Nor-Cal Intellisys Adaptive Pressure Controllers - Manual (Page 42)

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I
ntellIsys
A
dAptIve
p
ressure
C
ontrollers
APC-OP-LIT 1/12
12.0 - Product Support
CAUTION: DO NOT open the enclosure. Damage to equipment may occur, and unauthorized access to internal parts will void the warranty.
Troubleshooting
Some basic troubleshooting can be done by the user referring to the instructions and suggestions in the table below which describes common symptoms
and recommended actions. The Nor-Cal Products’ APC controller module is designed for years of maintenance free operation. Electronics MTBF has been
determined to be in excess of 10,000 hours continuous operation. There are no user serviceable parts or components inside the enclosure. If a problem does
occur with the APC control electronics or software, please refer to the basic troubleshooting instructions below or contact Nor-Cal Products Intellisys Customer
Support to obtain additional instructions or a Return Materials Authorization number.
TAbLE 12.1 – POSSIbLE FAILURE mODES AND RECOmmENDED ACTIONS
SymPtom PoSSIBle cAuSeS recommenDeD ActIon
The APC does not appear to turn
on. No LEDs are illuminated
The APC is not receiving power properly
Check external power supply, cabling and pin assignments. Try to restart the APC by
reconnecting power supply. Operate OPEN/CLOSE switches.
The APC is on (one or more
LEDs illuminated) but it will not
respond to commands
The initialization safety lock function is active.
The amber FAULT LED should be on and the
OPEN/CLOSE LEDs should be blinking.
Issue the JC command via the RS-232 serial port to execute the initialization sequence.
The RS-232 serial or Analog/TTL connections
are not properly made
Check cabling and pin assignments. Make sure CTS, RTS and DSR connections are not made.
Communication settings disagree between
the APC and the host
If RS-232 is used, make sure host is set for 9600 Baud, 1 stop bit and no parity.
Cycle power to the APC to refresh dip switch settings.
A communications timeout has occurred Call for Intellisys Technical Support
The APC does not operate and
only the amber FAULT LED is on.
The valve plate and/or actuator is jammed
Cycle power to attempt re-initialization. Or, with power OFF, try to move valve plate by hand.
If stuck, call for Intellisys Technical Support.
There is something wrong with the motor
drive circuitry or the internal power supply
circuitry.
Call to obtain an RMA#.
The valve plate position does not
agree with the indicated position
The APC software has lost track of valve
position
Cycle power and allow for re-initialization. If problem repeats or persists,
call for Intellisys Technical Support.
Pressure control performance is
unsatisfactory
The APC is not receiving the gauge pressure
signal, or the signal is very noisy.
Check the gauge cabling and signal stability. Also, check for electrical noise or system
vibrations, especially if a 100 mTorr (or similar) gauge is used.
The APC is in valve position control mode Put the APC in the correct mode by issuing the proper RS-232 or DeviceNet command
System design or operating range may be
outside the capabilities of the Adaptive
Pressure Control Algorithm
Call for Intellisys Applications Support.
The controller / valve will not
respond to a new set point value
The new set-point value is too close to the
old set-point value
When using serial communications, the difference between two set-point values should be
more than 0.01%. When using analog/TTL communications, the new set-point has to be at
least 25 mV higher or lower than the old set-point.
There is too much noise on the set-point
signal (analog mode, only)
In order to not “chase moving targets” due to electrical noise, the APC will only accept
a new set-point value if the stability of the signal is within a 50 mV band. Set-point signals
with a high level of noise will therefore not be accepted and the controller / valve will
remain in its present mode.
The LEDs are illuminated in an
unknown fashion
Please refer to Table 12.2 on the next page describing valid LED combinations.
WARNING: When working with or troubleshooting Nor-Cal APC products extreme care must be taken to avoid putting bodily parts
in or near the valve gate mechanism or other moving parts. These may move suddenly and unexpectedly, and many of them are driven
with sufficient force so as to cause significant harm and possibly even dismemberment. Nor-Cal Products recommends that a lock-out
and tag-out procedure be strictly followed whenever human physical intervention is required on all of its control valves.