Protecting Multi-Tool Vacuum Processes with Visual Pressure Alerts
A Simple, Visual Solution to Protect Process Uptime
When multiple tools share a single vacuum pump, maintaining stable foreline pressure is critical. In one recent application, a customer was operating five tools connected to a single vacuum pump, all of which function reliably below 558 Torr but become inoperable if pressure rises above that threshold. The challenge was clear: the customer needed a dependable, easy-to-use control solution that would prevent over-pressure conditions while giving operators immediate visibility into system status.
DigiVac delivered a purpose-built solution that combined intelligent pressure control, clear visual alerts, and simple operator interaction—all integrated around the Fyra Vacuum Controller.
Components Used in the System
The solution includes:
- Fyra Vacuum Controller, configured with:
- 775i pressure sensor
- 4V sensor drive card
- Throttle card
- Relay card
- KF25 electromagnetic bellows valve
- Dry relay contacts set for 558 Torr with 10 ft, 2-conductor cable
- Red and green light tower, fully integrated
- One-page setup instructions and a complete wiring diagram
The Challenge: Preventing Over-Pressure in a Shared Pump Environment
With multiple tools tied into one pump, foreline pressure fluctuations can quickly impact production. The customer needed to:
- Control when the vacuum pump and valve are allowed to operate
- Clearly alert operators when pressure exceeds the allowable range
- Allow flexibility for changing pressure limits or future system reconfiguration
- Keep operation intuitive and minimize training requirements
Rather than adding complexity, the solution needed to make system status immediately obvious – at a glance.
The DigiVac Solution: Visual Alerts and Intelligent Control
To meet these requirements, DigiVac engineered a control and alert system centered on the Fyra vacuum controller, enhanced with a red/green light tower and a custom Start button function.
Key elements of the solution include:
- User-adjustable pressure threshold set initially at 558 Torr
- Light tower integration for instant visual feedback
- Green light: system within acceptable pressure range
- Red light: pressure exceeds tool operating limits
- Start button logic that temporarily disables relay setpoints during initial pump-down
- Automatic valve control to protect the system during pressure excursions
This approach ensures operators always know whether the system is safe for tool operation, without needing to interpret gauges or controller screens.
How the Configuration Works
The system is designed to be intuitive and repeatable. Here is the process:
- Idle Mode
- Chamber is at atmosphere with the valve closed
- If pressure is above the setpoint, the red light is illuminated
- System Start
- Operator presses the Start button
- Relay setpoints are temporarily disabled
- Valve opens and the system begins evacuating
- Reaching the Setpoint
- Once pressure drops below 558 Torr, relay control is enabled
- Red light turns off; green light turns on
- Pump continues pumping until shut off
- Normal Operation Complete
- System remains in this state until the operator presses Stop, wherein the system will return to Idle mode
- Anomaly Protection
- If pressure rises above the setpoint at any time, the valve automatically closes
- Green light turns off; red light turns on – immediately alerting the operator
This closed-loop response protects both the tools and the process while minimizing operator intervention.
Conclusion: Clear Visibility, Better Control, Reliable Operation
This custom foreline control solution enables operators to instantly see when their vacuum system is within or outside the allowable pressure range, reducing risk and improving uptime. By integrating a light tower and custom relay logic into the Fyra controller, DigiVac delivered a solution that is both technically robust and operator-friendly.
The result is an adjustable system that protects sensitive tools, simplifies operation, and demonstrates how DigiVac combines standard products with application-specific engineering to solve real-world vacuum challenges.
Want More Info?
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Check out another, similar solution DigiVac worked on recently that includes an audible alarm as well!
