EZT-570i Technical Manual 1. Overview This technical manual 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 diagnostic service in order to better assist you in locating the section(s) that apply to your situation.
EZT-570i Technical Manual 2. Where Do I Begin? The EZT-570i is a Distributed Control System (DCS) that uses different hardware layers to perform the various functions needed to operate the chamber. These include the user interface (HMI), the control module (CM) which handles system monitoring and protection, as well as process control (9300 controllers).
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This section is for experienced service personnel only. Changing certain settings from the original factory settings can cause damage to equipment and/or injury to personnel. CSZ is not responsible for damages or losses attributed to unauthorized changes of these settings.
If all of the wiring appears to be in good condition, then the last step is to replace the RS485 communications adapter on the EZT-570i control module. When replacing the communications adapter, make sure to disconnect power prior to removing and replacing the current adapter.
EZT-570i Technical Manual 4. 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.
EZT-570i Technical Manual 4.1 Conditioning System When the main 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/bath output will turn on and enable the heating/cooling logic.
EZT-570i Technical Manual After the stager start delay, system 2’s output (Q4) will turn on and the rate master control output (Q40) will turn off. The cooling output of the 9300 will now be used to control system 2 cooling solenoids.
EZT-570i Technical Manual This process will continue until the defrost temperature switch input (I41) is made indicating that the suction temperature of the coil has warmed up to the defrost temperature setting. 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.
EZT-570i Technical Manual 4.1.5 Conditioning System Failures and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS Chamber air circulator(s) not turning Chamber event not turned on. Turn on chamber event. Conditioning system disabled (altitude Altitude above controllable limit for chambers). temperature. Decrease altitude or turn off altitude system.
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EZT-570i Technical Manual SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS Compressor internal thermal overload Allow compressor to cool. Check tripped. refrigeration system/injection valve operation. Chamber in humidity mode. Check humidity system type. System 2 disabled for single stage humidity operation. Refrigeration system not enabled or Check configurator settings.
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EZT-570i Technical Manual The logic for the system ‘B’ refrigeration system is the same as that shown in the chart above for a standard chamber with a single refrigeration system. The logic is merely duplicated and tied to different outputs for the control of the second system.
EZT-570i Technical Manual 4.2 Humidity System When the humidity system is enabled, the humidity system output (Q32) will turn on. This turns on 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, system 2 compressor (Q4) will then be turned off as long as humidity is on.
EZT-570i Technical Manual 4.2.1 Humidity System Failures and Corrective Actions SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS Humidity system not turning on. Humidity event not turned on. Turn on humidity event. Air temperature outside of humidity Change temperature set point to control range.
EZT-570i Technical Manual 4.3 Auxiliary Cooling System The auxiliary cooling system can be installed as a boost system or a low range control system. When set as a boost, it will assist the refrigeration system in lowering chamber temperatures quickly. As a control, it will take over once the low temperature limit of the refrigeration system is reached and continue cooling the chamber down to an ultimate low of the auxiliary cooling medium (LN2 or CO2).
EZT-570i Technical Manual 4.4 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 chamber and purge events are turned on.
EZT-570i Technical Manual 4.5 Altitude System When the altitude system is enabled, the altitude system output (Q45) will turn on. This turns on the vacuum pump and any isolation valves to seal the chamber. The maximum dive output (Q46) and maximum vacuum output (Q47) are controlled by the configurator settings.
EZT-570i Technical Manual 4.6 Fluid Systems 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.
EZT-570i Technical Manual 4.7 Transfer Mechanism Transfer mechanisms are used on thermal shock 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 drive or one or more air cylinders to move the basket between the different temperature zones.
Figure 5-1 Web Server/Modbus/VNC Communication Settings For more detailed information on communication format, commands and functionality of the 232/485 serial interfaces, see the EZT-570i User Communication Reference Manual. When connecting remote devices to the EZT’s communication ports, make sure that the equipment is properly grounded as required by the manufacturer’s instructions...
EZT-570i Technical Manual 5.1 Serial Communications Troubleshooting The EZT-570i 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 “CECP Serial Mode” screen.
Connection to controllers is accomplished via an RS232 (single) or RS485 (one to many) connection. This allows for up to 20 EZT-570i controlled chambers to be connected to a single PC using RS485. EZ-View requires the use of serial port #1 (COM1) on the computer it is installed on. EZ-View does not allow modifications to the port number.
EZT-570i Technical Manual 5.2 GPIB Communications Troubleshooting 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 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.
EZT operating information via the EZT’s web server. To use either interface, you must use the assigned IP address to access the EZT-570i. To obtain the correct IP address, go to the “Web Server/Modbus/VNC” screen under the chamber setup menu.
EZT-570i Technical Manual 6. User Interface (HMI) Troubleshooting The EZT-570i’s user 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 EZT570i application.
EZT-570i Technical Manual 6.1 HMI Troubleshooting 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. Check/correct polarity of power source.
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EZT-570i Technical Manual SYMPTOM PROBABLE CAUSES CORRECTIVE ACTIONS alarm message. and control module not properly Correct/repair. connected. Electrical noise in system or remote PC Check for proper shielding of communicating too fast with EZT. communication wiring. Turn off electrically noisy devices.
EZT-570i Technical Manual 6.1.1 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.
RS232 serial link. In order for the link to operate properly, the serial port on the HMI must be set for RS232. If the serial port is not set properly, the EZT-570i application will not start and will remain on the splash screen.
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EZT-570i Technical Manual Once the CECP utility window is shown, touch the “Serial” port icon to access the serial port settings. Figure 6-5 CECP 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 control module.
EZT-570i Technical Manual 6.1.3 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.
EZT-570i Technical Manual 6.1.3.2 USB Mouse Calibration Procedure Begin by connecting a mouse to the EZT’s USB port. Using the mouse, you can navigate the screen just like using a desktop PC. Begin by selecting “Chamber Setup” from the main setup menu.
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EZT-570i Technical Manual Figure 6-10 System Maintenance Setup menu Access Press the “Yes” button to proceed to the CECP utility. Figure 6-11 Calibrate Touch Press the “Touch Screen” icon on the CECP settings screen and then press “Calibrate” to start the calibration process.
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EZT-570i Technical Manual 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.
EZT-570i Technical Manual 7. Deciphering EZT Input/Output (I/O) Operation The inputs and outputs of the EZT-570i 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.
EZT-570i Technical Manual 7.1 Standard Input Configuration Dual Refrigeration refers to a refrigeration type selection of “tandem” or “redundant” meaning there are two duplicate refrigeration systems cooling the chamber.
EZT-570i Technical Manual 7.1.1 Input Description of Use Chamber Limit (I0): 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...
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EZT-570i Technical Manual Sys2 Hi/Lo Pressure Safety (I5): 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.
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EZT-570i Technical Manual 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 (Q3) until the input turns off.
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EZT-570i Technical Manual 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).
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EZT-570i Technical Manual monitor screen) and the input is off (requires manual reset of E- Stop button). Fluid Temperature Safety (I44): The fluid system temperature safety input is used to indicate that the fluid temperature limit has been exceeded (LC chambers).
EZT-570i Technical Manual 7.1.1.1 Custom Input Description of Use (DTS, VTS, TSB) Basket Left (I6): 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.
EZT-570i Technical Manual 7.1.1.2 Custom Input Description of Use (Dual Refrigeration) Sys ‘A’ Hi/Lo Pressure Safety (I3): The system ‘A’ hi/lo pressure safety input is used to indicate that the system 1A or system 2A compressor has exceeded its high or low pressure operating range.
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EZT-570i Technical Manual System 1B Pumpdown Switch (I31): This input is a control input for pumpdown (if equipped). There is no user indication for this input. When refrigeration system requires pumpdown, this input is wired to a low pressure switch on the suction line of system 1B compressor.
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EZT-570i Technical Manual Sys ‘B’ Protection Module (I37): The system ‘B’ compressor protection module input is used to indicate that the system 1B or system 2B 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...
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EZT-570i Technical Manual System ‘B’ Boiler Thermostat (I46): The system ‘B’ boiler thermostat input is only used when there are independent system plenums since this usually results in a boiler on each plenum. Thus, this input is used to indicate that the boiler on plenum ‘B’...
EZT-570i Technical Manual 7.2.1 Output Description of Use Audible Alarm (Q0): This output is used to turn the audible alarm on and off under fault conditions. Maximum Cool Enable (Q1): This output is used to enable and disable the maximum cooling solenoids based on the percentage of output set up in the configurator.
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EZT-570i Technical Manual Chamber Light(s) (Q5): This output toggles on and off to turn the chamber light(s) on and off when the light icon on the HMI is pressed. Window Heater (Q6): This output is used to turn the window heater(s) on and off based on the air temperature set point set in the configurator.
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EZT-570i Technical Manual output will be of so that the wet coil solenoid can be cycled on and off. 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 instead of the wet coil solenoid.
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EZT-570i Technical Manual 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 (I40) 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-570i Technical Manual 7.2.1.1 Custom Output Configuration (Altitude) Low Speed Fans (Q2): This output is used 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 (Q44) can turn on and control the air circulators.
EZT-570i Technical Manual 7.2.1.2 Custom Output Configuration (DTS, VTS, TSB) Hot (left) Chamber (Q40): 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 for a TSB.
EZT-570i Technical Manual 7.2.1.3 Custom Output Configuration (Tandem/Redundant Refrigeration) System ‘B’ Heat/Cool Enable (Q40): This output is used to disable the cooling output from the 9300 controller when equipped with hot gas defrost. When defrost is on, this output will be off to prevent any cooling from taking place in order to defrost the cooling coil.
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EZT-570i Technical Manual System 2B Compressor (Q47): This output is used to turn system 2B 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 1B output turns on.
EZT-570i Technical Manual 7.3 Control Module 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 diagnose a wiring or component problem in the system.
Once you are logged in as “Factory”, you have the ability to exit the EZT570i 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-570i application.
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EZT-570i Technical Manual With the power turned off, remove the SD card from the bottom of the HMI. Turn the power back on and allow the HMI to boot up to the Windows CE desktop (blue screen). Insert the SD card back into the slot in the HMI making sure to insert it in the proper orientation.
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EZT-570i Technical Manual Figure 8-4 EZT570i Folder Select “EZT570i Config” from the EZT570i folder to start the configurator program. Figure 8-5 EZT570i Config When the configurator application starts, it will default to the “Number of Loops/Monitors” screen.
EZT-570i Technical Manual 8.2 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 and how many analog inputs and outputs are installed on the EZT.
Sets the name of the loop (what its controlling). This description is used throughout the loop and trend screens as well as input selection screen for data logging in the main EZT-570i runtime application. 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.
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EZT-570i Technical Manual Heat 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. Max Cool%: Sets the loop percentage of output at which the maximum cool output is enabled.
8.4 Chamber Options The “Chamber Options” screen is accessed from the “Chamber” menu. This screen is used to define what type of chamber the EZT-570i is being used on and enables special logic for certain types of chambers. Figure 8-8 Chamber Options...
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EZT-570i Technical Manual The logic turns on output Q44 for the left chamber using event 1 while event 2 becomes the center chamber. Output Q40 becomes the right chamber control output using event 7 with output Q35 being enabled for the max heat output control.
8.5 Refrigeration Options The “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-570i is to control it. Figure 8-9 Refrigeration Options The Advanced button provides access to additional refrigeration system settings used with Rate Master, Tandem, Redundant and Tundra II systems.
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EZT-570i Technical Manual 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 may occur.
Defines the setpoint for chamber air temperature below which the rate master refrigeration system will switch from single stage operation to cascade operation. Note that the actual air temperature setpoint on the EZT-570i must be at or below the “RateMaster Lockout” setpoint for the switchover to occur.
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When enabled, logic in the EZT-570i will be activated and use a 9300 controller to monitor the suction temperature and pressure at the compressor and shut down the system if a floodback condition is detected.
8.6 Humidity Options The “Humidity Options” screen is accessed from the “Chamber” menu. This screen is used to define what type of humidity system the chamber has and how the EZT-570i is to control it. Figure 8-11 Humidity Options You must press the “Set” button to save changes to the humidity system type selection. Be sure to press the “Set”...
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EZT-570i Technical Manual 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”...
EZT-570i Technical Manual 8.7 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.
EZT-570i Technical Manual 8.8 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. Figure 8-13 Aux Cooling Options You must press the “Set” button to save changes to the auxiliary cooling type selection. Be sure to press the “Set”...
EZT-570i Technical Manual 8.9 Configuration Options The “Configuration Options” screen is accessed from the “Chamber” menu. This screen is used to set general values relating to altitude system operation and other options. Figure 8-14 Altitude Options Set the value of each item by touching the respective number field. Enter the correct value using the keypad and press done.
EZT-570i Technical Manual 8.10 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. Figure 8-15 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.
EZT-570i Technical Manual 8.11 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. Figure 8-16 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.
EZT-570i Technical Manual 8.12 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. Figure 8-17 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.
EZT-570i Technical Manual 8.13 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. Figure 8-18 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.
EZT-570i Technical Manual 8.14 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. Figure 8-19 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.
EZT-570i Technical Manual 8.15 Special Settings Tagnames Access the “Special Settings” screen from the “Event/Alarm Tags” menu. This screen is used to set the names for the different “special settings” values in the EZT application. Figure 8-20 Special Settings Names To change or edit a tag name, touch the position for the alarm and change the name using the pop- up keypad.
EZT-570i Technical Manual 8.16 Completing EZT570i 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.
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EZT-570i Technical Manual List of Tables Table 5-1 Common Serial Communication Problems and Corrective Actions ........32 Table 5-2 Common EZ-View Start-up Problems and Corrective Actions ..........33 Table 5-3 Common GPIB Communication Problems and Corrective Actions ........34 Table 5-4 Common Ethernet Communication Problems and Corrective Actions ....... 35 Table 7-1 Chamber Events ........................
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