Press O to AUTO RUN wan e AHOLD continue B zZ a Use 4 or v to select the pass code digit 1 Press O to continue PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com Use 4 or v to select CONF to enter the configuration level Press me O to continue Due to
36. kmanship for 1 one vear from date of purchase This warrantv excludes damage caused bv improper installation and intentional or inadvertent misuse e g operating into an unsuitable load In the event of a warrantv claim Luxel Corporation reserves the right to either repair or replace the unit at our discretion A EG PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com Specifications Operation Temperature range 0 to 1500 type C 0 to 1200 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 oom mma 2 sets Environment 0 to 55 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 max USGS anna dessin g a 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 oooooo WWW 0 to 40 Vac at 0 to 30 A Mechanical EVNiGlOSUIG Hansen adan aini mana 8 43 W x 5 25 Hx 15 07 L inches excluding handles EEN 7T e ee PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www l
37. luxel com RADAK ll Configuration LUXEL Power Controller 11 Il Item Description Alarm 1 setpoint 600 C Maximum furnace temperature indicates end of source material 600 C chosen for illustration only Alarm relay close on Alarm 1 active Sensor break Furnace over temp or temp unknown Reset power controller return furnace control to power controller and signal deposition controller to stop Programmable relay 1 close on Event output 1 Triggered by power controller program signals the deposition controller that the furnace is at deposition temperature and enables external furnace control Digital input 1 Reset Controller on Open Resets power output to minimum and terminates program operation Digital input 2 Tied to event output 1 causes program Wait on close operation to hold while deposition controller runs the deposition Digital input 3 Standby on close Tied to deposition controller end of process alarm fault etc causes event output 1 to clear transferring control of the furnace back to the power controller resuming program operation for source shutdown wee een ee Ee eae ee ee age Phone 360 378 4137 PO Box 1879 515 Tucker Ave Friday Harbor WA 98250 www luxel com Fax 360 378 4266 Email radak luxel com RADAK II Power Deposition
38. ly adjusted by the controller Automatic Mode The RADAK Power Controller is normally operated in automatic mode If the MAN light is on press the AUTO MAN button to select the automatic mode 2404 In the home display both the process value and process setpoint are opi ll op shown The setpoint is adjusted by pressing the A or w buttons Two seconds after releasing either button the displav blinks to show that the controller has accepted the new value and the controller adjusts output power as required to obtain and maintain the new setpoint The RADAK Power Controller s power response characteristics are determined by the PID and output parameters described in the Tuning section below T N f RUN AUTO e Q In 4 V A applying power Manual Mode Manual mode is used when direct operator control of output power level is desired To operate the controller in manual mode press the AUTO MAN button to toggle from auto to manual mode The MAN light will illuminate indicating manual mode operation OP1 will light whenever output 1 is on indicating that the controller is The lower display now indicates the percent power output by the controller Output can be adjusted by pressing the 4 or w buttons NOTE Extreme caution should be exercised when using the RADAK Power Controller in manual mode as power is applied without regard to process value Operating without the RADAK
39. n wire so that functions can be used together when it makes sense to do this Functions for I O cable 3 relay output Wire Marking Wire Color Function 0 Red Relay 1 1 White Relay 1 2 Green Relay 2 3 Black Relay 2 The relay outputs are similar to the alarm changeover relay with the exception that the two relays do not offer both normally closed and normally open contacts They can be configured for either NO or NC operation to simply connect or disconnect one side to the other when active and reverse this when inactive The relays can be configured to provide an event output explained further in the Event outputs below which is activated by a running program in the temperature controller A ee eee PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller lI Il Remote Control Functions Functions for I O cable 5 external SCR control select II Wire Marking Wire Color Function 0 Black External SCR control select common 1 Red External SCR control select The remote control functions allow an external system controller to operate the internal control relays that select whether the SCR is controlled by the temperature controller or by an outside device such as a deposition monitor II et PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harb
40. ning There are three settings available cont When power is restored the program continues from where it was interrupted when power was lost All parameters such as setpoint and time remaining in the active segment will be restored to their power down values For applications that need to bring the measured process value to the setpoint as soon as possible this is the best strategv RmP b When power is restored the setpoint starts at servos to the current measured value and then ramps to the target setpoint 2404 2404 OP OP2 of the active segment at the last ramp rate used by the program This strategy provides a smoother recovery RSEt When power is restored the program terminates Use 4 or v to select the desired power fail strategy RMPB Press O to continue Servo type When a program is run the setpoint can start either from the initial controller setpoint or from the current process value When the program starts the transition of the setpoint to its starting point is called servoing The normal method is to servo to the process value to PV producing a smooth start to the process To guarantee the time period of the first segment to SP should be select to jump immediately to the current segments process setpoint Use 4 or v to select the servo
41. ntroller None use DB9 serial or Computer controller access adapter Thermocouple Power output SCR control None use male BNC cable External device deposition controller input A SCR control input Power input The input power requirement for the RADAK Power Controller Il is a single 15 Ampere circuit at 115 Vac 60 Hz via a standard three prong grounded outlet other input voltages and frequencies can be optionally supplied Svstem fuse This fuse installed on the main input ine hot conductor protects the entire instrument from an overcurrent situation Input power to all components inside the RADAK Power Controller Il passes through this fuse first Its primary purpose however is to limit the current available to the output transformer and associated wiring and components The correct replacement fuse is 4 x 20 mm 10 Amp 250 Volt fast blow It is important that replacement fuses match these specifications exactly so that the system and operator are adequately protected Warning installing a fuse bearing a different rating from the specified fuse rating can result in damage to the power controller wiring and any attached device or cause a fire Page 1 PO Box 1879 515 Tucker Ave Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller lI I Controller fuse This fuse installed on the ine hot conductor supplving power
42. or WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il CHAPTER 3 Operation Vour RADAK power controller has been designed for maximum versatilitv and offers two different operating configurations The first and most basic is pushbutton operation In this mode all parameters are set and anv programming is done using the buttons on the front of the Eurotherm 2404 temperature controller along with the switches provided on the front and rear panels of the power controller While this operating mode provides access to all of the features of the controller itis more time consuming to enter programs and requires manuallv starting the controller A second operating mode RS 232 serial is also available If vour RADAK power controller is connected to a personal computer running the Windows platform you can use the Eurotherm iTools software to set all controller parameters as well as to easilv enter sophisticated time temperature profiles The most current version of iTools is a free download available from Eurotherm at http www eurotherm com itools If you are connected to a different type of computer or a PC not running the Windows platform you can either use a standard communications program in local mode to operate the power controller or vou can construct custom software to operate the controller This chapter has been arranged by function to provide both the person commissioning
43. oroughly 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 bv the temperature controller is a PID Proportional Integral Derivative algorithm widelv used for general control applications By adjusting the three terms P l and D along with output scaling and power cutback to reduce overshoot the algorithm can be tuned for anv 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 steadv furnace temperature An alternative to phase angle firing zero crossing SCRs are much less expensive but produce small oscillations of the furnace temperature at steadv 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 Fi
44. ox 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il Gain scheduling The RADAK Power Controller Il can maintain two sets of PIDs for controlling processes that exhibit large differences in control responses at different temperature To enable gain scheduling follow the steps outlined in Enabling gain scheduling pg 19 Once enabled the gain transfer setpoint and PID values can be defined both PID parameters will now be visible in the operator level 2404 OPI OP2 To set the gain transfer setpoint enter the full access level as detailed above Press L to reach the PID list Press U as required to reach the G SP screen Use 4 or v to set the setpoint 500 Press O to continue Press O and U simultaneously to return to the home display or press D as required to cycle to other lists Once enabled and set run auto tune below the gain transfer point to aural ou set PID1 and again above the transfer point to set PID2 L y Auto tune Refer to the Eurotherm 2404 manual pg 4 2 for a description of the auto tune process Auto tune can be run from either the operator or full access levels Starting with the process at ambient temperature enter the process setpoint for which you wish to tune the controller Press D as required to reach the Atune list Press O
45. roller Il 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 necessarv to fabricate a metal support plate to secure the inboard side of the cabinet This consists of a simple 5 inch by 9 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 Rapak Power Controller Il series instruments can be mounted side by side using only 51 4 vertical inches of rack space Electrical Connections The following figure shows the rear panel of the RADAK Power Controller II a ee PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 1 Thermocouple o SCR Control Input O Fower Output Remote I O Fuses System Controller gf OO EJ P ower Input 104 2A Component Supplied Accessories Function Power input Power cable Mains voltage input System fuse 10 A fast blow 5x20 mm Protects entire instrument spare Controller fuse 2 A fast blow 5x20 mm spare Protects temperature co
46. rshoot the process setpoint If the process value deviates from the process setpoint by a predetermined amount the RADAK Power Controller can place the running program on hold The holdback strategy determines how when and if the controller reacts to the deviation There are four holdback types OFF Disables the holdback and the program continues regardless of process value Lo Holds the program back when the process value deviates below the setpoint by more than the holdback value Hi Holds the program back when the process value deviates above the setpoint by more than the holdback value bAnd Holds the program back when the process value deviates above or below the setpoint by more than the holdback value WESSEN sT e VK age Phone 360 378 4137 PO Box 1879 515 Tucker Ave Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller lI Il The holdback tvpe can be defined and applied to the whole program default or to each section individually To enable defining holdback for each segment see Holdback strategy pg 21 Ramp Units rmP U Determines the time units SEc min or Hour in the denominator of any ramp rate subsequently specified in the program For example if C are defined as the controllers display units by selecting min as the ramp units any ramp rates specified in the program will be in C min Dwell Units dwL U Determines the time units SEc m
47. rst 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 wee ee OEE EEE eee PO Box 1879 515 Tucker Ave age 5 Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il CHAPTER 2 Installation This chapter describes the installation procedures for connecting a RADAK Power Controller Il to a vacuum svstem containing a RADAK evaporation furnace For connection to other devices it is recommended that vou 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 injurv or death Mechanical Installation The Rapak Power Cont
48. s the steps required to input and run a sample profile Once input and run the RADAK Power Controller will execute the following profile D Step to 200 C Temperature Profile Dwell at 200 C for 2 minutes weg Ramp to 1500 C over 15 minutes 1400 Dwell at 1500 C for 20 minutes i 18004 Ramp to 200 C over 10 minutes eal Dwell at 200 C for 5 minutes 8 600 Reset power controller Es End program 5 0 10 20 30 40 50 PO Box 1879 515 Tucker Ave Page 24 Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il From the Home display press D until you reach the ProG LiSt vu header pressing O will take you directly to the first screen of the i us program The holdback strategy selected in this step applies to the whole program Use 4 or vw to select the holdback type bAnd Press O bAnd to continue ik les SP2 REM Use 4 or v to set the holdback value 5 Press O to continue AUTO L RUN MAN o k HOLD D K D Use 4 or v to select ramp units sec min Press O to continue Use 4 or v to select the dwell units min Press O to continue Use 4 or v to set the number of times the program cycle s to be repeated 1 Press O to continue 2404 Use 4 or v to select the program segment to be modified 1 Press O to continue
49. ted level Press O to continue Once in the full access level navigation is the same as in the operator level Press D as required to scroll through the parameter AN fe lists and use U as required to scroll through the individual parameters in the selected list Press D and O simultaneously at any time to return to the home display Configuration Access Level The configuration level is used to set the fundamental properties of the controller This level addresses parameters such as I O module configuration program operation temperature units etc Improper settings in this level may cause basic controller to operation errors Errors made in this level can result in system process damage and can be difficult to trouble shoot In short if you don t know what you re doing don t do it For a detailed discussion of unit configuration and configuration parameters see pg 18 Edit This level is used to define which parameters can be viewed altered by the operator The edit level also allows the promotion of a parameter to the home list See the Eurotherm 2404 manual page 3 4 for a full discussion of the edit level The following example details the steps required to make the gain scheduling transfer setpoint accessible in the operator level Using the edit level Enter the Edit level using the same procedure as outlined in ZS
50. tion level see High temperature limit pg 20 further restrictions can be placed on controllers output in the form of soft limits The controllers output power high low and ramp rate limits are set in the full access output list The following steps are required to access the RADAK Power controller s full access level Press 5 until you reach the access list header ACCS Press O to continue AUTO e en Use 4 or v to select the pass code digit 1 Press U to continue In Kei LS a y PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 1 Il Use 4 or v to select FuLL to enter the selected level Press U to continue Press D as required to reach the Output list oP Press U as required to reach the high output power limit screen OP Hi Use A or v to adjust the high power limit This value will vary depending on the process being controlled selecting 50 to 60 should provide a safe starting point for low temperature processes Press O to continue Use this procedure to set the low output power and output rate limits Press D and U simultaneously to return to the home display or press L as required to cycle to other lists FN NOTE These settings only affect the power applied to the RADAK
51. to reset the program Modifying Program Parameters Program parameters can be temporarily modified during program execution Place the program into hold by pressing the RUN HOLD button Program parameters such as ramp setpoint and dwell times can now be modified in the remaining segments of the program These changes are temporary and only affect the program during this execution Modified parameters will reset to their original settings when the program terminates wee eee ee Oa eee ee ee PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il Tuning If tuned properly the RADAK Power Controller Il controller is a highly stable temperature controller Improper tuning can lead to process instabilities and difficultv controlling deposition rate The Eurotherm 2404 Installation and operation handbook provided with vour RADAK Power Controller provides a good explanation of the tuning process General notes on tuning The controller s one shot auto tuning process provides a good basis for controller operation Prior to running the one shot tuning consider limiting the processors output power Limiting output power pg 22 Itis also advisable to note the current PID settings prior to running auto tune If the auto tune results are unsatisfactorv refer to the Eurotherm 2404 manual pg 4 4 for manual tuning Better results mav be
52. to continue to the tune screen Use 4 or v to select on Press D and O simultaneously to return to the home display The process value and process setpoint will now be shown tune will flash periodically in the lower display until the tuning process is complete Adaptive tune Refer to the Eurotherm 2404 manual pg 4 3 for a description of the auto tune process Adaptive tune can only be selected from the full access level To start adaptive tuning enter the full access level as detailed above Press D to reach the tunE list Press U as required to reach the drA screen Use 4 or vw to select on to start adaptive tunning Press O to continue From the drA t screen use 4 or v to set the adaptive tune trigger REM setpoint 5 Press U to continue Press D and O simultaneously to return to the home display or press D as required to cycle to other lists NOTE For best results gradually decrease the trigger setpoint allowing the process to stabilize until the desired accuracy and stability is obtained Once the process is tuned either increase the trigger setpoint or disable adaptive tuning to prevent tuning oscillations PO Box 1879 515 Tucker Ave age Friday Harbor WA 98250 www luxel com Phone 360 378 4137 Fax 360 378 4266 Email radak luxel com LUXEL Power Controller 11 Il Autom
53. ture A thermocouple cable has been supplied with the power controller comprised of 6 feet of the proper tvpe of extension wire fitted with a mating connector for the rear panel jack This wire should be routed away from sources of electrical noise such as high frequency power supplies and electric motors If the length must be increased it is preferable to replace the cable with a single length rather than splicing an additional length of cable to the supplied cable If the required length is fairly long gt 20 feet it is better to use a shielded thermocouple cable to reduce its susceptibility to electrical noise Finallv if the required length is very long 250 feet a signal retransmitter or amplifier should be used A much better solution to these applications is to site the power controller closer to the furnace and operate the controller remotely using either RS 232 communications or the provided digital I O functions The unprepared thermocouple extension cable ends must be connected to the vacuum feedthrough to which the furnace thermocouple is connected This vacuum feedthrough should be compatible with the thermocouple tvpe C or K Proper vacuum feedthroughs for thermocouples are readilv available from vacuum svstem parts suppliers or are supplied with the optional installation kit from Luxel Corporation or its distributors Power output The heavv 10 gauge output cable delivers the current supplied bv the power controller to the
54. type to PV Press O to continue PO Box 1879 515 Tucker Ave age Friday Harbor www luxel com WA 98250 Phone 360 378 4137 Fax 360 378 4266 Email radak luxel com LUXEL Power Controller 11 1 Event outputs This setting toggles availabilitv of programmable digital event outputs Use 4 or v to select YES to enable event outputs or NO disable event outputs This option is available in the RADAK Power Controller IIP only Press O to continue Svnchronization Svnchronization allows communication between controllers using the PDSIO bus This option is not currently available in the RADAK Power Controller line Contact Luxel Corp or Eurotherm for additional information on this feature Use 4 or v to select NO or YES to disable or enable synchronization respectively NOTE the RADAK Power Controller does not use the svnchronization feature This setting has no effect on the Rapak Power Controller operation Press O to continue AUTO EN MAN e Press D to proceed to other sections or D and O simultaneously to jump directly to the Exit Use 4 or w to select YES to reboot the controller NOTE this step is required once the configuration level is entered Limiting output power Once the controllers high temperature limit has been set in the configura
55. ut 2 Start i n Lu Input D Stop 1 O n c Ke Output 1 End 2 n D Output Q Deposit 1 Sequence Step 1 2 B 4 15 6 7 8 9 10 11 12 aa En PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il CHAPTER 4 Maintenance The RADAK Power Controller Il has been carefullv designed to require essentially no attention for manv vears of use However two verv simple operations should be performed periodicallv to ensure efficient and long lived performance First periodicallv inspect all of the electrical cables connected to the rear panel of the controller These should be free from excessivelv chafed cracked or otherwise damaged insulation In addition inspect all cable connections for tightness and damage to anv crimped terminals Repair anv faultv or questionable wiring before operating the power controller Should the power controller ever require cleaning please follow these simple instructions to ensure that the cleaning operation does not cause damage to the controller Unplug the power controller before cleaning Use a soft cloth dampened with water and a mild non abrasive soap to clean the front panel and temperature controller face If scratches are present in the temperature controller face it mav be possible to remove them using a clear plastic cleaner and polish available
56. uxel com Email radak luxel com General Incorporates Eurotherm Model RS 232 Communications Auto Tune algorithm Output Channels Programmer Stored Programs Program Segments Stored programs can be linked I O 1PV Analog inputs SR external Software selectable input source All common thermocouple types Custom linearization profile All standard RTDs pyrometers Voltage current inputs User calibration External control inputs Digital I O 3 input 2 SPST 1 SPDT Control schemes PID external Relay outputs PC Interface Eurotherm iTools software for configuration and control RE PO Box 1879 515 Tucker Ave age Phone 360 378 4137 Friday Harbor WA 98250 Fax 360 378 4266 www luxel com Email radak luxel com LUXEL Power Controller 11 Il CHAPTER 1 General Description The RADAK Power Controller Il is constructed of three primary components carefully selected to work together and provide complete functionalitv 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 functionalitv to the primarv components These components include switches relavs connectors and an auxiliarv power supply The temperature controller is a Eurotherm model 2404 This unit described th

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