Home

EZT-560 Touch Screen User`s Manual

Contents

1. 59 F 60 r w 0x003B 0x003C System Status Monitor Loop 1 Setpoint 0x003D 0x003E Loop 1 Process value Loop 1 Percentage of Output Bit1 Humidity Water Reservoir Low Bit2 Humidity Disabled temperature out of range Bit3 Humidity High Dewpoint Limit Bit4 Humidity Dewpoint Limit Bits Door Open Bit6 not used Bit7 not used Bit8 not used Bit9 Service Air Circulators Bit10 Service Heating Cooling System Bit11 Service Humidity System Bit12 Service Purge System Bit13 Service Altitude System Bit14 Service Transfer Mechanism This parameter is bit oriented The value must be converted to binary and the status of each bit checked to verify status 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 10000 10000 100 00 100 00 Note that value must be converted from whole number i e divide by 100 to convert the decimal number from the value read 63 r w 64 r w 65 r w 66 r w 0x003F 0x0040 0x0041 0x0042 Loop 1 Autotune Status Loop 1 Upper Setpoint Limit Loop 1 Lower Setpoint Limit Loop 1 Alarm Type Selection Autotune Off Initiate Autotune Autotune Active Terminate Autotune RMA O 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten
2. FLUID SYS HIGH PSI Press each alarm to change name Press Accept to Save Figure 9 15 Critical Chamber Alarm Names To change or edit a tag name touch the position for the alarm and change the name using the pop up keypad Note that alarm names are limited to 20 characters in length NOTE Altering the alarm names from those listed on the EZT Configuration sheet provided with the chamber may cause operator confusion when diagnosing alarms Use discretion when altering tag names 85 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 9 12 Critical Refrigeration Alarms Access the Critical Refrigeration Alarms screen from the Event Alarm Tags menu This screen is used to set the names for the different refrigeration system alarms 2 Loops Chamber Event Alarm Tags Critical Refrig Alarms SYS1 HILO PSI SYS1 LOW OIL PSI SYS1 HI DISCHARGE TMP SY S1 COMP MONITOR PUMPDOWN DISABLED NOT USED NOT USED NOT USED Press each alarm to change name Press Accept to Save Figure 9 16 Critical Refrigeration Alarm Names To change or edit a tag name touch the position for the alarm and change the name using the pop up keypad Note that alarm names are limited to 20 characters in length NOTE Altering the alarm names from those listed on the EZT Configuration sheet provided with the chamber may cause operator confusion when diagnosing alarms Use discretion when altering tag names 86 EZT 560 Chamber Tr
3. inhibited when the altitude system is enabled The vacuum system used to control the internal chamber pressure can not operate with the addition of moisture Only altitude chambers with vacuum systems specifically designed to operate with the presence of moisture will allow humidity control with the altitude system enabled 3 2 1 3 Auxiliary Cooling The auxiliary cooling system utilizes LN2 or CO2 as a boost cooling medium to assist the refrigeration system in lowering the chamber air temperature It is an inexpensive method for fast cooling transitions without having to make the investment in a high horsepower refrigeration system that may rarely be used It can also be used as the primary cooling source for ultra low temperature operation on chambers designed to operate at temperatures below 84 C 120 F When this option is installed on the chamber turn the Aux Cooling event on When the boost is required during a pull down the EZT 560 will turn on the boost cooling solenoids and inject LN2 or CO2 into the chamber to drop the temperature as required Once the set point is achieved the boost solenoids will close in order to conserve LN2 or CO2 since it is no longer required and allow the refrigeration system to maintain the temperature If your chamber is designed for ultra low temperature operation and the set point is below the minimum achievable temperature for the refrigeration system the EZT 560 will disable the refrigerati
4. to store 1 192 168 1 105 S TERE W Web Server Enable ave Settings E Modbus Slave Enable To disable the slave uncheck the check box next to Modbus Slave Enable and press the Save Settings button This will turn off the serial server Next enter system maintenance and select Calibrate Touch Screen from the system maintenance setup menu Press the Calibrate Touch button to enter the CECP utility 85 Cincinnati Sub Zero EZT 560 User s Manual Select the Set serial port mode tab Set the COM3 mode to RS485 DO NOT change the COM1 mode or the EZT 560 will fail to start COM1 mode must be RS485 System Settings OK Set serial port mode 4 gt SetCOMimode RS495 Set COM3 mode Figure 9 1 Serial Port Mode Once the change is made select the Save tab and save the change to the registry The serial port mode change will not be retained unless you do this Press the OK button at the top right of the window to close the CECP utility Press the Return to Setup button on the calibrate touch screen and navigate back to the PC Comms Web Server screen in the chamber setup menu Place a check in the modbus slave enable check box and press the Save Settings button This will turn the slave back on The EZT 560 is now set to use EIA 485 for serial communications The EZT 560 s communication interface supplies two RJ 11 connectors for convenient daisy
5. 24 Deviation High Alarm Selected 40 Deviation Low Alarm Selected 56 Deviation Both Selected NOW O 103 r w 0x0067 Loop 4 Alarm Mode Bit1 Off alarm self clears Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 104 r w 0x0068 Loop 4 Alarm Output Assignment 0 No Output Selected 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8 Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 105 r w 0x0069 Loop 4 High Alarm Setpoint 106 r w 0x006A Loop 4 Low Alarm Setpoint 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 107 r w 0x006B Loop 4 Ala
6. 3 2 1 Standard Chamber Options The first event is the switch that turns the chamber on and off This will enable air circulators pumps heating cooling systems and any other components associated with the operation of the chamber This event is present on all chambers Depending on the options provided with your chamber additional events may also be present 3 2 1 1 Humidity The humidity event turns the chamber s humidity system components on and off Note that when humidity is turned off the relative humidity is still measured and displayed however no control takes place to obtain the target set point The humidity system will not operate unless the chamber event is also turned on NOTES on humidity system operation Temperature Extremes When operating your environmental chamber at extreme air temperature set points below freezing 0 C 32 F or above boiling 100 C 212 F the chamber is not capable of controlling humidity This is due to the physical properties of air and its ability to hold moisture at standard atmospheric pressures when at these temperatures 20 EZT 560 User s Manual Cincinnati Sub Zero To prevent malfunction or damage to the chamber the EZT 560 control system automatically disables the humidity system components when outside of the valid operating temperature range The event will remain on however so once the air temperature within the chamber returns to valid operating temperatures hu
7. Cincinnati Sub Zero EZT 560 Environmental Chamber Controller User s Manual EZT560 Manual REVB 1 Cincinnati Sub Zero EZT 560 User s Manual TABLE OF CONTENTS OVOIVIOW cenis a e a a E aa 5 ti Saby Mane E E 5 12 Abo t the EZT 560 kii anaa aaa aaa En an E a aeaa EE aE Aa aa a EA EEA A 6 1 3 TouchScreen Interface sipna eaaa a i aaa aa aaan ENa a EIEEE 7 T31 Menu Navigaionnancnennii iia TR 8 TVA Print Feature Saaier e ira a a a aaa aa aa a E LEERE 11 Monitoring sasssa E E 12 2 1 LOOP VIEWS aiiin a aana aaa aa e aa aara a Ea Ee E E a eE 12 2 1 1 omde LOOP VEW Feeeccacatceseiecees ehiderraeace E E T E 12 2 1 2 Dual Loop VICW vases cacasectasccadedincccadereancd ccvecenatandexedsaanensagantaneds cart aiaia aa 13 2 1 3 ALOS VICW nisinsin E anna tan E E a a 13 PE E E L TE E E E E S EE E E A 14 2 2 1 Loop BargraphS cesoisuiii iiinn ainia iiaa adii ad aiaa aa aaa 14 2 2 2 Loop TreondSisissiii iaia aaa a aaa ad a aaa adaa 14 2 3 Alarm MONIT assisia a a aaa a aaa a aa iaa ai aaa a iE 16 2 A gt SAARI PETO E T EE EE EE EES 17 29 System Status MONO Me e erreese a A O 18 Single Set Point Operations sssrinds eaa RANEA AAAA RALA ASAA 19 3 1 Single Set Point Adjustment 0 ce te nr eee reer etna eee e teaser teeeeetaeeeereaa 19 3 2 Manual Event Control Chamber On Off 00 0 2 cece ettee ee etneee erties ee eieeeeeeeeeeesnaeeeee 20 3 2 1 Standard Chamber Options cccccccececeeceeceeeeeeeeeeeeeaeceeeeeeese
8. EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero TABLE OF CONTENTS cont d 8 Deciphering EZT Input Output V O Operation 22 ccccccccececneeeeeeceeeeetecneaeceseeeeeetessenesaeeeeeentes 51 8 1 Standard Input Configuration cece eter treet eee ete ee ee reeee ee tieeeee teases tieeeestneeeeeeea 52 8 1 1 Input Description Of Use 0 2 0 ccceeececcecce cece ee eeeeeceeeeeeeeeeeeccaeeeeeeeeeeececenaseeeeeeeeeee 53 8 1 1 1 Custom Input Description of Use DTS VTS TSB 58 8 2 Standard Output Configuration c cece eee e teeter ene ee ee eeneee eee teeeee tees nasten nanten nnne ee 59 8 2 1 Output Description Of Use 20 2 0 ecececccce cece ee eeeeecee cece ee ee tec aaaaeaeeeeeeeeeseneisaeeeeeeteee 61 8 2 1 1 Custom Output Configuration Altitude sse esseen e eeeeeene neer eerr neeese 65 8 2 1 2 Custom Output Configuration DTS VTS TSB cceeeeeeeeeeeereeeeees 66 8 3 PLC Status Indicators 0 cece tere ire eee ieee AAEE EE AANER EEEN 67 8 3 1 I O Ribbon Cable Connections oeseri irees irena niine EAA E aa 68 9 Adjusting EZT Configuration options cccccccccccceceeeenneeeeeecneeeceeaaeeeseeeaeeeseeaeeeseeaeeessesaeeeeeeaaes 69 9 1 Accessing the EZT Configurator sessen TAE EE 70 9 2 Number of Loops Monitors c ccccccceeeeeeeeeee cece cece cece ceaeaeeeeeeeseceeaaeceeeeeeesecsnncaeaeeeeeereee 72 9 3 Loops Monitor Tagnames 2 icici a EEE AEE dees 73 9 4 Chamber O
9. KEE Si Figure 3 1 Single Set Point Adjustment To adjust the set point 1 1 1 Select one of the loop views from the main View menu 2 Input the set point temperature Press the numeric display for the set point SP for temperature The set point adjust keypad will pop up on the screen Enter the desired set point value and press the Done button ENTER TEMPERATURE SETPOINT Clear Cancel 2 a a ee 3 6 9 Figure 3 2 Numeric Entry 3 Turn the Chamber event on to start the chamber see section 3 2 below Cincinnati Sub Zero EZT 560 User s Manual 3 2 Manual Event Control Chamber On Off Events are the switches used to turn the chamber its related functions and optional systems on and off These events can be manually turned on and off as well as programmed into profiles so that they can be turned on and off at set time intervals Update Press Update button to update events COMM cHameer OMe Humit OM aux cooune OM ory air Figure 3 3 Manual Event Control To turn the chamber and optional events on off 1 Select the Manual Event Control from the main View menu 2 Select the events you wish to turn on by checking the check box next to each event in the list box To turn off events de select the check box next to the event 3 Press the Update button to set the new event status Note that the events will not turn on or off until the update button is pressed
10. Lubricate if applicable SYS COMPRESSOR HRS Check compressor oil level Verify static pressures Clean air cooled condenser if applicable air cooled units Inspect condenser water connections if applicable water cooled units Verify proper temperature and differential pressure HUMIDITY SYSTEM HRS Inspect water connections and filter cartridge if applicable Clean humidity water reservoir if option present If atomizer system remove spray nozzle and clean Inspect compressor motor and diaphragm for wear Clean water filter Inspect for build up of deposits on humidity sensor Clean filter tip of sensor Use caution so as not to damage sensor tip DRY AIR PURGE HRS Inspect air lines for leaks Inspect filters and clean if necessary HEATER CYCLES Inspect electrical connections and heater SSR for loose or frayed wiring Tighten loose connections 120 EZT 560 User s Manual Cincinnati Sub Zero Elapsed Service Counter Description Service Action SYS CMP STARTS Inspect wiring and power contactors for loose connections Tighten or repair as necessary Inspect compressor mounts vibration isolators for wear Tighten loose mounts or replace isolators if worn COOL VALVE CYCLES RHCOOL VALVE CYCLES Inspect valve body for corrosion Look for cracks in valve stems Inspect electrical connections on solenoid coil Requires authorized refrigeration service personnel
11. Note caution and warning symbols that appear throughout this manual are to draw your attention to important operational and safety information A NOTE marks a short message to alert you to an important detail A CAUTION safety alert appears with information that is important for protecting your equipment and performance A WARNING safety alert appears with information that is important for protecting you others and equipment from damage Pay very close attention to all warnings that apply to your chamber Device Under Test DUT Protection The environmental chamber is equipped with high heat limits and or safety devices These devices are installed to protect the chamber from exceeding design limits These devices remove power from the chamber s heaters ONLY and DO NOT remove power from the device under test Provisions must be made by the end user to de energize the tested device in the event of an over temperature condition For this reason the chamber is equipped with a DUT safety relay that should be connected to the device s power supply control circuit ata minimum This relay will open and de energize the device under test to prevent a runaway thermal condition whenever the chamber is not operating See wiring example below 120V ac L1 L2 hd kd fuse 120V 24V transformer mechanical contactor G 2 DUT coil safety relay Figure 1 1 DUT Safety Connections Cincinnati Sub Zero EZT 560 User
12. s Manual 1 2 About the EZT 560 The EZT 560 Environmental Controller is a DCS Distributed Control System which uses different hardware layers to perform the various functions needed to operate the chamber including user interface system monitoring and protection as well as process control This type of platform allows for more flexibility in chamber design while providing a high level of reliability and control accuracy The heart of control is performed by individual Fuzzy PID controllers one for each process This allows for the utmost in performance by providing a separate processor for each loop The process controllers utilize the latest technology with built in adaptive tuning This means that the process controllers continuously monitor the operation of the chamber and adjust their control parameters to achieve the most stable control possible without any user intervention Adjusting PID parameters is a thing of the past The chamber s systems and components are monitored and controlled by the core CPU of the EZT to insure that limits are not exceeded and profiles are executed precisely The chamber is protected from adverse operating conditions without the need for user intervention or knowledge on system operation The user interface provides local operator control and monitoring of the system It can track all user actions with its built in security module as well as log process information and store it for later use Together t
13. Action that anticipates the rate of change of the process and compensates to minimize overshoot and undershoot Derivative control is an instantaneous change of the control output in the same direction as the proportional error This is caused by a change in the process variable PV that decreases over the time of the derivative TD The TD is in units of seconds droop In proportional controllers the difference between set point and actual value after the system stabilizes EIA See Electronics Industries of America EIA TIA 232 and 485 Data communications standards set by the Electronic Industries of America and Telecommunications Industry Association Formerly referred to as RS Recognized Standard Electronics Industries of America EIA An association in the US that establishes standards for electronics and data communications fuzzy logic A mathematical control algorithm that monitors past response of a system to predict future response and automatically adjust PID parameters in order to adapt to process hysteresis A change in the process variable required to re energize the control or alarm output Sometimes called switching differential integral control I Control action that automatically eliminates offset or droop between set point and actual process temperature limit or limit controller A highly reliable discrete safety device redundant to the primary controller that monitors and
14. Degrees C F Service Monitors Service Info Setup Calibrate functions will suspend all operations for the E2T 560 Operation will not resume until Calibrate Touch window is closed Set Date Time Calibrate Touch Screen i 5 j Calibrate Touch Return To Setup Exit Application TEMPERATURE UNITS on Select functions from buttons listed above Figure 3 18 Calibrate Touch Access Select the Contrast tab from the system settings screen Use the slider to adjust the screen brightness to the desired level System Settings OK HOME Directory Change Contrast lt gt Contrast 14 Figure 3 19 Contrast Setting Close the system settings window by pressing the OK button at the top right of the window You can then return to the normal operating screens and resume operation of the chamber NOTE If you had to disable communications prior to performing the calibration procedure be sure to re enable the communications so that any software used to monitor or operate the chamber will be functional 18 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 4 Resolving Chamber Alarms This section covers known alarms available on all standard CSZ chambers Note that custom equipment may have features and or alarms that are specific only to that piece of equipment Alarms that relate to certain options not present on a chamber indicate that there is a wire crossed somewhere in the system See
15. Else profile writes are complete Segments written total number of segments created for profile downloadTimerer2 Enabled False stop download timer hide progress bar and download messages Unlock screen if user locked to block other actions here f_profWrite False profile write completed reset flag if used End If End Sub 114 EZT 560 User s Manual Cincinnati Sub Zero 9 5 Ethernet Web Server Connectivity The EZT 560 allows a user to remote monitor chamber operations anywhere via a PC s standard web browser To connect the EZT 560 to a network just connect the EZT s Ethernet port to your network using a standard CAT5 cable connection The EZT will be automatically assigned an IP address via the network s DHCP server You must use the assigned IP address to access the EZT 560 To obtain the correct IP address go to the PC Comms Web Server selection under the chamber setup menu Write down the IP address you will need to enter this in your web browser Enter Slave address for PC communications Enable Disable web server and press Save Settings to store 192 168 1 105 W Web Server Enable E Modbus Slave Enable Save Settings NOTE Contact your IT department prior to connecting the EZT 560 to your network Company policy may prohibit the use of web servers for security reasons Cincinnati Sub Zero is not responsible for the use of nor makes any claims as to the security of the web server inter
16. If the loop is a monitor loop the set point and percentage of output will remain at the minimum range of the bargraph since no values are associated with these on a monitor input The range of the set point and process value bargraphs can be changed by adjusting the Lo and Hi limits and pressing the Set button TEMPERATURE 100 80 60 3 Figure 2 4 Loop Bargraph Li EE E Ea 2 2 2 Loop Trends The loop trend can display the set point SP process variable PV and percentage of output history over a period of time The vertical axis determines the range of displayed data while the horizontal axis determines the history period The maximum time period that can be shown in the trend is 4 hours HUMIDITY i Setup 1 00 PM 2 00 AM 3 00 PM 4 00 AM 5 00 PM Figure 2 5 Loop Trend The trends on the EZT 560 have a unique drag n zoom feature By using your finger to select an area on the screen the trend will zoom in on that area To select a portion of the trend touch and hold the screen with your finger Drag your finger across the trend and a box will be drawn around the area Removing your finger from the screen will cause the trend to redraw the trend with the i ty 9 selected area To return to the normal view touch the x or y axis and select zoom normal 14 EZT 560 User s Manual Cincinnati Sub Zero Trend Setup To adjust the displayed variables range and hist
17. SERVICE XFER SYS indicator has audible alert if enabled Basket transfer mechanism components have exceeded service interval Perform service and clear elapsed service count 27 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 5 Chamber Operating Problems This section provides direction on troubleshooting chamber operation when no alarm condition is present It is broken into sub sections for temperature humidity altitude control etc Locate the section that most closely relates to the problem at hand in order to help diagnose and solve it Section 5 1 Conditioning System This section covers typical problems that may arise with the chamber s heating and refrigeration systems It includes information regarding the operation of temperature limited sheath heaters for special use as well as information on rate master and defrost operating conditions in order to help diagnose any problems that may occur with their operation Section 5 2 Humidity System This section covers typical problems that may arise with the chamber s humidity system It also includes information regarding the operation of the low RH mode frozen coil in order to help diagnose any problems that may occur during operation Section 5 3 Auxiliary Cooling System This section covers typical problems that may arise with the chamber s auxiliary cooling system It includes information regarding the operation of both the boost cooling a
18. Slow down communication rate from remote PC minimum 500ms scan rate Profile download working but profile is not updating after download Write error during transfer Incorrect step count or steps transferred Profile write to EZT not at correct transfer rate Verify proper profile step data format Verify total profile steps match number of steps transferred Transfer step data at proper rate 1 step per second 49 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 7 3 Ethernet Communications Troubleshooting The EZT 560 allows a user to remote monitor chamber operations anywhere via a PC s standard web browser To connect the EZT 560 to a network just connect the EZT s Ethernet port to your network using a standard CAT5 cable connection The EZT will be automatically assigned an IP address via the network s DHCP server You must use the assigned IP address to access the EZT 560 To obtain the correct IP address go to the PC Comms Web Server selection under the chamber setup menu Enter the following link in your PC s browser address window http IPaddress ezt html from example address in figure 7 1 http 192 168 1 105 ezt html Table 7 3 Common Ethernet Communication Problems and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS Web page not updating Connection to EZT lost Page update period not elapsed Check EZT connection to
19. This turns on the vacuum pump and isolation valves to seal the chamber The minimum dive output Q44 and minimum vacuum output Q46 turn on with the altitude event to enable the control circuits for increasing and decreasing the pressure inside the chamber They are typically not used and are provided for special applications The maximum dive output Q45 and maximum vacuum output Q47 are controlled by the configurator settings When the loop output percent exceeds the configurator set point for the on delay period the maximum output will turn on They operate as boost outputs i e they are on off outputs not proportioning outputs They connect additional air and vacuum supply circuits to the control outputs in order to boost chamber performance The altitude system automatically disables humidity auxiliary cooling and dry air purge when it is turned on These systems can not run when the altitude system is on The conditioning system is allowed to run until the altitude reaches the conditioning system disable set point set in the configurator Once this altitude is reached both heating and cooling is shut down During the allowed operating range the air circulator motors will switch to high speed output Q1 once the high speed fan enable set point is reached This improves the heating and cooling performance due to the low air density in the chamber 5 5 1 Common Altitude System Failures and Corrective Actions SYMPTOM PROBABLE CAUS
20. Use of AWG 24 twisted pair provides excellent results If shielded cable is used terminate the shield at one end only Always follow the manufacturer s instructions supplied with the interface converter See Biasing of Buses next Biasing of Buses The EIA 485 standard requires the bus to be biased for reliable communication This means to provide termination resistors across the T R and T R wires One resistor is placed at the PC or PLC where it connects to the EIA 485 bus The second resistor is placed at the last controller on the network Do not place resistors at each controller The impedance of the wires used for the bus determines the resistor value For twisted pair the value is typically 120 ohms In addition it may be necessary to have a pull up and pull down resistor between the power supply and ground of the interface adapter Check the documentation that came with your interface adapter Biasing the bus reduces reflection of signals sent down the bus These reflections are sometimes referred to as a standing wave This condition is most notable when communicating at high baud rates 74 EZT 560 User s Manual Cincinnati Sub Zero 9 2 1 1 Interface Converters The purpose of an interface converter is to allow two different buses to be connected together Interface converters are required when connecting an EIA 232 port to an EIA 485 bus The EIA 485 bus is a half duplex bus This means that it can only send or receive da
21. from the main setup menu View Profiles ai Securi Log Help 33 2 27 5 TEMPERATURE O00 I Figure 3 15 Setup Menu Access oY Select PC Comms Web Server from the setup menu Power Recovery Setpoint Limits Event Tagnames ecove Process Alarm Tagnames Alarm Settings Product Gontral Condenstation Control Defrost Settings PC Comms Web Server System Maintenance POWER RECOVERY Figure 3 16 Chamber Setup Menu Access Deselect the check boxes if necessary for Web Server and Modbus Slave Enable and press the Save Settings button Next select System Maintenance from the setup menu Power Recovery Setpoint Limits Event Tagnames Enter Slave address for PC communications J Process Alarm Tagnames nunications Enable Disable web server and press Save press Save Settings to store gamet Product Gontral Condenstation Control 1 192 168 1 105 Defrost Settings 168 1 105 PC Comms Web Server i E web Server Enable SS ERE ave Settings a F g E Modbus Slave Enable System Maintenance Aa are PC COMMS WEB SERVER G amp LAAN OR Figure 3 17 PC Comms Web Server 17 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide You will be prompted with a message stated that Maintenance mode will put system in offline condition Continue Select Yes From the setup menu select Calibrate Touch Screen then press the Calibrate Touch button view KEM Hep Sr
22. menu This screen is used to define what type of humidity system the chamber has and how the EZT 560 is to control it File Loops Chamber Event Alarm Tags Set Humid Options Pe A Not Installed Cmp On Cmp Off Diy 90 Cmp On Diy Hum Min SP oo Cmp Off Hum Max SP 100 0 Condensation Off Figure 9 10 Humidity Options NOTE You must press the Set button to save changes to the humidity system type selection Be sure to press the Set button prior to switching to another configuration screen or any change to the humidity system type will not be saved Parameter Descriptions Humid Type Sets the type of humidity system installed on the chamber Humidity Installed is for single stage tundra systems or cascade systems without a separate RH cooling circuit on system 1 Single stage humid installed is for cascade systems that run in single stage mode during humidity have separate RH cooling circuit on system 1 Cmp On Sets the loop percentage of output required to enable the refrigeration system in order to provide dehumidification Cmp On Dly Sets the delay in seconds for which the loop percentage of output must exceed the cmp on before the refrigeration system is turned on Cmp Off Sets the loop percentage of output required to disable the refrigeration system because dehumidification is no longer required Cmp Off Dly Sets the delay in seconds for which the loop percentage of outpu
23. menu provides navigation back to the main menu screen Setup Menu The Setup menu provides access to the EZT 560 s setup screens and the link to the offline system maintenance area Help Menu The help menu provides simple help regarding settings and use of screen parameters Cincinnati Sub Zero EZT 560 User s Manual Logging Menu Start Stop Logging Select Points For Lagging Hist View Time Setup Open History File Hist View Channel Setup Delete History File View History Plot Main View File Utilities View Averages Report Show Help Figure 1 6 Logging Menu Navigation Views Menu The Views menu provides navigation back to the main menu screen Edit Menu The Edit menu provides access to the history files and the EZT 560 file utilities DataLogging Menu The Datalogging menu provides access to the logging setup and historical file viewing utility Help Menu The help menu provides simple help regarding settings and use of screen parameters System Maintenance Menu Degrees C F Service Monitors Service Info Setup Set Date Time j un Calibrate Touch Screen Input Calibration Show Help Chamber Setup Exit Application Output Calibration About EZT 560 Figure 1 7 System Maintenance Menu Navigation Views Menu The Views menu provides navigation back to the online setup screens Setup Menu The Setup menu provides access to the service monit
24. pressure 124 and flow 125 monitoring VTS Logic Enabled Enables the logic for basket position and dual zone control Loop 1 is set for hot chamber control and loop 2 for cold chamber control The logic turns on output Q1 for the hot chamber using event 1 while event 2 becomes the cold chamber Outputs Q46 and Q47 for basket up and down are enabled through events 5 and 6 Inputs 116 and 126 are used for basket position monitoring for hot and cold chamber positions respectively The door switch input 121 is monitored to disable the transfer if either door is opened DTS Logic Enabled Enables the logic for basket position and three zone control Loop 1 is set for the left hot chamber control loop 2 for the center cold chamber control and loop 3 is for the right hot chamber control Loops 4 and 5 are set for product control for the left and right basket respectively The logic turns on output Q1 for the left chamber using event 1 while event 2 becomes the center chamber Output Q10 becomes the right chamber control using event 7 with output Q16 being enabled for the max heat output 75 Cincinnati Sub Zero TSB Logic Enabled EZT 560 Chamber Troubleshooting Guide control Outputs Q44 and Q45 for basket left and right are enabled through events 5 and 6 Inputs 114 and 115 are used for basket position monitoring for left and right chamber positions respectively The door switch input 121 is monitored to disable the trans
25. profile entry screen This opens the set point and time entry window From this window enter in the time duration of the step in hours minutes and seconds as well as the required set point s for the step Once the entries have been made return to the profile entry screen by pressing the Done button Hours 2 Mins 5 Secs 0 TEMPERATURE SP 253 5 Done HUMIDITY SP 43 6 ALTITUDE SP PRODUCT SP Figure 4 5 Profile Set Point Entry 28 EZT 560 User s Manual Cincinnati Sub Zero Entering a Soak Step The set point entry for a step defines the target set point i e the set point that will be achieved by the end of the step Thus if the set point of a step matches the previous step s set point the chamber will soak remain at that set point for the entire step Entering a Ramp Step A ramp step is merely a step with a set point that is different from the previous step The chamber will ramp from the previous set point to the set point of the current step linearly over the current step s time This generates a ramp to the current set point Determining Ramp Rate In order to enter a ramp rate you must calculate the time it will take to go from the previous set point to the new target set point For example if you desire a ramp rate of 5 degrees per hour from the previous step s 20 degree set point to the new 85 degree set point the step time will be the difference in temperature of 65 degrees divided by the rate
26. requires manual reset of E Stop button The fluid system temperature safety input is used to indicate that the fluid temperature limit has been exceeded LC chambers This input is active high i e the input must be on in order for the alarm to be indicated When active input on the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is off requires manual reset of limit device The fluid system pressure safety input is used to indicate that the fluid system has exceeded maximum operating pressures LC chambers This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is off The fluid system flow safety input is used to indicate that the fluid system has proper flow LC chambers This input is active low i e the input must be off in order for the alarm to be indicated EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is off The EZT has a built in time delay to disable the low flow alarm until the pump has had a chance to start and begin moving fluid 5 seconds If the input does not turn on within the start de
27. w _1 converted becomes 0x3120 23 converted becomes 0x3332 207 0x00CF Profile Name Characters 7 and 8 ___ converted becomes 0x8224 w The _ indicates a space in the above example Itis 208 0x00D0 Profile Name Characters 9 and 10 recommended that all empty characters be filled with a space w rather than a null character 209 0x00D1 Total Number of Steps in Profile 1 99 w 210 0x00D2 Guaranteed Soak Band Loop 1 3276 8 3276 7 32768 32767 w 211 0x00D3 Guaranteed Soak Band Loop 2 Note that value must be converted to whole number i e w multiply by ten to convert the decimal number to the proper 212 0x00D4 Guaranteed Soak Band Loop 3 value for a write w 213 0x00D5 Guaranteed Soak Band Loop 4 w 214 0x00D6 Guaranteed Soak Band Loop 5 w 110 EZT 560 User s Manual Cincinnati Sub Zero The following table contains the profile step data registers Download only the number of steps set in register 209 during the download process NOTE Register numbers listed are relative values To convert to absolute values add 40001 Register Description Use 215 w 0x00D7 Step 1 Time hours 0 999 216 w 0x00D8 Step 1 Time MM SS 0 59 Minutes high byte 0 59 Seconds low byte Parameter contains both minutes and seconds for the profile step duration The value will be an integer value based on the combined bytes of both the minutes and seconds In order t
28. 0 59 Minutes low byte Parameter contains both hours and minutes of system clock The value will be an integer value based on the combined bytes of both the hours and minutes In order to obtain the individual values split the word into its two component bytes Example 0x1131 read from EZT high byte 0x11 converted to decimal 17 5pm low byte 0x31 converted to decimal 49 minutes 4 0x0004 Clock seconds 0 59 89 Cincinnati Sub Zero EZT 560 User s Manual Register Description Use 5 0x0005 Restart Mode 0 Continue r w 1 Hold 2 Terminate 4 Reset 6 0x0006 Recovery Time 0 32767 seconds r w 7 0x0007 Defrost Operating Mode 0 Defrost Disabled r w 1 Defrost in Manual 2 Defrost in Auto 8 0x0008 Auto Defrost Temperature Setpoint 32768 32767 3276 8 3276 7 r w Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 9 0x0009 Auto Defrost Delay 0 32767 minutes R w 10 0x000A Defrost Status 0 Not in Defrost r 1 In Defrost 2 Prechill 11 Ox000B Time Remaining until next Defrost 0 32767 minutes r 12 0x000C Product Control Mode 0 Product Control Off r w 1 Product Control in Deviation Mode 2 Product Control in Process Mode 13 0x000D Product Control Upper Setpoint 32768 32767 3276 8 3276 7 r w Note that value must be conv
29. 0x0014 Actual Dewpoint divide by ten to convert the decimal number from the value r read 21 0x0015 Chamber Light Control 1 Turn on off chamber interior light w Parameter automatically resets to 0 once set 22 0x0016 Chamber Events Bit1 Chamber Event 1 r w Bit2 Chamber Event 2 Bit3 Chamber Event 3 Bit4 Chamber Event 4 Bits Chamber Event 5 Bit Chamber Event 6 Bit Chamber Event 7 Bit8 Chamber Event 8 Bit9 Chamber Event 9 Bit10 Bit11 Bit12 Bit13 Bit14 Bit15 This parameter is bit oriented i e enabling the different bits of the word enables 1 or disables 0 the event Note that not all events may be present on your chamber or additional events may be present depending upon options Consult your chamber manual Example Turn on Chamber 0000000000000001 1 decimal converts to 0x0001 With chamber on turn on dry air purge 0000000000001001 9 decimal converts to 0x0009 23 0x0017 Customer Events Bit1 Customer Event 1 r w Bit2 Customer Event 2 Bit3 Customer Event 3 Bit4 Customer Event 4 Bits Customer Event 5 Bit Customer Event 6 Bit7 Customer Event 7 Bit8 Customer Event 8 Bit9 Customer Event 9 Bit10 Customer Event 10 Bit11 Customer Event 11 Bit12 Customer Event 12 Bit13 Customer Event 13 Bit14 Customer Event 14 Bit15 Customer Event 15 This parameter is bit oriented i e enabling the different bits of the word enables 1 or disables 0 the events These are avai
30. 0x10 to transmit the profile to the EZT 560 See Section 9 2 4 Packet Syntax for the command format CAUTION It is the user s responsibility to make sure that the format and data ranges for each step is followed correctly Failure to do so can result in erratic control and or damage to equipment The following table contains the profile format and special function registers These values must be downloaded as the first step of the profile or the download will not execute correctly NOTE Register numbers listed are relative values To convert to absolute values add 40001 Register Description Use 200 0x00C8 AutoStart On Off 0 AutoStart Off w 1 AutoStart by Date 2 AutoStart by Day 201 0x00C9 AutoStart Time YY MM 0 99 Year high byte w 1 12 Month low byte Parameter contains both year and month for the profile to start when AutoStart by Date selected The value will be an integer value based on the combined bytes of both the year and month In order to set the value combine the two component bytes into the word Example Start Date of January 2006 decimal 6 2006 converted to high byte 0x06 decimal 1 January converted to low byte 0x01 set value of 0x0601 to EZT 202 0x00CA AutoStart Time DAY DOW 1 31 Day of Month high byte w 0 6 Day of Week low byte 0 Sunday Monday Tuesday Wednesday Thursday Friday Saturday OnahWN Parameter contains both day and day of week for the profile
31. 2 DISCHARGE THERMOSTAT BO1 4 113 SYSTEM 2 COMPRESSOR SAFETY MODULE BO2 26 114 BOILER HI TEMPERATURE THERMOSTAT BASKET LEFT BO2 24 115 BOILER LOW WATER LEVEL FLOAT BASKET RIGHT BO2 22 116 WATER RESERVOIR LOW LEVEL FLOAT BASKET UP BO2 20 117 SYSTEM 1 DEFROST PRESSURE CONTROL BO2 18 120 DEFROST TEMPERATURE SWITCH BO2 16 121 DOOR SWITCH BO2 14 122 EMERGENCY STOP BO2 12 123 FLUID SYSTEM TEMPERATURE SAFETY HOT BATH FLUID SAFETY BO2 10 124 FLUID SYSTEM PRESSURE SAFETY COLD BATH FLUID SAFETY BO2 8 125 FLUID SYSTEM FLOW SAFETY BATH LEVEL SAFETY BO2 6 126 CARGOCAIRE FAULT BASKET DOWN BO2 4 127 COMBUSTIBLE MONITOR Connection This column designates the physical wire connection point to the PLC for the input Input 52 This column designates the input address to the PLC as well as the marking used to identify wiring and hardware associated with the input EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 8 1 1 Input Description of Use Chamber Limit 10 The chamber limit input is used to indicate that the chamber temperature safety has tripped This input is active high i e the input must be on in order for the alarm to be indicated When active the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is no longer active requires manual reset of chamber limit device Product Safety 11 The product safety input is used to indicate that the redundant product
32. 71 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 9 2 Number of Loops Monitors The number of loops monitors screen is accessed from the Loops menu It is used to configure the EZT for the number of control loops that are present 9300 controllers how many monitor inputs are used Eagle input module and how many analog outputs are on the PLC Chamber Event Alarm Tags TOTAL at OF TOTAL it OF CONTROL LOOPS MONITOR LOOPS EE E TOTAL A AA CG OUTPUTS Figure 9 6 Number of Loops Monitors Set the number of each item by touching the respective number field Enter the correct value using the pop up keypad and press done The EZT can have up to 5 control loops 8 monitor loops and up to 4 analog outputs maximum NOTE Configuring more control loops or monitor loops than are present on the chamber will cause the chamber to shut down with a loop comms failure alarm Parameter Descriptions Total of Control Loops Sets the number of 9300 control loop displays that are shown on the loop view screens trend etc of the EZT one for each controlled process i e temperature humidity etc NOTE The Loops Monitor Tagnames screen is where the mode of the control loop is selected and enabled disabled If a loop is being removed you must first change the loop to disabled and then change the total number of control loops Only changing the number of control loops will remove the display fr
33. 9600 baud as the data rate for the EZT 560 Thus a device used to communicate with the EZT 560 must have its serial port set for 9600 baud in order to for data communications to work properly Start and Stop Bits The start bit informs the receiving device that a character is coming and a stop bit tells it that a character is complete The start bit is always a 0 The stop bit is always a1 The human speech equivalent of these bits could be a clearing of the throat to get someone s attention start bit anda pause at the end of a phrase stop bit Both help the listener understand the message A stop bit has a value of 1 or a mark state and it can be detected correctly even if the previous data bit also had a value of 1 This is accomplished by the stop bit s duration Stop bits can be 1 1 5 or 2 bit periods in length CSZ has chosen to use the default and most common length of 1 period for the EZT 560 A device used to communicate with the EZT 560 must also have its serial port set to use a stop bit of 1 in order for data communications to work properly Parity Bit Besides the synchronization provided by the use of start and stop bits an additional bit called a parity bit may optionally be transmitted along with the data A parity bit affords a small amount of error checking to help detect data corruption that might occur during transmission You can choose either even parity odd parity mark parity space parity or none at all
34. ASCII 29 0x001D Profile Name chars 7 amp 8 r Swap each character pair and combine to form TEST 123 30 Ox001E Profile Name chars 9 amp 10 r 31 0x001F Profile Start Date YY MM 0 99 Year high byte r 1 12 Month low byte Parameter contains both current year and month of profile start date The value will be an integer value based on the combined bytes of both the year and month In order to obtain the individual values split the word into its two component bytes Example 0x0601 read from EZT high byte 0x06 converted to decimal 6 2006 low byte 0x01 converted to decimal 1 January 32 0x0020 Profile Start Date DAY DOW 1 31 Day of Month high byte 0 6 Day of Week low byte 0 Sunday Monday Tuesday Wednesday Thursday Friday Saturday OahWN Parameter contains both day of month and day of week of profile start date The value will be an integer value based on the combined bytes of both the days In order to obtain the individual values split the word into its two component bytes 92 EZT 560 User s Manual Cincinnati Sub Zero Register Description Use Example 0x1701 read from EZT high byte 0x17 converted to decimal 23 23 day of month low byte 0x01 converted to decimal 1 Monday 33 0x0021 Profile Start Time HH MM 0 23 Hours high byte 24hr format military time 0 59 Minutes low byte Parameter contains both hours and minutes of profile start
35. C 14 F During the switch from single stage to cascade mode the cascade cooling control output Q13 will turn on and the maximum cooling output Q15 will be disabled This allows some of system 1 s capacity to be diverted to the cascade condenser to pre cool it prior to system 2 starting while still supplying cooling to the chamber After the stager start delay system 2 s output Q3 will turn on and the rate master control output Q10 will turn off 29 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide The cooling output for the 9300 will now be used to control system 2 cooling solenoids The maximum cool output Q15 is then re enabled so that it can turn on system 2 s maximum cool solenoids if needed For safety when the air temperature is below 20 C 4 F the system will only start and run in cascade mode This prevents system 1 s evaporator from becoming a condenser due to the lower chamber temperature and causing liquid slugging of system 1 s compressor Defrost Operation There are two selections for defrost Defrost can be configured for regular or large horsepower The large horsepower selection is typically used on systems 7 5HP and larger The difference between the selections defines how system 1 is controlled in order to cool system 2 With standard defrost the system 1 compressor is cycled on and off based on system 2 head pressure With large horsepower defrost system 1 compressor remains in operati
36. CORRECTIVE ACTIONS Humidity system not turning on Humidity not turned on Air temperature outside of humidity control range Altitude system on altitude chambers Humidity not enabled in configurator Turn on humidity event Change temperature set point to within allowable humidity control range Turn off altitude system Check configurator settings Chamber not humidifying Maximum dewpoint limit reached Boiler filling with water heating up Blown boiler heater fuse 9300 controller output off Atomizer nozzle clogged Atomizer water supply low Atomizer air supply low Check system status monitor Chamber operating at maximum humidity level Check water supply Allow time for boiler to heat up Replace fuse Verify proper 9300 controller configuration Check set point Replace 9300 controller Check clean atomizer nozzle Check water supply Increase flow rate Verify air compressor operation Check for leaks cracks in tubing Chamber not dehumidifying Minimum dewpoint limit reached Dehumidification coil logged with moisture 9300 controller output off Cooling solenoid clogged failed Wet coil EPR valve not set operating correctly Check system status monitor Chamber operating at minimum humidity level Check coil Warm up chamber to remove moisture build up Verify proper 9300 controller configuration Check set point Replace 9300 contro
37. Check basket position and adjust if necessary Check basket position sensors adjust replace Close chamber door Chamber not heating Chamber event not on Conditioning system disabled altitude chambers Blown heater fuse Sheath heater limit tripped 9300 controller output off Chamber in defrost if equipped Turn on chamber event Altitude above controllable limit for temperature Decrease altitude or turn off altitude system Replace fuse Check heater limit Maximum temperature reached Verify proper 9300 controller configuration Check set point Replace 9300 controller Check defrost status Allow defrost to complete or terminate defrost System 1 compressor not turning on Chamber event not on Conditioning system disabled altitude chambers Blown fuse Compressor internal thermal overload tripped Chamber in defrost if equipped Refrigeration system not enabled or compressor percent on set point not exceeded for delay time Turn on chamber event Altitude above controllable limit for temperature Decrease altitude or turn off altitude system Replace fuse Allow compressor to cool Check refrigeration system injection valve operation Check defrost status Allow defrost to complete Compressor will cycle as needed Check configurator settings Refrig system type should match installed system type 31 Cincinnati Sub Zero EZT 560 C
38. Defrost Delay Time in minutes between defrosts when auto mode is enabled This is based on Individual operating conditions It may take some analysis to determine how long your chamber can run before defrost is required Temperature SP Temperature below which defrost is enabled when in auto mode After the defrost delay defrost will be activated If at any time the chamber temperature rises above the set point temperature the delay timer will be reset and the countdown will begin anew the next time the chamber temperature drops below the set point 46 EZT 560 User s Manual Cincinnati Sub Zero 5 9 PC Comms Web Server This screen allows the user to set the slave address for the EZT 560 controller on the serial communication link to a PC and view the IP address if connected to a network It also provides selections for enabling and disabling the Modbus slave serial communications and web server For more information regarding the use of the EZT 560 data communications see section 9 Enter Slave address for PC communications Enable Disable web server and press Save Settings to store 192 168 1 105 W Web Server Enable W Modbus Slave Enable Figure 5 9 PC Comms Web Server Save Settings 47 Cincinnati Sub Zero EZT 560 User s Manual 6 Security The EZT 560 provides an enhanced array of security features The security model provides an administrator with the tools to add up to 30 users to the system Each us
39. Dly Sets the delay in seconds for which the loop percentage of output must exceed the max heat before the max heat output will turn on Cool Dly Sets the delay in seconds for which the loop percentage of output must exceed the max cool before the max heat output will turn on 74 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 9 4 Chamber Options The Chamber Options screen is accessed from the Chamber menu This screen is used to define what type of chamber the EZT 560 is being used on and enables special logic for certain types of chambers File Loops Chamber Event Alarm Tags Chamber Options VTS Logic Enabled RC Logic Enabled DTS Logic Enabled LC Logic Enabled TSB Logic Enabled Chamber Door Switch Control Off Figure 9 8 Chamber Options Only one selection can be made ata time If a new selection is made the other selection will turn off automatically For standard temperature and humidity or altitude chambers all options will typically be off Parameter Descriptions All Options Off Used for all standard temperature humidity altitude chambers RC Logic Enabled Enables the logic for the RC blower motor The logic ties event 8 to output Q1 to turn the RC blower motor on and off with the event LC Logic Enabled Enables the logic for pump control and fluid system monitoring The logic turns on output Q1 for the pump with event 1 and enables the input alarm logic for high temperature 123
40. EZT 560 Cincinnati Sub Zero EZT 560 User s Manual 2 Monitoring The chamber view screens provide various means of verifying chamber operation and performance The displays are accessed from the main menu under View Single Loop View Dual Loop view All Loops View Loop Bargraphs Loop Trends Manual Event Control Alarm Monitor Alarm History System Status Monitor 2 1 Loop Views The loop screens provide different viewing options for the control and monitoring of chamber processes such as temperature humidity altitude etc The loop screens allow you to adjust the current set points SP and view the process variables PV and percentages of output for each loop The set points can be modified from these screens by touching the set point field Upon selecting a set point the pop up numeric entry pad will appear from which the set point can be entered However if a profile is active the set point fields are locked out from user adjustment If the loop is monitor only the set point and percentage of output will not be displayed since no control is associated with the input 2 1 1 Single Loop View The single loop view display shows one control loop or monitor input at a time The auto tune feature is accessible from this screen 33 2 KER m Figure 2 1 Single Loop View 12 EZT 560 User s Manual Cincinnati Sub Zero 2 1 2 Dual Loop View The dual loop view display shows two cont
41. EZT 560 User s Manual 1 3 1 Menu Navigation The EZT 560 display provides the user with an intuitive interface for navigating through the different menus and settings without having to go multiple levels deep in screens like other button style systems The EZT 550 provides a Windows like feel with drop down menus and online help at all times This section of the manual provides an overview of the menu items and structure Main Menu default on power up Single Loop View Dual Loop View All Loops View Loop Bargraphs Profile Entry Loop Trends Setup Profile Status View Manual Event Control Log On 3 Run Profile Log Off Alarm Montor Hold Profile Alarm History Stop Profile i View Audit Trail System Status Monitor Stop Profile All OFF Chamber Setup View Current User Figure 1 3 Main Menu Navigation View Menu The View menu provides navigation to all standard view screens These include loop view bargraph trend alarm monitor and alarm history operation screens Profiles Menu The Profile menu provides access to the profile editing and monitor screens From these screens a user can open save edit delete and run profiles Setup Menu The Setup menu provides access to system and controller setup options Security Menu The Security menu provides access for user logon as well as audit trail viewing if the security system is enabled with users and the
42. EZT does not initiate frozen coil mode until the measured dewpoint in the chamber is below 10 C 50 F This prevents the coil from loading up with moisture prematurely and reducing the duration of time at which the coil can affectively control low humidity levels in the chamber When frozen coil mode is initiated the dry air purge system output Q34 and air control solenoid output Q35 turn on The air control solenoid output transfers control of the purge air supply to the chamber over to the dehumidification output of the 9300 loop controller 5 4 1 Common Dry Air Purge System Failures and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS Purge system not supplying dry air to chamber Purge system off No compressed air supply Purge flow meter adjusted too low Supply control valve clogged failed Turn on purge event Supply compressed air to purge system Verify adjust flow meter for proper flow rate Inspect valve Clean Replace if necessary Dry air purge not turning on Purge event not turned on Chamber operating in humidity mode Altitude system on altitude chambers Turn on purge event Purge automatically controlled Dry air purge will turn on when required Turn off altitude 36 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 5 5 Altitude System When the altitude system is enabled the altitude system output Q43 will turn on
43. EZT will coerce the set point to the minimum or maximum value allowed The system status monitor will then indicate that limiting is taking place and in which direction by illuminating the appropriate LED on the system status monitor screen Low RH Frozen Coil For chambers equipped with the low RH frozen coil option the EZT monitors the temperature and relative humidity set points and calculates the resulting dewpoint When this value is below the standard wet coil range the EZT automatically switches to frozen coil mode This allows the chamber to reach lower humidity levels than what is capable with standard humidity The EZT does not initiate frozen coil mode until the measured dewpoint in the chamber is below 10 C 50 F This prevents the coil from loading up with moisture prematurely and reducing the duration of time at which the coil can affectively control low humidity levels in the chamber When frozen coil mode is initiated the frozen coil control solenoid output Q36 and frozen coil bypass solenoid output Q37 turn on The frozen coil control solenoid output transfers control of the frozen coil solenoid to the dehumidification output of the 9300 At this point the dehumidify enable output Q30 will turn off so that the normal wet coil solenoid will be disabled 33 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 5 2 1 Common Humidity System Failures and Corrective Actions SYMPTOM PROBABLE CAUSES
44. High Limit Bit2 Product Safety Bit3 Boiler Over Temperature Bit4 Boiler Low Water Bits Dehumidifier System Fault Bit6 Motor Overload Bit7 Fluid System Temperature Bit8 Fluid System Pressure Bit9 Fluid System Low Flow Bit10 not used Bit11 not used Bit12 not used Bit13 Emergency Stop Bit14 Combustible Monitor Bit15 Transfer Error This parameter is bit oriented i e more than one alarm can be present at a time The value must be converted to binary and the status of each bit checked to see if the alarm is on 1 or the alarm is off 0 Example 0x1000 read from EZT converted to binary 0001000000000000 Bit13 on Emergency Stop 58 0x003A Refrigeration Alarm Status Bitt System 1 Hi Lo Pressure Bit2 System 1 Hi Lo Pressure Bit3 System 1 Discharge Temperature Bit4 System 1 Protection Module Bits Pumpdown Disabled Bit6 not used Bit7 not used Bit8 not used Bit9 System 2 Hi Lo Pressure Bit10 System 2 Hi Lo Pressure Bit11 System 2 Discharge Temperature Bit12 System 2 Protection Module This parameter is bit oriented i e more than one alarm can be present at a time The value must be converted to binary and the status of each bit checked to see if the alarm is on 1 or the alarm is off 0 Example 0x10 read from EZT converted to binary 0000000000010000 Bit5 on Pumpdown Disabled 95 Cincinnati Sub Zero EZT 560 User s Manual Register Description Use
45. Insulate supply lines Install automatic purge system to bleed off gas in order to maintain liquid in supply line Inspect valve Clean Replace if necessary 35 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 5 4 Dry Air Purge System The dry air purge system can work independently or as part of the humidity system If the chamber is a standard dry unit non humidity or the humidity system is off the dry air purge output Q34 will turn on when the purge event is turned on The purge system will run continuously supplying dry air to the chamber until the event is turned off If the chamber is equipped with humidity the dry air purge system output Q34 will be turned off when the humidity system is turned on This is done in order to allow the humidity system to control the humidity level If the purge system was allowed to continue operation it would be constantly trying to dry the chamber regardless of the humidity set point The humidity system control logic will allow the dry air purge system to operate during period of 100 dehumidification to help speed the drying out process For chambers equipped with the low RH frozen coil option the purge system will run during humidity operation The EZT monitors the temperature and relative humidity set points and calculates the resulting dewpoint When this value is below the standard wet coil range the EZT will automatically switch to frozen coil mode The
46. LO MB AH TMP DISABLE MB RH Hi DEWPOINT LIMIT MB RH Lo DEWPOINT LIMIT MB poor oren Figure 4 2 System Status Monitor Pressing the Silence button will quiet the audible alarm The status condition will have to clear and return in order for the alarm to sound again Table 4 2 Common Status Alarms and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS 1 Humidity Monitors RH H20 RESERVOIR LO indicator has audible alert Optional humidity water reservoir low Jumper wire missing Add more water Add jumper wire from VCC to input on EZT If water reservoir option not installed input must be jumped out to prevent alarm RH TMP DISABLE RH HI DEWPOINT LIMIT 26 Humidity system is disabled because the air temperature is outside allowable humidity operational limits Air temperature and humidity set point exceed maximum allowable dewpoint limit for the chamber Turn off humidity system Set temperature set point within proper operating range Adjust humidity temperature disable set points See Section 9 Adjusting EZT Configuration Options Set temperature and humidity set points to within allowable dewpoint range for the chamber Adjust dewpoint limit See Section 9 Adjusting EZT Configuration Options EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS RH LO DEWPOINT LIMIT Air te
47. Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 124 0x007C r w 125 0x007D r w PV1 Monitor High Alarm Setpoint PV1 Monitor Low Alarm Setpoint 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 126 0x007E r w PV1 Monitor Alarm Hysteresis 0 32767 0 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 127 0x007F 128 0x0080 r w PV2 Monitor Process value PV2 Monitor Alarm Type Selection 32768 32767 3276 8 3276 7 Note that value must be converted from whole number i e divide by ten to convert the decimal number from the value read Alarm Off Process High Alarm Selected Process Low Alarm Selected Process Both Selected Nauvo 102 EZT 560 User s Manual Cincinnati Sub Zero Register Description Use 129 0x0081 PV2 Monitor Alarm Mode Bit1 Off alarm self clears r w Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned a
48. To copy files to the USB I Stick Check the checkbox next to Copy To I Stick Press the specific button that represents the file type to copy Profile etc All files from directory will be copied with progress status displayed to user To erase files from internal compact flash Check the checkbox next to Delete From Internal Storage Press the specific button that represents the file type to erase Profile etc All files from directory will be erased with progress status displayed to user To copy files to I Stick and then erase files from internal compact flash Check Delete From Internal Storage and Copy To I Stick checkboxes Press the specific button that represents the file type to copy erase Profile etc All files from directory will be copied and then erased with progress status displayed to user Alarm Files Audit Trail Files Delete From Internal i Copy To I Stick E aene Figure 7 8 File Utilities NOTE Use only Cincinnati Sub Zero l Stick USB memory cards for copy file utilities CSZ has tested and validated the l Stick for proper operation and performance CSZ does not guarantee or support the use of any other USB memory device 58 EZT 560 User s Manual Cincinnati Sub Zero When files are being copied to the I Stick storage device a directory for each file type will be created to store the copied files The directory structure is as follows Profile files directory P
49. Users List 6 1 2 1 Delete User The administrator can delete a user by selecting the user from the list To select a user touch the UserlD in the list box and press the Delete User button 6 1 2 2 Change User Password The administrator can also change the password of a user in the system This may have to be done if password aging is set up for the user or for other security reasons To change a password select the user by touching the UserID in the list box and press the Change Pswrd button Enter the new password and confirm the password Press the Accept button to change the password 6 1 3 User Rights The User Rights tab provides the administrator the ability to assign rights to each user level Operator Supervisor and Administrator Select the user type from the drop down box and then enable or disable specific program functions rights by selecting the checkbox next to the function If the checkbox is selected the user right will be enabled for the user level currently being edited The Select All and Clear All buttons will select or clear all rights in the user rights list view You must press the Accept button for each user level to save the selections for that user type before selecting another user type from the drop down list or entries made will not be saved Add User Users User Rights Security Options User Group erns a gt O Trend Setup O Bararaph Limits Pre
50. are open there isn t much to consider LC Chambers When the chamber event is turned on the fluid system pump is started in order to keep fluid flowing through the system to condition the test product The fluid is heated and cooled as it flows through the heater barrel and heat exchanger much like the air across the heater and evaporator in a typical chamber The fluid system is equipped with safeties that insure that fluid is flowing through the system prior to allowing heating or cooling of the fluid to commence This protects the system and components from damage that may occur by operating with no fluid flow The heating and cooling outputs function in the same manner as a standard chamber except they are controlling fluid temperature instead of air TSB Chambers When the chamber event is turned on the fluid system pumps are started in order to keep fluid flowing through the system to condition the test product Some smaller TSB s merely have mixers in the bath to promote flow over the heaters and evaporator mounted in the baths The fluid is heated and cooled as it flows through the heater barrel and heat exchanger much like the air across the heater and evaporator in a typical chamber The fluid system is equipped with safeties that insure that fluid is flowing through the system prior to allowing heating or cooling of the fluid to commence This protects the system and components from damage that may occur by operating with no flui
51. chambers DTS VTS TSB to move a basket loaded with test product from one extreme temperature to another These systems may utilize a single motor or one or more air cylinders to move the basket Motor Operated Transfer Mechanism Motor operated transfer mechanisms are typically used on TSB s They consist of a gear motor drive with a lever arm attached to the output shaft The motor direction is switched between clockwise and counterclockwise in order to move the basket back and forth between the baths Limit switches are used to indicate each of the three positions hot cold and unload The motor direction is determined by the current position indicated by which position switch is on and the desired position set by the events The motor runs until the limit switch for the desired position is met Air Cylinder Operated Mechanism Air operated transfer mechanisms for DTS and VTS chambers are relatively simple A single air cylinder is used to move the basket between the two available positions Because of the design the basket provides the mechanical stop for the cylinder The cylinder continues to push on the basket thus sealing the gasket surface to keep the hot and cold chambers separate Limit switches are positioned on each end of the cylinder in order to identify the basket position TSB transfer mechanisms employing air cylinders are more complicated They use two cylinders one for up and down motion and the other fro side to side moti
52. door if equipped to prevent the door from being opened during a transfer When the transfer is complete the output turns off This output is used to turn on the transfer mechanism to move the basket to the left on a DTS or TSB Fora DTS it transfers the left basket into the left hot chamber and the right basket into the center cold chamber On a TSB it transfers the basket from the cold or unload position to the unload or hot position This output is used to turn on the transfer mechanism to move the basket to the right on a DTS or TSB Fora DTS it transfers the right basket into the right hot chamber and the left basket into the center cold chamber On a TSB it transfers the basket from the hot or unload position to the unload or cold position This output is used to turn on the transfer mechanism to move the basket up on a VTS or TSB equipped with a pneumatic transfer mechanism For a VTS the basket is transferred into the hot chamber On pneumatic TSB systems this lifts the basket out of the baths so that it can move from side to side It also holds the basket up when the unload position is selected This output is used to turn on the transfer mechanism to move the basket down on a VTS or TSB equipped with a pneumatic transfer mechanism For a VTS the basket is moved into the cold chamber On pneumatic TSB systems this lowers the basket into the baths once it is positioned over the hot or cold bath EZT 560 Chamber Troub
53. for ramp soak guaranteed soak etc 2 Start Date Displays the date and time at which the profile was started 3 Estimated Stop Date Displays the calculated stop date and time of the profile Note that this may vary due to wait for and guaranteed soak steps set in the profile 4 Current Step Indicates the step number currently being executed 5 Step Time Left Displays the time remaining in the current step 6 Wait for Input Indicates the input being monitored if a wait for condition is present 7 Wait Setpoint Indicates the setpoint for the wait for condition if active 8 Target Setpoints Displays setpoints for each controlled process of the chamber i e temperature humidity altitiude etc 9 Current Jump Step Dynamic field that is active only if step is a jump step Displays the step number that profile will jump to at completion of the step 10 Current Jumps Remaining Dynamic field that is active only if step is a jump step Displays the number of jumps remaining for the step 11 Last Jump from Step Dynamic field that is active only if a jump has been made Displays the last step a jump was made from 12 Last Jump to Step Dynamic field that is active only if a jump has been made Displays the last step a jump was made to 13 Total Jumps Made Dynamic field that is active only if a jump has been made Displays the total count of all jumps made 35 Cincinnati Sub Zero EZT 560 User s Manual 4 7 Pro
54. for identification enquiry inquiry start of text end of text end of transmission acknowledge negative acknowledge and escape The ASCII code is sometimes written in a base 16 number system that is called hexadecimal or hex for short The numbers 0 through 9 represents the first ten digits of this system and the letters A through F represents the final six digits The 128 ASCII character codes with the decimal binary and hexadecimal equivalents are listed in the table below ASCII Control Codes ASCII Control Codes are used to give instructions to the remote device and result in specific actions such as a line feed instruction on a printer ASCII Control Codes the first 33 ASCII characters non printable are important for the operation of communicating equipment They give instruction to remote devices that result in specific actions such as a line feed on a printer Holding down the keyboard control key while pressing the appropriate keyboard key will send these values 71 Cincinnati Sub Zero EZT 560 User s Manual ASCII Chart Char Code Decimal Binary Hex Char Code Decimal Binary Hex NUL Ctrl 0 00000000 00 Shift 2 64 01000000 40 SOH CtrlA 1 00000001 01 A Shift A 65 01000001 41 STX Ctrl B 2 00000010 02 B Shift B 66 0100
55. gs soak band requires scale by 10 values are for SP s so scale by 10 for PLC writeValue Clnt profileData x f_profRegsToWrite 10 End Select Else elements 1 to 99 of profarray which holds data for each segment Select Case x Case 0 To 6 hours mins secs chamber events cust events gs events wait or loop input wait for monitor input first 6 elements require no scale by 10 writeValue Cint profileData x f_profRegsToWrite Case 7 wait for input setpoint value for SP so scale by 10 writeValue Clint profileData x f_profRegsToWrite 10 Case 8 9 jump step and jump count are integers dont scale by 10 writeValue Cint profileData x f_profRegsToWrite Case 10 To 14 setpoint values for loop1 5 scale by 10 writeValue Clnt profileData x f_profRegsToWrite 10 End Select End If ModProf WordVal x writeValue modbus master array code line is modbus server dependent for multi writes Next ModProf Address f_regAdd start register for profile download code is modbus server dependent ModProf Size 15 size of array code is modbus server dependent ModProf Trigger trigger comms write command is modbus master dependent increment writes for end of loop when total writes equal total number of segments in profile f_writeNum f_writeNum 1 f_profRegsToWrite f_profRegsToWrite 1 increment registers within profile for write f_regAdd f_regAdd 15 increment to next 15 profile registers
56. incremental drop in pressure of the chamber This causes the chamber to lose capacity as the altitude increases If you wanted to maintain a linear rate for the entire transition over the operating range of the chamber you could end up having a very long test The chamber may do 5Kft a minute up to 50Kft but if it is only 100ft per minute after that to 100Kft it limits your transition to 100ft per minute That is all you have if you want a linear transition You must use the minimum capacity rate Most chamber Capacities are provided as an average of best to worst and with no product load Chamber manufactures have no way to rate the chamber any other way because it is unknown as to what the customer will use it for and what they are testing Product load also plays a large part in temperature performance The transition rate of the chamber will vary not only based on refrigeration capacity but also on the thermal mass of the product The more heat the product can absorb or the fact that it generates heat will slow down the cooling process but speed up the heating process This will cause a large difference between the heating and cooling rates that the chamber can achieve with that product load What is the Proper Rate The first step in getting the proper response out of the chamber is to program your ramp step so that the rate of change does not exceed the capacity of the chamber at any point along that step That does not mean that you shoul
57. input 16 Loop 5 Input 32 PV1 Monitor Input 64 PV2 Monitor Input 128 PV3 Monitor Input 256 PV4 Monitor Input 512 PV5 Monitor Input 1024 PV6 Monitor Input 2048 PV7 Monitor Input 4096 PV8 Monitor Input 32768 32767 3276 8 3276 7 Note that value must be converted from whole number i e divide by ten to convert the decimal number from the value read 93 Cincinnati Sub Zero EZT 560 User s Manual Register Description Use 44 0x002C Profile Current Jump Step 1 99 45 0x002D Profile Current Jumps Remaining 0 999 46 0x002E Profile Loop 1 Target Setpoint 47 0x002F Profile Loop 2 Target Setpoint 48 0x0030 Profile Loop 3 Target Setpoint 49 0x0031 Profile Loop 4 Target Setpoint 50 0x0032 Profile Loop 5 Target Setpoint 32768 32767 3276 8 3276 7 Note that value must be converted from whole number i e divide by ten to convert the decimal number from the value read 51 52 0x0033 0x0034 Profile Last Jump from Step Profile Last Jump to Step 1 99 1 99 53 0x0035 Profile Total Jumps Made 0 32767 54 0x0036 Alarm Acknowledge 1 Alarm Silence 2 Pumpdown Reset The parameter automatically resets to 0 55 0x0037 EZT Alarm Status Bitt Loop 1 Sensor Break Bit2 Loop 2 Sensor Break Bit3 Loop 3 Sensor Break Bit4 Loop 4 Sensor Break Bits
58. limits the temperature of the process or a point in the process When temperature exceeds or falls below the limit set point the limit controller interrupts power through the load circuit A limit controller can protect equipment and people when it is correctly installed with its own power supply power lines switch and sensor Modbus A digital communications protocol owned by AEG Schneider Automation for industrial computer networks Modbus RTU Remote Terminal Unit an individual Modbus capable device on a network overshoot The amount by which a process variable exceeds the set point before it stabilizes A 2 EZT 560 User s Manual Cincinnati Sub Zero Common Terms and Definitions cont d PID Proportional integral derivative A control mode with three functions proportional action dampens the system response integral corrects for droop and derivative prevents overshoot and undershoot process variable PV The parameter that is controlled or measured Typical examples are temperature relative humidity altitude etc The high process variable is the highest value of the process range expressed in engineering units The low process variable is the lowest value of the process range proportional control P Output effort proportional to the error from set point For example if the proportional band is 20 and the process is 10 below set point the heat proportioned effort is 50 percent r
59. loop controls utilize fuzzy logic to continuously adapt to the process in order to maintain it as close as possible to the set point The controls merely need base line knowledge on the performance of the chamber and test load To obtain this performance knowledge the controller can be tuned using the one touch tune All Cincinnati Sub Zero chambers are factory tuned however the chambers are typically empty and under no load Unless specific performance tests were performed at the factory for your particular needs the base line performance may not be accurate once your product is placed inside the chamber The one touch tune makes it easy to tune the chamber to your product and performance needs Just run the chamber at ambient conditions and press the AT button on the single loop display screen for the process to be tuned The AT button will remain green for the duration of the tune to indicate it is working Once complete you are ready to test product PID contol when property tuned PID Fuzzy control Temperature Set point Figure 3 4 Tune Control Response As you change product configurations or other loads within the chamber you can re tune to the new configuration All subsequent tests with that configuration will perform optimally It is recommended that only one loop be tuned at a time so that they do not interfere with the tune of the other loop 24 EZT 560 User s Manual Cincinnati Sub Zero 4 Profil
60. must be created If the startup folder does exist open the folder and make sure the file Shortcut to EZT560 is in the folder If it is not then it must be added The CF card holds a copy of the startup folder needed for proper operation To replace either the missing folder or shortcut copy the startup folder from the compact flash card to the NORFlash directory To do so open the storage card folder from My Computer Touch the Startup folder to select it and then select Copy from the Edit menu Return to the NORFlash directory and then select Paste from the Edit menu to paste the startup folder into the NORFlash directory Cycle power to the EZT so that it can perform its normal boot sequence fle Eat View Go Favorites x JJadaress My Computer z E oc amp fe Application My Network NORFlash Data Documents ieee oes a YB oe ie Program Files Temp Windows i _ Control Figure 3 2 My Computer File Access 10 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 3 1 2 Configure Serial Port 1 Mode Serial port 1 on the back of the HMI is used to communicate with the PLC over port 2 on the CPU This is a two wire RS485 serial link In order for the link to operate properly the serial port on the HMI must be set for RS485 Write Error Error during write to controller Check cable or setup wiring Figure 3 3 Write Error on Boot To check the
61. of the CRC register is zero repeat step 3 else Exclusive OR the CRC register with the polynomial value 0xA001 5 Repeat steps 3 and 4 until eight shifts have been performed When this is done a complete 8 bit byte will have been processed 6 Repeat steps 2 through 5 for the next 8 bit byte of the command message Continue doing this until all bytes of the command message have been processed The final contents of the CRC register is the CRC value When transmitting the CRC value in the message the upper and lower bytes of the CRC value must be swapped i e the lower order byte will be transmitted first 76 EZT 560 User s Manual Cincinnati Sub Zero Cyclical Redundancy Checksum CRC Algorithm unsigned int calc_crc unsigned char start_of_packet unsigned char end_of_packet unsigned int crc unsigned char bit_count unsigned char char_ptr Start at the beginning of the packet char_ptr start_of_packet Initialize CRC crc OxFFFF Loop through the entire packet do Exclusive OR the byte with the CRC crc unsigned int char_ptr Loop through all 8 data bits bit_count 0 do If the LSB is 1 shift the CRC and XOR the polynomial mask with the CRC if cre amp 0x0001 f crc gt gt 1 crc 0xA001 If the LSB is 0 shift the CRC only else crc gt gt 1 while bit_count lt 7 while char_ptr lt end_of_packet return crc 77 Cincinnati
62. off in alarm condition BO1 25 QO Air circulator motor output BO1 23 Q1 RC blower motor output BO1 21 Q2 System 1 compressor output BO1 19 Q3 System 2 compressor output BO1 17 Q4 Chamber light output BO1 15 Q5 Window door frame heater output BO1 13 Q6 Product limit output BO1 11 Q7 Audible alarm output 122 EZT 560 User s Manual Cincinnati Sub Zero Digital I O CPU Connector 2 terminal I O ADDR Operation BO2 26 114 Boiler over temperature safety input BOILER OVERTEMP off in alarm condition Basket left TSB DTS BO2 24 115 Boiler low water input BOILER LOW WATER off in alarm condition ignored with humidity system off Basket right TSB DTS BO2 22 116 Water reservoir low water input RH H2O RESERVOIR LO off in alarm condition ignored with humidity system off Basket up VTS TSB with air pneumatic transfer mechanism BO2 20 117 System 1 defrost pressure control Used to control system 1 refrigeration system for cascade condenser cooling control to maintain system 2 pressure BO2 18 120 Defrost temperature switch Terminates defrost once coil temperature reached BO2 16 121 Door switch Input on signals door is open Used to indicate transfer mechanism disabled on VTS DTS TSB BO2 14 122 Emergency stop input EMERGENCY STOP on in alarm condition BO2 12 123 Fluid system temperature safety input FLUID SYS TEMP on in alarm condition BO2 10 124 Fluid sy
63. pump pressure and flow Verify valves are in proper position 21 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS FLUID SYS HI PSI Fluid system high pressure safety tripped Restriction in fluid system Reset high pressure safety Check for debris clogged filters in fluid system Verify all isolation valves are open FLUID SYS LOW FLOW Fluid flow safety tripped Verify fluid level Check for restrictions in system Check pump operation and service if necessary MOTOR OVERLOAD Motor overload tripped Requires manual reset Motor drive VFD fault if present Consult drive manual supplied with chamber for error code and troubleshooting information Blown Fuse Replace fuse Check motor for overload condition i e bearing wear binding shaft etc PRODUCT SAFETY Optional product safety limit tripped Manually reset limit to clear alarm Check limit set points and verify properly set for current testing TRANSFER ERROR Basket not in proper position Check for mechanical obstructions in 3 Refrigeration Safeties Bad out of adjustment position switch Low air pressure or slipping motor clutch in transfer mechanism basket transfer mechanism Verify basket in proper position Adjust replace switch Verify air supply and pressure Check clutch motor assembly PUMPDOWN DISABLED SYS HILO PSI Chamber p
64. r w Note that value must be converted from to whole number i e 70 0x0046 Loop 1 Low Alarm Setpoint divide multiply by ten to convert the decimal number from the r w value read or to the proper value for a write 71 0x0047 Loop 1 Alarm Hysteresis 0 32767 0 3276 7 r w Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 72 0x0048 Loop 2 Setpoint 32768 32767 3276 8 3276 7 r w Note that value must be converted from to whole number i e 73 0x0049 Loop 2 Process value divide multiply by ten to convert the decimal number from the r value read or to the proper value for a write 74 0x004A Loop 2 Percentage of Output 10000 10000 100 00 100 00 r Note that value must be converted from whole number i e divide by 100 to convert the decimal number from the value read 75 0x004B Loop 2 Autotune Status 0 Autotune Off r w 1 Initiate Autotune 2 Autotune Active 4 Terminate Autotune 76 0x004C Loop 2 Upper Setpoint Limit 32768 32767 3276 8 3276 7 r w Note that value must be converted from to whole number i e 77 0x004D Loop 2 Lower Setpoint Limit divide multiply by ten to convert the decimal number from the r w value read or to the proper value for a write 78 0x004E Loop 2 Alarm Type Selection Alarm Off r w Process High Alarm Selected Process Low Alarm Selected Process Bo
65. receives a read R or write W command it converts the GPIB characters into HEX bytes assembles the packet and transmits it to the Modbus device This simplifies communications with the EZT 560 by automatically handling the Modbus protocol By utilizing the two read and write commands it is possible to access all of the EZT 560 s parameters See the parameter list in the Getting Connected section of this manual for the list of registers and their associated values For a complete description and detailed explanation of the 4899 and all of its associated commands see section 3 Operation of the 4899 manual provided with your chamber 83 Cincinnati Sub Zero 9 3 1 Command Structure EZT 560 User s Manual There are five base commands that are required to configure and operate the GPIB controller in order to communicate with the EZT 560 controller These commands are listed in the table below All commands are generated using standard ASCII text characters Command Use SYST COMM GPIB ADDR addr GPIB Address Command Sets the GPIB controller s device address for subsequent commands Value for addr is 1 to 30 This is the address you will use to communicate with the EZT over the GPIB bus SAV 0 Save Configuration Command Saves current 4899 configuration in nonvolatile memory so that on next power up settings such as the GPIB address will remain in tact R reg num Read Register Command commas 527 for 52
66. safety has tripped if equipped This input is active high i e the input must be on in order for the alarm to be indicated When active the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is no longer active requires manual reset of product safety Motor Overload 12 The motor overload input is used to indicate that a motor overload relay has tripped off due to a motor overload condition if equipped This input is active high i e the input must be on in order for the alarm to be indicated When active the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is no longer active requires manual reset of motor overload It may also be used to indicate a failure of a VFD if one is used to control motor speed If the VFD is at fault check the manufacturer s manual for troubleshooting and diagnostic information Typically pressing the stop reset button on the drive should clear the fault condition Sys1 Pumpdown Switch 13 This input is a control input for pumpdown if equipped There is no user indication for this input When the refrigeration system requires pumpdown this input is wired to a low pressure switch on the suction line of system 1 compressor When the pressure rises the switch closes and turns on the input The EZT then turns on the system 1 compressor output Q2 until t
67. settings screen to start the calibration process System Settings ma Touch Screen settings LCD settings MAC adl 4 P Figure 3 13 Touch Screen Settings EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero Using a stylus or the tip of a plastic pen cap touch and hold on the center of each point marked by the crosshairs on the screen Once all points have been measured touch anywhere on the screen to accept the settings and complete the calibration routine CAUTION Do not use any metal or sharp edged instruments on the screen or permanent damage to the screen may result Carefully press and briefly hold stylus on the center of the target New calibration settings have been measured Repeat as the target moves around the screen Press the Enter key to accept new settings Press the Esc key to cancel Press the Esc key to keep the old settings Figure 3 14 Touch Calibration Screen Close the system settings window by pressing the OK button at the top right of the window You can then return to the normal operating screens and resume operation of the chamber NOTE If you had to disable communications prior to performing the calibration procedure be sure to re enable the communications so that any software used to monitor or operate the chamber will be functional EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 3 1 4 Screen Contrast Adjustment Procedure Begin by selecting Chamber Setup
68. so that it can be pumped into the high side of the system If the chamber is equipped with the pumpdown mode of operation the Pumpdown button will be provided on the Alarm Monitor screen This provides a manual way to reset pumpdown mode Pumpdown will be automatically disabled if main power is off for more than 30 minutes This is due to the fact that without main power the crankcase heater will be off and can not warm the compressor Depending on the temperature of the compressor this could allow refrigerant to accumulate in the compressor causing a potentially damaging start up The Pumpdown Disabled alarm will notify the operator of this condition The chamber will not operate when pumpdown is disabled Pumpdown will automatically reset after the main power has been on for a period of 4 hours or it can be immediately reset by pressing the Pumpdown button EZT 560 User s Manual Cincinnati Sub Zero 2 4 Alarm History The alarm history screen provides easy access to historical alarm data To access an alarm file press the Open File button on the upper right corner of the display Select the desired alarm file from the list and press Open All alarms that occurred on that date will be displayed in the list box Alarm Description Dae CHAMBER HI LIMIT 10 22 2005 PRODUCT SAFETY 10 22 2005 BOILER LOW WATER SAFETY 10 22 2005 MOTOR OVERLOAD 10 22 2005 Figure 2 8 Alarm History To clear the alarms
69. the ability to select individual points for logging view datalog files and start stop logging operations The logging ability of the EZT 560 provides an easy to use convenient method to obtain electronic data without the need for additional equipment 7 1 Start Stop Logging The main system data logging screen is used to start or stop the logger and also to add a file prefix to entered before the date time stamp if the user enters one The main logging screen will display the current data file name if system logging is enabled as well as the currently loaded file name on the bottom status bar if a historical file is loaded To start the log press the Logging On button controller variables must be assigned first by selecting the Select Points For Logging menu item Any time logging is enabled the Logging On button will be green Days before new file is started Ew Prod173 Current Data File Prod173_10 21 2004_10 21 15 Figure 7 1 Start Stop Datalogging The logging rate is adjusted on this screen by changing the value for the Days before new file is started parameter Files can be 1 to 31 days long before system starts a new file with datalog rate dependent on file selection length The data log rate in minutes is the number of days selected for file length If 5 days is selected for file length the datalogger will save to disk every 5 minutes 53 Cincinnati Sub Zero EZT 560 User s Manual
70. the basket VTS TSB is in the cold chamber down position There is no user indication for this input EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 8 2 Standard Output Configuration CONNECTION INPUT STANDARD ALTITUDE DTS VTS TSB BO1 25 Qo AIR CIRCULATORS LOW SPEED FANS COLD CHAMBER DTS CENTER BO1 23 Q1 RC BLOWER HIGH SPEED FANS HOT CHAMBER DTS LEFT BO1 21 Q2 SYSTEM 1 COMPRESSOR BO1 19 Q3 SYSTEM 2 COMPRESSOR BO1 17 Q4 CHAMBER LIGHT S BO1 15 Q5 WINDOW DOOR FRAME HEATER S BO1 13 Q6 PRODUCT LIMIT BO1 11 Q7 AUDIBLE ALARM BO2 25 Q10 RATE MASTER CONTROL HOT CHAMBER DTS RIGHT BO2 23 Q11 SYSTEM 1 SOLENOIDS BO2 21 Q12 DEFROST SOLENOID BO2 19 Q13 SYSTEM 1 CASCADE SOLENOID CONTROL RATE MASTER DEFROST BO2 17 Q14 MINIMUM COOL ENABLE BO2 15 Q15 MAXIMUM COOL ENABLE BO2 13 Q16 MINIMUM HEAT ENABLE MAX HEAT DTS RIGHT BO2 11 Q17 MAXIMUM HEAT ENABLE DTS LEFT BO3 20 Q30 DEHUMIDIFY ENABLE BO3 18 Q31 RH COOL ENABLE BO3 16 Q32 HUMIDITY SYSTEM BO3 14 Q33 MAXIMUM HUMIDIFY ENABLE BO3 12 Q34 DRY AIR PURGE SYSTEM BO3 10 Q35 AIR CONTROL SOLENOID BO3 8 Q36 FROZEN COIL CONTROL SOLENOID BO3 6 Q37 FROZZEN COIL BYPASS SOLENOID BO3 19 Q40 LN2 SUPPLY SOLENOID BO3 17 Q41 LN2 CONTROL SOLENOID BO3 15 Q42 LN2 BOOST SOLENOID BO3 13 Q43 NOT USED ALTITUDE SYSTEM IN TRANSFER DOOR LOCK BO3 11 Q44 NOT USED MIN DI
71. the chamber event 1 is turned on and off If defrost is enabled this output will turn off the air circulator s during defrost and will turn back on once defrost is complete RC Blower Q1 This output is active on RC units and is used to turn the RC blower on and off when the chamber is on and event 8 is turned on and off If defrost is enabled this output will turn off the blower during defrost and will turn it back on once defrost is complete System 1 Compressor Q2 This output is used to turn system 1 compressor on and off based on the demand for cooling or dehumidification The output turns on when the loop percentage of output exceeds the on percentage for the delay period set in the configurator The output will turn off the compressor when the loop percentage of output exceeds the off percentage for the delay period set in the configurator The output also turns on and off with the pressure switch input 13 if pumpdown is enabled If main power is off for more than 30 minutes the input will be ignored and the output will remain off until pumpdown is reset automatically after 4 hours or manually by the operator The output is also controlled by the defrost pressure switch 117 When defrost is enabled the output will turn system 1 compressor on and off with the input in order to maintain the discharge pressure of system 2 at the proper range during defrost Note that when large horsepower defrost is enabled the output
72. the chamber is doing what it is supposed to based on how it is configured Section 6 _ Process Control Problems This section covers issues related to process control Why is the chamber not controlling to set point Why is the chamber not following the profile It provides information on how and why the controller responds to certain conditions and tips on how to improve response time Section 7 Remote PC Communication Problems This section covers issues involving the use of the serial Ethernet and optional IEEE interfaces available on the chamber when trying to connect to a remote PC and establish a communication link for monitoring and or control Section 8 Deciphering EZT Input Output I O Operation This section reviews the functionality of the inputs and outputs of the EZT and how they are used and controlled This section can assist you in determining if there is a wiring or hardware problem that may be causing the chamber to not operate properly Section 9 Adjusting EZT Configuration Options This section reviews the use of the EZT s configurator and how the settings affect the operation of the chamber This section is for experienced service personnel only Changing certain settings from the original factory settings can cause damage to equipment or injury to personnel When in doubt consult the factory EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 3 User Interface HMI Troubleshooting The EZT 560 s us
73. the drop down menu it is possible to select the port mode RS232 or RS485 Table 7 1 Common Serial Communication Problems and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS EZT not responding to commands from PC Modbus Slave not enabled Wrong slave address Wrong serial port mode setting Wrong communication port settings in PC or wrong command format Enable Modbus slave on PC Comms Web Server screen Use slave address set in EZT or change EZT slave address to match Verify serial connection used and set mode setting to match RS232 RS485 Verify proper protocol used Modbus Verify proper serial port settings used in PC Comm alm at PLC Check Cable alarm message Remote PC communicating too fast with EZT Slow down communication rate from remote PC minimum 500ms scan rate Profile download working but profile is not updating after download Write error during transfer Incorrect step count or steps transferred Profile write to EZT not at correct transfer rate Verify proper profile step data format Verify total profile steps match number of steps transferred Transfer step data at proper rate 1 step per second 48 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 7 2 GPIB Communications Troubleshooting The GPIB communication option is provided through the use of ICS s Model 4899 GPIB to Modbus Controller
74. tiiran asna EEE EEANN 49 Figure 8 1 PLC Input Output Indicators ccececcecceceeeeeeececeeaeceeeeeeeseceaaaeceeeeesesecaeaaeeeeeeeeeesesncaneeeess 67 Figure 8 2 Ribbon Cable Connection ieisieccaciviecceusindgeasseledceepacaccaney caceesvelengeepiladeacey yacaedauedeabevcendevadece 68 Figure 9 1 Exit Application 0 cccceccccsecceceeeeeeececeaeceeeeeeesecaeaeeeeeeeeeececeaaaeceeeeeeeseccasaeeeeeeesesensaaeeeeeess 70 Figure 9 2 Windows Start Menu cece nee eee tnree erent eerie ee eerie eee esieee ee tieeeeeteeeeetneeeeerneeeeetaa 70 Figure 9 3 Storage Card cee rt nie ee eee ener ee nieee ANEAN ee taeeeenaeeeeeeea 71 Figure 9 4 EZ T360 Folder enciso cit iets cha cases vacd seat atee cis yied dennnetbechvvaqdagshaeectvvind gien a 71 Figure 9 5 EZ T560 Connig aan atte ciaveestphanntededi likens teecepbiestealv R a nes 71 Figure 9 6 Number of LOOpS MOnitors cccceecceceeeeeenee eee enne ee ee ee NNNNA na SARRAN ANENE ENNEN RAR NANESENA ANNAK 72 Figure 9 7 Loop Monitor Tagnames sesde sareie ies insa nennen nap RASSA NEE EEN AN AAS EEEREN a 73 Figure 9 3 Chamber Optom eriei niar sana EA NEA E EE aT 75 Figure 9 9 Retrigeration Options secera sagn act Seti fads nani EASA EE EEAS RASPONA ites 77 Figure 9 10 Fumidiy Op tons cis ipct lessee ces ga esasa e ade ca vaca caspian peed deca d aed dads 79 Figure 9 11 Purge Lo RA Options s i 2 33 its rnes nesana enaA EA ESENE EE ities RETA 81 Figure 9 12 Aux Cooling Options ecoin EA Sa NE
75. time The value read from the EZT 560 will be an integer value based on the combined bytes of both the hours and minutes In order to obtain the individual values split the word into its two component bytes Example 0x1131 read from EZT high byte 0x11 converted to decimal 17 5pm low byte 0x31 converted to decimal 49 minutes 34 0x0022 r w Profile Estimate Stop Date YY MM See Profile Start Date YY MM 35 0x0023 Profile Estimate Stop Date DAY DOW See Profile Start Date DAY DOW 36 0x0024 Profile Estimate Stop Time HH MM See Profile Start Time HH MM 37 0x0025 Profile Start Step 1 99 S 0x0026 Profile Current Step 1 99 30 0x0027 Profile Last Step 1 99 z 0x0028 Profile Time Left in Step HHH 0 999 41 0x0029 42 Ox002A 43 Ox002B Profile Time Left in Step MM SS Profile Wait for Input Profile Wait for Setpoint 0 59 Minutes high byte 0 59 Seconds low byte Parameter contains both minutes and seconds of remaining step step time The value read from the EZT 560 will be an integer value based on the combined bytes of both the minutes and seconds In order to obtain the individual values split the word into its two component bytes Example 0x1131 read from EZT high byte 0x11 converted to decimal 17 minutes low byte 0x31 converted to decimal 49 seconds 0 Not Waiting 1 Loop 1 Input 2 Loop 2 Input 4 Loop 3 Input 8 Loop 4
76. to start when AutoStart is enabled The value will be an integer value based on the combined bytes of both the day and day of week In order to set the value combine the two component bytes into the word Example Start day of 23 and day of week is Monday decimal 23 converted to 0x17 high byte decimal 1 Monday converted to 0x01 low byte set value of 0x1701 to EZT 109 Cincinnati Sub Zero EZT 560 User s Manual Register Description Use 203 Ox00CB AutoStart Time HH MM 0 24 Hours high byte 24hr format military time w 0 59 Minutes low byte Parameter contains both hour and minutes for the profile to start when AutoStart is enabled The value will be an integer value based on the combined bytes of both the hour and minutes In order to set the value combine the two component bytes into the word Example Start time of 5 49 pm decimal 17 5pm converted to 0x11 high byte decimal 49 converted to 0x31 low byte set value of 0x1131 to EZT 204 0x00CC Profile Name Characters 1 and 2 These parameters store the operating profile s name up to 10 w characters in length uses ASCII character set Characters are stored in sequence from low byte to high byte Example 205 0x00CD Profile Name Characters 3 and 4 w Profile name is TEST 123 TE converted becomes 0x4554 206 0x00CE Profile Name Characters 5 and 6 ST converted becomes 0x5453
77. to one of the 9300 controllers To locate the problem connection change the temperature humidity altitude etc set points and watch the display of the 9300 controllers If the set point does not change on the corresponding 9300 controller that is the connection giving the problem Check the wiring between the Gateway and 9300 controller to make sure that there are no nicks in wiring shorts or wire crossings Check to make sure that the 9300 controller has the proper setup and communication address corresponding to the 9300 setup sheet provided with the chamber If two or more controllers have the same address this will also cause a communication failure Also verify that the rear connector on the 9300 controller is inserted properly If the rear connector is not fully inserted or is inserted improperly the communications connections may not be making proper contact on the rear connector body and also cause the alarm After verifying all connections and settings with no change the 9300 controller is most likely at fault and should be replaced 25 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 4 2 Status Alarms Status alarms do not shut down the chamber They are used to alert the user of certain operating conditions The alarms may or may not sound an audible alarm Status monitor alerts are signaled by an intermittent beeping of the audible alarm Status Monitor For Non Critical Alarms MB RH H20 RESERVOIR
78. troubleshooting procedures may require access to live electrical components operating at lethal energy levels Extreme caution and proper A protective gear is required These procedures should only be performed by qualified service personnel Failure to follow proper OSHA regulations may result in serious injury or death EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 2 Where Do Start Looking The EZT 560 Environmental Controller is a mini DCS Distributed Control System which uses different hardware layers to perform the various functions needed to operate the chamber These include the user interface HMI system monitoring and protection PLC as well as process control 9300 controllers This type of platform distributes the work load of controlling the chamber into different devices and allows us to break the system down into these layers for troubleshooting which makes diagnosing problems less complicated Instead of looking at the system as a whole look at each component and focus on what task it is performing and whether or not it is doing it right Start from the component level when tracing a problem and work backwards from what is not working Some problems are obvious If am trying to enter a set point and the touch screen is not responding to my touch then it is a problem with the HMI However when the chamber is not doing something it is supposed to is it the controller or something else Over 90 of the time i
79. water starts boiling and moisture begins to enter the chamber The controller backs of on the humidify output until it eventually turns off but the water continues to boil due to the thermal mass of the boiler and heaters This causes the chamber to overshoot its humidity set point It isn t because the controller was telling it to do the wrong thing it is because of the delay in how the boiler reacts To control the overshoot the controller must react slower The problem is that the chamber then responds slower to set point changes because the control output stays low to minimize the overshoot It is a balancing act The dynamics of the chamber and product load greatly affect the amount of overshoot that you may have and it can vary with set point There are two possible way to minimize overshoot yet still achieve desirable performance The first is to ramp the set point rather than make large set point changes When you make large step changes the controller reacts with large output changes The key is to maintain a steady moderate output that builds up less momentum The difficulty is that there is no set formula for calculating this rate It is dependant upon the chamber and product However keeping it just under the maximum capacity of the chamber is the most beneficial Don t let the controller reach maximum output The chamber can t go much faster anyway and it prevents the controller reaching that give it all you got until we g
80. write 95 r w 0x005F Loop 3 Alarm Hysteresis 0 32767 0 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 96 r w 0x0060 Loop 4 Setpoint 97 98 99 r w 0x0061 0x0062 0x0063 Loop 4 Process value Loop 4 Percentage of Output Loop 4 Autotune Status 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 10000 10000 100 00 100 00 Note that value must be converted from whole number i e divide by 100 to convert the decimal number from the value read Autotune Off Initiate Autotune Autotune Active Terminate Autotune ARMA O 99 Cincinnati Sub Zero EZT 560 User s Manual Register Description Use 100 r w 0x0064 Loop 4 Upper Setpoint Limit 101 r w 0x0065 Loop 4 Lower Setpoint Limit 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 102 r w 0x0066 Loop 4 Alarm Type Selection Alarm Off Process High Alarm Selected Process Low Alarm Selected Process Both Selected
81. 00 20 i 96 01100000 60 Shift 1 33 00100001 21 a A 97 01100001 61 H Shift 34 00100010 22 b B 98 01100010 62 Shift 3 35 00100011 23 c C 99 01100011 63 Shift 4 36 00100100 24 d D 100 01100100 64 Shift 5 37 00100101 25 e E 101 01100101 65 amp Shift 7 38 00100110 26 f F 102 01100110 66 K 39 00100111 27 g G 103 01100111 67 Shift 9 40 00101000 28 h H 104 01101000 68 Shift 0 41 00101001 29 l l 105 01101001 69 y Shift 8 42 00101010 2A j J 106 01101010 6A Shift 43 00101011 2B k K 107 01101011 6B 44 00101100 2C l L 108 01101100 6C 45 00101101 2D m M 109 01101101 6D 46 00101110 2E n N 110 01101110 6E I 47 00101111 2F o O 111 01101111 6F 0 0 48 00110000 30 p P 112 01110000 70 1 1 49 00110001 31 q Q 113 01110001 71 2 2 50 00110010 32 r R 114 01110010 72 3 3 51 00110011 33 s S 115 01110011 73 4 4 52 00110100 34 t T 116 01110100 74 5 5 53 00110101 35 u U 117 01110101 75 6 6 54 00110110 36 v V 118 01110110 76 7 7 55 00110111 37 w W 119 01110111 TT 8 8 56 00111000 38 x X 120 01111000 78 9 9 57 00111001 39 y Y 121 01111001 79 Shift 58 00111010 3A z Z 122 01111010 TA 59 00111011 3B Shift 123 01111011 7B lt Shift 60 00111100 3C Shift 124 01111100 7C 61 00111101 3D Shift 125 01111101 7D gt Shift 62 00111110 3E j Shift 126 01111110 TE Shift 63 00111111 3F DEL Delete 127 01111111 TF 72 EZT 560 User s Manual Cincinnati Sub Zero 9 2 Serial Communica
82. 0010 42 ETX Ctrl C 3 00000011 03 03 Shift C 67 01000011 43 EOT Ctrl D 4 00000100 04 D Shift D 68 01000100 44 ENQ Ctrl E 5 00000101 05 E Shift E 69 01000101 45 ACK Ctrl F 6 00000110 06 F Shift F 70 01000110 46 BEL Ctrl G 7 00000111 07 G Shift G 71 01000111 47 BS Ctrl H 8 00001000 08 H Shift H 72 01001000 48 TAB Ctrl 9 00001001 09 l Shift 73 01001001 49 LF Ctrl J 10 00001010 OA J Shift J 74 01001010 4A VT Ctrl K 11 00001011 0B K Shift K 75 01001011 4B FF Ctri L 12 00001100 oc L Shift L 76 01001100 4C CR Ctrl M 13 00001101 oD M Shift M TT 01001101 4D so Ctrl N 14 00001110 0E N Shift N 78 01001110 4E SI Ctrl O 15 00001111 OF o Shift O 79 01001111 4F DLE Ctrl P 16 00010000 10 P Shift P 80 01010000 50 DC1 Ctrl Q 17 00010001 11 Q Shift Q 81 01010001 51 DC2 CtrlR 18 00010010 12 R Shift R 82 01010010 52 DC3 Ctrl S 19 00010011 13 S Shift S 83 01010011 53 DC4 Ctrl T 20 00010100 14 T Shift T 84 01010100 54 NAK Ctrl U 21 00010101 15 U Shift U 85 01010101 55 SYN Ctrl V 22 00010110 16 Vv Shift V 86 01010110 56 ETB Ctrl W 23 00010111 17 Ww Shift W 87 01010111 57 CAN Ctrl X 24 00011000 18 X Shift X 88 01011000 58 EM Ctrl Y 25 00011001 19 Y Shift Y 89 01011001 59 SUB Ctrl Z 26 00011010 1A Z Shift Z 90 01011010 5A ESC Ctrl 27 00011011 1B 91 01011011 5B FS Ctrl 28 00011100 1C 92 01011100 5C GS Ctrl 29 00011101 1D 93 01011101 5D RS Ctrl 30 00011110 1E e Shift 6 94 01011110 5E US Ctrl 31 00011111 1F IE Shift 95 01011111 5F SP SPACE 32 001000
83. 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 140 0x008C r w PV3 Monitor Alarm Hysteresis 0 32767 0 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 141 0x008D 142 0x008E r w PV4 Monitor Process value PV4 Monitor Alarm Type Selection 32768 32767 3276 8 3276 7 Note that value must be converted from whole number i e divide by ten to convert the decimal number from the value read Alarm Off Process High Alarm Selected Process Low Alarm Selected Process Both Selected Nawo 143 0x008F r w PV4 Monitor Alarm Mode Bit1 Off alarm self clears Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 144 0x0090 r w PV4 Monitor Alarm Output Assignment 0 No Output Selected 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Cus
84. 5 provided with adapter cables and power supply 75 Cincinnati Sub Zero EZT 560 User s Manual 9 2 2 Protocol Protocol describes how to initiate an exchange It also prevents two machines from attempting to send data at the same time There are a number of different data communications protocols just as there are different human cultural protocols that vary according to the situation The protocol portion of EZT 560 communications is very important because it provides a quality of communication that others often don t have Protocol driven communications are more accurate because they are less prone to both operator and noise errors Protocol maintains system integrity by requiring a response to each message It s like registered mail you know that your letter has been received because the post office sends you a signed receipt In EZT 560 data communications a dialog will continue successfully as long as the messages are in the correct form and responses are returned to the protocol leader If the operator enters an incorrect message or interference comes on to the data line there will be no response In that case the master must retransmit the message or go to a recovery procedure If an operator continues to enter an incorrect message or interference continues on the data line the system will halt until the problem is resolved CSZ has selected Modbus RTU as the protocol of choice Modbus RTU enables a PC or PLC to read and wr
85. 6 EZT 560 User s Manual 10 Diagnostics Cincinnati Sub Zero This section provides technical help for diagnosing problem conditions with your chamber The information provided here covers typical options and accessories If you are unable to diagnose a problem through the use of this guide contact Cincinnati Sub Zero s Service Department 10 1 Alarm Codes and Troubleshooting WARNING Some of the procedures may require access to live circuitry Dangerous accidental contact with line voltage is possible Only qualified service personnel should be allowed to perform these procedures Potentially lethal voltages are present inside the unit Alarm Description Corrective Action Input ALARM BOILER OVERTEMP Indicates user configurable alarm is on for input listed Boiler exceeded operating temperature Check water supply and water level Verify low water float operation Reset high temperature safety on boiler BOILER LOW WATER Boiler water level low Check water supply Check low float operation Check operation of fill level float and water supply solenoids Check and replace filters if necessary CHAMBER HI LIMIT Chamber high limit safety tripped Limit must be manually reset or power cycled to chamber to reset Verify proper air flow in chamber Do not set temperature set point above chamber design limits COMBUSTIBLE MONITOR Optional air monitor detected hazardous condition Ven
86. 7 2 Logging Setup The Select Points for Logging screen allows the user to select any point s from the system for data logging The Select All and Clear All buttons provide a quick way to select or deselect all points in the system Select datalog points and press Accept Pointstolog ooo l C TEMPERATURE O HumMiDITY C ALTITUDE O PRODUCT W Log On Startup W Log On Profile Run Figure 7 2 Logging Setup Use the checkbox to enable disable a point for logging When selections are completed press the Accept key to write the point selection to memory This is important so that the EZT 560 saves the settings for power up operation New settings will not take effect until the Accept button is pressed Log On Startup The log on startup option automatically turns logging on whenever the chamber is powered on Log On Profile Run The log on profile run option is a convenient method for gathering information that pertains only to the operation of a profile When selected the EZT 560 will turn the logger on at the beginning of a profile and off once the profile is completed 54 EZT 560 User s Manual Cincinnati Sub Zero 7 3 History Files Historical files are stored on the internal compact flash memory of the EZT 560 All files can be opened and viewed on a trend graph 7 3 1 Open Delete History Files The data logging Edit menu provides three options for handling stored historical file
87. 7 degrees 52 7 and Out of 100 00 Reads one or multiple EZT 560 registers User specifies starting register reg and number of registers to be read num The is an optional symbol so programs like ICS s GPIBKybd program can recognize the command as a query and automatically read the response Values for reg are 0 to 32767 Values for num are 1 to 60 Responses are returned as 16 bit decimal values separated by R 61 1 reads EZT 560 loop 1 process value Example response is R 60 3 reads three successive registers for loop 1 SP PV and Out Example response is 550 527 10000 for SP of 55 0 PV of WB reg num w 0 w n Write Block Command Writes one or multiple 16 bit words w i to one or multiple registers Starting register reg Number num specifies how many words are to be written Values for reg are 0 to 32767 Values for num are 1 to 60 Values for w are 0 to 65535 WB 60 1 550 writes a set point of 55 0 to loop 1 E Read Error Command Error values are O No errors present 1 Exception Code 1 2 Exception Code 2 3 Exception Code 3 100 CRC Error 84 Reads and clears the Modbus Error Register and bit 6 in the Event Status Register Returns an error code whose value is 0 to 255 101 Timeout Error indicates no characters received 2nn Partial or corrupted message nn is number of received bytes EZT 560 User s Manual Cincinnati Sub Zero 9 4 Getting Connected EAI 232 Connections To connect
88. 9 6 122 User Ebena aa AA Na 49 6 1 21 Delete USO aaronii aaa EA EAEN 50 6 1 2 2 Change User PaSSWord ccccececccceeeeeeneeeeteneeeeeteneeeeeeieeeeetiieeeeeetneeeeess 50 B23 User RIQINS sci cat tvaevevecgaceatessaeeeds caveegees edi dhatoedherncevareaeeivaaees eres kak nue E 50 6 1 4 Security OPtions 2 0 ec ete ee tee renee eee ee eee ER i 51 6 2 User Log OWO sirener eski nck dena eth ia ad ck dea eae ech pee eee 52 6 3 View Audit Tasic nioran tae vided ance ak ade ee eee te 52 6 4 Current WSOP acisini cnt i e N Series hae EN teehee ene ee ENSE 52 Vi LOGGING E E E E seeceebtedncees 53 LA Stant otop Logghgeesrisis iaaa aa aa AAE a ANE TN a 53 T2 LOGGING SStUP eei a capes aaa a ANE NEE ANTE 54 Ta PBN Fles eena ae a 55 7 3 1 Open Delete History FileS essseeesrsnnessrneseernnnrsnnassennansnnnadeennannnsnnaatennaatannaaeennaanan 55 Ta Vion Histon PlObrseroriaka ira ia Aa ENE 55 7 3 2 1 History Plot Time Setup sssersiidinrn niiina anana inan kK N EARRAN a TiNa 56 7 3 2 2 History Plot Channel Setup sissssssiresieirinnaisivaanuii denkin naii 57 7 3 3 View Averages Report c cccccsciicceesedsecessecceeetsecedaetneccaqetbnseneqeneeccceensaeseaenveddeeennacie 57 TA Pile UGGS nionean EEA Ea 58 8 System Maintenance cccssccceceeseneeeeeseneeeeeseneeeeseeneeeeseeeeeseseeeseeessseeeeeeseeeesesseneesassaneesaseeneeennes 60 8 1 Degrees C F SelectON airinn Aa ES N T 61 8 2 Service MONIOMS scsercereaisnin dia nin a ER EA
89. ANDARD VTS TSB DTS 1 CHAMBER HOT CHAMBER BATH ON LEFT CHAMBER 2 HUMIDITY COLD CHAMBER CENTER CHAMBER 3 AUX COOL AUX COOL AUX COOL 4 PURGE PURGE PURGE 5 ALTITUDE XFR HOT XFR LEFT 6 XFR COLD XFR RIGHT 7 XFR UNLOAD RIGHT CHAMBER 8 RC BLOWER 9 INITIATE DEFROST INITIATE DEFROST INITIATE DEFROST 10 11 12 13 14 15 The chamber loops are also predefined and their use varies according to the type of chamber and options present The following table defines the standard use of the control loops Table 8 2 Control Loops LOOP STANDARD VTS TSB DTS 1 TEMPERATURE HOT CHAMBER BATH LEFT CHAMBER 2 DUT HUMIDITY ALTITUDE COLD CHAMBER BATH CENTER CHAMBER 3 DUT ALTITIUDE DUT RIGHT CHAMBER 4 DUT DUT LEFT BASKET 5 DUT RIGHT BASKET 51 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 8 1 Standard Input Configuration CONNECTION INPUT STANDARD CHAMBER CONFIGURATION DTS VTS TSB BO1 26 10 CHAMBER LIMIT BO1 24 11 PRODUCT SAFETY BO1 22 12 MOTOR OVERLOAD BO1 20 13 SYSTEM 1 PUMPDOWN SWITCH BO1 18 14 SYSTEM 1 HI LO PRESSURE SAFETY BO1 16 15 SYSTEM 1 OIL PRESSURE SAFETY BO1 14 16 SYSTEM 1 DISCHARGE THERMOSTAT BO1 12 I7 SYSTEM 1 COMPRESSOR SAFETY MODULE BO1 10 110 SYSTEM 2 HI LO PRESSURE SAFETY BO1 8 111 SYSTEM 2 OIL PRESSURE SAFETY BO1 6 112 SYSTEM
90. ATURE TEMPERATURE HOT CHAMBER BATH LEFT CHAMBER 2 PRODUCT HUMIDITY ALTITUDE HUMIDITY COLD CHAMBER BATH CENTER CHAMBER 3 l PRODUCT PRODUCT ALTITUDE PRODUCT RIGHT CHAMBER a T PRODUCT DUT LEFT BASKET 5 DUT RIGHT BASKET The chamber events also vary based on the model of chamber and options present In order to turn the chamber and associated options on and off it is necessary to set the proper event The chart below provides the chamber event number and its associated function based on the chamber model The chamber events are listed in order from top to bottom on the EZT s event screen The EZT can use a combination of up to nine chamber events INPI ALTITUDE VTS TSB MODELS DTS MODELS EVENT 1 CHAMBER HOT CHAMBER BATH ON LEFT CHAMBER 2 HUMIDITY COLD CHAMBER VTS ONLY CENTER CHAMBER 3 AUX COOL AUX COOL AUX COOL 4 PURGE PURGE PURGE 5 ALTITUDE XFR HOT XFR LEFT 6 XFR COLD XFR RIGHT 7 XFR UNLOAD TSB ONLY RIGHT CHAMBER 8 RC BLOWER 9 INITIATE DEFROST INITIATE DEFROST VTS ONLY INITIATE DEFROST CENTER ONLY 88 EZT 560 User s Manual Cincinnati Sub Zero User Responsibility Adhere to the following table of registers and their allowable data ranges Do not attempt to write to any other register number than those listed below Do not write to registers that are for options your unit does not have Failure to do so c
91. Chamber Troubleshooting Guide Profile Setpoint Chamber Response Temperature Figure 6 2 Profile Ramp Response How do make the Chamber Respond more like the Profile There is a trick you can use to force the chamber to respond to the profile with less lag It does require that you add more steps to your profile however These extra steps are used to force the controller to respond quicker and in a way give the controller the ability to anticipate the next set point change during the ramp All you need to know is what the offset is during the ramp i e what is the difference between the set point and the actual value in the chamber during the ramp step This is the lag or offset that is introduced during the start of the ramp in which the controller output is ramping up to the necessary value to maintain the rate of change in the chamber Knowing this value you will need to add two steps for each ramp in the profile in which the lag is undesirable One before the actual ramp step and one after The steps are going to be used to offset the ramp by the lag value Prior to the ramp step insert a new step Make this step with a time of zero in order to make an immediate set point change The set point for the step is going to be the previous step s set point the one you are ramping from with the offset added to it or subtracted from it You will add the offset if your ramp step is increasing or subtract it if your ramp step
92. Cycle power Calibrate touch screen see Section 3 1 3 Ambient temperature around HMI must be between 0 C 32 F and 45 C 113 F Turn off EZT Bring ambient temperature to within allowable range Replace HMI 5 Screen Difficult to See Screen looks like an Etch a Sketch Screen contrast out of adjustment HMI operating temperature exceeded Screen failure Adjust screen contrast see Section 3 1 4 Ambient temperature around HMI must be between 0 C 32 F and 45 C 113 F Turn off EZT Bring ambient temperature to within allowable range Replace HMI Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 3 1 1 Configure Windows CE Startup Directory The startup directory must be stored in the NORFlash directory in the HMI This area is backed up to flash memory so it is retained when power is removed and is automatically started once the boot sequence has been completed on power up To check the startup directory touch the thin gray bar at the bottom of the screen to display the start menu Touch the Start button and select Programs and then Windows Explorer Ye Favorites j Documents Figure 3 1 Windows Start Menu From My Computer open the NORFIash directory The NORFlash directory may contain several folders and or files however we are only concerned with the Startup folder If the startup folder does not exist then it
93. EA E 82 Figure 9 13 Altitude OptlonS escosesa EAEAN EA ANNEER AES ORE RE E EA 83 Figure 9 14 CSZ Event Names escorre eiani mas Anaren enian AANEREN NENE asinine deen TARTEKA 84 Figure 9 15 Critical Chamber Alarm Names saeeesseesseseeerreererrsseerreerinnnastennaarnnnaatenaaennnnantenaaennnnaaaannne 85 Figure 9 16 Critical Refrigeration Alarm Names cccccceeceeeetcneeeeenneeeeeeceeeseeaeeeeesaeeeeeeeneeeseeaes 86 Figure 9 17 Non Critical Alarm Names 00 cccccccceeeeeeeeneee erence ee ee tees eeeaeeeeeeaeeeeeesieeesseneeeeeeiineeeeeaes 87 Figure 9 18 Maintenance Alarm Names c cccccccceeeeeeeeeeeeeneeeeeenneeeee tees eeeaeeeseeiaeeeseeneeeeeeieeeenines 88 Figure 9 19 EEPROM Configuration Back Up cccccccceeeeeeeeeeeenneeeeeeneeeeesceeeeeeiaeeeeesieeeetenateeeseaes 89 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero List of Tables Table 4 1 Common Critical Alarms and Corrective Actions 0 0 c ccccccccseeeeccsseeeeeeeeecsesseeeeesuaaeueeeeeueas 20 Table 4 2 Common Status Alarms and Corrective Actions ccccccccccccceeeccsseeeeeeeeecceeeeeeeeesaueeeeeaaaaes 26 Table 7 1 Common Serial Communication Problems and Corrective Actions 48 Table 7 2 Common GPIB Communication Problems and Corrective Actions 00ccceecceceee seen 49 Table 7 3 Common Ethernet Communication Problems and Corrective Actions 0 ccccccceeeeeees 50 Table 8 1 Chamber Event ccccccccccccccccccsceeeccseeceeseeecs
94. EE EEE 62 8 2 1 Service Monitor Setup snenie e A E eA 62 8 3 Set Date Time iiini ree id EEEN EEEE A eae tes 64 6 4 Touch Screen Calibration o sesctecteelcteteet cacti cect eee E E EEEE EEEE EE 65 814 1 LOD Setting site visirieveheccde ses a AE E AAN a edie 66 8 5 Calba ea a a A a A a a 68 85 1 Anput Caliban seri inienn na aN 68 8 5 1 1 Calibrating Control INDUuts saarnaa aa 68 8 5 1 2 Calibrating Monitor INputs 0 ecceeeeeeeeeee eee eeeeeeneeeeeeneeeeeetnaeeeeesneeeeees 68 8 9 2 Output Calibration nerina e a NA 69 Cincinnati Sub Zero EZT 560 User s Manual TABLE OF CONTENTS cont d 9 COMMUNICATIONS ccccceceeeececcseesecesseeeeneeeeeusueeseuaueeeeaueseauauseseenauseseaueuseeuaueeeseauseseaeeseaesanaes 71 9 1 DefinitiOMiOl TeS aei kinana a A reese ela natok sides E ans needa adbeast 71 9 2 Serial COMMUNICATION 0 ccc ce eee e cece cecee cess seuu sees ee sesuuaeeeesaauueeeeeessesaueeeeeeaaeeeenaneeeees 73 9 2 1 Interface Standard 20 0025 ccccceseieeneececesccecddcsecs chee sncenedeecncossivensvsutenvcesdieusbessnesvanssnens 74 9 2 1 1 Interface Converters 2 0 cece cecccsceeeeeeeeeceseeeeecesseuueeeesesseseueeeesuaaaeeeeanes 75 1 Foam eo 6 1 eee Reem ne ot Des nN el Une ne CO Er 76 9 2 3 Write your own Modbus Application cccccccceeceeceeceeeeeeeeeceaeaaeeeeeeeeesessncaeeeeees 78 9 2 4 Packet SyMtar cenciccsiccecetessatececsdeteneesantecsciaceanssvvtt
95. EMY siscdcesssancdensutcnedsnvind caves cugaenatedentpucedaanpevcrgaebualedantpactadsnydiccaeevicegdetedteeeyanens 37 Figure 9 2 Set Point LIMIS ieii nea arraia iE AEA EEEE RAAN A 38 Figure 9 3 Event Tagnaimes wvi cecieesencecensiccccensscccauewvcugdenyacdeannyecuaennydcccennwedteakydlcdensyacdecentvctecunsiteeaavilees 39 Figure 5 4 Process Alarm TAagQnames isccccccsscdecetsaieceshuceadensanccadensaccdaunwedeedevvancdennvacuedsnvanscaeumnctacebanices 40 Figure 5 9 Alarm SeNgS act siscdcavssccccanaatcdenyeaccaaarewvcuadenpiccdaneyecuaannydccdenawedteaesyaicaar vans AA EA 41 Figure 9 6 Product Control as sisccccvsccrcaensancdcapsicccdedaadededanvacedcneveceadenaadedeuvwedtadavuaicdannsacdeasesineredenienegeaatees 43 Figure 5 Condensation Control ssmsssissssirasriirinr eiiiai N KANAE EA AKRANES A EARRA 45 Figure 5 8 Defrost Settings ccccceeeee rent rere neers ee etne ee erent ee ee eeee ee naeeeeeeaeeeeeeieeeeeeiaeeeneneeeeeeaes 46 Figure 5 9 PC Comms Web Servet ccccecccceceeeetireeeeetneeeeeeenieeeeeenieeeeeeeeeeeedeeeeeeeieeesesiaeeeeseiaeeeeniaes 47 Figure 6 1 Security Add User ccccccecceceeeeeeeeseeceaeeeeeaceceeeeeceaeeesaaeeseeeeseaeeesaaeeseneeseaeeeseaeessaeeeenees 49 Figure 6 2 Security Users List 0 0 2 ecceeeee cence eee ne ee ee etne ee ee ee esses aeeeeeeaaeeeeesaaeeesesaeeesesiaeeeeeeieeeeeeaes 50 Figure 6 3 Security User Rights 0 eccceeeeeeeeee sence ee eeneee eee eaeeeeeeaeeeeeeaaeeeeesaeeeseeaeeeesenaeee
96. ES CORRECTIVE ACTIONS Chamber not increasing in altitude Altitude turned off Turn on altitude event Vacuum pump not running Check replace fuse Reset overload Leak in chamber Check for leaks Check door gaskets and latches for tight seal 9300 controller output off Verify proper 9300 controller configuration Check set point Replace 9300 controller Vacuum control valve clogged failed Inspect valve Clean Replace if necessary Chamber not decreasing in altitude Altitude turned off Turn on altitude event No compressed air supply Check supply chamber with compressed air Check pressure regulator setting 9300 controller output off Verify proper 9300 controller configuration Check set point Replace 9300 controller Air supply control valve clogged failed Inspect valve Clean Replace if necessary 37 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 5 6 Fluid System Fluid systems can vary considerably between different types of chambers LC s TSB s and explosion proof chambers are typical candidates for fluid systems For LC s and TSB s it is the only means of heating and cooling the product under test Troubleshooting fluid system problems generally ends up with a heating or cooling system diagnosis As long as fluid is flowing at the proper rate temperature control falls back to the heating and cooling systems As long as the pump is operating properly and all isolation valves
97. If power is returned in less time than this setting the chamber will resume operation where it left off Note that profile run time stops while the power is off If power is returned after a time longer than this setting the EZT 560 will take action based on the Recovery State parameter Recovery State on Power Up Power Out OM oo Time COMM TERMINATE aren COMM continue Seconds Figure 5 1 Power Recovery Hold Select hold to have the chamber return to operation at the same point it was prior to the power outage If a profile was running the profile will still be active however it will remain in hold until manually set to continue Terminate Select terminate to have the chamber default to the off state on power up Ifa profile was active prior to the power outage the profile will also be stopped Reset Select reset to automatically restart the profile that was running at power failure Use this option if it is critical for a profile to run from start to finish without interruption Continue Select continue to have the chamber pick up where it left off on loss of power Ifa profile was running prior to the power outage it will resume where it left off and continue through the rest of the profile 37 Cincinnati Sub Zero EZT 560 User s Manual 5 2 Set Point Limits The set point limits screen allows the user to adjust the minimum and maximum operating set points allowed for the control loops These limits can be used to
98. Indicates power is correctly supplied to the HMI oo q Panel mounting clamp ye 4 places only 1 shown Front View Side View CF card socket Dip switches RICE Rear View Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 3 1 Common HMI Failures and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS 1 Black Screen PWR indicator is off Power is off Turn on power CPU indicator is off Wrong polarity of power source Blown Fuse on HMI Check correct polarity of power source positive to 24V terminal negative common to GND terminal Replace fuse PWR indicator is on CPU indicator is off Screen saver is on Bad backlight Touch screen to disable screen saver Replace HMI PWR indicator is on CPU indicator is on Power glitch Bad USB cable damaged I Stick Improperly inserted damaged CF card HMI hardware failure Cycle power to EZT Check supply voltage must be 24 1 Vdc Remove I Stick replace USB cable Verify CF card inserted properly Replace CF card Replace HMI 2 Blue Screen EZT560 application not starting CF card missing improperly inserted or erased Windows CE startup directory not properly configured Card socket damaged Verify CF card is inserted properly Check CF card for EZT560 operating files Check configure proper startup directory
99. Limit Sets the maximum dewpoint that the chamber will control to In essence this limits the maximum humidity that the chamber can achieve at a given temperature This value is primarily used to protect modular walk ins The modular walk in panels can not withstand high temperature and humidity levels Standard chambers typically have a setting of 100C 212F Modular walk ins are limited to 70C 158F 81 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 9 8 Auxiliary Cooling Options The Aux Cooling Options screen is accessed from the Chamber menu This screen is used to define what type of boost cooling the chamber has if equipped File Loops Chamber Event Alarm Tags Aux Cool Options Aux Cooling Type Boost Cool Temp SP Disable Aux Cool On EE 100 00 Aux Cool On Delay Figure 9 12 Aux Cooling Options NOTE You must press the Set button to save changes to the auxiliary cooling type selection Be sure to press the Set button prior to switching to another configuration screen or any change to the auxiliary cooling type will not be saved Parameter Descriptions Aux Cooling Type Sets the type of boost cooling system installed on the chamber Aux cool boost is for the standard boost option that is used to assist the refrigeration system Aux cool control is for chambers that have extended low temperature operation which go colder than the range of the re
100. Loop 5 Sensor Break Bit PV1 Monitor Sensor Break Bit7 PV2 Monitor Sensor Break Bit8 PV3 Monitor Sensor Break Bit9 PV4 Monitor Sensor Break Bit10 PV5 Monitor Sensor Break Bit11 PV6 Monitor Sensor Break Bit12 PV7 Monitor Sensor Break Bit13 PV8 Monitor Sensor Break Bit14 not used Bit15 EZT internal communications failure This parameter is bit oriented i e more than one alarm can be present at a time The value must be converted to binary and the status of each bit checked to see if the alarm is on 1 or the alarm is off 0 Example 0x0120 read from EZT converted to binary 0000000100100000 Bit6 and Bit9 on PV1 and PV4 Sensor Break 56 r 0x0038 Input Alarm Status Bit1 Loop 1 Alarm Bit2 Loop 2 Alarm Bit3 Loop 3 Alarm Bit4 Loop 4 Alarm Bits Loop 5 Alarm Bit6 PV1 Monitor Alarm Bit7 PV2 Monitor Alarm Bit8 PV3 Monitor Alarm Bit9 PV4 Monitor Alarm Bit10 PV5 Monitor Alarm Bit11 PV6 Monitor Alarm Bit12 PV7 Monitor Alarm Bit13 PV8 Monitor Alarm 94 EZT 560 User s Manual Cincinnati Sub Zero Register Description Use This parameter is bit oriented i e more than one alarm can be present at a time The value must be converted to binary and the status of each bit checked to see if the alarm is on 1 or the alarm is off 0 Example 0x0002 read from EZT converted to binary 0000000000000010 Bit2 on Loop 2 Alarm 57 0x0039 Chamber Alarm Status Bitt Chamber
101. Section 8 Deciphering EZT Input Output I O Operation for assistance on locating the cause Using the alarm description search the alarm table for the alarm description Included with the alarm description will be information on what causes the alarm and what must be done in order to clear the alarm condition WARNING The following diagnostic activities may require access to live circuitry Dangerous accidental contact with line voltage is possible Only qualified A service personnel should be allowed to perform these tasks Potentially lethal voltages are present inside the unit Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 4 1 Critical Alarms Critical chamber alarms will shut down the chamber and sound an audible alarm The operating screen background on the EZT display will turn red to provide visual indication of the alarm condition Pannon siewe cea Alarm Description Dae sd PUMPDOWN DISABLED 2 9 2006 Figure 4 1 Alarm Monitor Pressing the Silence button will quiet the audible alarm and reset the screen background to blue If the alarm condition has cleared the chamber will resume operation If the alarm condition is still present the chamber will not restart until the condition is cleared Pressing the Clear button will remove the alarm from the monitor window if the alarm condition has cleared If the alarm condition is present the alarm can not be cleared from the monitor window Tab
102. Some converters get their power from the handshake lines of the PC If you rely on this method you will need to wire these additional lines In addition your software must set these lines high A more reliable method is to use the external power supply This is especially necessary when using a laptop computer See the documentation that comes with your converter for more detail Not all converters are equal in performance If your chamber operates in a harsh electrically noisy environment this can cause less robust converters to work intermittently or not at all CSZ has only tested the converters listed below however CSZ makes no claims as to the performance or compatibility of these converters with your PC or PLC device These converters are equipped with automatic send data control circuits driver control in the converter hardware so you don t have to work with software at all The circuit monitors data flow and enables the driver during transmission and automatically disables it when no data is being sent There is no need to rework software or install new drivers B amp B Electronics 707 Dayton Road PO Box 1040 Ottawa IL 61350 Phone 815 433 5100 http www bb elec com Part 4850l19TB for EIA 232 to EIA 85 Part 485PS2 external power supply required if handshake lines unavailable for power RESmith 4311 Smith Drive Hamilton OH 45011 Phone 513 874 4796 http www RS485 com Part ASC24T B9FPS for EIA 232 to EIA 48
103. Sub Zero 7 Remote PC Communication Problems This section covers troubleshooting basics for user communications to the EZT This is for PC to EZT communications not internal communication between EZT components The user communication capabilities are enabled from the PC Comms Web Server screen under the chamber setup menu Enter Slave address for PC communications Enable Disable web server and press Save Settings to store 192 168 1 105 W Web Server Enable E Modbus Slave Enable Figure 7 1 User Communication Settings Save Settings For more detailed information on communication format commands and functionality of the user communication connections see the EZT 560 User s Manual 47 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 7 1 Serial Communications Troubleshooting The EZT 560 allows a user to remote monitor and control chamber operations over an RS232 or RS485 communications connection Only one may be used at a time The connection type is enabled from the System Settings screen System Settings OK Set serial port mode Set COM1 mode Set COM3 mode frases Figure 7 2 Serial Port Mode Settings The system settings can be accessed through the Calibrate Touch Screen menu item under system maintenance and selecting Calibrate Touch You can then select the serial port mode tab to access the port settings COM3 is used for user communications Using
104. Sub Zero EZT 560 User s Manual 9 2 3 Write your own Modbus Application Listed below are a few of the more common software packages that claim to support the Modbus protocol CSZ does not recommend any one software package nor supports the implementation of any software package not sold by CSZ This list is provided as informational only CSZ makes no claims as to the performance or compatibility of any software package with your particular PC or PLC hardware Contact the software manufacturer for more information in applying their software LabView by National Instruments 6504 Bridge Point Parkway Austin TX 78730 5039 Phone 512 794 0100 http www natinst com Ol 2000 by Software Horizons Inc 10 Tower Office Park Suite 200 Woburn MA 01801 2120 Phone 617 933 3747 http www shorizons com SpecView by SpecView LLC 41 Canyon Green Court San Ramon CA 94583 Phone 510 275 0600 http www specview com Wonderware 2000 by Wonderware Corp 100 Technology Drive Irvine CA 92718 Phone 714 727 3200 http www wonderware com 78 EZT 560 User s Manual Cincinnati Sub Zero If you already have a software application that uses Modbus you can simply skip to EZT 560 parameter table in the Getting Started section for the information your program will need The rest of this section provides information for writing a software application that uses Modbus 1 You need to code messages in eight bit bytes with event parit
105. The 4899 is an IEEE 488 2 compatible GPIB device that can control Modbus slave devices It accepts simple GPIB bus commands that are used to create Modbus RTU packets that are transmitted serially to the Modbus slave devices in this case the EZT When this option is provided it is connected to the EZT s RS485 serial connection For the GPIB interface to be used the EZT must have its serial port mode setting for COM3 set to RS485 The connection type is enabled from the System Settings screen System Settings OK Set serial port mode 4 gt frases Set COM1 mode Set COM3 mode Figure 7 2 Serial Port Mode Settings The system settings can be accessed through the Calibrate Touch Screen menu item under system maintenance and selecting Calibrate Touch You can then select the serial port mode tab to access the port settings COM3 is used for user communications Using the drop down menu it is possible to select the port mode RS232 or RS485 Table 7 2 Common GPIB Communication Problems and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS GPIB interface not responding to read write commands 4899 power turned off Wrong bus address Missing termination character Turn 4899 power switch on Verify 4899 GPIB bus address Use proper termination character LF Comm alm at PLC Check Cable alarm message Remote PC communicating too fast with EZT
106. The sensor is then connected to a limit device This limit device monitors the temperature and turns off the power supply to the heater when the surface temperature exceeds the maximum operating limit The limit device overrides any call from heating by the chamber controller Once the temperature drops below the operating limit power is restored to the heaters if heating is still required The operating temperature limit is dictated by the flammable material The maximum operating temperature of the heater surface can be no higher than 80 of the auto ignition temperature of the flammable material in degrees centigrade Rate Master Operation With rate master the operation of the refrigeration system varies with temperature When the air temperature is above 20 C 4 F and air temperature set point is 10 C 14 F or above the system operates in single stage mode The system 1 compressor output Q1 solenoids output Q11 and the rate master control output Q10 will be on when cooling is required The rate master control output is used to switch the cooling output of the 9300 loop controller from the system 2 cooling solenoids over to the system 1 cooling solenoids The maximum cool output will turn on and off based on the demand for cooling and the control settings in the EZT configurator The refrigeration system will switch over to cascade mode when the air temperature drops below 0 C 32 F and the air temperature set point is below 10
107. U Connector 1 CPU Connector 2 16 Point Output Card 32 Point Output Card 0 13 10 113 14 27 114 127 0 17 Q30 Q47 0 17 Q30 Q47 0 7 Q0 Q7 10 17 Q10 Q17 20 37 Q50 Q67 CRE ER RS CELI LLET SRSRESESISS ESS SS E Figure 8 1 PLC Input Output Indicators 67 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 8 3 1 I O Ribbon Cable Connections The PLC input and output connections are made through ribbon cables to break out wiring boards for individual conductors The ribbon cables may or may not be keyed If the cable is not keyed it can be inserted upside down This will cause the chamber to not function correctly and can cause numerous alarms to appear on the EZT none of which are real The ribbon cables are marked with a red stripe down one side indicating pin 1 When inserting the ribbon cables make sure that the red stripe is oriented the same direction on both the PLC and the break out board That is pin 1 to pin 1 or pin 20 to pin 20 for example Red Stripe Designating Pin 1 Side of Cable S SEE ERS E ov ewe e E o o o m kam Pin 1 on Connector my ip Terminal 1 on Break Out Board Me Pee Figure 8 2 Ribbon Cable Connection 68 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 9 Adjusting EZT Configuration options The EZT configurator is used to set the functionali
108. VE TRANSFER LEFT BO3 9 Q45 NOT USED MAX DIVE TRANSFER RIGHT BO3 7 Q46 NOT USED MIN VACUUM TRANSFER UP BO3 5 Q47 NOT USED MAX VACUUM TRANSFER DOWN Connection This column designates the physical wire connection point to the PLC for the output Output This column designates the output address in the PLC as well as the marking used to identify wiring and hardware associated with the output 59 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide CONNECTION INPUT STANDARD DTS VTS TSB BO4 25 Q50 CUSTOMER EVENT 1 BO4 23 Q51 CUSTOMER EVENT 2 BO4 21 Q52 CUSTOMER EVENT 3 BO4 19 Q53 CUSTOMER EVENT 4 BO4 17 Q54 CUSTOMER EVENT 5 BO4 15 Q55 CUSTOMER EVENT 6 BO4 13 Q56 CUSTOMER EVENT 7 BO4 11 Q57 CUSTOMER EVENT 8 BO4 25 Q60 CUSTOMER EVENT 9 BO4 23 Q61 CUSTOMER EVENT 10 BO4 21 Q62 CUSTOMER EVENT 11 BO4 19 Q63 CUSTOMER EVENT 12 BO4 17 Q64 CUSTOMER EVENT 13 BO4 15 Q65 CUSTOMER EVENT 14 BO4 13 Q66 CUSTOMER EVENT 15 BO4 11 Q67 NOT USED Connection This column designates the physical wire connection point to the PLC for the output Output This column designates the output address in the PLC as well as the marking used to identify wiring and hardware associated with the output 60 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 8 2 1 Output Description of Use Air Circulator s QO This output is used to turn the chamber air circulator s on and off when
109. When even or odd parity is being used the number of marks logical 1 bits in each data byte are counted and a single bit is transmitted following the data bits to indicate whether the number of 1 bits just sent is even or odd For example when even parity is chosen the parity bit is transmitted with a value of 0 if the number of preceding marks is an even number For the binary value of 0110 0011 the parity bit would be 0 If even parity were in effect and the binary number 1101 0110 were sent then the parity bit would be 1 Odd parity is just the opposite and the parity bit is 0 when the number of mark bits in the preceding word is an odd number Mark parity means that the parity bit is always set to the mark signal condition and likewise space parity always sends the parity bit in the space signal condition Since these two parity options serve no useful purpose whatsoever they are almost never used CSZ has chosen to use even parity with the EZT 560 A device used to communicate with the EZT 560 must also have its serial port set to use even parity in order for data communications to work properly 73 Cincinnati Sub Zero EZT 560 User s Manual 9 2 1 Interface Standards An interface is a means for electronic systems to interact It s a specific kind of electrical wiring configuration CSZ has selected to use two of the most common serial interfaces used today This provides both a simple 1 to 1 connection to a PC or PLC using readil
110. afety The system 2 oil pressure safety input is used to indicate that the system 2 compressor oil pressure is below the proper operating range if equipped This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is on requires manual reset of oil pressure safety The system 2 discharge thermostat input is used to indicate that the system 2 compressor discharge temperature has exceeded the maximum operating range if equipped This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is on automatically resets after allowed to cool down EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero Sys2 Protection Module 113 The system 2 compressor protection module input is used to indicate that the system 2 compressor protection module has detected an improper phase condition loss or the compressor motor windings have overheated if equipped This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor scre
111. al number from the value read or to the proper value for a write 83 r w 0x0053 Loop 2 Alarm Hysteresis 0 32767 0 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 84 r w 0x0054 Loop 3 Setpoint 85 0x0055 Loop 3 Process value 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 86 0x0056 Loop 3 Percentage of Output 10000 10000 100 00 100 00 Note that value must be converted from whole number i e divide by 100 to convert the decimal number from the value read 87 r w 0x0057 Loop 3 Autotune Status Autotune Off Initiate Autotune Autotune Active Terminate Autotune RMA O 88 r w 0x0058 Loop 3 Upper Setpoint Limit 89 r w 0x0059 Loop 3 Lower Setpoint Limit 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 98 EZT 560 User s Manual Cincinnati Sub Zero Register Description 90 r w 0x005A Loop 3 Alarm Type Selection 0 Alarm Off 3 Process High Alarm Se
112. allows the system to be fine tuned to the minimum amount of overshoot required to obtain the desired product temperature The process mode has the benefit of maximum change rates by allowing the air temperature to go to absolute limits This allows the product to achieve set point temperature as quickly as possible but does so at the cost of stability If the part has a large thermal lag the air temperature control may oscillate uncontrollably once the product reaches set point because of the large overshoot In most cases deviation control is the recommended choice 44 EZT 560 User s Manual Cincinnati Sub Zero 5 7 Condensation Control The optional condensation control feature is for situations in which condensation is undesirable or detrimental to the product being tested When enabled the rate of rise in temperature is limited in order to allow the humidity control system to strip moisture from the chamber in order to keep the dewpoint of the air below the product temperature If the dewpoint of the air were to exceed the product temperature moisture could form on the product s surface Condensation Control Off Accept Temperature Ramp Rate Limit 0 Dewpoint 0 DP Limit 0 Monitor Mode Input Selection COMB Sinale Input COMM pRoouct om Low Input COMB Hi Input Figure 5 7 Condensation Control There are many factors that can affect the performance of the chamber including product placement mass of product and air d
113. amp A programmed increase in the temperature of a set point system range The area between two limits in which a quantity or value is measured It is usually described in terms of lower and upper limits RTD resistance temperature detector A sensor that uses the resistance temperature characteristic to measure temperature serial communications A method of transmitting information between devices by sending all bits serially over a single communication channel set point SP The desired value programmed into a controller For example the temperature at which a system is to be maintained T C thermocouple A temperature sensing device made by joining two dissimilar metals This junction produces an electrical voltage in proportion to the difference in temperature between the hot junction sensing junction and the lead wire connection to the instrument cold junction A 3 Cincinnati Sub Zero EZT 560 User s Manual List of Figures Figure 1 1 DUT Safety COnnections eee ener eeeene ee eeeaeeeeeeaaeeeeeeaaeeeeeeaeeeseeneeeeseaeeeseeneeeseeaes 5 Figure 1 2 Touch Screen Interface ee ecceeseeeeeeeeeeeceeeaeeeeeeaeeeeeeaaeeeseeaaeeeeeeaeeeseeaeeeeseiaeeeeeeeneeeeeenaes 7 Figure 1 3 Main Menu Navigation 00 0 2 cc cccceeseeceeeneeeeeeneeeeeeeaeeeseeaeeeeeeeaaeeeeeeaeeeseeaeeeeeenaeeeseeneeeeeenaes 8 Figure 1 4 Profile Menu Navigation ccececeeeee re eeeeneeeeeeeneeeeeeaeeeeeeeaeeeeeeaeee
114. an result in erratic control and or damage to equipment NOTE Register numbers listed are relative values To convert to absolute values add 40001 Register Description Use 0 Ox0000 EZT 560 Mode 0 Offline maintenance mode r 1 Online When the EZT 560 is in maintenance mode the system no longer updates parameter values and the chamber is inoperative 1 0x0001 Clock YY MM 0 99 Year high byte r 1 12 Month low byte Parameter contains both current year and month of system clock The value will be an integer value based on the combined bytes of both the year and month In order to obtain the individual values split the word into its two component bytes Example 0x0601 read from EZT high byte 0x06 converted to decimal 6 2006 low byte 0x01 converted to decimal 1 January 2 0x0002 Clock DAY DOW 1 31 Day of Month high byte r 0 6 Day of Week low byte 0 Sunday 1 Monday 2 Tuesday 3 Wednesday 4 Thursday 5 Friday 6 Saturday Parameter contains both day of month and day of week of system clock The value will be an integer value based on the combined bytes of both the day of month and week In order to obtain the individual values split the word into its two component bytes Example 0x1701 read from EZT high byte 0x17 converted to decimal 23 23 day of month low byte 0x01 converted to decimal 1 Monday 3 0x0003 Clock HH MM 0 23 Hours high byte 24hr format military time r
115. anana EE AAAA 65 Figure 8 7 Save ReQIStry ecceeceeeeee cence ee eene ee erect A ARENAN AANREKENEN ANNARA AEEA AAEE EAEE 66 Figure 8 8 LOD Settings 2 2 csececesesceasecdacceeecevseteeeegaceatetiaedees cpieeag toaszne ovgaseaseevaeaeeseeviatas ergata aaedenaeeee 66 Figure 8 9 CONTAS terei iia iiini iea e E EE SENEE OENE SEARE eee 67 Figure 8 10 Monitor Input Calibration ccceecceeeeeeenee ee enneee eee eneeeeeeaeeeeeeaeeeeeeieeeeesieeeeensneesenaes 68 Figure 8 11 Output Calibration 20 00 ccc ecee eee eene ee eee te anainn ankan ee taaeeeeeecaeeeeesaeeeesesnaeeeeeineesenaes 69 Figure 9 1 Serial Port Mode 00 0 0 cece eeeceee ee eene eee e entree eee ae ee eee ae eee eeeaeeeeeeaeeeeesaeeeeeeaeeeeeeenaeeeenseeeeeeaes 81 A 5 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide EZT560 Chamber Troubleshooting Guide REVA Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide TABLE OF CONTENTS Te OVOIVIOW verve si aE AEE OOE OEA EAO EAE Setanta eels 4 ti Safety mormo E E 4 1 2 Howto Use this CGulEnesuucsnicisonincoiriin aiii ih E EE saad EEA RE 4 2 Whore DoT Start LOOKING errien aaa Aa ERARE EAE E EN EEAO 5 3 User Interface HMI Troubleshooting 221 2cccccccecceesceeeeseeceeeeeeaaeceeneeeceaesesaaeseeneeseneeeseeeesnaeeeenstees 7 3 1 Common HMI Failures and Corrective Actions ccceccceeeeetteeeeeenneeeeeeeeeeseeaaeeeeeenaeeeeeeaas 8 3 1 1 Configure Windows CE Startup Directory essseseee
116. and Modbus Slave Enable and press the Save Settings button Next select System Maintenance from the setup menu View Setup Help Power Recovery Setpoint Limits Event Tagnames Enter Slave address for PC communications J ProcessjAlarm Tagnames nunications Enable Disable web server and press Save press Save Settings to store ees Product Gontral Condenstation Control 1 192 168 1 105 Defrost Settings 168 1 105 PC Comms Web Server eae fi Web Server Enable Ce ae Enable ave Settings g E Modbus Slave Enable System Maintenance Ene E ee PC COMMS WEB SERVER amp amp El pc coMMSMWEB SERVER amp Figure 3 10 PC Comms Web Server 14 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero You will be prompted with a message stated that Maintenance mode will put system in offline condition Continue Select Yes From the setup menu select Calibrate Touch Screen Setup Degrees C F Service Monitors Service Info Setup Set Date Time Calibrate Touch Screen Exit Application E TEMPERATURE UNITS Figure 3 11 System Maintenance Setup menu Access Press the Calibrate Touch button Calibrate functions will suspend all operations for the EZT 560 Operation will not resume until Calibrate Touch window is closed Calibrate Touch Return To Setup Select functions from buttons listed aboye Figure 3 12 Calibrate Touch Press the calibrate button on the system
117. byte CRC low byte CRC high byte Packet returned from EZT 560 nn 06 nn nn nnnn nannn controller address 1 byte write command 0x06 register high byte register low byte data high byte data low byte CRC low byte CRC high byte Example Write register 60 temperature set point of controller at address one to 20 degrees Sent 01 06 00 3C 00 C8 48 50 Received 01 06 00 3C 00 C8 48 50 81 Cincinnati Sub Zero EZT 560 User s Manual Write Registers Command 0x10 NOTE This command is for use with profile download only It is used to transmit profile data one step at a time to the EZT 560 See Section 9 4 2 for the profile parameters and their use If this command is used to write to registers other than the correct profile step registers the EZT 560 will respond with the acknowledge that the message was received however the command will not be executed Packet sent to EZT 560 nn 10 nn nn 00 OF 1E nn nn nn nn nn nn controller address 1 byte _f write command 0x10 starting register high byte starting register low byte number of registers to write high byte 0x00 number of registers to write low byte Ox0F number of data bytes 0x1E data high byte data low byte register n data high byte register n data low byte CRC low byte CRC high byte Packet returned from EZT 560 nn 10 m
118. can be changed by using the proper command string see section 9 3 Note that the PC communications address set in the EZT 560 should always be 1 This is the default address that the IEEE interface will use when communicating on its serial interface to the EZT 560 controller 87 Cincinnati Sub Zero EZT 560 User s Manual 9 4 1 EZT 560 Control Parameters The EZT 560 is capable of utilizing up to five control loops and eight monitor inputs The following parameter table lists the associated values for all of the loops inputs and their associated alarms by the loop or monitor input number While the monitor inputs will be easy to decipher since they are shipped from the factory with the relative number in their tag name the loops are not The loop names are defined by the chamber process they control i e temperature humidity etc since the number of control loops required and their function can vary between different chamber models For all chamber models loop 1 will always be the temperature loop As each loop is scrolled through from left to right on the EZT interface the loop number will increment by one for each loop view until all loops are viewed and the interface wraps back around to loop 1 The chart below provides a loop number to controlled parameter reference for use in selecting the desired parameter from the parameter list ita e ALTITUDE MODELS AA DTS MODELS LOOP 4 TEMPERATURE TEMPERATURE TEMPER
119. cecenaeaeeeeeeeeetenanes 20 3211 FAMILY eheann sah ceaneaieuvne a E EE 20 3 212 AMMUGS e dena e adver a EE EE 22 3 2 1 3 Auxiliary Coolie aei a E E 22 3 2 1 4 Dry Air Purge Low RH Option c ccceecceeeeececeeeeeeeeseeeeeseeeeesnaeenseeeeeas 23 3 2 1 5 Customer Event Option 0 cccccccceceececeeeeeeeseceecaeeeeeeeseseeceneaeeeeeeeeeeenaeas 23 3 9 ONE POUCH TUNING reran a boelausueeeacenieer aces E 24 Profile Operation ccccsesscesscssseesseeeseeessssneesneesceensnsesnenseesseeesneesaeesaeessoessaessesesesegeensaesanenanenaes 25 A1 Prone EMI eonen A A cael el dee 26 AV Step EVOMS nosines inann a a a aa Aa 27 412 GS EVentS eiaei Mien ni eaa aaa a a N 27 AVS Wait FOl area a eea a Aa ra aa E Ea T 28 4 1 4 Set Point Step Time ccccccccceessceceesceeeeseeeeeeceeaeeeceeaeeeesesaeeeessseeeeseesieeeeseaes 28 AS AVUUIIN Piette cos xeustoaata chet a teano E neath aatunael E 29 A 2i AWOSE Aiae ncaa cece a aoe aA Ree at Uo an eae eae one lanes aes 30 4 3 Guaranteed Soak Limits ccccccceceeeceeceeceeeeeeeeeeecaaeeeeeeeeesecaaeceeeeeeesecsnaeeeeeeeensessaaeees 31 4 4 Plot Profile ee 32 4 5 Start Stop Profile ccceccececcece cece eeeeeeeneaeeeeeeeceeceaeeeeeeeeesesecaeeeeeeeeeseesecaeeeeeeeeeseesnnaeees 33 4 5 1 Hold Resume a Profile ccccece cece ce eeeeeeeeeceeceeeeeeeeeesecaeaeeeeeeeseeecnieaeeeeeeeeeeeeees 34 4 5 2 Advance Previous Next Step cccccceceeeeeeeecneceeeeeeeseccaeaeee
120. chaining of multiple chambers to a single PC or PLC s serial port The connection requires only two wires pins 3 and 4 of the RJ11 connection The PC or PLC s serial port must be equipped for RS 485 half duplex communications or an interface converter must be used 86 EZT 560 User s Manual Cincinnati Sub Zero PC PLC Serial Connection EZT 560 Serial Connections Description Pin RJ11 1 Description T R B SO DATA B T R A 4 DATA A Chamber 1 Pin RJ11 2 Description 3 DATA B 4 DATA A Pin RJ11 1 Description 3 DATA B 4 DATA A Chamber 2 Pin RJ11 2 Description 3 DATA B 4 DATA A Pin RJ11 1 Description DATA B 4 DATA A Chamber N Required PC PLC Serial Port Settings Baud Rate 9600 Data Bits 8 Stop Bits 1 Parity Even The EZT 560 is configured with a default address of 1 The address can be changed by selecting a new value via the PC communications Setup menu Using the following parameter list format the proper commands using the afore mentioned Modbus protocol packet structure GPIB lIEEE 488 Connections optional If your chamber is equipped with the optional IEEE communications port connect the chamber to your PC s IEEE port using a high quality shielded cable Up to 15 devices can be connected ona single IEEE bus The IEEE interface is configured with a default address of 4 The address
121. chanism components require regular maintenance Perform service and clear elapsed service count for corresponding components NOTE An audible signal can be associated with the service alerts See section 10 2 Service Monitors for detailed information on the service alerts 119 Cincinnati Sub Zero 10 2 Service Monitors EZT 560 User s Manual WARNING Perform lock out tag out procedures and remove main power from the chamber prior to performing any service procedures Service should only be performed by qualified service personnel Elapsed Service Counter Description AIR CIRCULATOR HRS Service Action Inspect locking collars on fans Tighten if necessary Inspect fan blades for damage or loose blades Replace fan blade if necessary DO NOT attempt repair Inspect motor bearings for excessive wear slop Lubricate if applicable Inspect heaters for corrosion and replace if insulators cracked or damaged RC BLOWER HRS Inspect locking collars on blower wheel Tighten if necessary Inspect blower wheel for damage or loose blades Replace wheel if necessary DO NOT attempt repair Inspect motor bearings for excessive wear slop Lubricate if applicable ALTITUDE SYS HRS Change vacuum pump oil filter Check oil level in vacuum pump Check for leaks Add oil if needed If applicable inspect drive belts and replace if worn Re tension belts Inspect motor bearings for excessive wear slop
122. cinnati Sub Zero EZT 560 User s Manual 4 4 Plot Profile The currently loaded profile can be viewed by using the Plot Profile utility This allows you to see if the profile you programmed matches the desired profile To view the profile select Plot Profile from the profile Views menu 50 0 40 0 30 0 20 0 10 0 0 0 Mins 0 TEMPERATURE Figure 4 8 Profile Plot The EZT 560 will automatically generate a graphical representation of your profile and display it on the screen The Y axis auto scales to fit the set points within the profile The X axis auto scales to the number of steps in the profile Note that jump steps are not shown 32 EZT 560 User s Manual Cincinnati Sub Zero 4 5 Start Stop Profile To start a profile it must first be loaded The currently loaded profile is shown at the bottom of the profile entry screen To start the profile select Run from the Run menu Run Profile Hold Profile Stop Profile Stop Profile All OFF Advance Next Step Advance Prev Step You will then be prompted to enter the step number for the profile to start on default is step 1 Profile Start Lai 1 Li Figure 4 9 Profile Start Use the scroll buttons to adjust the start step if required and press the Start Profile button The profile will then be transferred into the profiler memory and started once the transfer is complete The Profile Status screen will automatically appear upon sta
123. d 24 Deviation High Alarm Selected 40 Deviation Low Alarm Selected 56 Deviation Both Selected NOWO 115 0x0073 r w Loop 5 Alarm Mode Bit1 Off alarm self clears Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 116 0x0074 r w Loop 5 Alarm Output Assignment 0 No Output Selected 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8 Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 117 0x0075 r w Loop 5 High Alarm Setpoint 118 0x0076 r w 119 0x0077 r w Loop 5 Low Alarm Setpoint Loop 5 Alarm Hysteresis 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a
124. d with an erroneous value or result in a time out response i e the EZT will not respond with a return message Messages with the wrong format timing or CRC are also ignored A response will not be given to them Only messages with the proper format timing and CRC will be acknowledged It is the user s responsibility to handle the error appropriately within their own software and determine whether to resend the message or halt for operator intervention User Responsibility Refrain from altering prompts that do not appear on the EZT 560 s front panel or are not included on the specific model Care must also be taken that the process can not cause damage to property or injury to personnel if the wrong commands are sent due to operator error or equipment malfunction Be sure to use limit devices on any equipment placed inside the chamber that can generate heat to prevent system runaway 79 Cincinnati Sub Zero EZT 560 User s Manual 9 2 4 Packet Syntax Each message packet begins with a one byte controller address from 0x01 to OxF7 The second byte in the message packet identifies the message command read 0x03 write 0x10 or loop back 0x08 The next n bytes of the message packet contain register addresses and or data The last two bytes in the message packet contain a two byte Cyclical Redundancy Checksum CRC for error detection Packet format nn nn nnnn nnnn address 2 f command SSS registe
125. d flow The heating and cooling outputs function in the same manner as a standard chamber except they are controlling fluid temperature instead of air Hot baths are typically for heating only They do not have any means of cooling the fluid Cold baths may or may not have heaters in order to warm up and operate at elevated temperatures Typically cold baths are for cooling only Explosion Proof Chambers Explosion proof chambers typically use hot oil systems as the means for heating the chamber Explosion proof classifications require that no component even upon failure can ignite the flammable substance present Electric heaters can short or rupture in a failure condition thus causing an explosion Also the surface temperature of the heaters is critical to safety The heater can not operate over 80 of the auto ignition temperature of the flammable material or this can also cause an explosion Hot oil systems may be equipped with independent temperature controls This control device will maintain the fluid at a preset temperature The chamber temperature control will then cycle solenoids to control the flow of the fluid into a heating coil in the chamber thus heating the air Since the fluid is maintained at a safe temperature even if the coil were to rupture there is no source of ignition present 38 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 5 7 Transfer Mechanism Transfer mechanisms are used on thermal shock
126. d operate at 100 either Keep in mind that if you are maxing out the chamber it has no ability to control It is all the chamber has to keep up Even the slightest variation can cause the chamber to fall behind A properly programmed ramp should never exceed 80 of the chamber s capacity at any point along the ramp Ideally it should never exceed 50 but that is impractical My Rate is set Correctly so why is the Chamber not Following It The first question to ask is whether or not the chamber is maintaining the ramp rate Keep in mind that you will always have a lag in the response of the chamber Remember that the controller must see a difference between the set point and process variable in order to increase its output When you start a ramp the difference between the actual process and the set point begins to increase at a set rate Thus the controller output will begin to do the same However there is a delay between the controller output and the response of the chamber Heaters have to warm up coils have to cool down etc However once the ramp begins the controller will adjust the output to meet the rate and follow it the rest of the way The chamber will follow the profile but it will be offset by the delayed response of the chamber This is the normal response of the controller Remember all it knows is that the set point changed and that it should adjust its output by the PID math calculation 45 Cincinnati Sub Zero EZT 560
127. d the use of each point Note that this list covers all standard configurations and the use of the inputs and outputs on your chamber is dependant upon chamber type and options present Digital I O CPU Connector 1 terminal I O ADDR Operation BO1 26 10 Chamber limit safety input CHAMBER HI LIMIT on in alarm condition BO1 24 11 Optional product safety input PRODUCT SAFETY on in alarm condition BO1 22 12 Motor overload drive fault input MOTOR OVERLOAD on in alarm condition BO1 20 13 Pumpdown input When system equipped with pumpdown mode pressure switch 7PS will activate input and enable the system 1 compressor BO1 18 14 System 1 refrigeration pressure safety input SYS1 HILO PSI off in alarm condition BO1 16 15 System 1 compressor oil pressure safety SYS1 LOW OIL PSI off in alarm condition BO1 14 I6 System 1 compressor discharge temperature safety SYS1 HI DISCHARGE TMP off in alarm condition BO1 12 I7 System 1 compressor protection module SYS1 COMP MONITOR off in alarm condition BO1 10 110 System 2 refrigeration pressure safety input SYS2 HILO PSI off in alarm condition BO1 8 111 System 2 compressor oil pressure safety SYS2 LOW OIL PSI off in alarm condition BO1 6 112 System 2 compressor discharge temperature safety SYS2 HI DISCHARGE TMP off in alarm condition BO1 4 113 System 2 compressor protection module SYS2 COMP MONITOR
128. dict future response and automatically adjust PID parameters in order to adapt to process hysteresis A change in the process variable required to re energize the control or alarm output Sometimes called switching differential integral control I Control action that automatically eliminates offset or droop between set point and actual process temperature limit or limit controller A highly reliable discrete safety device redundant to the primary controller that monitors and limits the temperature of the process or a point in the process When temperature exceeds or falls below the limit set point the limit controller interrupts power through the load circuit A limit controller can protect equipment and people when it is correctly installed with its own power supply power lines switch and sensor Modbus A digital communications protocol owned by AEG Schneider Automation for industrial computer networks Modbus RTU Remote Terminal Unit an individual Modbus capable device on a network overshoot The amount by which a process variable exceeds the set point before it stabilizes EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero Common Terms and Definitions cont d PID Proportional integral derivative A control mode with three functions proportional action dampens the system response integral corrects for droop and derivative prevents overshoot and undershoot process variabl
129. e we know what the product is we know it is a live load versus a dead load we know how big the chamber is how much heat is has the controller has no knowledge of this Its entire response to a change in set point is based completely off of a math problem using those three terms The three terms define the chamber to the controller In essence they contain the capacity of the chamber how much heating and cooling capacity it has for example what the product load is what the thermal mass of the chamber itself is etc It is a lot of information to put into three terms This is why a small load change in a chamber has a small affect on control but a big load change in a chamber can have a large impact The product load is a portion of the tuning PID parameters the more the product load changes the more the tuning parameters must change in order to accurately describe the chamber to the controller so it can see what the chamber is doing Thus if you change the product load drastically but do not change the tuning parameters to match the controller will see the chamber with a small load and not a big one Then when the chamber does not respond like it would with a small load the controller will become confused and not control the chamber correctly which could result in a large overshoot or oscillation around set point All the controller knows is what the set point is what the process value is and based on that difference do the math
130. e PV The parameter that is controlled or measured Typical examples are temperature relative humidity altitude etc The high process variable is the highest value of the process range expressed in engineering units The low process variable is the lowest value of the process range proportional control P Output effort proportional to the error from set point For example if the proportional band is 20 and the process is 10 below set point the heat proportioned effort is 50 percent ramp A programmed increase in the temperature of a set point system range The area between two limits in which a quantity or value is measured It is usually described in terms of lower and upper limits RTD resistance temperature detector A sensor that uses the resistance temperature characteristic to measure temperature serial communications A method of transmitting information between devices by sending all bits serially over a single communication channel set point SP The desired value programmed into a controller For example the temperature at which a system is to be maintained T C thermocouple A temperature sensing device made by joining two dissimilar metals This junction produces an electrical voltage in proportion to the difference in temperature between the hot junction sensing junction and the lead wire connection to the instrument cold junction Cincinnati Sub Zero EZT 560 Chamber Troubleshoo
131. e Operation A profile is a set of instructions programmed as a sequence of steps The EZT 560 handles the profile steps automatically in sequence The EZT 560 can store hundreds and even thousands of profiles with up to 99 steps in each profile This section covers the use and operation of the EZT 560 profiler To access profile utilities select Profile Entry from Profiles menu Profile Status view Run Profile Hold Profile Stop Profile Stop Profile All OFF 25 Cincinnati Sub Zero EZT 560 User s Manual 4 1 Profile Entry Profiles are created and edited from the Profile Entry screen The following instructions describe the steps involved for programming profiles 1 To create a profile go to the Profile Entry screen 2 From the Edit menu select New Profile and select Yes to create a new profile 3 Enter the number of steps for the profile you want to create Note that the number of steps can be changed at any time during the profile entry to shorten or lengthen the profile as required Profiles can be from 1 to 99 steps in length 4 For each step enter the events set points and time duration of the step 5 Save the profile STEP TIME HH MM SS Figure 4 1 Profile Entry Edit Menu Options New Profile Clears any existing profile entry data so that a new profile can be entered Insert Step Inserts a step into the current profile at the current step number Delete Step Deletes the c
132. e Time from the maintenance setup menu The current date and time will be displayed in the field entry windows Day 05 22 Hrs Mins Secs 10 22 15 DOW Sun Sat 0 through 6 4 set Time Figure 8 4 Set Date Time To make adjustments touch the desired field entry box The pop up keypad will appear allowing a new value to be entered Once all corrections are made press the Set Time button A message window will appear to acknowledge that the new date and time have been accepted Press OK to close the message window NOTE The time is set in 24 hour military time The day of week must be set correctly in order for the profile autostart by day to function correctly 64 EZT 560 User s Manual Cincinnati Sub Zero 8 4 Touch Screen Calibration After extended use and many hours of operation it may be necessary to recalibrate the touch screen of the EZT 560 A typical sign that the screen may be out of adjustment is inaccurate responses when attempting to press buttons check boxes or adjust fields on the display The calibration utility is provided in order to readjust the screen when this happens NOTE Even after calibration some fields may require finesse to operate Check boxes require precise presses even when the screen is in full calibration Most response issues result from fat fingering the display Use the tip of your finger or a stylus if necessary to operate the unit To access the screen calibratio
133. e door is closed the chamber will turn back on EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 9 5 Refrigeration Options Refrigeration Options screen is accessed from the Chamber menu This screen is used to define what type of refrigeration system the chamber has and how the EZT 560 is to control it File Loops Chamber Event Alarm Tags W Set Refrig Options Refrig Type INo Refrigeration Cmp On cmp Off Dly Cmp On Dly Stager Dilys v J cmp Off Defrost Off R PumpDown Reset Pumpdown Off Tone Out 4 Figure 9 9 Refrigeration Options NOTE You must press the Set button to save changes to the refrigeration and or defrost type selections Be sure to press the Set button prior to switching to another configuration screen or any change to the refrigeration and or defrost type will not be saved Parameter Descriptions Refrig Type Sets the type of refrigeration system installed on the chamber can be none WARNING Do not change the refrigeration type to any selection other than what is installed on the chamber and called out on the EZT Configuration form supplied with the chamber or the refrigeration system may not operate properly and damage can occur Cmp On Sets the loop percentage of output required to turn enable the refrigeration system because cooling is required Cmp On Dly Sets the delay in seconds for which the loop output must exceed the cmp on before the refrig
134. e not set the chamber will not run 4 1 2 GS Events The GS Events are used to turn on the guaranteed soak option for one or more of the controlled loops In order to enable a guaranteed soak in a step you must select the loop s to be monitored by turning on the corresponding event To enter the GS events press the GS Events button This opens the guaranteed soak event entry window From this window select the events that are to be on during the step Once the selections are complete return to the profile entry screen by pressing the Back to Step Data button Select Loops for guaranteed soak Guaranteed Soak Events oO TEMPERATURE O HUMIDITY O PRODUCT Back To Step Data Figure 4 3 Profile Guaranteed Soak Events NOTE It is not recommended to use guaranteed soak events for ramping steps The ramp rate could be affected if the process variable deviates from the soak band because the profile will be placed in hold When the profile is in hold the step length will be extended and the set points will no longer ramp at the set rate If the desire is to insure that the chamber is at temperature for example prior to beginning a soak use the wait for feature To set the guaranteed soak band for each loop of the profile see section 4 2 Soak Limits 27 Cincinnati Sub Zero EZT 560 User s Manual 4 1 3 Wait For The wait for function is a powerful tool for pausing a profile until a particular process variable
135. e screen and drag your finger across the screen to make a window around the particular area of interest Once you remove your finger from the screen the plot will zoom in to that particular section To return to the full plot touch either the x or y axis and select Zoom Normal 55 Cincinnati Sub Zero EZT 560 User s Manual The Cursor button enables a cursor that can be scrolled across the plot in order to display the value of each variable at that particular time When the cursor is enabled the name for each variable will become the actual value at the current cursor position As the cursor is scrolled across the plot the value will change accordingly Pressing the Cursor button again will turn off the cursor and restore the variable names Start 6411 2005 End 8 25 2005 nd Done 100 0 60 0 60 0 40 0 20 0 0 0 0841 11 59 PM 0846 11 59 PM Figure 7 4 History Plot Cursor 7 3 2 1 History Plot Time Setup Select Hist View Time Setup from the Datalogging menu The history time setup allows the user to select any time frame zoom in out to view historical data A historical data file must be loaded using the Edit Open History File menu item before data can be plotted The History Plot Setup screen displays the start and end time for the currently loaded file in hours and minutes Use the sliders to adjust the time span for historical viewing if desired File Start At File End At Figure 7 5 History Pl
136. ead or to the proper value for a write 175 Ox00AF r w PV8 Monitor Alarm Hysteresis 0 32767 0 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 176 0x00B0 Special Use Special Use 177 0x00B1 Special Use Special Use 178 0x00B2 Special Use Special Use 179 0x00B3 Special Use Special Use 180 0x00B4 EZT 560 Offline Downloading Profile 0 EZT 560 Online 1 EZT 560 Offline Profile Download When the EZT 560 is offline refrain from writing to any control registers In offline mode there are no updates made to any control registers After a profile transfer to the EZT 560 from a PC the EZT 560 will go into profile download Do not write to any registers until profile download is complete Once profile download complete normal operation may commence 108 Indicates parameters associated with options not available on all chambers EZT 560 User s Manual Cincinnati Sub Zero 9 4 2 EZT 560 Profile Parameters Profiles must be downloaded one step at a time with a 1 second pause between steps Each step consists of 15 registers including the first 15 which contain the format and special function registers See the provided example code for assistance in creating the proper download sequence You must use the write multiple registers command
137. ed up to the defrost temperature This will initiate a 15 minute timer in the EZT Defrost will continue for another 15 minutes to insure that the coil is completely defrosted Once the 15 minute defrost time has elapsed prechill is started In prechill the defrost solenoid will be turned off and the minimum cooling output Q14 will be turned on This will allow the refrigeration system to pre cool the coil prior to starting the air circulators Once the defrost temperature switch turns off indicating that the suction line has dropped below the defrost temperature a one minute timer begins Once this timer is complete prechill will terminate the air circulators will turn back on and the system will resume normal operation 30 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 5 1 1 Common Conditioning System Failures and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS Chamber air circulator s not turning on Chamber event not turned on Conditioning system disabled altitude chambers Blown fuse Motor overload tripped Chamber in defrost if equipped Basket not in correct position DTS VTS Chamber door open if door switch enabled in configurator Turn on chamber event Altitude above controllable limit for temperature Decrease altitude or turn off altitude system Replace Fuse Reset overload Check defrost status Allow defrost to complete or terminate defrost
138. eeded by touching its description on the Service Monitor screen A pop up window will ask if the count is to be cleared for the item you selected Select Yes to clear the count Note that the Service Monitor screen must be showing the Elapsed count The service monitor screen can be set to display the elapsed service interval or the life total for the component based on the selection made in the Service Info Setup screen The alert method can also be disabled if this feature is not desired 8 2 1 Service Monitor Setup The service monitor display options as well as alert action can be adjusted from the Service Info Setup screen ELAPSED SERVICE OR TOTALS om ELAPSED SERVICE ol ortas ENABLE DISABLE SERVICE ALARMS om SERVICE ALERT OFF om SERVICE ALERTS ON om ALERTS W SUDIBLE ALARM Figure 8 3 Service Monitor Setup 62 EZT 560 User s Manual Cincinnati Sub Zero Elapsed Service or Totals Selects which count is to be displayed on the Service Monitor screen Enable Disable Service Alarm Selects the method of service notification or disables alerts completely Service alerts are disabled by default To make changes place a check in the appropriate check box and press the Accept button For information regarding the service monitors and what they mean see section 10 Diagnostics 63 Cincinnati Sub Zero EZT 560 User s Manual 8 3 Set Date Time The date and time can be adjusted by selecting Set Dat
139. eeecxueeanecseateagesyieteseruictanessaadeeestaeee 80 9 3 GPIB IEEE 488 Communication sesssssesseeereserrsstrresttrrssttrnnatttrtsnttnnntttnnssttnnnnttn nanten 81 93 1 Command StrUctUrenornarencssicaninain E EEE EE 81 94 Getting Conmecled creia a R O 81 9 4 1 EZT 560 Control Parameters cccccccccccccecesseseeeeceeeeaaeeeeeeeeeeeeaneasaseeeeseeaeanenenes 81 9 4 2 EZT 560 Profile Parameters 0 cc ccccccccccccecccsceeecceseeeseeseeeseeeeesesaueeeeeeaaeeseueeseeeaa 81 9 5 Ethernet Web Server Connectivity 0 0 20 cceceeeeenee cette ee ee eeneeeeetaeeeee tees eetaeeeestnaeeeeee 81 10 Diagnos CS xa ciiciciccsscs naisia anaa SAAANA SAARELA AAA ASA REASON RASA 81 10 1 Alarm Codes and Troubleshooting sessssseeessesrreserreseerresttrtnnttrtnsttnrnnatennnntennnntennnntennnnenn 81 102 Semice Monitors inanasan aS EKTA AAE EEOAE EEA A EA Eea 81 TO SVOASSIINMEN S iipasi iea a a E EE E EEE ean Perea REE 81 Appendix Common Terms and Definitions List of Figures EZT 560 User s Manual Cincinnati Sub Zero 1 Overview This manual has been tailored to cover all of the specific features and options available on the EZT 560 environmental chamber controller Note that all options and or features may not be available for your particular chamber It is highly recommended that you read this manual thoroughly and understand all aspects of the EZT 560 s operation prior to operating your chamber 1 1 Safety Information
140. eeeeeeesenenaeeeeeeeeetensaees 34 4 6 Profile Status View ccccccccecseccee cece eeeeeecaeeeeeeeeeseeeaaaeaeeeeeeecescaeeeeeeeeeesesecsaaeeeeeeeeeesaeees 35 4 7 Profile Worksheet 0 cccccccceeseceeeeeeeeeceeeaeceeeeeeeececeeaaeaeeeeeeeseseaaaeeeeeeeeesecenaeeeeeeeeeseeseneeees 36 EZT 560 User s Manual Cincinnati Sub Zero TABLE OF CONTENTS cont d Di Chamber Setup sasssa cecdeanzsncanase a EA aAa a Aa E EAA eA A EEA ARAARA EEEa A EEEE 37 5 1 Power RECOVERY osi esiiiisrirenasrnni inneni nAra TEANA AnA ENA AA Aa EE RAAEN AEA Ka AAAA ARRAREN AEEA 37 5 2 Set Point LIMIS cs cyesees et Nek edevaecesetdstes fees ak an desencesendae EAR leak a desore es enalias syndadeevedeieednsne 38 9 3 Event TAQGMAMEGS uc lcccteeeccssdeveces sve cncesehcvane desateesbtdvags dyes tenes nt aah desenecste raK EAA N EAT 39 5 4 Process Alarm Tagnames c ccccccccceeceeeeeeeseeeeeeeteeeeeesecneeeeeseeeeeeseneeeeseeaeeeseeaeeeeseeaeees 40 5 9 Alamr Settings ccs sic sis as eke desetk eran shacezetsuaks dauetecsandyacs iKON EANAN EATEN EEEE aN a 41 96 Product COMMUN 225 ack Anes desta fiend event ee da eee yes aka rah Aad ETA EEREN AEEA KANEA Ea 43 5 7 Condensation Control 0 cece neee nee teenie erties eerie nese eieee ee tieeeeseiieeeeetieeeerteeeeetaa 45 5 8 Defrost Settings eee ener ener ee ere ere 46 0 9 PO COMMS Nep Sanal siicczccotecte iaaa E E E aed 47 E E a a a E a a 48 61 Secun Sepeni E N A a ANE A 49 ELI Add USO aena a A A 4
141. eeeieeeeeeeaes 50 Figure 6 4 Security Options cece e ence eee etter rene ee een ne ee eet ae eee eeeaaeeeeeeaeeeeenaeeeseecaeeeenenaeeeeenaes 51 A 4 EZT 560 User s Manual Cincinnati Sub Zero List of Figures cont d Figure 7 1 Start Stop Datalogging ccccccccesceceeceeeeeeeeeeeeeeeeeeceaaeeeeaaeeaaeeeceaeeecaaeesensessaneeseaeeteeeesenees 53 Figure 7 2 Logging SCtU Pisa iieccessisceeebtteeetenieceeerl deeb aete REE EEEE A AA EATERS 54 Figure 7 3 History PlOt i cccisisccecesteceectd onana a ENE ETENE EAT 55 Figure 7 4 History Plot Cursof asia oana ana ainan A ANN EANA E AAA ERN 56 Figure 7 5 History Plot Time Setup ecinissniiriiaariinei aani AENEA EEE NAA NAERAN ERANS 56 Figure 7 6 History Plot Channel Setup ssnseiscsresiiinrsiknaNan aeiia NRTA NEAN ARANAN AKENE ERANS 57 Figure Averages Repol esrus shiatik inian an ARNAN EEA AAAA TEE ET 57 Figure 79 File UUlileS ciena A ANAE A NAAA 58 Figure 8 1 Degrees C F Selection cccccccecedeccetesdcceetsedecceeseddenersedeeneetsidsaaanvacdaaetnadeceensidseeenseeneaennecces 61 Figure 8 2 Semice Monitors sssrinin dinaanan Aia NNa ANAE EA NANE a tees 62 Figure 8 3 Service Monitor Setup seeseianisnuaniini iana a AN AA EEA NAAK RANEREN NAAR ERREEN 62 Figure 8 74 Set Date Time iic vieccnvsececanvetcaaenvelncahvelega dheittdageveed ANE EKA EANN 64 Figure 8 5 Touch Screen Calibration seseecsninaniisns ankaii ANAE ANKRA NENANA RANAN 65 Figure 8 6 Touch Screen Setting ariseirneninirniiini i
142. een NOTE You must press the Set button to save changes to the input type Be sure to press the Set button prior to switching to another loop or another configuration screen or any change to the input type will not be saved Parameter Descriptions Input Type Sets the type of control loop temperature humidity altitude etc WARNING Do not alter the loop type to any selection other than what is called out on the EZT Configuration form supplied with the chamber or the chamber may not operate properly and damage to equipment can occur Any changes made without prior authorization by CSZ will void the chamber warranty Tagname Sets the name of the loop what its controlling This description is used throughout the loop and trend screens as well as input selection for data logging Alm1 Message Sets the alarm message that will be used for input alarms This will be the name displayed on the alarm monitor screen when the user configurable alarm is active Eng Units Sets the units for the input degrees C F RH KFT etc The units are displayed on the single and dual loop display screen Max Heat Sets the loop percentage of output at which the maximum heat output is enabled Max Cool Sets the loop percentage of output at which the maximum cool output is enabled 73 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide Dec Pos Sets how many decimal positions to use when displaying an input always 1 Heat
143. elay period set in the configurator this output will turn on Dry Air Purge System Q34 This output is used to turn the dry air purge system on and off with chamber event 4 It will also turn on automatically when the chamber is equipped with the frozen coil low RH option when needed to reach a low humidity condition Air Control Solenoid Q35 This output is used when the chamber is equipped with the frozen coil low RH option It is used to switch the purge air supply solenoid control between the dehumidification output of the 9300 controller when the humidity system is on or the dry purge system output when only dry air purge is on 63 Cincinnati Sub Zero Frozen Coil Control Solenoid Q36 Frozen Coil Bypass Solenoid Q37 LN2 Supply Solenoid Q40 LN2 Control Solenoid Q41 LN2 Boost Solenoid Q42 Customer Event Outputs Q50 66 64 EZT 560 Chamber Troubleshooting Guide This output is used to enable and disable the control of the frozen coil solenoid from dehumidification output of the 9300 controller In normal humidity mode this output will be of so that the wet coil solenoid can be cycled on and off Q30 When operating in frozen coil mode this output will turn on in order to allow the dehumidification output of the 9300 controller to control the frozen coil solenoid This output is used to turn on the bypass solenoid in order to bypass the EPR valve on the dehumidification coil when running in
144. em low on charge Automatically resets after approximately 30 45 minutes Check compressor fuses Check contactor wiring for possible single phasing Check adjust expansion valve Check system pressure sight glass for bubbles Add charge if necessary 23 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 4 1 1 Diagnosing and Correcting Loop Communication Failures The EZT 560 Loop Comms Failure alarm indicates that there is a problem with communications between the PLC and the 9300 loop controllers The communications between the PLC and the 9300 controllers is performed by the Gateway module When this error occurs the chamber will shut down and will not be able to be restarted until the alarm condition is cleared The cause of this alarm may lie in one of several areas To help diagnose where the problem is follow the sequence of operation below Early Model Gateway Late Model Gateway Gateway Sequence of Operation When power is applied to the EZT560 via the 24Vdc power supply the EZT560 will begin its boot up sequence At the same time the Gateway starts its communications program and attempts to communicate with the PLC and 9300 controllers The OK indicator light on the Gateway will be steady on to indicate power is applied and it is running its communications program The Gateway is also equipped with two indicator lights to show that the communication connection has been made to the PLC a
145. en and the input is on automatically resets after built in timeout period Boiler Thermostat 114 The boiler high temperature thermostat input is used to indicate that the boiler has overheated This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is on requires manual reset of thermostat Boiler Low Water 115 The boiler low water input is used to indicate that the boiler is low on water This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen The low water safety has a built in delay to prevent the activating of the alarm until the boiler has been given sufficient time to fill 30 minute delay upon turning on the humidity event If the boiler has not filled up in the allotted time the alarm will sound Once the boiler has reached the proper operating level the alarm will sound immediately upon loss of level Water Reservoir Low 116 The water reservoir low input is used to indicate that the humidity system water reservoir is low on water if equipped This input is active low i e the input must be off in order for the alarm to be indicated When active input off
146. en for them to perform and what they are monitoring To alter tagnames select Process Alarm Tagnames from the Setup menu KEI Tagname TEMPERATURE Alm Message TEMPERATURE ALARM Figure 5 4 Process Alarm Tagnames To change the name of the event select the event by touching its current tag name The pop up keypad will appear allowing you to enter a new description Once complete select Done and the new name will appear in the event tag name list box Once the change has been made press the Set button to save the changes to memory 40 EZT 560 User s Manual Cincinnati Sub Zero 5 5 Alarm Settings The EZT 560 provides user configurable alarms for each input The alarms are activated when the process value or temperature leaves a defined range A user can configure how and when an alarm is triggered what action it takes and whether it turns off automatically when the alarm condition is over Kin ay Accept Aam Type mn E Modes Low SP 0 Hi SP Figure 5 5 Alarm Settings Alarm Types Process A process alarm uses one or two absolute set points to define an alarm condition A process alarm can be set for high only low only or both high and low NOTE The alarm settings for the product loop are fixed as a process alarm for both high and low alarm The alarm set points should be set by the user to protect the product under test from damage in the event of a thermal runaway condition De
147. enable the control circuits for heating and cooling They are typically only used and wired into the control circuit when the chamber is equipped with defrost In defrost the outputs would turn off in order to disable the heating and cooling outputs while defrost is running The maximum cool output Q15 and maximum heat output Q17 are controlled by the configurator settings When the cooling or heating output percent exceeds the configurator set point for the on delay period the maximum output will turn on They operate as boost outputs i e they are on off outputs not proportioning outputs They connect additional heating and cooling circuits to the control outputs in order to boost chamber performance Heating operation is relatively basic however the refrigeration system operation is more complicated with staging of compressors etc Depending upon options present on the chamber it may include rate master refrigeration system operation and or defrost The sequence of operation then varies from that of a typical chamber Temperature Limited Sheath Heaters Temperature limited sheath heaters are used in applications where there is or may be the presence of a flammable substance within the chamber These heaters operate at lower surface temperatures than standard nichrome wire open heating elements and their surface is not electrically live This allows a temperature sensor typically a thermocouple to be placed on their surface
148. equired to obtain low humidity levels the frozen coil and dry air purge systems will start in order to achieve the target set point When no longer required they will automatically turn off This option also provides the benefit of being able to manually use the dry air purge system by turning the purge event on and off However in the case where the low RH option is installed the humidity system must be disabled for the dry air purge to function manually 3 2 1 5 Customer Event Option The EZT 560 controller has the ability to control up to 15 event output relays These outputs can be manually turned on and off and they can also be controlled programmatically through a running profile They can be used to start and stop devices under test within the chamber turn signal beacon lights on and off to indicate steps within the test cycle etc With this option a pair of binding posts is provided on the chamber for external connection to each relay individually CAUTION The customer event output connections are rated for 24V AC DC and are capable of switching up to 6A of current resistive To switch high power loads the event relay must be used as the switch to turn a power contactor on and off to supply power to the load device 23 Cincinnati Sub Zero EZT 560 User s Manual 3 3 One Touch Tuning All of the EZT 560 control loops feature the one touch tune No more tuning parameters to adjust or settings to change The EZT 560
149. er files from the internal compact flash card unless using the EZT 560 File Utilities The EZT 560 will not operate properly if you do so WindowsXP and Excel are trademarks of the Microsoft Corporation 59 Cincinnati Sub Zero EZT 560 User s Manual 8 System Maintenance System maintenance options are available from the Chamber Setup menu To access system maintenance select System Maintenance from the chamber setup menu Power Recovery Setpoint Limits Event Tagnames Process Alarm Tagnames Alarm Settings Product Control Condenstation Control Defrost Settings PC CommsMeb Server System Maintenance NOTE Prior to entering system maintenance all automatic chamber operations must be stopped This includes data logging and profile operation Upon selecting system maintenance an alert will tell the user that the chamber will be taken off line The user can select No to return to the chamber setup menu without shutting down any current operations If the user selects Yes all operating systems of the chamber will stop 60 EZT 560 User s Manual Cincinnati Sub Zero 8 1 Degrees C F Selection The EZT 560 can display temperatures in either degrees C or F To change the units select Degrees C F from the Setup menu Select units of measure for temperature readings Figure 8 1 Degrees C F Selection Press the appropriate button to select the desired units A message box wil
150. er interface is an embedded Windows CE device Once powered up it will follow a typical boot up sequence similar to any PC running a Microsoft Windows product and automatically start the EZT560 application The EZT560 application is what provides the operating screens loop views trends logging etc that the user can navigate through to change set points create and run profiles and so on The HMI and EZT560 application do not operate or perform any control tasks for the chamber They are used for user input information gathering and monitoring of chamber operations only The information is exchanged over an RS485 serial communication link between the HMI and the EZT 560 s CPU mounted on the electrical sub panel A failure of the HMI or EZT560 application will not cause the chamber to shut down The CPU will continue to operate the chamber under its last given instructions In order to stop the chamber power must be removed from the chamber NOTE If the HMI fails to boot up properly when power is restored to the chamber the chamber will not begin operation The HMI must boot up into the EZT560 application in order for the chamber to start The CPU will not start the chamber until it receives a signal from the HMI that it has booted up and the EZT560 application is running properly Status Indicating Lights COM Indicates activity over the Ethernet communications link CPU Indicates processor status during specific operating tasks PWR
151. er must have a unique ID full name and password Three levels of users are provided to include operator supervisor and administrator levels Specific access rights can be assigned to each user level as well as password aging for each user Re authentication is provided if enabled for any parameters that will change a control parameter which could upset the process i e setpoint tuning etc Re authentication requires that the logged in user must log in again before the process value will actually be changed This feature is provided for extra security The following example will make re authentication clearer A supervisor logs on the system The supervisor then steps away from the system to take a phone call but does not log out before leaving If another user tries to change the control setpoint on any loop the system will require another login by an authorized user for that level before the control setpoint is actually changed This provides an extra level of protection to make the system more tamper proof NOTE Default UserlD is FACTORY Default Password is CONTROL 48 EZT 560 User s Manual Cincinnati Sub Zero 6 1 Security Setup All security parameters are accessed via the Security menu p Log On Log Off View Audit Trail View Current User 6 1 1 Add User The Add User tab provides the ability to add up to 30 users to the system Select the type of user from the drop down list O
152. eration system is turned on Cmp Off Sets the loop percentage of output required to disable the refrigeration system because cooling is no longer required Cmp Off Dly Sets the delay in seconds for which the loop output must exceed the cmp off before the refrigeration system is turned off Stager Dly Sets the stager start delay time in seconds for system 2 on cascade systems Defrost Sets the defrost mode based on installed defrost components Defrost On is used for smaller compressors typically smaller than 7 5hp Large HP Defrost is used for larger systems typically larger than 7 5hp 77 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide The large horsepower defrost is used to control the cascade condenser liquid line cooling solenoids on cascade systems It cycles the solenoids on and off to maintain system 2 head pressures rather than cycling the system 1 compressor on and off Cycling large horsepower compressors is detrimental to the life of the compressor and is not recommended by the manufacturer Pumpdown On Off Enables or disables pumpdown mode Pumpdown Reset Time Out Sets the time in seconds for which the chamber can be without 78 power before pumpdown will be disabled and require manual reset or the four hour automatic reset delay EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 9 6 Humidity Options The Humidity Options screen is accessed from the Chamber
153. erted from to whole number i e 14 0x000E Product Control Lower Setpoint divide multiply by ten to convert the decimal number from the r w value read or to the proper value for a write 15 0x000F Condensation Control Mode 0 Condensation Control Off r w 1 Condensation Control On 16 0x0010 Condensation Control Monitor 1 Single Input r w Mode 2 Lowest Input 4 Highest Input 8 Average 17 0x0011 Condensation Control Input Bit1 Product r w Selection Bit2 PV1 monitor Bit3 PV2 monitor Bit4 PV3 monitor Bits PV4 monitor Bite PV5 monitor Bit7 PV6 monitor Bit8 PV7 monitor Bit9 PV8 monitor This parameter is bit oriented i e enabling the different bits of the word enables 1 or disables 0 the use of the input for condensation control Note that monitor inputs may not be available ion your system Example Select product PV1 PV5 PV6 and PV7 inputs 0000000011100011 227 decimal converts to Ox00E3 90 EZT 560 User s Manual Cincinnati Sub Zero Register Description Use 18 0x0012 Temperature Ramp Rate Limit 0 50 Temperature 0 0 to 5 0C r w 0 90 Temperature 0 0 to 9 0F Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 19 0x0013 Dewpoint Limit 32768 32767 3276 8 3276 7 r Note that value must be converted from whole number i e 20
154. es 1 or disables 0 the events 111 Cincinnati Sub Zero EZT 560 User s Manual Register Description Use 220 0x00DC Step 1 Wait for Loop Input 0 No Input Selected w 1 Loop 1 Input Selected 2 Loop 2 Input Selected 4 Loop 3 Input Selected 8 Loop 4 Input Selected 16 Loop 5 Input Selected Note that only wait for loop or wait for monitor input can be selected DO NOT enable both at the same time 221 0x00DD Step 1 Wait for Monitor Input 0 No Input Selected w 1 Monitor Input 1 Selected 2 Monitor Input 2 Selected 4 Monitor Input 3 Selected 8 Monitor Input 4 Selected 16 Monitor Input 5 Selected 32 Monitor Input 6 Selected 64 Monitor Input 7 Selected 128 Monitor Input 8 Selected Note that only wait for loop or wait for monitor input can be selected DO NOT enable both at the same time 222 0x00DE Step 1 Wait for Setpoint 3276 8 3276 7 32768 32767 w Note that value must be converted to whole number i e multiply by ten to convert the decimal number to the proper value for a write 223 0x00DF Step 1 Jump Step 1 99 w 224 0x00E0 Step 1 Jump Count 0 999 w Jump count of 0 disables jump 225 0x00E1 Step 1 Loop 1 Set Point 3276 8 3276 7 32768 32767 w 226 0x00E2 Step 1 Loop 2 Set Point Note that value must be converted to whole number i e w multiply by ten to convert the decimal number to the proper 227 0x00E3 Step 1 Loop 3 Set Po
155. eseeeesseerrsserrssterrnntennsnneennnneen 10 3 1 2 Configure Serial Port 1 Mode s sseireesrrinrerrririnnerriinnerirninernrnininnaniinndaakiinn nania 11 3 1 3 Touch Screen Calibration eoncrenccnrareneariii nR 13 3 1 3 1 Dip Switch Calibration Procedure ssessesseeeeseenennneeeeseeenrrnneessereneen 13 3 1 3 2 USB Mouse Calibration Procedure eseseeeresrieeerrrniirnnsrrrnenni 14 3 1 4 Screen Contrast Adjustment Procedure eusssseeeseessriscerrerrrirrereerreerrrnnseerreeres 17 4 Resolving Chamber Alarms vice ccssigeccgec ceevessgect aes N EEDEN AAAA EEDA KAEDA EREA 19 4 1 Critical Alarms 20 4 1 1 Diagnosing and Correcting Loop Communication Failures ccecceeeeeeeeeeees 24 4 2 Status Alarms 26 3 Chamber Operating Problenis risens iiaii ea eS ed eee ee ieee 28 5T Conditioning SYStOM cx ieteveseniedeccusdecetenctvcedevelactiacphcenaaiandadieeylnasesbndausedendaedebvlcdseibinearennes 29 5 1 1 Common Conditioning System Failures and Corrective ActionS ce 31 5 2 Humidity System 33 5 2 1 Common Humidity System Failures and Corrective Actions 0ccceeeee 34 5 3 Auxiliary Cooling System oo cee nr tre eee rene ernie ee erties ee eeeeerteeeestneeeeee 35 5 3 1 Common Auxiliary Cooling System Failures and Corrective Actions 35 5 4 Dry Air Purge System 0 cece iter tre ene ee ieee eerie ee eet ieee eee aeee ee teeeee teases aa aaaea 36 5 4 1 Common Dry Air Pu
156. eshooting Guide Cincinnati Sub Zero 9 7 Purge Lo RH Options The Purge Lo RH Options screen is accessed from the Chamber menu This screen is used to define what type of purge system is installed on the chamber and what dewpoint limits the humidity system is allowed to control to if equipped File Loops Chamber Event Alarm Tags Purge Lo RH Options Purge Low RH Type Not Installed Min Dewpoint Limit Max Dewpoint Limit Figure 9 11 Purge Lo RH Options NOTE You must press the Set button to save changes to the purge system type selection Be sure to press the Set button prior to switching to another configuration screen or any change to the purge system type will not be saved Parameter Descriptions Purge Low RH Type Sets the type of purge system installed Dry Air Purge is used when just the air dryer is installed Low RH Option Installed is used when the frozen coil option is installed Min Dewpoint Limit Sets the minimum dewpoint that the chamber will control to In essence this limits the minimum humidity level that the chamber can achieve at a given temperature This value is used to protect the refrigeration system from liquid refrigerant flood back that can happen when trying to achieve to low of a humidity level at lower air temperatures Standard humidity is limited to a 1 7C 35F dewpoint The low RH option is limited to a 28 8C 20F dewpoint Max Dewpoint
157. ess Low Alarm Selected Process Both Selected Nawo 171 0x00AB r w PV8 Monitor Alarm Mode Bit1 Off alarm self clears Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output 107 Cincinnati Sub Zero EZT 560 User s Manual Register Description Use Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 172 Ox00AC r w PV8 Monitor Alarm Output Assignment 0 No Output Selected 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8 Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 173 Ox00AD r w PV8 Monitor High Alarm Setpoint 174 Ox00AE r w PV8 Monitor Low Alarm Setpoint 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value r
158. et in the configurator this output will turn on 65 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 8 2 1 2 Custom Output Configuration DTS VTS TSB Hot left Chamber QO Cold center Chamber Q1 Hot right Chamber Q10 This output is used to turn on the left chamber of a DTS or the hot chamber of a VTS using chamber event 1 It is also used to enable both baths fora TSB When used for a DTS or VTS the output will turn off during a transfer to stop the fans and then turn back on once the transfer is complete This output is used to turn on the center chamber of a DTS or the cold chamber of a VTS using chamber event 2 It is not used fora TSB The output will turn off during a transfer to stop the fans and then turn back on once the transfer is complete This output is used to turn on the right chamber of a DTS using chamber event 7 The output will turn off during a transfer to stop the fans and then turn back on once the transfer is complete Maximum Heat right Enable Q16 This output is used to enable and disable the maximum heating In Transfer Door Lock Q43 Transfer Left Q44 Transfer Right Q45 Transfer Up Q46 Transfer Down Q47 66 SSR for the right chamber of a DTS When the loop output exceeds the maximum output on percentage for the on delay period set in the configurator this output will turn on This output is used to enable a locking mechanism on the chamber
159. et moves around the screen Press the Enter key to accept new settings Press the Esc key to cancel Press the Esc key to keep the old settings Figure 3 7 Touch Calibration Screen Once all points have been measured touch anywhere on the screen to accept the settings and complete the calibration routine The display will continue its boot up sequence and start the EZT560 application Set dip switch 1 off NOTE Dip switch one must be set to off or the calibration routine will start each time power is applied This will prevent the chamber from resuming operation on a power failure without user intervention Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 3 1 3 2 USB Mouse Calibration Procedure Begin by connecting a mouse to the USB port to the lower left of the display Using the mouse you can navigate the screen just like using a desktop PC Begin by selecting Chamber Setup from the main setup menu View Profiles EGJ Securi Log Help Chamber Setup 33 2 27 5 TEMPERATURE HUMIDITY DUAL VI 006 6 02 55 PM Y amp Figure 3 8 Setup Menu Access Select PC Comms Web Server from the setup menu Power Recovery Setpoint Limits Event Tagnames Process Alarm Tagnames Alarm Settings Product Gontral Condenstation Control Defrost Settings PC Comms Web Server System Maintenance POWER RECOVERY Figure 3 9 Chamber Setup Menu Access Deselect the check boxes if necessary for Web Server
160. et there The other method is applicable to chambers that have min max output configurations By setting the maximum output to turn off as soon as possible like a boost you cut the chamber capacity in half when you near set point Thus as the controller backs off on its output to control into set point you reduce the amount of capacity it has instantly in half which helps put the brakes on quickly to reduce the amount of overshoot on large step changes 44 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 6 1 3 Set Point Tracking Ramping Once of the misnomers that chamber users have is that they expect a chamber to follow a given profile exactly as it is programmed and if it doesn t it is not working correctly The problem is that they do not take into consideration the capacity of the chamber versus the ramp rate that the programmed and how the controller responds to a set point change The capacity of a chamber is its ability to increase or decrease a process by a certain amount whether it be temperature or altitude for example in a given amount of time Some capacities also vary over the operating range The vacuum pump on an altitude chamber for example has a lot of capacity at low altitude The chamber responds quickly and the air pressure within the chamber drops rapidly However as the pressure drops the amount of air decreases and the vacuum pump has less and less air to pump It has to start working harder for each
161. eusueeeeesaaeueeeeaeseeuuuaeseeeaaaeeeueseeueuaeseesauaeeeesanses 51 Table 8 2 Control LOOPS 2 0 ccececcccee cece cece ee cene eae ce cece eee ceaaaeceeeeeeesecaaaaeceeeeeeeseccaeaeeeeeeeeeeseseceeeeeeeeeeeee 51
162. face over your network The use of the EZT 560 web server is the responsibility of the end user To access and view the EZT 560 s status web page enter the following link in your PC s browser address window http IPaddress ezt html from example address http 192 168 1 105 ezt html The example below is typical of the EZT 560 web page appearance The web page updates automatically every 30 seconds and provides information on each individual loop profile status alarm status and event status 115 Cincinnati Sub Zero EZT 560 User s Manual Cincinnati Sub Zero EZT 560 Controller 12011 Mosteller Road Cincinnati OH 45241 1528 513 772 8810 LOOP DATA TEMPERATURE PV 24 9 SP 24 9 HUMIDITY PV 50 0 SP 50 0 PRODUCT PV 22 8 SP 24 9 PROFILE STATUS FOR WET PROFILE STATUS o BAG STARTDATE o oasa ESTIMATE STOP DATE O aaeoa CURRENT STEP S Poo STEP TIME LEFT o BZA WAIT FOR INPUT S owe WAIT SETPOINT S owe TEMPERATURE SP AQ HUMIDITY SP o JPRODUCTSP2 o SYSTEM ALARMS CHAMBER EVENTS CHAMBER o ON HUMIDITY ON JAUXCOOLING oo E DRY AIR PURGE a OE e E fm OFF CUST EVENT 1 oo o CUST EVENT 2 o o CUST EVENT 3 oo or CUST EVENT 4 oo o SCS CUST EVENT 5 oo oA SCS CUSTEVENT6 S OE eustTEveET7 o OE CUSTEVENT8 S OE eustTEveT9S o OE CUST EVENT 10 oo o CUST EVENT 11 ooo or CUST EVENT 12 oo o CUST EVENT 13 ooo or CUST EVENT 14 oo or CUST EVENT 15 ooo or 4 11
163. fer if any door is opened Enables the logic for basket position and dual zone control Loop 1 is set for the left hot bath control and loop 2 for the right cold bath control The door switch input 121 is monitored to disable the transfer if the lid door is opened Inputs 123 and 124 are enabled for the hot and cold bath fluid safeties respectively If the baths are equipped with low level floats 125 is used as a low level warning input Depending on the transfer mechanism used different inputs and outputs are used to transfer the basket to each position For motor operated transfer mechanisms outputs Q44 and Q45 for basket left and right are used to position the basket For air cylinder operated transfer mechanisms outputs Q44 and Q45 are used for the left and right movement with outputs Q46 and Q47 used to control the up and down movement Events 5 and 6 with event 7 for the unload position are used to select the three positions Inputs 114 and 115 are used to monitor the left hot and right cold positions Inputs 116 and 126 are used for up and down position monitoring for air cylinder control On units with a motor operated mechanism 126 is used for the unload position indication Chamber Door Switch Control Sets whether or not the opening and closing of the chamber door 76 when equipped with a door switch on input 121 turns the chamber off and on If enabled when the door is opened the chamber will shut down When th
164. file Worksheet The following table can be used as a template for creating profiles prior to entering them on the EZT 560 controller You can use this as a tool for quick checks to make sure all of your entries were made correctly Profile Name Date Programmed Programmed By Step Set point 4 2 3 4 5 Step Time H M S Chamber 4 Events 2 3 4 5 6 7 8 9 15 Customer 4 Events 2 3 4 5 6 7 8 9 10 12 12 13 14 15 GS 1 Events 2 3 4 5 Wait for Wait for Set point Jump Step Jump Count 36 EZT 560 User s Manual Cincinnati Sub Zero 5 Chamber Setup This section covers the use of extended controller features that enhance the functionality of your chamber To gain access to the chamber setup options select Chamber Setup from the Setup menu Chamber Setup 5 1 Power Recovery The power recovery settings direct the EZT 560 s response to the interruption of electrical power The EZT 560 s battery powered real time clock tracks the amount of time the power is out When power is restored the controller compares this amount of time to the Power Out Time setting and takes whatever action is selected in the Recovery State First determine how long the power can be interrupted without adversely affecting results Set the Power Out Time to this time
165. frigeration system Boost Cool Temp SP Disable Sets the temperature below which the refrigeration system is automatically disabled if aux cool control is selected The boost cooling system will then switch to control mode and start controlling temperature below this set point If aux cool boost is selected the boost outputs will be disabled below this set point to prevent the chamber from exceeding the limits of the refrigeration system CAUTION For boost only mode this set point must be set no lower than the minimum achievable temperature of the refrigeration system or the compressors can be damaged Aux Cool On Percentage Sets the loop percentage of output required to enable the boost cooling output Aux Cool On Delay Sets the delay in seconds for which the loop percentage of output must exceed the aux cool on percentage before the refrigeration boost cool output is turned on 82 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 9 9 Altitude Options The Altitude Options screen is accessed from the Chamber menu This screen is used to set the limits for the conditioning system if the chamber is equipped with altitude Loops Chamber Event Alarm Tags Altitude Options Window Heater Enable SP Alt Hi Speed Fan Enable SP 10 0 Alt Cond System Disable Figure 9 13 Altitude Options Set the different values by touching the respective number field Parameter Descriptions Wi
166. from the list box press the Clear button Do this to refresh the display prior to opening another alarm file All alarm files are stored by day using the day s date for the file name Thus a new file will be created every day in order to store any alarms for that day If no alarms occurred on a given day an alarm file will not be created for that day EZT 560 User s Manual Cincinnati Sub Zero 2 5 System Status Monitor The system status monitor provides non critical alarm information or alerts to indicate specific operational conditions or limits that have been reached in the chamber s operation Status Monitor For Non Critical Alarms A RH H20 RESERYOIR LO MB AH TMP DISABLE WB RH Hi DEWPOINT LIMIT MB RH Lo DEWPOINT LIMIT MB poor oren Figure 2 9 System Status Monitor Non critical alarms and alerts that require operator attention will be indicated by an intermittent beeping of the chamber s audible alarm This alert can be silenced through the use of the Silence button See section 10 Diagnostics for alarm codes and corrective actions 18 EZT 560 User s Manual Cincinnati Sub Zero 3 Single Set Point Operation The EZT 560 controller can function as either a static set point controller or as a profile controller The EZT 560 is in static mode single set point operation when it is not running a profile This section describes how to operate the chamber in this mode 3 1 Single Set Point Adjustment
167. frozen coil mode This output is used to turn the LN2 supply solenoid on and off based on chamber event 3 If the boost cool system is set for control mode it will automatically turn on when required in order for the chamber to obtain temperatures below the capabilities of the refrigeration system This output is used on chambers that go to ultra low temperatures i e temperatures that exceed the minimum operating temperatures of the refrigeration system When aux cool control is selected in the configurator the output will turn on to switch the cooling output of the 9300 to control the LN2 control solenoid The output is enabled when the air temperature set point and air temperature are below the boost cool SP disable set in the configurator This output is used to turn the boost cooling solenoid on and off based on the demand for cooling and settings made in the configurator It will turn on when the loop output exceeds the aux cool on percentage for the on delay time set in the configurator These outputs are directly controlled by the customer event selections and their use is dependant upon the settings made by the customer These outputs can also be configured as alarm outputs based on the loop alarm settings in the EZT They can be set to open or close on alarms EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 8 2 1 1 Custom Output Configuration Altitude Low Speed Fans QO This output is u
168. global setting that turns the EZT 560 security system on or off 51 Cincinnati Sub Zero EZT 560 User s Manual 6 2 User Log On Off When security is enabled a user must log on to the system in order to gain access to privileged items To log on to the system select Log On from the Security menu Enter the user UserID and Password on the login screen and press Done when finished If the entries made are valid the user will be logged onto the system In order for a user to log off the system select Log Off from the Security menu 6 3 View Audit Trail The View Audit Trail selection from the Security menu allows the user to view all audit trail files stored in memory This selection opens the audit trail viewer Press the Open Audit Trail button to open the explorer window Select the desired audit trail file and press the Open button The audit trail files are stored by date One file will be created for each day If no activity occurred during a given day no file will be available 6 4 Current User The Current User selection merely provides a means of identifying the current user logged into the system If none of the users configured in the system are logged on the current user will be displayed as CSZ System 52 EZT 560 User s Manual Cincinnati Sub Zero 7 Logging The EZT 560 logging features are accessed via the Log menu item The system data logging provides
169. gth NOTE Altering the alarm names from those listed on the EZT Configuration sheet provided with the chamber may cause operator confusion when diagnosing alarms Use discretion when altering tag names 88 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 9 15 Completing EZT560 Configuration Any changes made in the configurator program must be backed up prior to cycling power to the EZT First exit the configurator by selecting Exit from the File menu DO NOT cycle power to the controller yet First manually back up the settings to EEPROM To do this you must rotate the small pot on the CPU module Hi sasz Memory Back up Pot EELELLEL EELETLET STAT LED Xe LSS venawnso TE Figure 9 19 EEPROM Configuration Back up Gently turn the pot full counterclockwise then fully clockwise and back counterclockwise again The small STAT LED on the CPU will blink indicating that the configuration has been saved You can now cycle power to the EZT and allow it to boot up normally 89 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero Appendix Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide Common Terms and Definitions autotune A feature that automatically sets process control PID values to match a particular process in a system baud rate The rate of information transfer in serial communications
170. hamber Troubleshooting Guide SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS System 2 compressor not turning on Blown fuse Compressor internal thermal overload tripped Chamber in humidity mode Refrigeration system not enabled or stager start delay not exceeded Replace fuse Allow compressor to cool Check refrigeration system injection valve operation Check humidity system type System 2 disabled for single stage humidity Check configurator settings Refrig system type should match installed system type Wait for stager start delay period Chamber not cooling Chamber event not on Conditioning system disabled altitude chambers System low on refrigerant Cooling solenoid clogged failed Expansion valve clogged Charge in head lost Refrigeration system capacity exceeded 9300 controller output off Chamber in defrost if equipped Turn on chamber event Altitude above controllable limit for temperature Decrease altitude or turn off altitude system Check static pressures sight glass for bubbles Add refrigerant if necessary Check solenoid Clean replace if necessary Check expansion valve superheat setting Clean replace if necessary Reduce live load in chamber Verify proper 9300 controller configuration Check set point Replace 9300 controller Check defrost status Allow defrost to complete or terminate defrost Defrost not starting Suction
171. hand 1 1 Safety Information Note caution and warning symbols that appear throughout this manual are to draw your attention to important operational and safety information A NOTE marks a short message to alert you to an important detail A CAUTION safety alert appears with information that is important for protecting the equipment and performance A WARNING safety alert appears with information that is important for protecting you others and equipment from damage Pay very close attention to all warnings that apply to the chamber 1 2 Howto Use this Guide To begin using this guide start with Section 2 Where Do Start Looking This will assist you in finding the correct section for further information on how to diagnose and correct the problem NOTE Remember to keep it simple Don t try and solve everything at once Take each issue one at a time It may take several trips through this guide to correct each problem or locate the root cause of a single fault but by breaking it down into pieces you can simplify the process and solve it in less time In many instances one component failure or incorrect control setting can cause various chamber malfunctions that would point you in several different directions none of which may be correct Always try and work backwards from what is not working correctly and determine why Why is this not working what makes it work and or how should it work WARNING Certain
172. he input turns off When the input turns off indicating that the compressor has pumped down the EZT turns off the system 1 compressor output During pumpdown the system 1 solenoids output Q11 remains off in order to isolate the low side of the refrigeration system so it can be pumped down Sys1 Hi Lo Pressure Safety 14 The system 1 hi lo pressure safety input is used to indicate that the system 1 compressor has exceeded its high or low pressure operating range This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is on requires manual reset of high pressure safety 53 Cincinnati Sub Zero Sys1 Oil Pressure Safety 15 Sys1 Discharge Thermostat 16 Sys1 Protection Module I7 Sys2 Hi Lo Pressure Safety 110 Sys2 Oil Pressure Safety 111 Sys2 Discharge Thermostat 112 54 EZT 560 Chamber Troubleshooting Guide The system 1 oil pressure safety input is used to indicate that the system 1 compressor oil pressure is below the proper operating range if equipped This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is on requires manua
173. he system components form a complete SCADA supervisory control and data acquisition system for total chamber management The graphic displays shown in this manual are representative of typical chambers The screens may vary slightly based on options present on your chamber EZT 560 User s Manual Cincinnati Sub Zero 1 3 Touch Screen Interface The EZT 560 display is divided into three main sections the menu bar main display area and detail window View Profiles Setup Security Log Help Menu Bar Chamber Light On Off Print Screen Detail Window ey Figure 1 2 Touch Seah Interface Menu Bar Used to navigate through the available monitoring and control screens Main Display Area Contains the active items for the menu item selected Detail Window Provides display specific information Note that there are two special control icons located at the lower right corner of the screen in the detail window Light Icon Turns the interior chamber lighting on and off Printer Icon Prints the currently displayed screen to an HP 6540 6940 or 6980 color printer connected to the controllers USB port see Section 1 4 Print Features To select items on the display simply touch the desired text or numerical entry item Do not use any sharp or metal objects on the touch screen as they may damage the surface For detailed information regarding the different screen elements and their use see the following sections Cincinnati Sub Zero
174. hine to Machine Communication In order for machines to communicate with each other they need a code called a character format or character set They need rules called protocol to govern their conversation and prevent confusion and errors Computers need a connecting interface over which to communicate They may use one pair of wires to send information in one direction and another pair to send in the opposite direction full duplex Or they may use one pair to send in both directions half duplex Character Format The code or character format for the EZT 560 data communication is shared by virtually everyone in the electronics industry This code defines a computer stream of 1 s and 0 s that are created by varying a voltage signal in a regular manner This code is the American Standard Code for Information Interchange called ASCII Bits and Bytes The word bit is simply the contraction of the words binary digit A bit is the basic unit in ASCII It is either a 1 or a 0 A byte is a string of eight bits that a computer treats as a single character ASCII can use a single byte to represent each letter of the alphabet each digit and each punctuation mark we use ASCII The ASCII code defines 128 separate characters one for each letter digit and punctuation mark ASCII also includes control characters similar to those we find on computer keys such as backspace shift and return It also has nine communications control characters
175. i Sub Zero EZT 560 User s Manual 8 5 Calibration The calibration menu provides access to the analog input and output ranges for calibration Note that the Input Calibration will only be available if the monitor input option is provided on the chamber The Analog Output calibration will only be available if analog outputs have been provided for retransmit of signals to external devices such as a chart recorder 8 5 1 Input Calibration There are two methods for calibrating inputs to the EZT 560 The control inputs i e temperature humidity product etc must be done on through the individual 9300 PID control s located on the electrical panel The monitor input calibration is done through the EZT 560 touch screen interface 8 5 1 1 Calibrating Control Inputs See Chapter 4 Calibration of the Future Design FDC 9300 Self Tune Fuzzy PID Process Temperature Controller User s Manual provided with your chamber for procedures and instructions on calibrating the control inputs CAUTION Do not alter any other parameters or settings within the 9300 controls Any changes made to CSZ factory settings may cause unpredictable operation of the chamber which can result in damage to equipment and will void the chamber warranty 8 5 1 2 Calibrating Monitor Inputs The monitor option provides up to 8 separate type T thermocouple inputs for monitoring temperatures throughout the chamber The calibration range is fixed withi
176. ile settings will not be affected unless you save the profile 30 EZT 560 User s Manual Cincinnati Sub Zero 4 3 Guaranteed Soak Limits To access the guaranteed soak limits select Soak Limits from the profile Views menu The soak limits screen allows you to set the control tolerance for soak steps when in profile operation When the process variables differ from the step set points by more than the soak limits the profile will go into hold and the timer will stop until the process variables re enter the soak bands These limits apply to each step in the profile and only need to be set once TEMPERATURE SP HUMIDITY SP ALTITUDE SP PRODUCT SP Figure 4 7 Profile Guaranteed Soak Limits To change the limits touch the limit entry field Enter the new soak band via the keypad Note that setting a band limit too tight could prevent the profile from operating correctly because the chamber may not be able to control to such a tight band setting A typical band setting would be 1 C 1 8 F for temperature 3 for humidity and 1Kft for altitude Once the desired bands have been set press the Done button to return to the profile entry screen The soak limits are saved with the profile When changing the soak band settings be sure to save the profile in order to update the profile with the new settings This insures that each time the profile is loaded and run it will control to the proper band settings 31 Cin
177. ill overshoot the set point stop sign and run into the intersection and cause an accident This is where your derivative response takes affect You are anticipating that you will not stop in time so you begin applying the brake cooling This causes the car to slow down faster so that you can stop at set point the stop sign Summary As you can see from the example a temperature control loop on a chamber mimics what we do when controlling the speed of our car Now apply that to your car s cruise control Imagine how difficult it actually is to maintain the speed of a car when all you have is the set point and actual speed and you can t see what is coming How big is that hill Is it steeper on one side than the other Could you imagine trying to stop What if all you had was someone telling you to stop because there is a stop sign ahead Is it 1000ft away or only 100ft You would sure have to apply the breaks a lot harder when it is only 100ft away A control loop is only as good as the control parameters it is given and how well the process can be controlled They key to controlling any process is designing the process to be controllable If every time you pressed your gas petal the car went a different speed how do you know where to put it next time to get the same speed 42 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 6 1 1 Oscillation Around Set Point The typical response to a chamber that oscillates around a given
178. ing the hysteresis value from the alarm high set point 42 EZT 560 User s Manual Cincinnati Sub Zero 5 6 Product Control If the chamber is equipped with the product control option this screen will be accessible from the Chamber Setup menu So oo Lower Setpoint Upper Setpoint o Figure 5 6 Product Control Product control is a control strategy in which one control loop provides the set point for another loop It allows the process or part temperature to be reached quickly while minimizing overshoot Product control can be used to optimize the performance of chambers containing product with long thermal lag times If only single loop control is used i e air temperature the air will reach its designated set point and the chamber will hold at this temperature However the part in the chamber may take hours or even days to reach the temperature you desire due to its thermal mass As the part temperature approaches the set point the difference between the part temperature and the air temperature decreases This difference in temperature is what forces the heat to move between the part and the air The lower this difference the slower the heat moves The composition of the material whether it is a natural insulator or conductor also affects this rate of heat transfer The product control feature can be used to speed up this process and insure that your part reaches the set temperature It does this by monitoring the part
179. int value for a write w 228 0x00E4 Step 1 Loop 4 Set Point DO NOT exceed safe operating limits of chamber Set points w must be within chamber operational limits 229 0x00E5 Step 1 Loop 5 Set Point w 230 0x00E6 Step 2 data registers thru 244 0x00F4 w 245 0x00F5 Step 3 data registers thru 259 0x0103 w 260 0x0104 Step 4 data registers See step 1 thru 274 0x0112 all steps maintain same format w 1685 0x0695 Step 99 data registers thru 1699 0x06A3 w 112 EZT 560 User s Manual Cincinnati Sub Zero Profile Download Algorithm The download profile procedure as well as the timer procedure is provided in visual basic below These are sample procedures and CSZ does not take responsibility for end user actions The user must be very careful regarding ranges and user interaction during profile download Private Sub downloadProfile This sub will initiate the profile download and start the timer for profile download Timer should be set at 1 second intervals to make sure timeout from EZT controller does not occur Variables used in procedure User can select static form global variables or class type based on preference G_vary x x is array for each EZT in system First element is EZT number second element is EZT register EZT register are a total of 180 registers per EZT f_curProfileName is form var that holds currently loaded profile f_profRegsToWrite is form var that holds the current p
180. intranet Wait 30 seconds Can not open web page in web browser Web server disabled IP address entered incorrectly Invalid IP address Enable web server on PC Comms Web Server screen Verify web address format Cycle power to EZT EZT must be connected to intranet upon application of power to receive a valid IP address EZT not assigned valid IP address Not connected to intranet DHCP not set to automatically assign IP address on host server Verify connection to intranet Contact IT department for assistance 50 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 8 Deciphering EZT Input Output I O Operation The inputs and outputs of the EZT 560 are predefined for specific functions on all standard chamber designs This requires that certain inputs and outputs perform different functions based on the chamber type This section covers all of the standard inputs and outputs of the system and their use based on the chamber type For each input and output an individual functional description is provided on how the input or output is used The control of the EZT outputs are also defined by which chamber events are enabled The chamber events are predefined and their use varies according to the type of chamber and options present The following table defines the standard use of the events Table 8 1 Chamber Events EVENT ST
181. is decreasing Next increase or decrease your ramp step s set point by the offset so that you are actually overshooting your desired set point by the offset value Next add a step after your ramp step Make this step a time of zero so it is an immediate set point change and make the step s set point the desired ending set point of the ramp your original ramp step s set point Now when the profile is run and the chamber begins your ramp step the controller will see an immediate set point change of the offset value Its output will immediately increase to the output value that was required to hold it during the original ramp As the set point continues to ramp the controller will hold the output at this higher level to maintain the chamber closer to set point during the ramp As the chamber is reaching the end of the ramp the set point will continue to increase by the offset amount and overshoot the original set point This forces the controller to maintain the same output level all the way until the set point is reached Once the ramp is complete the second step that was added drops the set point down quickly to the original desired set point and the controller immediately backs of its output to minimize overshoot The one thing to note when doing this is that you will introduce some oscillation at the end of the ramp however it will settle out and the chamber will hold set point 46 EZT 560 Chamber Troubleshooting Guide Cincinnati
182. is initiated f_regAdd 201 registers for profile data start at register 200 in HMI Modbus master dependent based on zero based addressing End Sub 113 EZT 560 User s Manual Cincinnati Sub Zero Private Sub downloadTimer_Timer timer code that is initiated by downloadProfile procedure Timer should be set at a minimum of 1 second intervals write profile data array to PLC variables used in procedure User can select static form global variables or class type based on preference Dim x As Integer writeValue As Integer write values to EZT must be integer values profileData x x is array that holds profile data for currently active profile that is being edited 14 99 elements zero based refer to downloadProfile procedure for form or global variables used Error checking should go here f_profWrite True profile write in progress flag form var Not required user dependent to block other actions during download If f_writeNum lt totalNumSegs Then totalNumSegs should be var or reference to total number of segs created for profile for all element in profile array 15 elements total per segement zero based For x 0 To 14 14 total elements in profile If f_profRegsToWrite 0 Then first element that hold data global to complete profile Select Case x Case 0 To 9 autostart and profile name requires no scaling in element 0 writeValue Cint profileData x f_profRegsToWrite Case 10 To 14
183. istribution throughout the chamber The required ramp rate limit will be affected by these factors It may take a little trial and error to determine what setting is best for your testing needs Ramp Rate Limit Adjustable ramp rate limit Valid range is from zero to 5 0 C 9 0 F Note that a limit setting of zero will have no limiting affect on rate of rise Dewpoint Read only parameter which displays current dewpoint of the air within the chamber DP Limit Read only parameter which displays the maximum dewpoint that can be maintained without causing condensation on product Monitor Mode Defines the method of part temperature monitoring Single Input Uses single input i e single sensor located on part Low Input Uses input with the lowest part temperature Hi Input Uses input with highest part temperature Avg Uses average of all selected part temperature inputs Input Selection Used to select which inputs will be used for monitoring part temperature Note that the standard system has only one selection the product control loop input If the EZT 560 is equipped with the input monitor option the additional inputs will be listed for selection 45 Cincinnati Sub Zero EZT 560 User s Manual 5 8 Defrost Settings These settings will be available on special systems equipped with the hot gas defrost option This option is provided on systems that operate at ultra low temperatures for extended periods of time to periodica
184. ite directly to registers containing the EZT 560 s parameters With it you could read all 180 of the controller s parameters with three read commands Modbus Remote Terminal Unit RTU Gould Modicon now called AEG Schneider created this protocol for process control systems called Modbus It has the advantage over other protocols of being extremely reliable in exchanging information This protocol works on the principle of packet exchanges The packet contains the address of the controller to receive the information a command field that says what is to be done with the information and several fields of data Reading from these registers retrieves all information in the controller The last item sent in the packet is a field to ensure the data is received intact This is called a cyclic redundancy check sum See the example below for information on how to generate this value All information exchanged is in hex numbers The EZT 560 only supports the binary version of Modbus referenced as RTU The ASCII version is less efficient and is not supported The CRC Cyclical Redundancy Checksum is calculated by the following steps 1 Load a 16 bit register called CRC register with OxFFFF 2 Exclusive OR the first 8 bit byte of the command message with the low order byte of the 16 bit CRC register putting the result in the CRC register 3 Shift the CRC register one bit to the right with MSB zero filling Extract and examine the LSB 4 Ifthe LSB
185. ition cold bath There is no user indication for this input This control input is used to tell the EZT that the basket VTS TSB is in the hot chamber unload position There is no user indication for this input The hot bath fluid safety input is used on TSB s to indicate a problem with the hot bath fluid system pressure temperature This input is active high i e the input must be on in order for the alarm to be indicated When active input on the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is off requires manual reset of limit device The cold bath fluid safety input is used on TSB s to indicate that the cold bath fluid system has exceeded maximum operating pressures This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is off The bath level safety input is used on TSB s to indicate that a bath is low on fluid if equipped with level sensors This input is active high i e the input must be on in order for the alarm to be indicated When active input on the EZT will sound the alarm to obtain operator attention but will not shut down the chamber The alarm will be shown on the system status monitor screen This control input is used to tell the EZT that
186. itor indicator will illuminate to indicate that this condition is present If your chamber is not obtaining the desired humidity level check the status monitor to verify that you are not trying to operate the chamber at a point outside of the chamber s maximum dewpoint capability 21 Cincinnati Sub Zero EZT 560 User s Manual 3 2 1 2 Altitude The altitude event turns the chamber s altitude system components on and off Altitude chambers are specifically built to withstand atmospheric pressures They have heavy gauge liners with additional internal structure for reinforcement They simulate altitude by utilizing a vacuum pump to draw air out of the chamber The EZT 560 converts the resultant pressure within the chamber into feet thus altitude can be entered directly in feet The altitude system can operate independently of the chamber conditioning system NOTES on altitude system operation Chamber Temperature Control Limitations As altitude increases the air density within the chamber decreases The heating and cooling systems require a minimum amount of air flow in order to operate correctly and control the internal chamber air temperature The altitude system will inhibit the operation of the heating and cooling systems when the altitude increases beyond the design limits This limit is typically around 60Kft Humidity Control Limitations On most altitude chambers with the humidity system option operation of the humidity system is
187. l appear to acknowledge the units change Press OK to close make the switch The button for the selected unit will be illuminated green once selected CAUTION When changing display units profile set points will not be converted between units Separate profiles are required for each temperature range Equipment damage may result if profiles of alternate units are used 61 Cincinnati Sub Zero EZT 560 User s Manual 8 2 Service Monitors The service monitors provide service interval alerts and life total service numbers for chamber components and systems The service intervals are set by CSZ at the optimum period for system performance and reliability When a component exceeds its service interval a notification alarm can be generated This will alert notify the operator that service should be performed at the next available down period Description Interval Actual _ AIR CIRCULATORS 1000 SYS 1 COMPRESSOR 2250 SYS2 COMPRESSOR 2250 HEATERS 2000 HUMIDITY SYSTEM 2000 NOT USED NOT USED NOT USED Press Tagname to clear counter Figure 8 2 Service Monitors When a service interval is exceeded an alert can be set to illuminate the corresponding indicator on the System Status Monitor screen An audible alert can also be turned on to get the operator s attention In order to clear the service alert the elapsed service counter must be cleared To clear the service interval count you must select the count that has been exc
188. l customer event 2 output BO4 16 Q52 Optional customer event 3 output BO4 14 Q53 Optional customer event 4 output BO4 12 Q54 Optional customer event 5 output BO4 10 Q55 Optional customer event 6 output BO4 8 Q56 Optional customer event 7 output BO4 6 Q57 Optional customer event 8 output BO4 19 Q60 Optional customer event 9 output BO4 17 Q61 Optional customer event 10 output BO4 15 Q62 Optional customer event 11 output BO4 13 Q63 Optional customer event 12 output BO4 11 Q64 Optional customer event 13 output BO4 9 Q65 Optional customer event 14 output BO4 7 Q66 Optional customer event 15 output BO4 5 Q67 Not Used 125 EZT 560 User s Manual Appendix Cincinnati Sub Zero A 1 Cincinnati Sub Zero EZT 560 User s Manual Common Terms and Definitions autotune A feature that automatically sets process control PID values to match a particular process in a system baud rate The rate of information transfer in serial communications measured in bits per second accuracy Closeness between the value indicated by a measuring instrument and a physical constant or known standard offset An adjustment to eliminate the difference between the indicated value and the actual process value cascade Control algorithm in which the output of one control loop provides the set point for another loop The second loop in turn determines the control action derivative control D The last term in the PID control algorithm
189. l reset of oil pressure safety The system 1 discharge thermostat input is used to indicate that the system 1 compressor discharge temperature has exceeded the maximum operating range if equipped This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is on automatically resets after allowed to cool down The system 1 compressor protection module input is used to indicate that the system 1 compressor protection module has detected an improper phase condition loss or the compressor motor windings have overheated if equipped This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is on automatically resets after built in timeout period The system 2 hi lo pressure safety input is used to indicate that the system 2 compressor has exceeded its high or low pressure operating range This input is active low i e the input must be off in order for the alarm to be indicated When active input off the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is on requires manual reset of high pressure s
190. lable only with customer event output option Example Turn on Customer events 7 10 14 and 15 0110001001000000 25152 decimal converts to 0x6240 91 Cincinnati Sub Zero EZT 560 User s Manual Register Description Use 24 0x0018 Profile Status Control Values r w 0 Off 1 Terminate all off 2 Hold 4 Run Resume Monitor Values 8 Autostart 16 Wait 32 Ramp 64 Soak 128 Guaranteed Soak The control values allow the currently loaded profile to be started stopped or placed into hold The monitor values provide status on the current operating profile s condition Should the profile be placed into hold it will remain in hold and the parameter value will remain at 2 until the profile is resumed or terminated 25 0x0019 Profile Advance Step 1 Advance Previous Step w 2 Advance Next Step When profile is in hold the parameter is enabled and allows the user to manually repeat or advance steps in a profile The parameter automatically resets to 0 once set to indicate advance has taken place 26 0x001A Profile Name chars 1 amp 2 These parameters store the operating profile s name up to 10 r characters in length uses ASCII character set Characters 27 0x001B Profile Name chars 3 amp 4 are stored in sequence from low byte to high byte Example r 28 0x001C Profile Name chars 5 amp 6 0x4554 0x5453 0x3120 0x3332 0x0000 read from EZT r ET TS 1 32 converted to
191. larm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 130 0x0082 PV2 Monitor Alarm Output r w Assignment 0 No Output Selected 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8 Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 131 0x0083 PV2 Monitor High Alarm Setpoint 32768 32767 3276 8 3276 7 r w Note that value must be converted from to whole number i e 132 0x0084 PV2 Monitor Low Alarm Setpoint divide multiply by ten to convert the decimal number from the r w value read or to the proper value for a write 133 0x0085 PV2 Monitor Alarm Hysteresis 0 32767 0 3276 7 r w Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 134 0x0086 PV3 Monitor Process value 32768 32767 3276 8 3276 7 Note that value must be converted from whole numbe
192. lay period the alarm will be activated Cargocaire Fault 126 The dehumidifier system fault input is used to indicate that there is a problem with the Cargocaire if equipped This input is active high i e the input must be on in order for the alarm to be indicated When active input on the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is off requires manual reset service of dehumidifier unit Combustible Monitor 127 The combustible monitor input is used to indicate that there is a hazardous air mixture within the chamber This input is active high i e the input must be on in order for the alarm to be indicated When active input on the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is off may require manual reset of combustible monitor 57 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 8 1 1 1 Custom Input Description of Use DTS VTS TSB Basket Left 114 Basket Right 115 Basket Up 116 Hot Bath Fluid Safety 123 Cold Bath Fluid Safety 124 Bath Level Safety 125 Basket Down 126 58 This control input is used to tell the EZT that the basket DTS TSB is in the left position hot bath There is no user indication for this input This control input is used to tell the EZT that the basket DTS TSB is in the right pos
193. le 4 1 Common Critical Alarms and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS 1 Loop Alarms input ALARM Alarm set point exceeded on user Allow process value to return within set configurable alarm for input listed point limits Disable alarm for input Change alarm set point to value greater than process value for alarm type input SENSOR BREAK Loose or corroded sensor wiring Check wiring Verify lead connections Clean if necessary No power to sensor humidity altitude Verify power to sensor Check sensor Wrong signal type output signal type Wrong input type on 9300 controller Check dip switch settings and set input type for sensor used Wrong sensor type Use correct sensor type Bad sensor Replace sensor 20 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS LOOP COMMS FAILURE 9300 controller setup incorrectly Faulty communication wiring Gateway failure Incorrect EZT configurator loop monitor settings See Section 4 1 1 Diagnosing and Correcting Loop Communication Failures Verify loop monitor configuration settings See sections 9 2 and 9 3 for adjusting EZT configuration settings 2 Chamber System Safeties BOILER OVERTEMP Boiler over temperature protector tripped Water not at proper level Manually reset thermostat to clear alarm Check water le
194. lected 5 Process Low Alarm Selected 7 Process Both Selected 24 Deviation High Alarm Selected 40 Deviation Low Alarm Selected 56 Deviation Both Selected 91 r w 0x005B Loop 3 Alarm Mode Bit1 Off alarm self clears Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 92 r w 0x005C Loop 3 Alarm Output Assignment 0 No Output Selected 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8 Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 93 r w 0x005D Loop 3 High Alarm Setpoint 94 r w 0x005E Loop 3 Low Alarm Setpoint 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a
195. leshooting Guide Cincinnati Sub Zero 8 3 PLC Status Indicators All of the digital input and output points on the PLC have indicator lights that tell whether the input or output is on or off The lights are numbered for quick identification By using the status lights it can help you diagnose a wiring or component problem in the system For example if the output light on the PLC is on indicating that the output relay should be on and the relay is off it could indicate a bad relay or a problem with the wiring to the relay The CPU has connections for all inputs used on a standard system This includes inputs 10 117 and 120 127 It also has the output connections for the first 16 outputs used on standard chambers Q0 Q7 and Q10 Q17 The remaining outputs are used depending upon the options present on the chamber The outputs are added through the use of add on output modules that connect to the right side of the CPU For chambers without customer events a 16 point digital output card is added in order to obtain outputs Q30 Q37 and Q40 Q47 If customer event outputs are required a 32 point card is added in order to get Q50 Q57 and Q60 Q67 NOTE The output numbering is octal based That means that the outputs increment in groups of 8 The first group is outputs QO Q7 The second group is outputs Q10 Q17 The next incremental group starts with the addition of a digital output card It begins at output Q30 The range of Q20 Q27 is skipped CP
196. lication Pressing the Exit Application button will exit the E2T 560 application and suspend all chamber operations Figure 9 1 Exit Application If security is not enabled you will not have to log on to gain access to quit the application However if security is enabled and the default password is no longer valid then you must either obtain the necessary user name and password from the end user of the chamber or you can bypass the security by turning off power to the chamber With the power turned off remove the compact flash card from the back of the HMI Turn the power back on and allow the HMI to boot up to the Windows CE desktop blue screen Insert the CF card back into the slot in the HMI making sure to insert it in the proper orientation Touch the thin gray bar at the bottom of the screen to show the Windows task bar and select Windows Explorer from the start menu gt Internet Explorer Ea 8Y windows Explorer Figure 9 2 Windows Start Menu 70 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero Open the StorageCard folder ae Seen ite eee ure 9 3 Storage Card Fig Open the EZT560 folder Figure 9 5 EZT560 Config Once the configurator application starts it will default to the Number of Loops Monitors screen
197. line not below defrost thermostat setting Defrost thermostat not working Check thermostat setting Defrost not required Check thermostat set point and operation Adjust replace Defrost not terminating Defrost thermostat not working Check thermostat set point and operation Adjust replace 32 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 5 2 Humidity System When the humidity system is enabled the humidity system output Q32 will turn on This turns on the water supply solenoids and atomizer air compressor if applicable If the refrigeration system is set to run in single stage mode when humidity is on the RH cool output Q31 will turn on in order to connect the 9300 cool output to the RH cool solenoid System 2 compressor will then be turned off as long as humidity is on When running in standard humidity mode not low RH mode frozen coil the dehumidify enable output Q30 will turn on This allows the 9300 dehumidification output to control the wet coil solenoid The maximum humidify output Q33 will turn on whenever the humidification output percentage exceeds the set point in the configurator for the on delay time period An alarm delay is added to the boiler low water input 115 in order to allow it time to fill with water when the humidity system is first turned on The delay will prevent the alarm from going off for a period of 30 minutes Should the level not be made in that ti
198. ller Check solenoid Clean replace if necessary Check pressure and adjust replace if necessary 34 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 5 3 Auxiliary Cooling System The auxiliary cooling system has two modes of control It can be set as either a standard boost or as a control When set as a boost it will assist the refrigeration system in lowering chamber temperatures quickly As a control it will actually take over once the low temperature limit of the refrigeration system is reached and continue cooling down to an ultimate low of the cooling medium Auxiliary Cool Boost When the auxiliary cooling option is set for boost in the configurator the auxiliary cooling supply valve output Q40 will turn on when the event is enabled The EZT will then monitor the cooling percentage of output When it exceeds the auxiliary cooling on percentage set point for the on delay time period the boost cool output Q42 will turn on When the percentage of output drops below the on percentage set point the output will turn off The supply valve output will remain on as long as the event is on Only the boost output will cycle on and off for control Once the air temperature reaches the low limit set point in the configurator boost cool disable the boost cooling output will be disabled to prevent the chamber from going colder than what the refrigeration system can handle to protect the compressors Auxiliary Cool Co
199. lly warm the refrigeration coils and remove the normal ice build up Moisture in the air is naturally attracted to the cold surface of the refrigeration coils in the chamber This moisture freezes to the surface of the coil over time and can eventually cover the entire surface This will render the coil useless and block all airflow in the chamber In chambers that run through high and low temperature cycles the moisture does not accumulate to a detrimental level but in chambers that run at low temperatures for days or weeks at a time this can be a problem Hot gas defrost is a means of warming the refrigeration coils to melt the ice while minimizing the rise in air temperature within the chamber When defrost is enabled the air circulators shut down and the hot gas solenoid opens The hot gas flows through the refrigeration coil and melts the ice Once the coil reaches a preset temperature limit typically 10 C 50 F defrost terminates The refrigeration system then prechills the coil prior to turning on the air circulators This further prevents the warming of the chamber s contents Defrost can be set to run automatically or under manual control through the use of an event When auto mode is selected the EZT 560 will monitor the conditions of operation and automatically start defrost based on the parameters the user has entered Status Defrost Delay mins Temperature SP Auto Mode manua Figure 5 8 Defrost Settings
200. ly monitors many of the chamber safeties in order to provide specific alarm information so you know exactly what is preventing the chamber from running and do not have to search for it NOTE Analarm condition may be present and not indicated on the EZT if a hardware failure or wiring problem exists Keep this in mind when there are no obvious fault conditions present that would indicate why the chamber is not working properly In order to begin troubleshooting a chamber problem narrow down the search by determining which section of this guide the problem most likely falls into based on the information provided below Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide Section 3 User Interface HMI Troubleshooting This section covers typical problems that may arise with the EZT s display such as screen lock ups or the EZT failing to start due to communication or hardware problems Section 4 Resolving Chamber Alarms This section covers all alarm messages provided by the EZT in its alarm monitor Begin with this section to obtain information regarding any unresolved alarm messages that are not able to be cleared determine what is causing it and correct the problem Section 5 Chamber Operating Problems Use this section to diagnosis problems when no alarm messages are present Why are the compressors not turning on Why is humidity not turning on when the event is on This helps you determine if there is a real problem or if
201. m condition If the alarm is set for the shutdown mode of operation the chamber will turn off all systems in an alarm condition Output Assignment If the customer event option is supplied on the chamber the alarm can be assigned to one of the events Utilizing the close on alarm or open on alarm mode settings the event output will turn on and off with the alarm it is assigned to NOTE When setting an event output as an alarm the output can still function as an event Thus the output will be on if the event output is on or if the alarm state and mode tells it to be on More than one alarm can also be tied to the same output This allows one output to function as a remote indicator for any configured alarm condition Alarm Set Points High Set Point Hi SP The alarm high set point defines the process value or temperature that will trigger a high side alarm It must be higher than the alarm low set point Low Set Point Lo SP The alarm low set point defines the temperature that will trigger a low side alarm It must be lower than the alarm high set point Hysteresis DB An alarm state is triggered when the process value reaches the alarm high or alarm low set point Alarm hysteresis defines how far the process must return into the normal operating range before the alarm can be cleared It creates a zone inside each alarm set point This zone is defined by adding the hysteresis value to the alarm low set point or subtract
202. mber i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 155 0x009B PV6 Monitor Process value 32768 32767 3276 8 3276 7 r Note that value must be converted from whole number i e divide by ten to convert the decimal number from the value read 156 0x009C PV6 Monitor Alarm Type Selection O0 Alarm Off r w 3 Process High Alarm Selected 5 Process Low Alarm Selected 7 Process Both Selected 157 0x009D PV6 Monitor Alarm Mode Bit1 Off alarm self clears r w Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 158 0x009E PV6 Monitor Alarm Output r w Assignment 0 No Output Selected 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8 Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Cust
203. me the alarm will sound and shut down the chamber Once the water level is made the alarm will sound and shut down the chamber immediately upon loosing the input for safety Should the alarm occur silence the alarm from the alarm monitor screen and the chamber will begin operating again and restart the 30 minute alarm delay timer Temperature Limits The EZT limits the humidity system s operational range to a minimum and maximum temperature as set in the configurator These limits are typically set at freezing and boiling temperatures Once the air temperature exceeds either limit the EZT shuts down the humidity system automatically If the humidity system is shut down due to temperature limitations the system status monitor will indicate that this has occurred by illuminating the RH TMP DISABLE indicator The humidity system will restart automatically once the air temperature returns to within the set temperature range Dewpoint Limits In order to protect the refrigeration system and chamber from damage there are minimum and maximum dewpoint levels that are set in the configurator These limits in turn define the minimum and maximum relative humidity levels that the chamber will operate to at any given temperature The EZT uses these limits and internally calculates the minimum and maximum humidity level that the chamber will control to at the current chamber temperature Should the user enter a set point outside of those limits the
204. measured in bits per second accuracy Closeness between the value indicated by a measuring instrument and a physical constant or known standard offset An adjustment to eliminate the difference between the indicated value and the actual process value cascade Control algorithm in which the output of one control loop provides the set point for another loop The second loop in turn determines the control action derivative control D The last term in the PID control algorithm Action that anticipates the rate of change of the process and compensates to minimize overshoot and undershoot Derivative control is an instantaneous change of the control output in the same direction as the proportional error This is caused by a change in the process variable PV that decreases over the time of the derivative TD The TD is in units of seconds droop In proportional controllers the difference between set point and actual value after the system stabilizes EIA See Electronics Industries of America EIA TIA 232 and 485 Data communications standards set by the Electronic Industries of America and Telecommunications Industry Association Formerly referred to as RS Recognized Standard Electronics Industries of America EIA An association in the US that establishes standards for electronics and data communications fuzzy logic A mathematical control algorithm that monitors past response of a system to pre
205. ment 0 cc cece ee eeteee ee eete eee e ene eee ee tants eeeaeeeeeeaeeeeeeaeeeeeeenaeeeeeaes 19 Figure 3 2 Numeric Entry lt 2 tscccofetccth ticctt EA Seadsh ered acces eit s ceed eens EE E EE 19 Figure 3 3 Manual Event Control vcicccisccccecciiaceeditsdecectihecacceesetieenedudeceessiadcenesestceeebandidectstadeeteassicceniigiees 20 Figure 3 4 Tune Control RESpOMSC a c ciccccccticccccctsheceeesshecccenteccceneaseececeesesaceneteecdeceensiccetsaceeeesneiecctidiees 24 Figure 4 1 Profile Enty ccieiciet terete Nees ithe title RE 26 Figure 4 2 Profile Step Events 2 ccccicieede eect aa EAEE EEEE EAEE REEE 27 Figure 4 3 Profile Guaranteed Soak Events essseessseeeriserrrressrrrsnsrrrnndtnranannnnaattaanannnnaanaaaaanannaaaannaa 27 Figure 4 4 Profile Wait For put eccrircncsninsenccririiire anii EEEE 28 Figure 4 5 Profile Set Point EMY ecsrccianinroni AEE EEEE 28 Figure 4 6 Profile AUO Stafi encorcrririni anin AA EEEE EEEE 30 Figure 4 7 Profile Guaranteed Soak Limits 2 0 0 0 eee ceeeeee ene ee ee enteee ee eaeeeeeeaeeeeetaeeeeeeiaeeeeenenaeeeenaes 31 Figure 4 8 Profile Plots vsiccccs siscacetincceceseecnedseatecdsvevocdannyadcdanteddaasbuahesesy saccade vie A AEA 32 Figure 49 Profile Start lt cicccsisihtecaviddtecanyancdenpeasncdanewecreaanyacedaneys AEAEE EAEAN EA EATA 33 Figure 4 10 Profile Status VIEW s ccccsasececderiacccacersacccannwncegdanuatcccevecesashveetegsvaicdextenccedseualcceueeectecan vices 35 Figure 5 1 Power RECOV
206. midity control will resume at the target set point When humidity is disabled due to the chamber air temperature the corresponding System Status Monitor indicator will illuminate to indicate that this condition is present Minimum Humidity Limitations The standard humidity option provides a lower limit of humidity control relating to a 4 4 C 40 F dewpoint The dewpoint refers to the temperature at which the air contains the maximum amount of moisture it can hold When a surface drops to that temperature or below condensation will occur on that surface The dewpoint varies logarithmically with temperature and relative humidity This means that at higher temperatures a much lower humidity level can be obtained because the air can hold more moisture the warmer it becomes For example an air temperature of 85 C 185 F and relative humidity of 12 is the equivalent dewpoint of air at a temperature of 5 C 41 F and 79 Both of these values are at the minimum achievable dewpoint of the chamber and thus the minimum achievable humidity at the related temperature If you were to set the humidity set point at 0 for example the humidity level would never reach 0 since the chamber is not capable of removing any more moisture from the air The EZT 560 is programmed to determine what the minimum achievable humidity point is at any given temperature and will control to that limit Therefore the system will not overwork itself trying to reach an
207. mory so that it is retained when power is turned off Cycle power to the EZT and allow it to boot up normally 12 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 3 1 3 Touch Screen Calibration If the touch screen is severely out of calibration it can appear as if the HMI is locked up It may not respond to touch or will make it impossible to accurately select items in order to navigate to the normal screen calibration menu If this occurs there are two methods for correcting the screen s calibration The first one requires access to the dip switches on the back of the HMI the other requires the use of a USB compatible mouse 3 1 3 1 Dip Switch Calibration Procedure To begin switch power off to the EZT Gain access to the rear of the HMI and locate the dip switches to the upper right of the power plug connection Set dip switch 1 to the on up position Restore power to the EZT Allow the HMI to follow its normal boot sequence Once the Windows CE image is loaded the display will automatically start the touch screen calibration routine Using a stylus or the tip of a plastic pen cap touch and hold on the center of each point marked by the crosshairs on the screen CAUTION Do not use any metal or sharp edged instruments on the screen or permanent damage to the screen may result Carefully press and briefly hold stylus on the center of the target New calibration settings have been measured Repeat as the targ
208. mperature and humidity set point exceed minimum allowable dewpoint limit for the chamber Set temperature and humidity set points to within allowable dewpoint range for the chamber Adjust dewpoint limit See Section 9 Adjusting EZT Configuration Options 2 Chamber Monitors DOOR OPEN Chamber door s not closed Door switch out of adjustment bad Close chamber door Adjust replace door switch 3 Service Monitors SERVICE FANS indicator has audible alert if enabled Air circulator operating hours have exceeded service interval Perform service and clear elapsed service count SERVICE COND SYS indicator has audible alert if enabled Heating and or cooling system components have exceeded service interval Perform service and clear elapsed service count for affected components SERVICE HUMIDITY SYS indicator has audible alert if enabled Humidity system components have exceeded service interval Perform service and clear elapsed service count for affected components SERVICE PURGE SYS indicator has audible alert if enabled SERVICE ALTITUDE SYS indicator has audible alert if enabled Dry air purge system components have exceeded service interval Altitude system components have exceeded service interval Perform service and clear elapsed service count for affected components Perform service and clear elapsed service count for affected components
209. n alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 151 0x0097 PV5 Monitor Alarm Output 0 No Output Selected r w Assignment 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8 Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 152 0x0098 PV5 Monitor High Alarm Setpoint 32768 32767 3276 8 3276 7 r w Note that value must be converted from to whole number i e 153 0x0099 PV5 Monitor Low Alarm Setpoint divide multiply by ten to convert the decimal number from the r w value read or to the proper value for a write 154 0x009A PV5 Monitor Alarm Hysteresis 0 32767 0 3276 7 r w 105 Cincinnati Sub Zero EZT 560 User s Manual Register Description Use Note that value must be converted from to whole nu
210. n the EZT 560 Eagle hardware however the user can input an offset in order to adjust for sensor tolerances and lead affects Through the use of a simple ice bath all sensors can be corrected within a matter of minutes without having to disconnect leads or have expensive calibration equipment With the chamber at ambient temperature place a bucket of ice filled with water in the chamber Place all monitor input thermocouples into the ice bath Allow the probes to soak for a minimum of 30 minutes BEFORE entering an offset Select Input Calibration from the System Maintenance menu Enter the number of the input in the Input Num field The current reading from the input will be shown in the Cur PV field Input Num Cur PV Offset 1 4 Figure 8 10 Monitor Input Calibration 68 EZT 560 User s Manual Cincinnati Sub Zero The reading should be 0 C 32 F i e the ice bath temperature To zero the input enter the offset value in the Offset field and verify the reading Be sure to press the Accept button to save the new offset value before proceeding onto other inputs or exiting calibration or the offset value will be lost The total error for the monitor inputs is 3 5 C 6 3 F The input types are fixed and cannot be changed If replacing sensors be sure to replace with the same type 8 5 2 Output Calibration The EZT 560 can have up to 4 analog outputs which can be used to retransmit set
211. n the chamber or within the product under test To view the averages report select View Averages Report from the Datalogging menu Time from 12 01 to 17 55 Done Tagname i Average Temperature Humidity Altitude All Points Avg Figure 7 7 Averages Report 57 Cincinnati Sub Zero EZT 560 User s Manual 7 4 File Utilities The File Utilities screen allows the user to copy or erase files from the internal compact flash card Complete file directories for all EZT 560 file types can be copied to the USB I Stick or erased from the internal compact flash card Complete status for file functions as well as progress bar status is displayed for the operator during copy erase operations A quick note regarding file storage The files log files alarm history and audit files need some maintenance every now and then After a period of time storage devices fill up and files require backup or file deletion when no longer needed The File Utilities section of the EZT 560 provides all the functionality required for maintaining the internal compact flash card The internal compact flash card should not be removed from the EZT 560 interface Any change to compact flash directory structure moving or deleting files with a PC will cause the EZT 560 interface to stop operating and a new compact flash card will need to be ordered Never move or delete the directories unless using the internal EZT 560 file utilities
212. n utility select Calibrate Touch from the Setup menu Push the Calibrate Touch button Calibrate functions will suspend all operations for the E2T 560 Operation will not resume until Calibrate Touch window is closed Calibrate Touch Return To Setup Select functions from buttons listed above Figure 8 5 Touch Screen Calibration From the System Settings window touch the Calibrate button to start the calibration utility System Settings OK Touch Screen settings LCD settings MAC ad 4 gt Calibrate Figure 8 6 Touch Screen Settings Crosshairs will appear on the screen At each crosshair position touch the screen and hold position until the crosshairs move to the next calibration point Repeat this for each position in order to set the calibration The calibration requires five points the center and four corners Once complete the calibration utility will exit and return to the System settings window 65 Cincinnati Sub Zero EZT 560 User s Manual Use the scroll arrow button in the Systems settings window to scroll to the right until you see the Save tab Touch the Save tab and press the Save Registry button This will store the calibration parameters in memory If the settings are not saved the changes will be lost when power is cycled to the unit Press the OK button on the upper right corner of the System settings window to close the window and return to System Mainte
213. nance System Settings OK LCD settings Y MAC address Save System ve 4 gt Save registry Scroll Tabs Figure 8 7 Save Registry 8 4 1 LCD Settings The System Settings window also provides access to the contrast and backlight adjustment of the EZT 560 touch screen To access these settings perform the procedure above to access system settings however do not perform the calibrate touch procedure The backlight is set to never turn off by default To adjust the backlight select the LCD Settings tab from the system settings window Using the drop down menu and select the time period for which the backlight should turn off after no activity System Settings OK Touch Screen settings LCD settings MAC ad 4 gt Turn off backlight if not used for 10min 15mi fo min 30min a hed Never Figure 8 8 LCD Settings Proceed to the Save Registry tab to save any changes in order for them to be the default at the next power up If the screen appears too bright or too dim based on your ambient lighting you can adjust the screen brightness by selecting the Contrast tab from the System Settings window 66 EZT 560 User s Manual Cincinnati Sub Zero System Settings Figure 8 9 Contrast Use the slider to adjust the screen contrast to achieve the best picture for your viewing Remember to save any changes in order for them to be the default at the next power up 67 Cincinnat
214. nd 9300 controllers These indicator lights will flash on and off alternating with each other at high speed indicating that information is being exchanged back and forth between all of the devices Gateway to PLC Communications The top indicator light labeled IDEC on early model Gateways and PLC1 on late model Gateways will begin flashing on power up and continue flashing at all times It indicates communications between the Gateway and the PLC If this light is not flashing check the connection between the Gateway and the PLC to make sure the cable is connected to the port on the CPU If the cable is connected the OK indicator is lit and the light is not flashing the cable may be bad see note below or the Gateway is not functioning correctly and needs to be replaced NOTE When replacing an early model Gateway with a late model Gateway be sure to use the cable supplied with the new Gateway to connect it to the PLC DO NOT use the old cable The cables are not interchangeable between Gateway models Gateway to 9300 Controller Communications The bottom indicator light labeled MODBUS on early model Gateways and PLC2 on late model Gateways will begin flashing once the EZT560 application starts running on the HMI It indicates communications between the Gateway and the 9300 controller s The light will continue flashing during normal chamber operations If this light is flashing slowly or irregularly thi
215. nd atomizer air compressor if applicable BO3 14 Q33 Maximum humidify enable output BO3 12 Q34 Dry air purge control output BO3 10 Q35 Air control solenoid enable output Enables dry air purge control on systems with low RH option BO3 8 Q36 Enabled dehumidification control of frozen coil solenoid on systems equipped with low RH option BO3 6 Q37 Frozen coil bypass solenoid output Turns on solenoid to bypass EPR on wet coil for systems with low RH option BO3 19 Q40 LN2 supply solenoid control output BO3 17 Q41 LN2 control solenoid enable output Switches primary cooling control from refrigeration to LN2 for ultra temperature operation on specially equipped chambers BO3 15 Q42 LN2 boost solenoid Turns on to assist refrigeration systems on fast change rates BO3 13 Q43 Altitude system enable output BO3 11 Q44 Altitude system minimum dive output enable Transfer left output for DTS TSB chambers BO3 9 Q45 Altitude system maximum dive output enable Transfer right output for DTS TSB chambers BO3 7 Q46 Altitude system minimum vacuum output enable Transfer hot up output for VTS chambers BO3 5 Q47 Altitude system maximum vacuum output enable Transfer cold down output for VTS chambers 124 EZT 560 User s Manual Cincinnati Sub Zero Digital Output Expansion Connector 2 terminal I O ADDR Operation BO4 20 Q50 Optional customer event 1 output BO4 18 Q51 Optiona
216. nd cooling control modes in order to help diagnose any problems that may occur during operation Section 5 4 Dry Air Purge System This section covers typical problems that may arise with the chamber s dry air purge system It includes information regarding the operation of the low RH mode frozen coil in order to help diagnose any problems that may occur during operation Section 5 5 Altitude System This section covers typical problems that may arise with the chamber s altitude system Section 5 6 Fluid System LC TSB This section covers typical problems that may arise with the chamber s fluid system It also includes information regarding hot oil heating systems for special use on explosion proof EXP chambers Section 5 7_Transfer Mechanism DTS VTS TSB This section covers typical problems that may arise with the basket transfer mechanism It includes information regarding the operation for both air and motor operated systems 28 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 5 1 Conditioning System When the chamber event is turned on whether it be a standard ZP TSB or VTS for example temperature control is the primary function The air circulator output will turn on and enable the heating cooling logic Even though the air circulator output may vary based on the type of chamber it performs the same function The minimum cool output Q14 and minimum heat output Q16 turn on with the chamber event to
217. ndicator RH LO DEWPOINT LIMIT EZT 560 is limiting the minimum humidity level based on the minimum allowable dewpoint that the chamber can operate safely without causing potential damage to the refrigeration system Set temperature and humidity set points to within allowable chamber range no audible alert is associated with this indicator SERVICE FANS Service alert if enabled indicating that the prime air movers of the chamber require regular maintenance Perform service and clear elapsed service count for corresponding components SERVICE COND SYS Service alert if enabled indicating that the heating and or cooling system components require regular maintenance Perform service and clear elapsed service count for corresponding components SERVICE HUMIDITY SYS Service alert if enabled indicating that the humidity system components require regular maintenance Perform service and clear elapsed service count for corresponding components SERVICE PURGE SYS Service alert if enabled indicating that the dry air purge system components require regular maintenance Perform service and clear elapsed service count for corresponding components SERVICE ALTITUDE SYS Service alert if enabled indicating that the altitude system components require regular maintenance Perform service and clear elapsed service count for corresponding components SERVICE XFER SYS Service alert if enabled indicating that the basket transfer me
218. ndow Heater Enable SP Sets the temperature below which the window heater turns on Alt Hi Speed Fan Enable SP Sets the altitude in Kft above which the high speed fans will be turned on Alt Cond System Disable Sets the altitude above which the conditioning system will be automatically disabled 83 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 9 10 CSZ Events The CSZ Events screen is accessed from the Event Alarm Tags menu This screen is used to set the names for the events of chamber options present Event Alarm Tags CSZ Event Names Press each event to change name Press Accept to Save Figure 9 14 CSZ Event Names To change or edit a tag name touch the position for the event and change the name using the pop up keypad Note that event names are limited to 20 characters in length NOTE Altering the event names from those listed on the EZT Configuration sheet provided with the chamber may make their use unclear and cause operator confusion Use discretion when altering tag names 84 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 9 11 Critical Chamber Alarms The Critical Chamber Alarms screen is accessed from the Event Alarm Tags menu This screen is used to set the names for the different system alarms in the chamber File Loops Chamber Event Alarm Tags mE Critical Chamber Alarms CHAMBER HI LIMIT PRODUCT SAFETY BOILER OVERTEMP BOILER LOW WATER
219. ng shaft etc Replace fuse repair replace motor or drive PRODUCT SAFETY Optional product safety limit tripped Manually reset limit to clear alarm Check limit set points and verify properly set for product testing PUMPDOWN DISABLED Chamber power off for more than 30 minutes Will automatically reset in 4 hours Can be manually reset via alarm monitor screen Unit will not run with pumpdown disabled Input SENSOR BREAK Check sensor wiring for indicated input Verify lead connections If sensor requires power i e humidity altitude etc verify power to sensor Replace sensor SYS HILO PSI Refrigeration system system number high or low pressure safety tripped High pressure safety requires manual reset Check condenser for blockage clean if necessary Low pressure will automatically reset Check static pressure for possible leaks Service and further diagnostics require authorized certified refrigeration service personnel SYS LOW OIL PSI Refrigeration system system number oil pressure safety tripped Check compressor oil level Requires manual reset Service and further diagnostics require authorized certified refrigeration service personnel SYS HI DISCHARGE TMP SYS COMP MONITOR Refrigeration system system number discharge safety tripped Check liquid injection solenoid Automatically resets Service and further diagnostics require authorized ce
220. nnn 00 OF nnnn controller address 1 byte write command 0x10 starting register high byte starting register low byte number of registers to write high byte 0x00 number of registers to write low byte Ox0F CRC low byte CRC high byte 82 EZT 560 User s Manual Cincinnati Sub Zero 9 3 GPIB IEEE 488 Communication The GPIB communication option is provided through the use of ICS s Model 4899 GPIB to Modbus Controller The 4899 is an IEEE 488 2 compatible GPIB device that can control single or multiple Modbus slave devices It accepts simple GPIB bus commands that are used to create Modbus RTU packets that are transmitted serially to the Modbus slave device s The data transmission can be to a single Modbus device over an EIA 232 link or to multiple Modbus devices over an EIA 485 network The Controller s SCPI parser accepts IEEE 488 2 common commands SCPI commands and Modbus commands The IEEE 488 2 and SCPI commands are used to setup the Controller s Status Reporting Structure or to configure its GPIB and serial interfaces Any commands that end in a are a query and the Controller responds by outputting the requested data on the GPIB bus the next time it is addressed as a talker The 4899 includes a list of commands for controlling Modbus devices These commands specify the Modbus slave device address a read or write operation a register number and data or the number of registers to be read When the Controller
221. ntil the specified date or day and time of a 24 hour clock The autostart settings are stored with the profile To enter the desired start date or day select Auto Start Profile from the profile Views menu Choose the desired autostart method date or day and enter the start time settings Once the desired entries have been made press the Done button to return to the profile entry screen DOW Sun Sat 0 through 6 Month 5 Day Of Week Day 13 Hour 10 Year 06 Minute 22 AUTOSTART BY DATE Done Figure 4 6 Profile AutoStart Autostart by Date When this mode is selected the exact date and time must be entered Enter the month day year and time of day in hours and minutes for when the profile is to start The day of week entry is not used so its value is irrelevant Autostart by Day When this mode is selected only the day of week and time is required to be entered The date settings are ignored so the values are irrelevant NOTE The time is entered in 24 hour military time format To convert time from AM PM format into 24 hour format add 12 to the hours in PM time For example 2pm will be a value of 14 for hours A time of 5 30pm will be 17 hours 30 minutes The autostart settings are stored with the profile however autostart can be used as a one time setting Select a profile that you wish to autostart at a particular time make the desired autostart selections and run the profile The original prof
222. ntrol When auxiliary cooling is set for control in the configurator the auxiliary cooling system will operate according to the boost control logic until the low limit set point is reached The low limit set point in the configurator boost cool disable is the lowest safe operating range for the refrigeration system Once the low limit set point temperature is reached the refrigeration system is shut down and the control solenoid output Q41 will turn on This transfers the cooling output from the 9300 controller to the auxiliary cooling solenoid This allows the chamber to be controlled to temperatures below what the refrigeration system could handle 5 3 1 Common Auxiliary Cooling System Failures and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS Boost cooling not turning on Auxiliary cooling event not turned on Loop percentage of output not exceeding on percentage for delay period Air temperature at minimum allowable range Altitude system on altitude chambers Turn on auxiliary cooling event Check loop output percentage adjust configurator settings if necessary for performance Chamber at limits Can not go any colder Turn off altitude system Chamber not cooling faster with boost cooling on Cooling medium LN2 CO2 not reaching chamber as liquid Supply control valve clogged failed Allow boost cooling to run longer in order for liquid to reach chamber
223. o set the value combine the two component bytes into the word Example Step time duration of 30 seconds decimal 0 minutes converted to 0x00 high byte decimal 30 converted to 0x1E low byte set value of 0x001E to EZT 217 0x00D9 Step 1 Chamber Events Bit1 Chamber Event 1 Bit2 Chamber Event 2 Bit3 Chamber Event 3 Bit4 Chamber Event 4 Bits Chamber Event 5 Bit Chamber Event 6 Bit Chamber Event 7 Bit8 Chamber Event 8 Bit9 Chamber Event 9 Bit10 Bit11 Bit12 Bit13 Bit14 Bit15 This parameter is bit oriented i e enabling the different bits of the word enables 1 or disables 0 the event 218 Ox00DA Step 1 Customer Events Bit1 Customer Event 1 Bit2 Customer Event 2 Bit3 Customer Event 3 Bit4 Customer Event 4 Bits Customer Event 5 Bit Customer Event 6 Bit Customer Event 7 Bit8 Customer Event 8 Bit9 Customer Event 9 Bit10 Customer Event 10 Bit11 Customer Event 11 Bit12 Customer Event 12 Bit13 Customer Event 13 Bit14 Customer Event 14 Bit15 Customer Event 15 This parameter is bit oriented i e enabling the different bits of the word enables 1 or disables 0 the events 219 Ox00DB Step 1 Guaranteed Soak Events Bit Guaranteed Soak Loop 1 Bit2 Guaranteed Soak Loop 2 Bit3 Guaranteed Soak Loop 3 Bit4 Guaranteed Soak Loop 4 Bits Guaranteed Soak Loop 5 This parameter is bit oriented i e enabling the different bits of the word enabl
224. of 5 degrees per hour This equates to a time period of 13 hours Thus the new step will have a set point of 85 degrees with a step time of 13 hours NOTE A step time of zero can be entered for a step to implement an immediate set point change This will cause the chamber to ramp to a set point as quickly as possible Used in conjunction with a wait for on the following step maximum ramp rates can be achieved that are directly followed by a soak step at the same temperature 41 5 Jump The jump allows the profile to jump between different steps within itself This is useful for repeating the same ramp soak combination during extended cycle testing of product To enter a jump enter the step number to jump to and the number of jumps to be made A jump count of zero on a step indicates that no jump will be made regardless of what the jump step number is set to Jump Step This defines the step number that the profile will jump to at the completion of the step Jump Count This defines the number of jumps that will be made from the step Once all jumps have been made the profile will continue on to the next step in sequential order NOTE The jump count defines how many jumps will be made Thus if you wish to perform 10 cycles within a profile your jump count will be set to 9 10 minus the 1 you performed prior to reaching the jump step 29 Cincinnati Sub Zero EZT 560 User s Manual 4 2 Autostart Autostart pauses a profile u
225. oil When the refrigeration system is in defrost this input is used to begin the termination sequence for defrost by signaling that the coil defrost temperature has been met When the input first turns on the EZT will begin the 15 minute countdown to terminate defrost The thermostat is typically set for about 10 C 50 F After defrost times out the prechill step begins The refrigeration system will begin to cool the coil Once the thermostat sees the coil drop below the set point a 60 second prechill timer will begin At the end of 60 seconds the chamber will return to normal operation If the control loop is not calling for 100 cooling the prechill timer will begin its 60 second countdown regardless of the suction line temperature The door switch input is used to indicate if the chamber door is open or closed if equipped The door ajar status will be displayed on the system status monitor screen If the door control option is enabled the EZT will shut down the chamber when the door is opened This input is active high i e the input is on to indicate an open door status The emergency stop input is used to indicate that the emergency stop has been activated if equipped This input is active high i e the input must be on in order for the alarm to be indicated When active input on the EZT shuts down the chamber until the alarm is acknowledged silence button pressed on alarm monitor screen and the input is off
226. om the loop view screens but will not disable the loop If the 9300 controller is then removed the chamber will shut down on a loop comms failure alarm Total of Monitor Loops Sets number of monitor inputs connected to the Eagle module For each enabled input another loop is added to the loop view screens trend etc for viewing Total of Analog Outputs Sets the number of analog outputs connected to the PLC When one or more are enabled the Output Calibration menu item is system maintenance will be enabled in the EZT560 application This allows the user to set up the analog output for the type and signal range desired for retransmission to another device such as a chart recorder 72 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 9 3 Loops Monitor Tagnames The Loops Monitor Tagnames screen is accessed from the Loops menu This screen allows you to define what type of control loop it is what its name is and specific control output settings for the loop File Loops Chamber Event Alarm Tags s AM mm Loop p atai i Temperature Input Type Tagname TEMPERATURE Alm1 Message TMP ALARM Eng Units Dec Pos Max Heat J Heat Diy Max Cool Cool Wy Figure 9 7 Le Loop Monitor Tagnames The arrow keys provided on the upper right of the screen allow you to scroll through all available control loops and monitor loops that have been set on the Number of Loops Monitors scr
227. omer Event 15 Output 159 0x009F PV6 Monitor High Alarm Setpoint 32768 32767 3276 8 3276 7 r w Note that value must be converted from to whole number i e 160 0x00A0 PV6 Monitor Low Alarm Setpoint divide multiply by ten to convert the decimal number from the r w value read or to the proper value for a write 161 0x00A1 PV6 Monitor Alarm Hysteresis 0 32767 0 3276 7 r w Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 162 0x00A2 PV7 Monitor Process value 32768 32767 3276 8 3276 7 Note that value must be converted from whole number i e divide by ten to convert the decimal number from the value read 106 EZT 560 User s Manual Cincinnati Sub Zero Register Description Use 163 0x00A3 PV7 Monitor Alarm Type Selection 0 Alarm Off r w 3 Process High Alarm Selected 5 Process Low Alarm Selected 7 Process Both Selected 164 0x00A4 r w PV7 Monitor Alarm Mode Bit1 Off alarm self clears Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed
228. on Limit switches are placed on each end of both cylinders to provide position information to the EZT In order to transfer from one bath to the other the basket is first raised into position Once the basket is in the up position the EZT then controls the other cylinder to move the basket left or right over the opposing bath Once the basket is repositioned over the other bath it is then lowered into the bath 5 7 1 Common Transfer Mechanism Failures and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS Basket not transferring Limit switch failure Basket already in position Motor clutch slipping Blown fuse motor operated Binding in transfer basket mechanism Loss of low air pressure Check limit switches Adjust replace Transfer to other position Check adjust clutch tension Replace fuse Check cable tension pulleys etc for wear Repair replace Supply proper air pressure Check pressure regulator adjust Basket not transferring to proper position Limit switch failure Motor leads reversed Air lines to cylinder reversed Verify limit switch operation Swap motor leads Swap air lines 39 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 6 Process Control Problems This section covers issues related to the control of chamber process values i e temperature humidity altitude etc Its purpose is to give you more insight on how the chambe
229. on system and use the boost cooling system for the primary cooling source This automatically protects the refrigeration system from damage and optimizes system operation 22 EZT 560 User s Manual Cincinnati Sub Zero 3 2 1 4 Dry Air Purge Low RH Option The dry air purge event can provide two levels of operation Level 1 Level 2 The first level of this option is dry air purge only The purge only option consists of an air dryer which dries a small volume of air and discharges the dry air within the chamber This helps reduce condensation on surfaces within the chamber by drying the air When this event is turned on with the purge only option the air dryer will run continuously until the event is turned off If the chamber is also equipped with the humidity option and the humidity system is enabled the purge system will be disabled automatically by the EZT 560 The humidity system can not control the humidity level within the chamber if the purge system is continuously trying to dry out the chamber The second level of this option includes the frozen coil low RH option This option allows the chamber to reach a 29 C 20 F dewpoint This relates to lower relative humidity capabilities When the low RH option is installed and the humidity system is enabled the dry air purge system is operated in conjunction with the frozen coil automatically by the EZT 560 controller based on the air temperature and humidity set points When r
230. on while output Q13 cycles system 1 cascade cooling solenoids on and off to maintain system 2 head pressure Defrost can be manually initiated by turning on the defrost event or it can be automatically started by the EZT based on the defrost settings When in automatic mode the defrost timer will begin counting down whenever the air temperature set point is below the defrost set point Once the timer counts zero defrost is initiated for one cycle Upon completion of the cycle the timer will begin the next timed countdown Status Defrost Off Defrost Delay mins 720 Temperature SP Auto Mode a fo Figure 5 1 Defrost Settings Once defrost is started the air circulator output is turned off The minimum heat and cool outputs are also turned off This prevents any heating or cooling from taking place The defrost solenoid output Q12 will turn on and system 2 will continue operating This supplies hot gas to the coil If defrost is set up for regular operation system 1 compressor will be cycled on and off to provide cooling to system 2 based on the defrost pressure control input 117 If large horsepower defrost is selected the system1 compressor output Q2 will remain on and the cascade cooling output Q13 will be cycled on and off to provide cooling to the cascade for system 2 This process will continue until the defrost temperature switch input 120 is made indicating that the suction temperature of the coil has warm
231. ors and system settings Calibration Menu The Calibration menu provides access to the input monitor calibration offset and analog output calibration Help Menu The help menu provides simple help regarding settings and use of screen parameters 10 CZ EZT 560 User s Manual Cincinnati Sub Zero 1 4 Print Features The EZT 560 interface will print a variety of graphic trend and textual reports It can be connected to a standard USB inkjet printer HP model 6540 6940 6980 via the standard USB host port provided on the chamber No drivers are necessary operation is plug and play Note that the USB port can be used for I Stick data backup and printing by hot swapping at any time during the EZT 560 s operation The EZT 560 will alert the user to any problems during the print operation After a print error printer not connected or bad cable the EZT 560 will return to its normal operation after alerting the user The EZT 560 interface might change colors during printing to prolong ink cartridge life blue backgrounds require more ink than white backgrounds The EZT 560 interface will be locked until the print function is complete and then return to normal operation Important When using the HP 6940 or 6980 DeskJet printers the printers USB cable must be plugged into the EZT 560 interface after the EZT 560 is powered up and in normal operating mode and the printer is powered up and read
232. ory period touch the Setup button in the upper right corner of the trend display The Trend Setup screen will appear with the available adjustment controls Trend Zero Trend Span Time Mins 0 0 0 Select points to plot E Pv E a Figure 2 6 Trend Setup Trend Zero The zero value sets the minimum range of the vertical access for the trend variables Trend Span The span value sets the maximum range of the vertical access for the trend variables Time Mins The time interval is in minutes and adjusts the displayed time period for the trend The allowable range is from 4 to 240 minutes 4 hours Trend Points To adjust what items are shown on the trend select deselect the desired items by touching the check box next to the variable Press the Done or Cancel button to return to the trend screen Any adjustments made when the Cancel button is pressed will be disregarded Each time a trend setup is changed the trend will fill with previous history and then operate in real time mode with the current settings Cincinnati Sub Zero EZT 560 User s Manual 2 3 Alarm Monitor The alarm monitor screen displays any current and or previously silenced alarms according to time and date of occurrence On each new alarm occurrence The EZT 560 s screen background will turn red to notify the user of a new alarm Once the alarm is silenced the screen background will revert to the standard blue background however
233. ot Time Setup 56 EZT 560 User s Manual Cincinnati Sub Zero 7 3 2 2 History Plot Channel Setup Select Hist View Channel Setup from the Datalogging menu The history plot channel setup allows the user to plot up to 8 channels of data simultaneously Any point from the data file can be selected along with the color for each channel to be plotted Select Plot Calc Point fume I Te LoP ChanneiTagname cow TEMPERATURE HUMIDITY PRODUCT Figure 7 6 History Plot Channel Setup Use the drop down boxes to select a channel for the plot and then the color for the channel Press the Add Point button to add the point to the current list of historical plot channels The Clear All button will clear the list of all points so a new group can be added for plotting The Add All button will automatically fill the list with the first 8 channels if available and assign individual colors to each channel 7 3 3 View Averages Report The View Averages Report provides a text report that displays the average value over time for each channel selected in the History Plot Channel Setup screen Averages are calculated for the period of time selected in the History Plot Time Setup screen The report supplies the average value for each channel over time as well as the combined average for all channels selected This is a useful tool with the monitor option because it can be used for analyzing gradients withi
234. oubleshooting Guide Cincinnati Sub Zero 9 13 Non Critical Alarms Access the Non Critical Alarms screen from the Event Alarm Tags menu This screen is used to set the names for the different system status alarms such as service monitors RH H20 RESERVOIR LO RH TMP DISABLE RH HI DEWPOINT LIMIT RH LO DEWPOINT LIMIT DOOR OPEN Press each alarm to change name Press Accept to Save ccept Figure 9 17 Non Critical Alarm Names To change or edit a tag name touch the position for the alarm and change the name using the pop up keypad Note that alarm names are limited to 20 characters in length NOTE Altering the alarm names from those listed on the EZT Configuration sheet provided with the chamber may cause operator confusion when diagnosing alarms Use discretion when altering tag names 87 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 9 14 Maintenance Alarms Access the Maintenance Alarms screen from the Event Alarm Tags menu This screen is used to set the names for the different service monitors of each system component L ops Chamber SYS 1 COMPRESSOR HRS SYS 2 COMPRESSOR HRS HUMIDITY SYSTEM HRS DRY AIR PURGE HRS Press each alarm to change Accept name Press Accept ta Save Figure 9 18 Maintenance Alarm Names To change or edit a tag name touch the position for the alarm and change the name using the pop up keypad Note that alarm names are limited to 20 characters in len
235. ower off for more than 30 minutes High or low pressure safety tripped for system indicated System high or low on charge Condenser fouled dirty Condenser fan not operating air cooled units only Low water pressure flow or high water temperature water cooled units only Automatically resets in 4 hours Can be manually reset on alarm monitor screen Manually reset high pressure safety Low pressure automatically resets Check static pressures sight glass for bubbles Add remove refrigerant Clean condenser Check motor fan for proper operation Replace if necessary Supply water at proper temperature and pressure flow rate 22 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS SYS LOW OIL PSI Oil pressure safety tripped for system indicated System low on oil Manually reset oil pressure safety Check oil charge pentane level Add if necessary SYS HI DISCHARGE TMP Discharge safety tripped for system indicated Liquid injection valve solenoid not operating correctly System low on charge Automatically resets Check adjust expansion valve Check system pressure sight glass for bubbles Add charge if necessary SYS COMP MONITOR Compressor protection module tripped for system indicated Blown fuse Bad contactor Liquid injection valve solenoid not operating correctly Syst
236. perator Supervisor or Administrator Press each field to add the user ID full name and password no spaces allowed If the passwords do not match or the user ID is already used the EZT 560 will alert the user and not accept the entry Add User Users User Rights Security Options UserID MLAMBERT Full Name MARKLAMBERT Password kokok Confirm Password Password Aging Create User Figure 6 1 Security Add User Click on the password aging checkbox if you wish to enable password aging for this user If password aging is enabled and the password has expired a new password must be entered for the user by the system administrator before that user can log into the system again NOTE The system administrator can not use the Password Aging option This will lock the administrator out of the system thereby preventing the system administrator from managing passwords for the system users The EZT 560 will prevent administrators from using this option 6 1 2 User List The Users tab provides the administrator the ability to view information on each user entered into the system Password information is not available The user can be deleted from this tab and the password for each user can also be changed from this area 49 Cincinnati Sub Zero EZT 560 User s Manual Add User Users User Rights Security Options MLAMBERT MARKLAMBER GROSSMORE GILROSSMORE ADMINISTFA Figure 6 2 Security
237. perform control action State of other bits do not affect operation 165 0x00A5 r w PV7 Monitor Alarm Output Assignment 0 No Output Selected 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8 Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 166 0x00A6 r w PV7 Monitor High Alarm Setpoint 167 0x00A7 r w PV7 Monitor Low Alarm Setpoint 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 168 0x00A8 r w PV7 Monitor Alarm Hysteresis 0 32767 0 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 169 Ox00A9 PV8 Monitor Process value 32768 32767 3276 8 3276 7 Note that value must be converted from whole number i e divide by ten to convert the decimal number from the value read 170 0x00AA r w PV8 Monitor Alarm Type Selection Alarm Off Process High Alarm Selected Proc
238. points process variables or percentages of output from the installed control loops These outputs are optional and not included on all chambers CAUTION Some outputs may be provided for specific control functions depending upon the design of your chamber Do not alter these output settings unless you are sure that they are used for monitoring purposes only If you have any questions regarding the use of the output contact Cincinnati Sub Zero s customer service department for assistance The analog outputs can be configured to retransmit signals either in a 0 10V range or a 4 20mA range The minimum and maximum values of the output can be set to correspond to a specific value of the retransmitted source The output will retransmit this source linearly from the minimum to maximum range To configure an output select Output Calibration from the System Maintenance menu Retransmit Output Out Min 0 Out Max Retrans Type Retrans Output Source om Voltage om Current Figure 8 11 Output Calibration To configure an output first select the output number by entering the value in the Retransmit Output field Upon entering the value the outputs current configuration will be loaded and indicated by the LED s next to the selected type and source The minimum and maximum values will be shown in the Out Min and Out Max fields To make changes to the output s configuration place a check in the box next to
239. prevent operators from entering a value that exceeds the survivability limits of a product being tested KE Lower SP Limit Upper SP Limit Figure 5 2 Set Point Limits WARNING The set point limits are factory set for the maximum safe operating range of the chamber These limits are locked out from user adjustment by default at the factory User adjustment of these limits which exceed those limits set by the factory may result in damage to system components and will void the chamber warranty 38 EZT 560 User s Manual Cincinnati Sub Zero 5 3 Event Tagnames The names of the optional customer events can be changed to describe what function you have chosen for them to perform To alter event names select Event Tagnames from the Setup menu SIGNAL LIGHT AUX ALARM PROFILE ALERT PROFILE END ALERT OPERATOR Press each event to change name Press Accept to Save Figure 5 3 Event Tagnames To change the name of the event select the event by touching its current tag name The pop up keypad will appear allowing you to enter a new description Once complete select Done and the new name will appear in the event tag name list box Once all changes have been made press the Accept button to save the changes to memory 39 Cincinnati Sub Zero EZT 560 User s Manual 5 4 Process Alarm Tagnames The names of the optional monitor inputs and alarms can be changed to describe what function you have chos
240. proper security rights Log Menu The Log menu provides access to data log functions and the historical data viewer Help Menu The help menu provides simple help regarding settings and use of screen parameters EZT 560 User s Manual Cincinnati Sub Zero Profile Menu New Profile Insert Step Delete Step Main View Copy Step an ernie Paste Ste 5 Profile Status View __ Paste teP Hold Profile Profile Entry Select Profile Stop Profile Soak Limits Save Profile Stop Profile All OFF Auto Start Profile Save s Advance Next Step Plot Profile Delete Profile Advance Prey Step Show Help Figure 1 4 Profile Menu Navigation Views Menu The Views menu provides navigation back to the main menu and the profile view screens These include profile status profile entry soak limits autostart and plot profile screens Edit Menu The Edit menu provides all of the functions needed to open create edit and save profiles Log Menu The Run menu contains the profile control selections such as run hold and stop Help Menu The help menu provides simple help regarding settings and use of screen parameters Setup Menu Power Recovery Setpoint Limits Event Tagnames Process Alarm Tagnames Alarm Settings Product Control Condenstation Control Defrost Settings PC Comms Web Server Help Main view System Maintenance Show Help Figure 1 5 Setup Menu Navigation Views Menu The Views
241. ptions ciscccisicsccnnecnde dean acttanetccicnadcnvantiadanecaasdavaeadecnnecsadcnvanddnnnnddndies canacesdenvenddecnasadsd 75 9 5 Refrigeration OPUOMS ic caadicees heaianseigedeeceavieeeeedivadeevaveab sii doladegsieees aieaeesiavian ended eae eee 77 9 6 Humidity Options79 9 7 Purga LORE Optom eocena E E esiedde Guaviek ctgheas cieadiarseedtiae Guadeeanets 81 9 8 Auxiliary Cooling Options 20 0 2 ec EAEE EEEE AEAEE 82 9 9 Altitude Options 83 9 10 CSZ Events 84 9 11 Critical Chamber AlaiMS nanana iin RR RAS A RS eS en 85 9 12 Critical Refrigeration Alarm 0 ccc cine ee ttie reer tiieee ee te esse tiene eeetieeeeenieeeestneeeereaa 86 9 13 Non Critical Alarms airina led in SEN halodndiece 87 9 14 Maintenance Alarms minnene a eal dill dd ined ei science 88 9 15 Completing EZT560 Configuration ec cece eeceeee ee etteee ee eene nese tees CaTa 89 Appendix Common Terms and Definitions List of Figures List of Tables Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 1 Overview This guide has been written to aid in the troubleshooting of chamber operational issues and or malfunctions Note that not all options and or features discussed in this guide may be available or applicable to the particular chamber that is being serviced It is highly recommended that you read this material thoroughly prior to performing any chamber service in order to better assist you in locating the section s that apply to the problem at
242. r i e divide by ten to convert the decimal number from the value read 135 0x0087 PV3 Monitor Alarm Type Selection 0 Alarm Off r w 3 Process High Alarm Selected 5 Process Low Alarm Selected 7 Process Both Selected 136 0x0088 PV3 Monitor Alarm Mode Bit1 Off alarm self clears r w Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 103 Cincinnati Sub Zero EZT 560 User s Manual Register Description 137 0x0089 r w PV3 Monitor Alarm Output Assignment 0 No Output Selected 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8 Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 138 0x008A r w PV3 Monitor High Alarm Setpoint 139 0x008B r w PV3 Monitor Low Alarm Setpoint
243. r responds to varying load conditions and what it is capable of doing Once you know how the chamber reacts under certain conditions and why you may be able manipulate certain parameters in order to get the desired response from the chamber One of the main causes for poor process control is that the controller it not properly tuned for to the chamber All of the EZT 560 control loops feature one touch tuning No more tuning parameters to adjust or settings to change The EZT 560 loop controls utilize fuzzy logic to continuously adapt to the process in order to maintain it as close as possible to the set point The EZT 560 only requires base line knowledge on the performance of the chamber and the test load In order for the EZT 560 to obtain this performance knowledge the controller must be tuned using the one touch tune All Cincinnati Sub Zero chambers are factory tuned however the chambers are typically empty no product load Unless specific performance tests were performed at the factory for your particular needs the base line performance may not be as accurate once a product is placed inside the chamber The one touch tune makes it easy to tune the chamber to the product If there is a particular point that the chamber is having difficulties with run that condition and start the tune If the tune is for base line adjustment prior to a test just run the chamber at ambient conditions and press the AT button on the single loop display
244. reaches a predefined state This differs from the guaranteed soak function by being a single shot monitor With the guaranteed soak the process variable is monitored throughout the whole step If the process exceeds the upper or lower deviation the profile will hold until the process returns to within those limits The wait for function when enabled puts the profile in hold and waits for the process to achieve a particular value that you can set for the step Once the process reaches this set point value the profile will resume To enable a wait for in a step press the Wait For button This opens the wait for entry window From this window select the input to wait for and then enter the set point for the wait Once the entries have been made return to the profile entry screen by pressing the Back to Step Data button Wait for loop input TEMPERATURE bi Wait for monitor input Wait for input SP 0 Back To Step Data Figure 4 4 Profile Wait For Input NOTE The set point entry for a wait for is critical for the wait for to operate correctly During the wait the selected process input must cross the set point in order for the profile to resume operation If the selected input does not cross the set point value the profile will remain in hold on the step indefinitely 4 1 4 Set Point Step Time To enter the set point s and time for a step touch the set point time display table at the bottom of the
245. rge System Failures and Corrective Actions 05 36 5 5 Altitude System 37 5 5 1 Common Altitude System Failures and Corrective Actions eceseeeeeteees 37 5 6 Fluid System 38 5 7 Transfer Mechanism ccccccceeececcee cece eeeeeeceeeaeeeeeeeseescaaeaeeeeeeeeecaaeeeeeeeeesecsecausaeeeeeeseeea 39 5 7 1 Common Transfer Mechanism Failures and Corrective Actions 0 cece 39 6 Process Control ProblemS 21 cccccccccccceccseceeeeeeetecaaeaeeeeeeetesecsaeaaeeeeeeeeeseceeaaeeeeeeeseteesensisaseeeeeteees 40 6 1 Why is the Chamber Controlling like That 0 eccceeeeeeeeeeeeeeeeeeeecieeeee senses teases eneeeee 41 6 1 1 Oscillation Around Set Point cececcecceceeeeeeeeeee cece eeeeseceeaaecaeeeeeeeeetennaeaeeeeeetee 43 61 2 SQVEPSMOO eane tae canvas cabbncskuasennaceaahanaicancadancevadacaslelieasexusd E a 44 6 1 3 Set Point Tracking Ramping e cece ee eeeeeeeeeeenaeeeeeeaaeeeeeeaaeeeeeeeaeeeeeenaeeeeeeaas 45 7 Remote PC Communication Problems ccccccceeccececeeeeecnenseceeeeeeeeteseeaaeaeeeseeesessenieaeeeseentesseess 47 7 1 Serial Communications Troubleshooting c ccceeeeceeeeeeeeeeeeeeeeeeeeneeeeeenieeeeeeeeeeereneeeees 48 7 2 GPIB Communications Troubleshooting eeessesesssesseerranrennessennansnnnaneennnanannaaatennannannaaeenaa 49 7 3 Ethernet Communications Troubleshooting cccccecceeeeceeeeeeeeeeeteneeeeeenteeeeeeeneeeeetieeeee 50
246. rm Hysteresis 0 32767 0 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 108 r w 0x006C Loop 5 Setpoint 109 0x006D Loop 5 Process value 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 110 0x006E Loop 5 Percentage of Output 10000 10000 100 00 100 00 100 EZT 560 User s Manual Cincinnati Sub Zero Register Description Use Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 111 Ox006F r w Loop 5 Autotune Status Autotune Off Initiate Autotune Autotune Active Terminate Autotune AN gt O 112 0x0070 r w Loop 5 Upper Setpoint Limit 113 0x0071 r w Loop 5 Lower Setpoint Limit 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 114 0x0072 r w Loop 5 Alarm Type Selection Alarm Off Process High Alarm Selected Process Low Alarm Selected Process Both Selecte
247. rofile array point being written when timer ticks are active f_writeNum is form var that holds the current segment being written when timer ticks are active User error checking for sub should go here Check to see if profile is running before downloading profile see EZT register list for profile status register if EZT is offline mode or downloading a profile do not start profile download from PC and alert user If G_vAry f_EztNum 180 1 Then MsgBox Local EZT 560 is in the offline mode or running downloading a profile amp vbCrLf amp _ Writes from the PC can not be initiated at this time _ vbInformation Exit Sub End If Before download make sure to save the profile name to disk as well as to array registers within profile list EZT manual outlines profile register list Profile name is 5 registers 10 chars total and must be converted from text to integer values 2 chars per register If f_curProfileName Then MsgBoxOver You must load or save a Profile before download to processor vbInformation Download Profile Me hWnd Exit Sub End If following should disable graphic user interface for profile download while profile is being downloaded User dependent code but user should not press download button again during download of profile from PC to EZT controller f_profRegsToWrite 0 set var to zero each time profile download is initiated f_writeNum 0 set var to zero each time profile download
248. rofiles_mm_dd_yyyy hh_mm_ss Alarm files directory AlarmFiles_mm_dd_yyyy hh_mm_ss Audit files directory AuditFiles_mm_dd_yyyy hh_mm_ss Log files directory DataFiles_mm_dd_yyyy hh_mm_ss The reason for using the date and time as part of the directory name is to make sure the user can track the date and time of the file transfer If a user transfers a file type more than once in a single day the files will be grouped logically by time The data files can be opened directly with Microsoft Excel or any program that opens a comma separated file format You can copy or empty the DataFiles directory by simply plugging in the USB l Stick in a PC s USB host port This device then becomes like any removable disk attached to the computer and can be manipulated as once while plugged into the PC The I Stick requires no drivers when using WindowsXP operating system The CSZ Data Viewer program is a free Windows accessory program that allows users to view plot and print data files and is available from CSZ NOTE Alarm and Audit files are also written in a csv format and can be opened directly with excel after the I Stick is inserted into the PC after files are copied from internal compact flash to Stick memory device No additional software is required to view alarm or audit files Once files are deleted from EZT 560 storage devices they are gone and can not be retrieved Once again do not edit move or delete any oth
249. rol loops or monitor inputs at a time It provides a large standard display for control of both temperature and humidity common on most environmental test chambers TEMPERATURE HUMIDITY Figure 2 2 Dual Loop View 2 1 3 All Loops View The all loops view display shows all available control and monitor inputs available on the chamber in a tabular format From this view all setpoints process variables and output percentages can be monitored at a glance Press Tagname column to select SP for edit and field at bottom right to change value Tagname Value Setpoint Our_ TEMPERATURE 85 1 HUMIDITY 95 7 PRODUCT 83 9 No Tagname selected for edit o Figure 2 3 All Loops View The set point entry field is located at the lower right of this screen In order to modify a loop s set point select the loop by touching its tagname field in the table The loop s set point will then be available for edit Touch the edit field in order to enter the new set point Cincinnati Sub Zero EZT 560 User s Manual 2 2 Graphing There are two available graph formats for viewing each loop and monitor input of the EZT 560 These include a process bargraph display and a time trend display Each loop and monitor input has its own bargraph and trend with individual display settings 2 2 1 Loop Bargraphs The bargraph display shows three individual bars representing the set point SP process variable PV and percentage of output
250. rs and or data CRC Read Register s Command 0x03 This command returns from 1 to 60 registers Packet sent to EZT 560 nn 03 mnnn 00 nn_ nnnn read command 0x03 starting register high byte starting register low byte number of registers high byte 0x00 number of registers low byte CRC low byte CRC high byte controller address 1 byte _f f Packet returned from EZT 560 nn 03 nn nn nn nn nn nn nn controller address 1 byte f read command 0x03 number of bytes 1 byte first register data low byte first register data high byte register n data high byte register n data low byte CRC low byte CRC high byte Example Read register 61 chamber temperature of controller at address 1 Sent 01 03 00 3D 00 01 15 C6 Received 01030200 EC B9 C9 Message 236 OxO0EC temperature is 23 6 degrees 80 EZT 560 User s Manual Cincinnati Sub Zero Example Read registers 60 and 61 chamber setpoint and temperature of controller at address 1 Sent 01 03 00 3C 00 02 04 07 Received 01030401 90 01 48 FA 44 Message 400 0x0190 and 328 0x0148 setpoint is 40 0 and temperature is 32 8 degrees Write Register Command 0x06 This command writes a value to a single register Packet sent to EZT 560 nn 06 nnnn_ nnnn nnnn controller address 1 byte J write command 0x06 register high byte register low byte data high byte data low
251. rs with defrost When defrost in on this output will be off to prevent any heating from taking place in order to minimize chamber temperature rise Maximum Heat Enable Q17 This output is used to enable and disable the maximum heating SSR based on the percentage of output set up in the configurator When the loop output exceeds the maximum output on percentage for the on delay period set in the configurator this output will turn on Dehumidify Enable Q30 This output is used to enable and disable the control of the wet coil solenoid from dehumidification output of the 9300 controller In normal humidity mode this output will be on so that the wet coil solenoid can be cycled on and off When operating in frozen coil mode if equipped this output will turn off in order to allow the dehumidification output of the 9300 controller to control the frozen coil solenoid Q36 RH Cool Enable Q31 This output is active on cascade refrigeration systems that operate in single stage mode for humidity This output will turn on in order to allow the cooling output of the 9300 to control the system 1 cooling solenoid Humidity System Q32 This output is used to turn the humidity system on and off with chamber event 2 Maximum Humidify Enable Q33 This output is used to enable and disable the maximum boiler SSR based on the percentage of output set up in the configurator When the loop output exceeds the maximum output on percentage for the on d
252. rtified refrigeration service personnel Refrigeration system system number compressor protection module tripped Check fusing and contactor for proper operation Automatically resets after approximately 30 45 minutes Service and further diagnostics require authorized certified refrigeration service personnel TRANSFER ERROR Transfer fault Check for mechanical obstructions in basket transfer mechanism Verify proper sensor locations and operation for basket positions NOTE An audible signal will sound for all system alarms User can disable audible signal for input alarms if desired All view screen backgrounds will turn red on alarm 118 EZT 560 User s Manual Cincinnati Sub Zero System Status Description Corrective Action RH H2O RESERVOIR LO Optional Humidity water reservoir low Add more water an audible alert is associated with this indicator RH TMP DISABLE Temperature outside allowable humidity operational limits Turn off humidity system or set temperature set point within proper operating range no audible alert is associated with this indicator RH HI DEWPOINT LIMIT EZT 560 is limiting the maximum humidity level based on the maximum allowable dewpoint that the chamber can operate safely without causing potential damage to the structure of the chamber Set temperature and humidity set points to within allowable chamber range no audible alert is associated with this i
253. rting the profile so that the profile s operation can be observed NOTE If the profile was set up with the autostart feature enabled the profile will enter autostart mode Upon reaching the set date or day and time the profile will begin running To stop a profile there are two options These selections are available from the Run menu Stop Profile Stops the running profile but leaves the set points and events at their current values when the profile stops This allows you to stop a profile and continue its operation in manual mode without shutting down the chamber and causing a hiccup in control Stop Profile all off Stops the running profile and turns all events off The set points will remain at their current values when the profile stops however all chamber system stop This allows you to immediately stop a profile and all chamber operations 33 Cincinnati Sub Zero EZT 560 User s Manual 4 5 1 Hold Resume a Profile At any time during the operation of a profile the profile can be manually put into hold This stops the profile timer however the chamber continues operation under the current step settings at the time the profile was put into hold To put a profile into hold select Hold Profile from the Run menu and select Yes to put the profile into hold To resume the profile at the point in which it was put into hold select Run Profile from the Run menu and select Yes to continue
254. s Open History File Opens a history file for review Delete History File Allows the user to delete the currently loaded history file File Utilities Allows the user to copy files to an I Stick from internal storage as well as delete files See section 7 4 for more information NOTE The Delete History File function does not affect the currently running data file only the current history file loaded for review 7 3 2 View History Plot In order to view a historical data file it must first be opened by selecting Open History File form the data logging Edit menu Once the file has been opened the user has the ability to adjust the time period to plot from the file as well as what points are to be plotted pen History File Delete History File File Utilities To plot the file select View History Plot from the Datalogging menu The EZT 560 will open up a trend graph and plot the selected channels When you are done viewing the file press the Done button to return to the main datalogging menu Cursor Name b ggle Button Start 8M1 2005 End 8 25 2005 na Done 100 0 80 0 60 0 40 0 20 0 0 0 ee a eee 08 11 11 59 PM 08418 11 59PM 08 25 11 59 PM Figure 7 3 History Plot The plotted channels will be shown across the top of the graph in their associated colors The history plot provides the drag n zoom feature like the loop trends To zoom in to a particular section touch th
255. s a rcercesnii eeii ERENS ana eaoienetiete ARANAN EAT EEEE 15 Figure 3 14 Touch Calibration Screen sisisi eeii in Sania KA EEANN AEE ERRES 16 Figure 3 15 Setup Menu ACCESS iiercciciadedate cere cdee eaters atin rides EKAT AENEASE AAAA STOAREN SEES 17 Figure 3 16 Chamber Setup Menu ACCESS eesssssesrreseernnnssnneseennansannasetenndanannadeennaanannaaeenaaanannadeeennaaaan 17 Figure 3 1 7 PO Comms Web SeN scrios a E E EKAT EE EEE AEAT ES 17 Figure 3 13 Calibrate Touch ACCESS eccessi enine EEEE ATE A 18 Figure 3 19 Contrast Songes E attcaeeeeaniarveneedeende ens 18 Fguwe4 1 Alarmi MOnitOrsacsciciitccsesantearestevgareiancacueancdeanepiccaarestevaareiancaauyvedeadevy devaaryiancaeuevicieadieaerantes 20 Figure 4 2 System Status MONON wicsccvesicccervaxcesenesancacneadecgansviccdeuvevceaaueyanceaeuyvincdeyvavdugauedaiceeyeatiraeeivancds 26 Figure S 11 Deiros SeOtUINGS s 3 iictaces food cess sdetecivnaesechanseteces NE 30 Figure 6 1 Tune Control RESpOMSC cci cccceiss ceceessaceecesuascectas ceca susaceeee EEEE EEEE EE 40 Figure 6 2 Profile Ramp Response ccccceceeseceeceeeeeeeceeaneeceeeeeeeeseceanaeceeeeesasecanaeceeeeesatennaneeeseress 46 Figure 7 1 User Communication Settings 2 0 00 cccceeeceeeeeeeeneeeeeeeneeeeeenneeeeeeeaeeeeeeieeeeeeieeeeneneeeeeeaees 47 Figure 7 2 Serial Port Mode Settings 0 cccccccescecceeesccecesseceeeceessececeeeseteceesececenensneeeeeenseteceeesdedensnenes 48 Figure 7 2 Serial Port Mode Seung eresie
256. s indicates a loss of communications to the 9300 controller s NOTE When the EZT is in system maintenance mode communications to the 9300 controllers will be halted Communications will resume once the user returns to the normal operating screens 24 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero Steady Slow Flash Irregular Flash Rate If the light flashes approximately once per second at a steady pace it indicates a loss of communications to all 9300 controller s Check the wiring between the Gateway and 9300 controller s to make sure that there are no nicks in wiring shorts or wire crossings Check to make sure that the 9300 controllers have the proper setup and communication addresses corresponding to the 9300 setup sheet provided with the chamber If two or more controllers have the same address this will also cause a communication failure Also verify that the rear connector on each 9300 controller is inserted properly If the rear connector is not fully inserted or is inserted improperly the communications connections may not be making proper contact on the rear connector body and also cause the alarm After verifying all connections and settings with no change the Gateway is most likely at fault and should be replaced If the light flashes a few times at high speed and then a couple flashes on 1 second intervals and then back to a couple of high speed flashes and so on it indicates a loss of communications
257. screen for the process to be tuned The AT button will remain green for the duration of the tune to indicate it is working Once it is complete you are ready to test product PID control when property tuned PID Fuzzy control ___ Temperature Set point Figure 6 1 Tune Control Response As you change product configurations or other loads within the chamber you can re tune to the new configuration All subsequent tests with that configuration will perform optimally It is recommended that only one loop be tuned at a time so that they do not interfere with the tuning process of another loop 40 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero 6 1 Why is the Chamber Controlling like That The first step in understanding the chamber s response to a given set of conditions is to understand how the control system works All controllers whether it be the EZT Watlow F4 JC620 Chromolox 2104 etc all use a form of PID control You don t have to be an expert or have complete in depth working knowledge of how PID loops work but it helps to have an understanding of what it does in order to help diagnose control issues The term PID is an abbreviation for Proportional Integral and Derivative The terms are also sometimes referred to as gain reset and rate These terms refer to mathematical calculations that the controller uses to determine its output Unlike our ability to see what the chamber is doing i
258. sed to turn on the chamber air circulator s in low speed mode When the altitude exceeds the Alt Hi Speed Fan Enable SP in the configurator this output turns off so the high speed fan output Q1 can turn on and control the air circulators High Speed Fans Q1 This output is used to turn on the chamber air circulator s in high speed mode When the altitude exceeds the Alt Hi Speed Fan Enable SP in the configurator this output turns on When the altitude drops below the set point this output turns back off so the low speed fan output QO can turn on and control the air circulators Altitude System Q43 This output is used to enable and disable the altitude system and associated components with chamber event 5 Min Dive Q44 This output is used to enable and disable the 9300 controller output control of the minimum dive solenoid Max Dive Q45 This output is used to enable and disable the 9300 controller output control of the maximum dive solenoid When the loop output exceeds the maximum output on percentage for the on delay period set in the configurator this output will turn on Min Vacuum Q46 This output is used to enable and disable the 9300 controller output control of the minimum vacuum solenoid Max Vacuum Q47 This output is used to enable and disable the 9300 controller output control of the maximum vacuum solenoid When the loop output exceeds the maximum output on percentage for the on delay period s
259. see Section 3 1 1 Check socket for bent missing pins Repair replace HMI 3 Communications Error Error during write to controller Check cable or setup wiring message displayed at startup PLC not loaded with chamber control program Communication wiring between HMI and PLC not properly connected Serial port not set up properly on HMI PLC communication adapter port 2 not seated properly on PLC damaged Verify load proper program to PLC Both PWR and RUN LED s lit on PLC Check wiring connections Correct repair Verify correct serial port 1 mode on HMI see Section 3 1 2 Check connection between adapter and CPU Replace adapter port 2 EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS Comm alm at PLC Check Cable alarm message Communication wiring between HMI and PLC not properly connected Electrical noise in system or remote PC communicating too fast with EZT Check wiring connections Correct repair Check for proper shielding of communication wiring Turn off electrically noisy devices Disconnect remote PC or slow down communication rate from remote PC minimum 500ms scan rate 4 Screen Locked Up Screen does not respond to touch CE operating system locked up Touch screen out of calibration HMI operating temperature exceeded Touch screen failure
260. seeaeeeseeieeeseeneeeseenaes 9 Figure 1 5 Setup Menu Navigation cccceceeeeeeee ee eeeneeeeeeeeneeeeeeneeeeeeeaeeeeeeaeeeseeiaeeeseeneeeseeneeeeseaes 9 Figure 1 6 Logging Menu Navigation cccccececeeeetteeee ee ecieeeeeeneeeeeeieeeeeeneeeeeeneeeeesieeeeenenaeeeeeaes 10 Figure 1 7 System Maintenance Menu Navigation cccceeeeeceeceeeeeteeeeeeeneeeeeeteeeeeeieeeeeseneeeeneaas 10 Figure 1 8 Print Driver Notification ce eeccceeeeteee eee cne ee ee ecne ee ee tees ee taeeeeeeaeeeeeeeaeeeseenaeeeesineeeenaes 11 Fig re 2 1 Single Loop Vio W ssss c cag acces dirs E sated eats eabe dais send cn vssesldeag eae dare daeadanvaeegexe dened eat sands 12 Figure 2 2 Dual LOOP VIGW sec sascadivacccg ccvaeacddtae searadiw E E E EE EAO 13 Figure 2 3 All HOODS ViGW cers srscedivacecdingenece dda E cay eateganvstedadan E lavas vonededan canax uagaedeeeineess 13 Figure 2 4 Loop Barg raph s shez da vaccadevvedoce daa anbed dav E ven shazn dita odes anaxovesedeeeaeerss 14 PIQUE 2 5 LOOP Mond irrena div acves eveenare caus aiuats dau waned acts cuy outages detedadan uanazin ved shazasvoeadsdavnndaavenuteeeeiaades 14 PIQUE 2 6 Tondo eP E E salaccvesnededavaguedeevavers 15 Figure 2r Alarmi MOni oee E E EE 16 Figure 23 Alamo HISTON aeris anaE E E E A E O 17 Figure 2 9 System Status MONON s cccc ccsececavscced cavenedeceseneddcvbesnds cevediaaacayeatsueevesddaceeeatedenbeneecevegnedeneeneess 18 Figure 3 1 Single Set Point Adjust
261. serial port settings power down the EZT Remove the CF card from the back of the HMI and turn the power back on Allow the HMI to boot up to the Windows desktop Insert the CF card in the back of the HMI making sure that it is properly oriented Touch the small gray bar at the bottom of the screen to open up the start menu Press the Start button and select Windows Explorer from the programs menu Figure 3 4 Windows Start Menu Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide Open the StorageCard folder in order to gain access to the CECP utility The utility has an icon that looks like a hammer File Edit View Go Favorites aio x Adress h Po D g Storagecard Alm History Audit Data Files Def We al roy ame EZTSo0 Help Profiles Startup JC a 4 gt Figure 3 5 StorageCard File Access Open the CECP utility and select the Set serial port mode tab COM1 should be set for RS485 COM3 is used for remote PC communications and its mode does not affect the communications between the HMI and PLC System Settings DK Set serial port mode 4 gt Set COM1 mode RS485 Set COM3 mode Figure 3 6 Serial Port Settings Set the serial port mode for COM1 to RS485 using the drop down selection box Select the Save tab and press the Save registry button to save the settings This must be done in order to save the serial port settings to flash me
262. set point whether it be temperature humidity etc is that it is not tuned properly That is generally the case if the product load has been changed but what if it hasn t What if it is at one particular point In cases like that it would make sense to tune the chamber at the problem condition However that may cause the chamber to react sluggishly at other operating conditions which may be undesirable Oscillation is due to the controller s overreaction to the difference between the set point and process variable When a control loop comes into set point control some minor oscillation is expected as the control loop adjusts its output When the oscillations never cease however that is a different story That generally means the controller thinks that the chamber needs a lot of output to make a small change in the process little available heating and cooling capacity for example or the process is more sluggish than the controller thinks large product load which takes a long time to change temperature Many times the only solution is to tune the controller at the worst operating point This will provide you with the best control over your operating range The reason that this occurs is simply due to the varying capacity the chamber has at different operating conditions due to losses through the chamber wall capacity curve of the refrigeration system and other dynamics that are just laws of physics However on certain chambers you ma
263. ss Accept C Change Setpaints after assigning O Open Files each group O Save Files Figure 6 3 Security User Rights 50 EZT 560 User s Manual Cincinnati Sub Zero NOTE You must have at least one user with administrator access and the Access Security right option enabled in order to turn on security There is no back door to the system If the password is lost or forgotten you must contact Cincinnati Sub Zero s Service Department to order a new compact flash card 6 1 4 Security Options The Security Options tab provides the administrator the ability to set the global security options Add User Users User Rights Security Options Enter Number Of Days Before Hw Password Renewal Is Required 1 Re authenticate User During J Process Changes Enable Disable Audit Trail i Enable Disable Security Accept Figure 6 4 Security Options Enter Number Of Days Before Password Renewal Is Required This is a global setting for all users Password aging starts from the day the user is entered into the system Re authenticate User During Process Changes This feature requires that the logged in user must log in again before the process value at the controller will actually be changed Enable Disable Audit Trail This is a global setting that turns the audit trail on or off When the audit trail is turned on all operator actions are written to a daily log Enable Disable Security This is the
264. stem pressure safety input FLUID SYS HIGH PSI off in alarm condition BO2 8 125 Fluid system low flow safety input FLUID SYS LOW FLOW off in alarm condition BO2 6 126 Dehumidification system fault input DEHUM SYSTEM FAULT on in alarm condition BO2 4 127 Combustible monitor safety input COMBUSTIBLE MONITOR on in alarm condition BO2 25 Q10 Rate master control output Used to switch cooling control between system 1 and system 2 on rate master refrigeration systems BO2 23 Q11 System 1solenoid enable output Used to enable disable solenoids for pumpdown mode BO2 21 Q12 Defrost solenoid output Turns on defrost solenoid on systems equipped with defrost BO2 19 Q13 System 1 cascade cooling control output Used to isolate cascade condenser for large horsepower defrost and rate master system 1 cooling BO2 17 Q14 Cooling enable output Disables cooling in defrost BO2 15 Q15 Maximum cooling enable BO2 13 Q16 Heating enable output Disables heat in defrost BO2 11 Q17 Maximum heating enable 123 Cincinnati Sub Zero EZT 560 User s Manual Digital Output Expansion Connector 1 terminal I O ADDR Operation BO3 20 Q30 Dehumidify solenoid enable output BO3 18 Q31 RH cooling solenoid enable output Turns on system 1 cooling solenoid on cascade systems that operate system 1 only in humidity mode BO3 16 Q32 Humidity system enable output Turns on water supply solenoids a
265. t area with fresh air Possible asphyxiation or explosion hazard exists Keep personnel clear Keeps sources of ignition away from chamber DEHUMID SYSTEM FAULT Optional dehumidifier system fault Check manufacturer s manual provided with the chamber for troubleshooting and diagnostic information EMERGENCY STOP Investigate cause of stop Verify conditions are safe Reset emergency stop FLUID SYS TEMP Fluid system high temperature safety tripped Verify fluid level and flow Do not set temperature set point above fluid system design limits FLUID SYS HI PSI Fluid system exceeded operating pressure limits Check for restrictions in fluid system Verify all isolation valves are open Reset high pressure safety FLUID SYS LOW FLOW Fluid flow safety tripped Verify fluid level Check for restrictions in system Check pump operation and service if necessary GATEWAY COMMS FAILURE Check communication wiring between gateway communication module and 9300 loop controls Verify proper addresses on 9300 controllers Verify power to 9300 controllers and optional EAGLE input monitor if equipped Verify 9300 address 117 Cincinnati Sub Zero EZT 560 User s Manual Alarm Description MOTOR OVERLOAD Corrective Action Motor overload tripped or motor drive fault Requires manual reset of motor overload Check drive and motor fusing Check motor for overload condition i e bearing wear bindi
266. t can be attributed to a wiring fault or single component failure that prevents the system from operating It isn t the controller Example The chamber is at 75 F and the set point is 185 F The fans are running but it is not heating up What is wrong Instead of approaching the problem by asking why the controller is not calling for heat ask why are the heaters not on Using the electrical schematic for the chamber locate the power wiring for the heater Is there voltage to the heaters Is the heat output on i e is the solid state relay on to supply power to the heater Is the heater contactor on Is there a blown fuse Start from the heaters and work back This will allow you to find what is not allowing power to pass to the heaters It may even be several components like the contactor and solid state relay which both get power from a common wire that be shorted or open due to a limit device which just needs manually reset Remember the EZT performs the same function on the chamber as any other controller It has heat and cool outputs for controlling temperature based on a set point It has humidify and dehumidify outputs to control humidity based on a set point These outputs control the same heaters compressors and solenoids that any other controller would What it does provide that typical controllers do not is a user friendly touch screen for entering set points and monitoring chamber temperature and humidity It also individual
267. t must exceed the cmp off before the refrigeration system is turned off Hum Min SP Sets the minimum air temperature set point at which the humidity system will operate When the air temperature set point and or air temperature is below this value the humidity system will be automatically turned off and the system status indicator RH TMP DISABLE will be lit Hum Max SP Sets the maximum air temperature set point at which the humidity system will operate When the air temperature set point and or air temperature is above this value the humidity system will be automatically turned off and the system status indicator RH TMP DISABLE will be lit 79 Cincinnati Sub Zero Temp Comp On Off Condensation On Off 80 EZT 560 Chamber Troubleshooting Guide Enables or disables the humidity sensor temperature compensation algorithm in the EZT depending on whether or not a compensated sensor is used NOTE The compensation is for a Vaisala HMM30C sensor only Do not use it for other brands of sensors This should be disabled when using compensated humidity sensors If set incorrectly the EZT will not read the correct humidity in the chamber Enables or disables the condensation control option This feature can reduce the formation of condensation during testing on product within the chamber However it can greatly reduce the performance of the chamber This option is used for special circumstances only EZT 560 Chamber Troubl
268. ta at any given time Some interface converters on the market provide the ability to have full duplex with the EIA 485 bus This is accomplished by using two receivers and transmitters tied in tandem This type of converter will not work with the EZT 560 controller Be sure that the model you purchase is designed for half duplex Another consideration when selecting an interface converter is how the converter handles switching between transmit and receive Typically it is accomplished via a handshake line from the PC or PLC When data flows into the converter from the PC a handshake line is placed high When data flows out of the converter to the PC the handshake line is placed low In this way the handshake line controls the direction of information Another method of achieving this is to use a built in timer The converter switches to transmit when a character is sent to it from the PC After a period of time when the PC has not transmitted the converter switches to a receive mode It is important that you understand how your converter accomplishes this task You are required to wire this feature or make settings on the converter to enable this function The PC will not talk to the controller correctly with out properly setting this Your converter may also require settings through dip switches to set up communications parameters like baud rate data bits start bits stop bits and handshaking The converter may also require a separate power supply
269. temperature through the product control loop and based on the set point for product temperature generates a set point for the air temperature control loop This set point is then automatically fed into the air temperature control loop This allows the air to exceed the desired product temperature and increase the temperature difference between the part and the air This accelerates the transfer of heat between the air and product under test There are two modes of operation for the product control feature deviation and process These modes define how the air temperature set point is calculated Deviation This mode uses the lower and upper set points to generate a set point that is defined relative to the product set point The upper and lower range of the air temperature set point is calculated by adding and or subtracting these values as offsets from the product set point As the product set point changes the window defined by the upper and lower points automatically changes with it Process This mode uses the lower and upper set points as the upper and lower range of the air temperature set point The output of the product control loop is linearized between these two values in order to provide the set point for the air temperature loop 43 Cincinnati Sub Zero EZT 560 User s Manual The deviation mode has the benefit of limiting the maximum and minimum temperature that the air can achieve relative to the desired product set point This
270. th Selected 24 Deviation High Alarm Selected 40 Deviation Low Alarm Selected 56 Deviation Both Selected Nawo 97 Cincinnati Sub Zero EZT 560 User s Manual Register Description Use 79 r w 0x004F Loop 2 Alarm Mode Bit1 Off alarm self clears Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 80 r w 0x0050 Loop 2 Alarm Output Assignment 0 No Output Selected 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output Customer Event 8 Output Customer Event 9 Output Customer Event 10 Output Customer Event 11 Output Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 512 1024 2048 81 r w 0x0051 Loop 2 High Alarm Setpoint 82 r w 0x0052 Loop 2 Low Alarm Setpoint 32768 32767 3276 8 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decim
271. the EZT 560 to a PC or PLC s serial port a null modem cable is required This type of cable is designed to allow two devices to communicate with each other via their serial ports This cable differs from that of a standard cable in the fact that transmit and receive wires are reversed If one is not available a cable can be fashioned rather easily Use a high quality shielded cable and connect the leads as shown below PC PLC Serial Connection EZT 560 Serial Connection Description Pin Pin Description Shield Cover Cover Shield TXD Transmit Data 3 3 TXD Transmit Data RXD Receive Data 2 2 RXD Receive Data Signal Ground 5 5 Signal Ground Connect the cable between the EZT 560 s serial port and the desired serial port on the PC or PLC The serial port settings of the EZT 560 are fixed other than the controller address The PC or PLC s serial port must be set to match the EZT 560 s port settings EIA 485 Connections The EZT 560 s serial communications is configured for EIA 232 by default The Modbus slave can only communicate via one mode or the other 232 or 485 at a given time In order to use the EIA 485 connection you must change the serial communications mode To do this you must first disable the Modbus slave on the PC Comms Web Server screen under the chamber setup menu Enter Slave address for PC communications Enable Disable web server and press Save Settings
272. the EZT will sound the alarm to bring operator attention to the chamber The alarm will sound until acknowledged silence button pressed on system status screen This is a notification alarm only and does not shut down the chamber If the chamber has the humidity option but not the low water reservoir this input must be wired to VCC If not the low water alarm will always be present Jumping this input out prevents the alarm Sys1 Defrost Pressure Switch 117 This input is a control input for defrost if equipped There is no user indication for this input When equipped with defrost this input is wired to a pressure switch on the discharge of system 2 compressor This input is used to control system 1 cooling of system 2 When the input is on system 1 will cool the cascade condenser for system 2 When the input is off the EZT turns off cooling to the cascade by either turning of the cascade cooling solenoids Q13 for large HP defrost or by turning off system 1 compressor for standard defrost 55 Cincinnati Sub Zero Sys1 Defrost Thermostat 120 Door Switch 121 Emergency Stop 122 Fluid Temperature Safety 123 Fluid Pressure Safety 124 Fluid Flow Safety 125 56 EZT 560 Chamber Troubleshooting Guide This input is a control input for defrost if equipped There is no user indication for this input When equipped with defrost this input is wired to a thermostat on the suction line of the cooling c
273. the alarm may still be present The chamber will not restart until all alarms have been silenced and the alarm condition has cleared If the chamber does not restart upon silencing of the alarm verify that all manual reset safeties have been reset and the alarms have been cleared by pressing the Clear button This will remove all alarms from the list If the alarm is still present the alarm will not clear See section 10 Diagnostics for alarm codes and corrective actions sence Clear Alarm Description Dae PUMPDOWN DISABLED 2 9 2006 Figure 2 7 Alarm Monitor Pumpdown Chambers with large horsepower refrigeration systems have an automatic mode of operation called pumpdown The refrigeration system is in this mode whenever it is not running In pumpdown mode the system 1 compressor will automatically turn on and off at preset pressures in order to force the refrigerant into the high side of the system This serves as a means to protect the compressor on start up If pumpdown was not used refrigerant could migrate throughout the system and accumulate typically in the coldest location like the compressor crankcase On start up this refrigerant could enter the compressor as a liquid and cause permanent damage to the compressor In addition a crankcase heater is installed on the compressor and is energized when the compressor is not running This heats the oil in the crankcase of the compressor and boils out any refrigerant
274. the desired type and source for the output Enter the new minimum and maximum values for which the output is to retransmit Once all modifications have been made press the Accept button to save the changes If you do not press the Accept button all changes will be lost if you leave the screen or enter a new analog output number NOTE If you change the analog output type i e change from voltage to current or vice versa power must be cycled to the EZT 560 controller in order for the output to switch modes 69 Cincinnati Sub Zero 70 EZT 560 User s Manual Output Specifications Voltage Output Current Output Output Range 0 10Vdc 4 20mA Load Impedance 2K ohm minimum 300 ohm maximum Applicable Load resistive Total Error 1 of full scale EZT 560 User s Manual Cincinnati Sub Zero 9 Communications This section is targeted towards new users interested in using data communications with CSZ EZT 560 controllers The purpose of this section is to enable users to 1 Understand the basics of data communications via standard definitions interfaces and protocols 2 Setup and use a simple network of one or more EZT 560 controller s In this section numbers in the format 0x00 represent values in hexadecimal Numbers in the format 0 represent values in decimal and finally numbers in the format 00000000 represent values in binary unless otherwise stated 9 1 Definition of Terms Mac
275. the difference between your actual speed and the set point is getting smaller You end up holding your foot at a fixed position anticipating that your speed will match set point but you fall short 41 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide This is when the integral term of your control loop takes action You begin slowly depressing the throttle little by little and look at the response of the car chamber Each small change increases your speed until you eventually reach set point As long as nothing changes you will hold your foot at the same position because you have met set point However what if there is a disturbance you reach a hill live load in chamber is turned off The car begins to slow down temperature drops so you instinctively begin to depress the throttle again to maintain set point Once you reach the top of the hill and start down the other side live load turns back on the car speeds up temperature begins to rise You then have to back off of the throttle to maintain set point Now it is time to exit the freeway At the end of the off ramp is a stop sign Once you see the stop sign you get a set point of zero so you let all the way off of the throttle because it is a big set point change However as you watch the response of the car you see it is slowing and know it will eventually stop but not fast enough The inertia of the car built up heat is keeping it moving If you do not do something you w
276. the profile Upon a power failure you can also resume a profile s operation in this manner from the point that power was lost depending upon the power recovery action that is selected See section 5 1 for more information regarding power recovery options 4 5 2 Advance Previous Next Step The advance step function allows you to skip certain profile steps or repeat them by advancing to the desired step To advance to a previous or next step in the profile the profile must be first put into hold Once the profile is in hold the advance step menu items are enabled under the Run menu By selecting advance previous or advance next the current step will be decremented or incremented by 1 each time When the current step number is on the desired step place the profile back into run and the profile will continue operation from the beginning of the selected step 34 EZT 560 User s Manual Cincinnati Sub Zero 4 6 Profile Status View The profile status view provides all information regarding the operation of the current profile It can be accessed from the main Profiles menu as well as the profile Views menu Description Value PROFILE STATUS OFF START DATE 10 22 05 10 15 ESTIMATE STOP DATE 10 22 05 15 44 CURRENT STEP 3 STEP TIME LEFT 2 22 00 WAIT FOR INPUT NONE WAIT SETPOINT NONE Figure 4 10 Profile Status View 1 Profile Status Displays the current operating mode of the profile i e autostart run hold wait
277. then turn off after a 1 minute delay The output will also turn on whenever the humidity system is enabled This keeps the window clear during high dewpoint conditions in the chamber This output acts as a chamber run verification for the customer to use as a product under test enable As long as the chamber is running i e controlling temperature this output will be on When the chamber is turned off or in a critical alarm condition this output is off This output is used to turn the audible alarm on and off under fault conditions This output is used for rate master refrigeration systems It is used to switch cooling control between the system 1 and system 2 valves When the output is turned on system 1 is being used to provide the cooling to the chamber When the output is off system is being used to provide cooling the chamber like a typical cascade system This output is used to turn on the liquid line and hot gas solenoids on system 1 when the unit is equipped with pumpdown This allows the solenoids to open and close independently of system 1 compressor operation so that the system can be pumped down During normal cooling operation this output will turn on with the system 1 compressor output Q2 When the refrigeration system is no longer required to run this output will turn off to isolate the high side of the system while the compressor continues to run in order to pump down the system This output is used to t
278. ting Guide List of Figures Figure 3 1 Windows Start Menu eccceeeeeeeeeeeeeneee ee etne ee ee eeeeeetaeeeeeeeaaeeeeesaaeeeeeeaeeeseenaeeeeeeeaeeeeeaes 10 Figure 3 2 My Computer File ACCESS 0 eccceecccteeeeeeeteee erent ee een ee ee taeee ee teeeee nines eeeiieeeeeeneeeeeeaa 10 Figure 3 3 Write Error On Boot ccceeccceeee terete entree ee ieee eer nee ee eie ee ee eieee ee teee ee naeeeee tenes aeaaaee aaa 11 Figure 3 4 Windows Start Menu ccccceeeceeeeee tenner ee etne ee erent e eet uuna AEEA taaeeeeesaeeeeeeaeeeseeaeeeeeeniaeeseeaes 11 Figure 3 5 StorageCard File ACCESS eececeeeeteeeee tenets serene ee eeeaeeeeeeaeeeeeeaeeeeeeiaeeeeeeieeeeeeneeeeenaes 12 Figure 3 6 Serial Port Settings 20 0 0 ce te rr ier nr nee ee ee reee erties erties ee nnieeeeenneeeeetaa 12 Figure 3 7 Touch Calibration Screen c cece tree retiree ieee rie ee ee eeee ee teee ee teeeeeniieeeeeetaeeeenaa 13 Figure 3 8 Setup Menu ACCESS c cect etree eee te eee nee eee ee eee ie eter teaser teeeeeneeeeetieeeeesieeeeeenea 14 Figure 3 9 Chamber Setup Menu ACCESS cccceeeceeeeeeeeeneee eerste ee eeeaaeeeeeeaaeeeeeeaaeeeeesaaeeeeesaeeeeseaeeeeas 14 Figure 3210 PC Comms Neb Sere acrais an E E AA 14 Figure 3 11 System Maintenance Setup menu ACCESS 0 cece eeeeeeeeeeeeeeeee tees ee taeeeeetaeeeeeetnaeeeer 15 Figure 3 12 Calibrate TOUCH 03 ccassatenes enian AEE EEEE AEEA 15 Figure 3 13 Touch Screen Setting
279. tion The primary interface CSZ has chosen for the EZT 560 employs serial communication which is the exchange of data in a one bit at a time sequential manner on a single data line or channel Serial contrasts with parallel communication which sends several bits of information simultaneously over multiple lines or channels Not only is serial data communication simpler than parallel it is also less costly Baud Rate The baud unit is named after Jean Maurice Emile Baudot who was an officer in the French Telegraph Service He is credited with devising the first uniform length 5 bit code for characters of the alphabet in the late 19th century What baud really refers to is modulation rate or the number of times per second that a line changes state This is not always the same as bits per second BPS However if you connect two serial devices together using direct cables then baud and BPS are in fact the same Thus if you are running at 9600 BPS then the line is also changing states 9600 times per second Typical baud rates for computers are 300 600 1200 2400 4800 9600 and 19200 baud As the baud rate increases so does the transmission rate of data Thus you get more information in a shorter period of time However the faster the transmission rate the more susceptible it is to error due to the quality of the cable and sources of electrical noise in the environment In order to balance throughput with reliability CSZ has chosen to use
280. to convert the decimal number from the value read or to the proper value for a write Alarm Off Process High Alarm Selected Process Low Alarm Selected Process Both Selected 24 Deviation High Alarm Selected 40 Deviation Low Alarm Selected 56 Deviation Both Selected Nawo 67 r w 0x0043 Loop 1 Alarm Mode Bit1 Off alarm self clears Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 96 EZT 560 User s Manual Cincinnati Sub Zero Register Description Use 68 0x0044 Loop 1 Alarm Output Assignment 0 No Output Selected r w 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8 Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 69 0x0045 Loop 1 High Alarm Setpoint 32768 32767 3276 8 3276 7
281. to replace HUMIDIFY CYCLES If boiler system Inspect electrical connections and heater SSR for loose or frayed wiring Tighten loose connections DEHUMIDIFY CYCLES LOW RH VALVE CYCLES DIVE VALVE CYCLES VACUUM VALVE CYCLES Inspect valve body for corrosion Look for cracks in valve stems Inspect electrical connections on solenoid coil Requires authorized refrigeration service personnel to replace Inspect valve body and fittings for cracks or leaks Verify pressure regulator settings TRANSFER CYCLES Inspect transfer mechanism for wear Adjust slide mechanisms and or lubricate as necessary Inspect cables for fraying and replace if applicable NOTE The elapsed service intervals are set based on CSZ recommended operating conditions for the chamber These intervals may not be suitable to all applications due to varying operating conditions and environmental factors It is recommended that these be used as a guide only and that the end user determine and set up their own maintenance program based on use to insure reliable and long term chamber operation If you have any questions regarding maintenance procedures or would like recommendations for service procedures or programs contact Cincinnati Sub Zero s Service Department 121 Cincinnati Sub Zero EZT 560 User s Manual 10 3 I O Assignments The following table identifies the standard I O assignments for the EZT 560 controller an
282. tomer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8 Output 256 Customer Event 9 Output 512 Customer Event 10 Output 1024 Customer Event 11 Output 2048 Customer Event 12 Output 104 EZT 560 User s Manual Cincinnati Sub Zero Register Description Use 4096 Customer Event 13 Output 8192 Customer Event 14 Output 16384 Customer Event 15 Output 145 0x0091 PV4 Monitor High Alarm Setpoint 32768 32767 3276 8 3276 7 r w Note that value must be converted from to whole number i e 146 0x0092 PV4 Monitor Low Alarm Setpoint divide multiply by ten to convert the decimal number from the r w value read or to the proper value for a write 147 0x0093 PV4 Monitor Alarm Hysteresis 0 32767 0 3276 7 r w Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 148 0x0094 PV5 Monitor Process value 32768 32767 3276 8 3276 7 Note that value must be converted from whole number i e divide by ten to convert the decimal number from the value read 149 0x0095 PV5 Monitor Alarm Type Selection 0 Alarm Off r w 3 Process High Alarm Selected 5 Process Low Alarm Selected 7 Process Both Selected 150 0x0096 PV5 Monitor Alarm Mode Bit1 Off alarm self clears r w Bit1 O
283. ty of the EZT to match the chamber type and available options on the chamber The settings contained in the configurator affect the control of chamber components and systems Altering these values may only be done by CSZ authorized service personnel WARNING Changing certain configurator settings to values other than those listed on the EZT Configuration sheet provided with the chamber can cause damage to the chamber and present hazards to personnel Changes to any configurator settings not specifically called out in this manual may only be done with the consent of an authorized CSZ representative Failure to comply with this WARNING will void the chamber s warranty 69 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 9 1 Accessing the EZT Configurator To access the EZT configurator you must quit the EZT560 application and start the configurator program To do this you must have the proper security access to exit the EZT application All chambers leave the factory with a default user name and password Select Logon under the security menu and enter the default password information User FACTORY Password CONTROL Once you are logged in as Factory you have the ability to exit the EZT560 application To exit the application select System Maintenance from the chamber setup menu Select Exit Application from the system maintenance setup menu Press the Exit Application button to quit the EZT 560 app
284. unattainable point This prolongs system life and reduces wear and tear on humidity system components Thus if you set a set point of 0 you can be confident that the environment within the chamber will remain as dry as possible at any given temperature within the operating range When humidity is limited due to the fact that the minimum dewpoint has been achieved the corresponding System Status Monitor indicator will illuminate to indicate that this condition is present If your chamber is not obtaining the desired humidity level check the status monitor to verify that you are not trying to operate the chamber at a point outside of the chamber s minimum dewpoint capability Maximum Humidity Limitations Certain chambers have limitations on the maximum humidity level that they can operate at a given temperature in order to protect the chamber structure This limit typically applies to modular chambers These chambers are constructed of individual panels that lock together to form the chamber The panels have an inner chamber liner and outer skin with a foam insulation sandwiched between them They are primarily used for large walk in drive in chambers Due to the materials used in the construction of the modular panels the humidity is limited to a maximum 70 C dewpoint which corresponds to a maximum of 95 at 70 C 158 F When humidity is limited due to the fact that the maximum dewpoint has been achieved the corresponding System Status Mon
285. urn on the hot gas defrost solenoid on chambers equipped with defrost This output will turn on during the defrost period supplying hot gas to the cooling coil The system 1 cascade solenoid control output is used on chambers with rate master refrigeration systems It is used to disable refrigerant flow to the cascade when running in single stage mode This output is also used to control cooling of system 2 when in defrost on large horsepower systems This output will cycle on and off with the defrost pressure switch input 117 in order to maintain system 2 s head pressure in the proper range This allows system 1 compressor to run continuously so as not to cycle the compressor on and off EZT 560 Chamber Troubleshooting Guide Cincinnati Sub Zero Minimum Cool Enable Q14 This output is used to enable and disable the cooling output from the 9300 controller typically on chambers with defrost When defrost is on this output will be off to prevent any cooling from taking place in order to defrost the cooling coil Maximum Cool Enable Q15 This output is used to enable and disable the maximum cooling solenoids based on the percentage of output set up in the configurator When the loop output exceeds the maximum output on percentage for the on delay period set in the configurator this output will turn on Minimum Heat Enable Q16 This output is used to enable and disable the heating output from the 9300 controller typically on chambe
286. urrent step Copy Step Copies the current step data Paste Step Pastes previously copied step data to current step Select Profile Opens the file explorer window so that the user can select a profile from the profiles currently stored in memory Save Profile Saves any changes made to the current profile under the existing name If no name exists the user must enter one in order to save the profile Save As Allows the user to save the current profile to a different file name This is useful for making different versions of the same profile that only requires minimal changes Delete Profile Allows the user to delete the current profile 26 EZT 560 User s Manual Cincinnati Sub Zero 4 1 1 Step Events For each step of the profile you must input which events are to be on during the step To enter the step events press the Step Events button This opens the step event entry window From this window select the events that are to be on during the step Once the selections are complete return to the profile entry screen by pressing the Back to Step Data button Back To Step Data Press Update button to update events COMM cHamber OM dumioity COMM aux cooune Figure 4 2 Profile Step Events NOTE This must be done for each step individually Also for the chamber to operate the relevant chamber systems must be turned on via the event entry window Even though a profile may be in operation if the events ar
287. using the PID parameters and make that answer its output All controllers look for a difference between the set point and what the actual value is Based on this difference it adjusts its output Thus if you make a small set point change the output will respond slowly Depending on the capacity of the chamber it will take time for it to respond and raise or lower the actual value in the chamber to set point However if you make a large set point change the controller may respond by increasing its output very quickly which in turns makes the actual value in the chamber change much faster Control Loop Example Let us use driving a car for an example of a control loop and use you as the controller in this case The throttle and brake are your control outputs much like heat and cool in a chamber to control temperature You are sitting at a traffic light at the on ramp to the freeway the red light is a set point of zero and your current speed is zero so you do nothing However when the light turns green you get a set point of 65 MPH At the green light your first response is to put the petal to the metal 100 output because you are at a dead stop This is the proportional term response of your control loop i e foot You have a large difference between your actual speed and your set point speed As you speed up you begin letting off of the throttle to maintain a linear relationship between throttle position and speed from 0 to 65 MPH because
288. vel control float and replace adjust BOILER LOW WATER CHAMBER HI LIMIT COMBUSTIBLE AIR MONITOR DEHUM SYSTEM FAULT Boiler water level low Chamber high limit safety tripped Air flow in chamber below design limits Air temperature set point above design limits Optional air monitor detected hazardous condition Optional dehumidifier system fault Verify water supply to boiler Check low level float operation Limit must be manually reset or power cycled to chamber to reset Verify proper operation of air circulator s Remove blockage or lessen product load to achieve proper airflow Reduce set point Do not attempt to operate above design limits Vent area with fresh air Possible asphyxiation or explosion hazard exists Keep personnel clear Keeps sources of ignition away from chamber Check manufacturer s manual provided with the chamber for troubleshooting and diagnostic information EMERGENCY STOP Chamber emergency stop or remote stop activated Investigate cause of stop Verify conditions are safe Reset emergency stop FLUID SYS TEMP Fluid system high temperature safety tripped Fluid temperature set point above design limits Low fluid level Low flow Limit must be manually reset or power cycled to chamber to reset Reduce set point Do not attempt to operate above design limits Check fluid level in system and add fluid if necessary Verify
289. viation A deviation alarm uses one or two set points that are defined relative to the control set point High and low alarm set points are calculated by adding and or subtracting offset values from the control set point If the set point changes the window defined by the alarm set points automatically changes with it A deviation alarm can be set for high only low only or both high and low NOTE The deviation alarm type is not available for the optional monitor inputs The monitor inputs are not associated to a control set point Alarm Modes Self Clear Latching A latched alarm will remain active after the alarm condition has passed It can only be deactivated by the user An alarm that is not latched self clearing will deactivate automatically when the alarm condition has passed Close Open on Alarm An open on alarm condition means that the event output assigned to the alarm will be energized in a non alarm condition i e fail safe A close on alarm settings means that the output is normally open and will close in an alarm condition Audible On Off When the audible alarm is on an alarm condition will trigger the audible horn on the chamber and it will sound until silenced by the user If the audible alarm is off there will be no audible signal when an alarm condition is present 41 Cincinnati Sub Zero EZT 560 User s Manual Shutdown Continue An alarm set to continue will not affect the operation of the chamber when in alar
290. will remain on at all times and is not cycled on and off System 2 Compressor Q3 This output is used to turn system 2 compressor on and off based on the demand for cooling It turns on after the stager start delay time set in the configurator The timer begins once system 1 output turns on The output turns off when system 1 output turns off During single stage humidity operation the output is also turned off The output will remain off until humidity is turned off The stager start timer will begin again and turn on the output During defrost the output is forced on to maintain system 2 operation in order to provide hot gas for defrosting of the cooling coils Once defrost is complete the output will be controlled by normal cooling requirements Chamber Light s Q4 This output toggles on and off to turn the chamber light s on and off when the light icon on the HMI is pressed 61 Cincinnati Sub Zero Window Door Frame Heater Q5 Product Safety Q6 Audible Alarm Q7 Rate Master Control Q10 System 1 Solenoids Q11 Defrost Solenoid Q12 Cascade Solenoid Control Q13 62 EZT 560 Chamber Troubleshooting Guide This output is used to turn the window heater s on and off based on the air temperature set point set in the configurator When the air temperature drops below the set point the output will turn on after a 1 minute delay Once the air temperature rises above the set point the output will
291. write 0 32767 0 3276 7 Note that value must be converted from to whole number i e divide multiply by ten to convert the decimal number from the value read or to the proper value for a write 101 Cincinnati Sub Zero EZT 560 User s Manual Register Description Use 120 0x0078 k PV1 Monitor Process value 32768 32767 3276 8 3276 7 Note that value must be converted from whole number i e divide by ten to convert the decimal number from the value read 121 0x0079 r w PV1 Monitor Alarm Type Selection Alarm Off Process High Alarm Selected Process Low Alarm Selected Process Both Selected NOWO 122 0x007A r w PV1 Monitor Alarm Mode Bit1 Off alarm self clears Bit1 On alarm latches Bit2 Off close on alarm action of assigned alarm output Bit2 On open on alarm action of assigned alarm output Bit5 Off audible alarm off Bit5 On audible alarm on Bit6 Off chamber continues on alarm Bit6 On chamber shuts down on alarm Parameter is bit oriented only those bits listed perform control action State of other bits do not affect operation 123 0x007B r w PV1 Monitor Alarm Output Assignment 0 No Output Selected 1 Customer Event 1 Output 2 Customer Event 2 Output 4 Customer Event 3 Output 8 Customer Event 4 Output 16 Customer Event 5 Output 32 Customer Event 6 Output 64 Customer Event 7 Output 128 Customer Event 8
292. y one stop bit 8 even 1 2 Negative parameter values must be written in twos complement format Parameters are stored in two byte registers accessed with read and write commands to a relative address 3 Messages are sent in packets that are delimited by a pause at least as long as the time it takes to send 30 bits To determine this time in seconds divide 30 by the baud rate In the case of EZT 560 communications at 9600 baud this calculates to a minimum period of 3ms 4 Values containing decimal points such as process values and setpoints have the decimal point assumed i e the data exchange can only be performed using whole numbers Thus the value must be offset by a factor of 10 in order to exchange the data correctly For example a setpoint of 42 4 degrees must be sent as a value of 424 in order for the EZT 560 to set correctly Likewise a process value read from the EZT 560 with a value of 967 is actually 96 7 degrees Consult the parameter table for the proper format of each value 5 When monitoring a process try to keep the number of read and write commands to a minimum of 500ms between exchanges to a single controller Continuously reading data at a faster rate consumes an excess amount of the controller s processor time and does not provided any additional benefits in process monitoring Handling Communication Errors Reading or writing from to a register that does not exist or is currently disabled will typically respon
293. y available cabling as well as a multi drop connection where more than one EZT 560 can be placed on the line EIA 232 Full Duplex An EIA 232 formerly RS 232C interface uses three wires a single transmit wire a single receive wire and a common line Only two devices can use an EIA 232 interface A 3 to 24 volt signal indicates a 1 and a 3 to 24 volt signal indicates a 0 The EIA 232 signal is referenced to the common line rather than to a separate wire as in EIA 485 Thus an EIA 232 cable is limited to 50 feet due to noise susceptibility EIA 485 Half Duplex An EIA 485 interface uses two wires a T R a T R line A 5 volt signal is interpreted as a 1 a 5 volt signal as a 0 As many as 32 remote devices can be connected to a master on a multi drop network up to 4 000 feet long Wiring Most PCs and some PLCs have a standard EIA 232 port usually referred to as RS 232 In these instances you must use an interface converter to connect to EIA 485 These interface standards are required to have a multi drop system more than one controller on the bus See the list below for some vendors who sell these converters Should your PC or PLC have the appropriate interface just connect using the wiring shown in the Getting Started section For EIA 485 the terminal marked A usually connects to the T R while the B terminal connects to the T R of the EZT 560 controller The standards do not specify the wire size and type
294. y for printing neither device should be in startup mode When the USB cable is connected to the USB port the following dialog will appear on the EZT 560 display each time the printer cable is plugged in Unidentified USB Device _ if Enter the name of the driver for this USB device DriverName O e Figure 1 8 Print Driver Notification Press the X at the top right of the dialog box and the dialog will disappear The printer is now ready for printing text or graphics from the EZT 560 interface This dialog will not appear again unless the printer cable is disconnected and then re inserted into the EZT 560 USB interface connection The print driver in the EZT 560 interface provides standard USB printing using PCL 3 language support Since printer models change so often many manufacturers add features to new models of printers To take advantage of these new features Ethernet connectivity etc each manufacturer supplies driver disks for different Windows OS versions Since the EZT 560 is an embedded device no hard disk or moving parts installation of these drivers is not required The dialog box appears due to the additional functionality the USB printer is transmitting to the EZT 560 interface Pressing the X at the top of the dialog instructs the EZT 560 interface to ignore the advanced printer features and skip the installation of any print drivers that are not applicable to operation with the
295. y have the ability to vary output capacity at certain operating points Chambers equipped with min max outputs split the capacity of the system in half During minimum operation half the cooling capacity will be available to control chamber temperature However during maximum output the full 100 of the capacity will be available The maximum output is turned on when the output percentage of the control loop exceeds the on settings in the configurator Thus you can adjust when the full capacity is available Typically it is set to 100 This would require the control loop to call for 100 cooling The maximum output would operate like a boost and only be active when full cooling was required Problems may arise however when you actually need 75 of the cooling capacity to control a given point If the minimum only gives you 50 and you get all 100 at full output the chamber could oscillate because the control loop is not getting what is required to properly control the chamber It is either too little or too much By lowering the on percentage for maximum cool to 50 for example the full refrigeration system capacity would be available at 50 output thus when the controller calls for 75 it is getting 75 The question is when should it be set for a boost 100 and when should it be set for control That depends on the operating conditions and load in the chamber If the chamber load is greater than half of the system capacity at any point
296. you are operating then you may have to adjust the maximum output percentage Note that it is best to stay on minimum as much as possible because it can be a cacth 22 The more capacity you have the more each increase in output can affect the process If the capacity increase for each step in output is too much you can end up with control oscillations then as well 43 Cincinnati Sub Zero EZT 560 Chamber Troubleshooting Guide 6 1 2 Overshoot Overshoot is a difficult beast to tame and tends to cause the most aggravation and hardships when it comes to product testing The problem arises when we want the chamber to reach set point as quickly as possible yet stop on a dime The important thing to consider is that most good control loops overshoot their set point It is the amount of overshoot and duration that vary To reach set point quickly you must maintain a high output to get there However once you get there the output must drop off quickly so that the chamber can come into set point If there is a lot of thermal mass in the system it may cause the chamber to continue past set point like taking your foot off of the gas petal of your car and it not stopping right away Take a humidity boiler for example It has a large volume of water that must heat up prior to injecting any moisture into the chamber While the boiler is warming up the control output may keep increasing because it sees nothing happening in the chamber All of a sudden the

Download Pdf Manuals

Related Search

Related Contents

取扱説明書  Gasflag Manual - Crowcon Detection Instruments  10-523型 取扱説明書 ガスビルトインコンロ  Bleibatterie-Lader AL 600compact Art.-Nr.: 2 24 22 18  RAEPoint User Guide    ASP user manual  Atlona AT-HD-V44M video switch  Pure Digital EVOKE 1XT User's Manual  VlZtO VX37L HDTV10A User Manual Dear VlZlO Customer  

Copyright © All rights reserved. Failed to retrieve file