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Programming The Series 5000 Controller

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To create a program that will control a rectifier's output, select the Programs > Manage Programs menu item.

After the Program Manager opens, right click the folder to create a program and select New Program. If you need create a folder, select New Folder and a new folder will be created inside the selected folder.

Selecting New Program will open the Program Editor allowing you to build your program .

After the Program Editor opens, enter a name for the program. You can enter a description for the program as well. Next, select either Voltage, Current, Current Density or V/I Hybrid as the control mode from the drop-down menu. The Series 5000 Control is capable of controlling the rectifier's voltage and current during a process. This gives you absolute flexibility for your rectifier control. You could for example ramp a program to a particular current and at the same time not allow the voltage to exceed a specific set value. After some time however the voltage could be ramped again to a higher (or lower) level. If the control mode is selected as V/I Hybrid, secondary instructions are not available.

If you choose a voltage control mode, you will be entering the voltage instructions in the pane on the left. These instruction are referred to as the program's primary instructions. Current control instructions are referred to as secondary instructions and are entered in the right pane. If the control mode is current or current-density, the current control instruction are primary, voltage instruction are secondary and the sides they are enter inn are reveresed.

Note regarding secondary instructions:

You do not have to include secondary instructions. If no secondary instruction are entered, the secondary output is assumed to be the rectifier maximum output. For voltage control, the secondary output will be fixed at the rectifier's maximum output current. For current and current-density programs, the priamry output is fixed at the rectifier maximum voltage.

Regardless of the control mode, each instruction set (both primary and secondary) must begin with a Ramp instruction. Clicking the Ramp Button will add a ramp instruction to the program. You will then be asked to enter output you would like to change to followed by the amount of time it will take to reach the desired output.

To maintain the output at a specific value, click the Hold Button . You will then be asked to enter the amount of time to maintain the output. You can also add a Pause instruction to the program. When a pause instruction is encountered while a program is running, the rectifier outputs will be set to zero volts and zero amps and the general alarm will be activated to alert your operators. To add a Pause instruction, click the Pause Button While a program is paused, the operator can pull the load out of the tank and check the coating thickness. If the parts need more processing time, the operator can resume the program.

You can add multiple instructions very quickly by defining a pulse profile and adding it to the program. A pulse profile is like a small sub-program that can added to a program and allows you to quickly build slow pusle anodizing programs. Please see Managing Pulse Profiles for details.

To edit any, simple double clicking the instruction. Double-clicking a ramp instruction will allow you to change the desired output for that instruction and/or the time required to reach the output. Double-clicking a hold instruction allow you to change the time of the instruction. Note that if you change the output of a ramp instruction, all of the following instructions will be changed by the same amount. So if a ramp instruction was change from 14 volts to 15 volts, the output of every following instruction will be increased by one volt. To remove the last instruction, click the Delete Button .

You cannot insert instructions in the list. Instructions can only be added to the end of the instruction list. Likewise, only the last instruction can be removed.

If secondary instructions are used, the primary and secondary instruction sets must be reconciled. Reconciling the instructions ensures that both instructions set have the same total processing time. After entering all of the instructions, click the Reconcile button over the seconardy instruction set to reconile the program. If the instruction set are not of equal length, the program will attempt to reconcile itself if the last secondary instruction is a Hold instruction. In these cases, reconciliation occurs by adjusting the time of the last secondary instruction. If the last secondary instruction is not a hold, the program will not reconcile itself. For this reason it is good practice to end the secondary instruction set with a hold instruction.

A program must be reconciled before it is saved.

You can also include information with your programs. If you have a program that is for a particular part, you can include the part number and customer name with the program so your operators will not have to enter the information every time they run the program. To add information to a program click the Data Fields button from the program editor. Before adding data to a program, you must configure the data field first. Please see Managing Data Fields for details.

After click the Data Fields you can add data to the program button in the window that appears. Available data fields are shown in the list on the left side. Double-clicking a field in list will add it to the program. After adding a field, enter the value it should be when the program is run. If the value will always be what you enter, then by selecting the Fixed option, the operator will not be allowed to change the data. If most of the time the value is what you entered, but sometimes it changes, leave the fixed option unselected and the operator will have the opportunity to change it.