Tidal Engineering Synergy Nano 2, Synergy Micro 2, Synergy Compact, Synergy Nano 1, Synergy Micro Technical Manual
...
Nano, Micro 2, and Quattro
For One to Four Channel Systems
Tidal Engineering Corporation
2 Emery Ave
Randolph, NJ 07869
support@tidaleng.com
www.tidaleng.com
Document Number TE1813, Revision H: October 18, 2016
Synergy Controller Technical Manual, Revision H
Page 2
Revision History
Rev.
Date
Revision
C
June 16,2005
First Release
D5
June 27, 2006
Added revision page
Updated chapter numbering for sections 8.1.1, 9.7, 11.4
E
October 17, 2006
Updated for Synergy Controller application version 2.0.8.
Revised Synergy Controller Compact Interface Panel Layout figures
F
January 10, 2008
Updated for Synergy Controller application version 2.6.10.
Added bookmark hyperlinks to document
G
October 5, 2015
Updated for Synergy Controller application software version 3.0.7 Build 893.
Replaced CCFT Lamp replacement with LED upgrade procedure.
H
October 18, 2016
Unified Technical Manual Covers Synergy Controller Software and programming for all
Added for Synergy Micro 2 Controller configuration.
Updated Overlay and Web Touch Graphics.
Revised Software Upgrade instructions in section 7.
Added LCD Backlight CCFT Lamp Replacement instructions in section 7.
Updated command set Appendix C to 2.0.8 and added examples.
Add section on Macro capability and Bar Code Scanner application.
Added replacement parts list, Section 20 Appendix C.
General document review and edit.
Corrected error in “Analog Retransmit Connections Table”
Revised Output Mapping tables in section 6.10
Added UUT Module Mechanical Drawing
Added new section for User Programmable Alarm System.
Added 4-20 mA sensor wiring section.
Added Space and Altitude section
Added Altitude section in L Values for Altitude and Space Chamber Configuration.
Added LabVIEW driver section.
Added Deviation Alarm feature.
Added PID tuning guidelines
Added touch screen calibration for Micro unit
Simplified Olympic board schematic
Added Block Diagram
Added High and Low Res Event Screens
Added Input Calibration section
Added Retro Temperature Only Configuration
Add Safety section
Added USB Bar Code reader setup for Micro applications
Added Installation Section
Upgraded figures to show Synergy Micro 2 configuration.
Reorganized into 22 sections including 6 Appendices.
Added new section for e-mail features.
Added new section for network printing features.
Updated Space and Altitude section
Added Alarm feature enhancements.
Added touch screen calibration for Micro 2 unit
Simplified Olympic board schematic
three models: Synergy Micro 2, Synergy Quattro, Synergy Nano
Synergy Controller Technical Manual, Revision H
Page 3
Table of Contents
1.0 INTRODUCTION ........................................................................................................................................ 7
1.1 What’s New ................................................................................................................................................. 8
1.2 Controller Configurations ............................................................................................................................ 9
1.3 Company Information and Assistance ...................................................................................................... 13
2.0 SPECIFICATIONS .................................................................................................................................... 14
2.1 Data Sheet ................................................................................................................................................ 14
2.2 Block Diagrams ......................................................................................................................................... 15
2.1.1 Process Inputs ....................................................................................................................................... 17
2.1.2 Input Calibration and Scaling ................................................................................................................. 17
2.1.3 Channel Calibration ............................................................................................................................... 17
2.1.4 Channel PIDs ......................................................................................................................................... 17
2.1.5 Channel Primitives ................................................................................................................................. 17
2.1.6 Channel Setpoints ................................................................................................................................. 18
2.1.7 User Programmable Alarm System ....................................................................................................... 18
2.1.8 Logging System ..................................................................................................................................... 18
2.1.9 Analog Retransmit Outputs ................................................................................................................... 18
3.0 APPLICATIONS ........................................................................................................................................ 19
3.1 Environmental Test Chambers ................................................................................................................. 19
3.2 Process Ovens ......................................................................................................................................... 19
3.3 Thermal Platforms .................................................................................................................................... 19
3.4 Chillers ...................................................................................................................................................... 19
3.5 Other Equipment ....................................................................................................................................... 19
4.0 EQUIPMENT SAFETY AND CONTROLLER ALARMS ........................................................................... 20
4.1 Standard Alarm Limits .............................................................................................................................. 20
4.2 User Programmable Alarm Limits ............................................................................................................. 20
4.3 Secondary Controller Alarms .................................................................................................................... 20
4.4 Alarm System Testing ............................................................................................................................... 20
4.5 Alarm Notifications .................................................................................................................................... 21
5.0 FRONT PANEL AND CONTROLS ........................................................................................................... 22
5.1 Front Panel Layout ................................................................................................................................... 22
5.2 User Interface ........................................................................................................................................... 23
5.2.1 LCD Screen Touch Screen .................................................................................................................... 24
5.2.2 Function Keys ........................................................................................................................................ 25
5.2.3 Keypads ................................................................................................................................................. 26
5.2.4 Screen Navigation Keys ........................................................................................................................ 27
5.2.5 Navigating to a Screen Folder Path ....................................................................................................... 27
5.3 Screen Overview ........................................................................................................................................ 28
5.3.1 Setup Screen ........................................................................................................................................... 28
5.3.2 Maintenance Screen ................................................................................................................................ 29
5.3.3 Comm Screen .......................................................................................................................................... 30
5.3.4 Program Screen ....................................................................................................................................... 31
5.3.5 Run Screen .............................................................................................................................................. 32
5.3.6 Events Screen ......................................................................................................................................... 33
5.3.7 Graph Screen .......................................................................................................................................... 34
5.3.8 Main Screen ............................................................................................................................................. 35
6.0 SETUP SCREEN ...................................................................................................................................... 37
6.1 Setup Folder Root Menu........................................................................................................................... 37
6.2 Calibration ................................................................................................................................................. 38
6.2.1 Channel Calibration ............................................................................................................................... 38
6.2.2 Altitude Value ......................................................................................................................................... 41
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6.2.3 Guaranteed Soak ................................................................................................................................... 41
6.2.4 Input Calibration ..................................................................................................................................... 41
6.2.5 Virtual Sensors ...................................................................................................................................... 44
6.3 PID Settings .............................................................................................................................................. 47
6.3.1 Heat and Cool ........................................................................................................................................ 47
6.3.2 Cascade Control .................................................................................................................................... 48
6.4 Special Functions ..................................................................................................................................... 50
6.5 Settings List .............................................................................................................................................. 55
6.6 L – Values ................................................................................................................................................. 57
6.7 Logging ..................................................................................................................................................... 60
6.8 Chamber Setup ......................................................................................................................................... 67
6.9 Graph Settings .......................................................................................................................................... 69
6.10 LCD Settings ........................................................................................................................................... 69
6.11 Panel Lock .............................................................................................................................................. 69
6.12 Languages .............................................................................................................................................. 75
6.13 User Programmable Alarm System ........................................................................................................ 75
6.14 Resume Behavior ................................................................................................................................... 90
6.15 Main Screen Setup ................................................................................................................................. 90
6.15.1 Channel Displays ................................................................................................................................. 90
6.15.2 Sensor Displays ................................................................................................................................... 92
6.15.3 Chamber Light ..................................................................................................................................... 93
6.16 Event Screen Setup ................................................................................................................................ 94
7.0 MAINT SCREEN ....................................................................................................................................... 95
7.1 Operator Interface ..................................................................................................................................... 95
7.2 Alarm Functions ........................................................................................................................................ 96
7.3 Channel PIDs .......................................................................................................................................... 101
7.4 About Screen .......................................................................................................................................... 102
7.5 File Utilities ............................................................................................................................................. 102
7.5.1 Software Upgrade Procedures ............................................................................................................ 103
7.5.2 Export Screenshots ............................................................................................................................. 116
7.5.3 Logging ................................................................................................................................................ 116
7.6 Date and Time ........................................................................................................................................ 117
7.7 Restart .................................................................................................................................................... 117
8.0 COMM SCREEN .................................................................................................................................... 118
8.1 Communications Folder .......................................................................................................................... 118
8.2 RS-232 .................................................................................................................................................... 118
8.3 RS-485 .................................................................................................................................................... 119
8.4 IEEE 488 / GPIB ..................................................................................................................................... 119
8.5 Ethernet Network .................................................................................................................................... 119
8.5.1 Ethernet\IP Settings ............................................................................................................................. 120
8.5.2 WebTouch Remote ™ ......................................................................................................................... 120
8.5.3 FTP Server .......................................................................................................................................... 120
8.5.4 TCP/IP Server ...................................................................................................................................... 121
8.5.5 E-Mail ................................................................................................................................................... 121
8.5.5.1 Ethernet Network\E-Mail\Setup ........................................................................................................ 121
8.5.5.2 Ethernet Network\E-Mail\Addresses ................................................................................................. 122
8.5.6 Printer Setup ........................................................................................................................................ 122
9.0 PROG SCREEN ..................................................................................................................................... 126
9.1 Loading a File from Storage Card or USB Hard Disk ............................................................................. 126
9.2 Creating a New Program ........................................................................................................................ 127
9.3 Step Type Descriptions........................................................................................................................... 130
9.4 Synergy Controller Program Sheet ......................................................................................................... 132
9.5 Copying, Editing and Deleting a Step ..................................................................................................... 133
9.6 Saving a Program ................................................................................................................................... 133
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10.0 RUN SCREEN ...................................................................................................................................... 134
10.1 Loading a Program ............................................................................................................................... 134
10.2 Program Control ................................................................................................................................... 134
11.0 EVENTS SCREEN ............................................................................................................................... 136
11.1 Event Outputs ....................................................................................................................................... 136
11.1.1 Event Outputs Setup.......................................................................................................................... 137
11.1.2 Humidity Channel Event Outputs ...................................................................................................... 137
11.1.3 Event Output Board Options .............................................................................................................. 138
11.1.4 Event Output Board Connections ...................................................................................................... 139
11.2 UUT Temperatures ............................................................................................................................... 143
11.3 Digital Outputs ...................................................................................................................................... 143
11.4 Digital Inputs ......................................................................................................................................... 144
11.5 High Resolution Analog Inputs ............................................................................................................. 145
11.6 Low Resolution Analog Inputs .............................................................................................................. 145
12.0 GRAPH SCREEN ................................................................................................................................. 146
12.1 Temperature / Humidity / Air Temperature ........................................................................................... 146
13.0 MAIN SCREEN ..................................................................................................................................... 147
13.1 Steady State Operation ........................................................................................................................ 147
13.1.1 Entering a set point ............................................................................................................................ 147
13.1.2 Turn the chamber On .......................................................................................................................... 148
13.2 Main Screen Setup ............................................................................................................................... 148
13.2.1 Main Screen Graph Setup ................................................................................................................. 148
13.2.2 Chamber Light ................................................................................................................................... 149
13.2.3 Channel Text ..................................................................................................................................... 149
13.2.3 Sensor Displays ................................................................................................................................. 150
14.0 DATA ACQUISITION AND LOGGING ................................................................................................. 151
14.1 Data Logging Setup .............................................................................................................................. 151
14.1.1 “Deliver Test Results” Automatic Test Dat a Delivery .......................................................................... 154
14.1.2 Profile Logging ..................................................................................................................................... 158
14.1.3 Logging Commands ............................................................................................................................. 159
14.2 Logging Applications ............................................................................................................................. 160
14.2.1 Controller Tuning and Troubleshooting ............................................................................................... 160
14.3 Log File Format ...................................................................................................................................... 163
14.4 UUT Thermocouple Data Acquisition Module O ption ........................................................................... 167
14.4.1 Setup Procedure ................................................................................................................................ 169
14.5 Alarm Logging ........................................................................................................................................ 172
15.0 INSTALLATION AND TROUBLESHOOTI NG ...................................................................................... 173
15.1 Installation Check List ........................................................................................................................... 173
15.2 Chamber Configuration Selection ......................................................................................................... 173
15.3 Controller Setup .................................................................................................................................... 173
15.4 Generic Chamber Types ...................................................................................................................... 174
15.4.1 Generic Temperature Only ................................................................................................................ 175
15.4.2 Generic Temperature/Temperature, Dual Thermal Shock ................................................................ 177
15.4.3 Generic Temperature/Humidity ......................................................................................................... 179
15.4.4 Generic Temperature/Humidity Single Stage .................................................................................... 181
15.4.5 Generic Temperature/Pressure, A l titude and Space ......................................................................... 183
15.4.6 Generic Temperature/Humidity/Pressure, Altitude ............................................................................ 190
15.4.7 Generic Temperature/Vibration ......................................................................................................... 192
15.4.8 Retro Temperature Only .................................................................................................................... 194
15.5 Device Primitives and Logic Flow Charts ............................................................................................. 196
15.8 Alarm System Test ............................................................................................................................... 209
15.9 Control System Verification .................................................................................................................. 209
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15.10 Controller Splash Screen .................................................................................................................... 209
16.0 CONTROLLER TUNING AND CALIBRATION..................................................................................... 210
16.1 PID Tuning ............................................................................................................................................ 210
16.2 Cascade (Part) Temperature Control ................................................................................................... 214
16.2.1 Cascade Control Setup ...................................................................................................................... 215
16.2.2 Configuring Cascade Software ........................................................................................................... 216
16.2.3 Using Cascade Mode ........................................................................................................................ 221
16.3 Two-Point Calibration ........................................................................................................................... 224
16.4 End to End Calibration .......................................................................................................................... 225
16.5 Touch Screen Calibration ..................................................................................................................... 226
17.0 APPENDIX A COMMUNICATIONS ................................................................................................... 228
17.1 Frequently Used Commands ................................................................................................................ 228
17.2 Synergy Controller Command Set ........................................................................................................ 229
17.3 Profile Creation and Control Commands .............................................................................................. 272
17.4 Software Applications and Networks .................................................................................................... 275
17.4.1 SimpleComm Communications Software .......................................................................................... 275
17.4.2 Synergy Manager, Chamber Control Soft war e f or Desktop PC ........................................................ 285
17.4.3 Ethernet MAC Address ...................................................................................................................... 293
18.0 APPENDIX B SETTINGS LIST .......................................................................................................... 297
19.0 APPENDIX C DELIVERING RESULTS ............................................................................................. 304
19.1 Network Printing ................................................................................................................................... 304
19.2 E-Mail Delivery ...................................................................................................................................... 305
19.2.1 E-Mail Setup ........................................................................................................................................ 307
19.2.2 E-mail Format ...................................................................................................................................... 310
19.3 FTP Server Export ................................................................................................................................ 311
19.4 USB Flash Drive Export ........................................................................................................................ 313
19.5 Web Touch Remote™ - Synergy Controlle r Web Server ..................................................................... 314
19.6 FTP Server ........................................................................................................................................... 318
19.7 LabVIEW ™ Driver ............................................................................................................................... 319
19.8 SimpleComm Examples ....................................................................................................................... 325
20.0 APPENDIX D BAR CODE SCANNER SETUP .................................................................................. 328
20.1 Synergy Controller Macros ................................................................................................................... 328
20.2 Using a Bar Code Scanner with a Synergy Controller ......................................................................... 328
20.3 Bar Code Scanner Equipment ............................................................................................................... 328
20.4 Bar Code Scanner Installation ............................................................................................................... 329
20.5 Barcode Interface Specifications .......................................................................................................... 332
20.6 Controller Setup .................................................................................................................................... 332
20.7 Testing and Troubleshooting ................................................................................................................ 335
21.0 APPENDIX E APPLICATION NOTE LIST.......................................................................................... 338
22.0 APPENDIX F PART NUMBERS ......................................................................................................... 339
22.1 Controllers ............................................................................................................................................ 339
22.2 Output Board Options ........................................................................................................................... 340
22.3 Software Options .................................................................................................................................. 341
22.4 Accessories .......................................................................................................................................... 341
22.5 Spare Parts ........................................................................................................................................... 343
Synergy Controller Technical Manual, Revision H
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1.0 INTRODUCTION
Welcome to the Synergy Controller line of t ouch screen control systems designed and manufactured by Tidal
Engineering Corporation. Synergy Controllers incorporate the latest innovations in environmental test
chamber and process oven control and are designed to improve eff iciency and simplify test programming
and documentation tasks.
The Synergy Micro 2 Controller employs features t hat maximize the capabilities of your test chamber. It i s
designed to take complete command of the cham ber’s conditioning systems with total programming of
process variables su ch as temperature and humidity versus time.
The Synergy Controller employs communication capabilities for the “Global Factory”, where data is gathered
from around the globe via the Internet; from around the factory floor via Ethernet; and from around the test
lab via IEEE 488, RS-485, and RS-232. In addition, these controll ers feature: E-mail, FTP, HTTP (Web),
PDF plotting, and now Cloud resources.
One of the most powerful features of the Synergy Controller is the WebTouch Remote ™ Web Serv er which
permits control of the equipment from anywhe re i n the world using a standard web browser. To support
global deployment, the Synergy Controller can support multiple languages and employs built-in on-line Help
and Wizard systems.
The Synergy Controller utilizes Microsoft’s advanced Windows™ Embedded Compact operating system.
Windows Embedded Compact is a modular, state-of-the-art, multi-tasking, real-time system. It offers the
latest touch screen technology and incorporates Screen Navigation keys and a friendly and powerful user
interface.
The Synergy Controller supports USB Hard Disks for data logging, program download / upload. File f ormat is
Windows™ compatible, and program, logging a nd calibration files can all be exchanged with the desktop.
File names are also Windows compatible so meaningful names can be used.
Eight Screen Navigation keys provide immediate acc ess to all areas in the system; i.e. the controller is easily
switched between setup, programming, and di agnostic tasks. While entering information on one screen, you
can switch to another screen to view a setting or parameter, and then return to where you left off on the
previous screen. Navigation and control buttons on every screen pe rmi t easy access to chamber functions
and options. Color real-time data graphing displays important trend information and the versatility and the
simplicity built into the new Synergy Controller makes it enjoyable to operate.
The Synergy Controller software was first releas ed i n 2001 and has been steadily improved through a
continuous process. Numerous software version s have been released in an effort to improve the usability,
reliability and features of the controller. This ma nual refers to the features in the newest major upgrade of
the Synergy Controller application, version 3.0.7. Some of the feature s described in this manual were not
available in previous versions. Check the Tidal Engineering website (www.tidaleng.com) for informati on on
the latest version, the newest features, and upgrades.
We welcome feedback on the Synergy Controller and this document and appreciate suggestions for
improvements and new features. Thank y ou for choosing Tidal Engineering’s Synergy Controller.
Synergy Controller Technical Manual, Revision H
Page 8
1.1 What’s New
The latest software version, Version 3.0.7 B ui ld 893x, offers some powerful new features and capabilit i es
including:
• E-mail
o Alarms
o Log Files
o Plots
• Network printing features.
o PDF plots
o Print directly to a network printer.
• User alarms
o Custom alarms for pressure transducers, Basket jam
• Main screen layout features
o Display additional sensor values for user information
o Chamber light switch
o Toggle switch
o Font size options; Large, Medium, Small
o FTP Server
• New Output Primitive Types
o PWM – General purpose time proportioning output (Up to 8)
o ON/OFF – Thermostatic Primitive. (Up to 8)
• Updated Help System
o Spanish Language
o Edited for clarity
• Graph
o Improved graph timing accuracy and resolution
o Additional Graph Scaling features; Time Scale and Vertical Scale
• Events Screen
o New parameter turns off Humidity events and displays 9 total User Events
o Display friendly event names like GN2 Purge or LN2 Enable
• Alarm Screen
o Alarm information enhanced; i.e. Alarm shows source of Digital Input DIN 1
• Improved Cascade Control Algorithm
o Control Boost Heat and Boost Cool explicitly
• Command Set
o 200 new commands
• Logging Feature
o Profile Logging
o Profile log Auto-Removal
o Export file naming
o Warn when full
o Stop logging or Overwrite option when full.
o Added Header to all logs and settings that includes chamber information
o Logging PID Values, constants and variables
• Programming
o Added Pause Step
o Change Setpoint while paused
o Added a “Wait For Tolerance” Parameter for each channel.
o Display Program Name in the Title Bar of all screens
• Standard Alarms
o Added Deviation Alarm Feature
o Added Alarm Delay
o Custom Behavior capability
• Added Chamber Name feature to allow each chamber to be uniquely identified in chamber in logs & e-mails
• Virtual Sensors
o Virtual Pressure
o Wet-Bulb/Dry Bulb
o Virtual Kft sensor for altitude chambers
• Remote Start Stop Feature controlled by assignable Digital Inputs
• Analog Programming for setpoints
• Added Resume Behavior options
• FTP Server
Appendix A, “Deliver Test Results with Synergy Co nt roll er” added to highlight the various ways the controll er
can format and deliver test results.
Synergy Controller Technical Manual, Revision H
Page 9
1.2 Controller Configurations
Type
Synergy Micro 2
Synergy Micro
Synergy Micro V
Synergy V
Synergy Compact
Icon
P/Ns
TE2174-3
TE1704-3
TE1704-5
TE1364
TE1530, TE1666
Processor
ARM
ARM
ARM
x86
x86
Floppy Drive
No
No
No
Yes
Yes
OS
5.0.E1
5.0
5.0
2.11 and 4.2
2.11 and 4.2
Synergy Micro 2
P/N TE2174-3
Processor ARM
Floppy Drive: No
OS: P/N TE2144
Synergy Micro
P/N TE1704-3
Processor ARM
Floppy Drive: No
This technical manual supports the Synergy Micro 2 and the legacy Synergy Micro and Synergy Micro V
configurations. In many cases the features of t hese configurations are identical.
The Synergy V and Synergy Compact configurations are supported by the prior technical manual (Rev F).
The unique features of each configuration are listed in the table below along with an icon for each. Features
that aren’t supported by all five configurations are identif ied in t hi s doc um ent with the appropriate icons.
The following table shows each of the above co nfigurations with the corresponding image.
Synergy Controller Technical Manual, Revision H
Page 10
Synergy Compact
P/N TE1666, TE1530
Processor: X86
Floppy Drive: Yes
OS: P/N TE1360
Synergy V
P/N TE1364
Processor: x86
Floppy Drive: Yes
OS: P/N TE1360
Synergy Micro 2 V
P/N TE2174-5
Processor Arm
Floppy Drive: No
OS: P/N TE2144
The Synergy V and Synergy Compact configurations below are supported by prior technical manuals; Rev F.
Synergy Controller Technical Manual, Revision H
Page 11
In addition to the full-sized Synergy Mic ro and Micro 2 Controllers, Tidal Engineering offers the more
Type
Synergy Nano 1
Synergy Nano 2
Synergy Nano 3
Synergy Nano +
Icon
P/Ns
TE1858-1
TE1858-2
TE1858-3
TE1858-4
Processor
ARM
ARM
ARM
ARM
Main Outputs
(6) Open Collector
(6) ElectroMechanical Relays
(6) SSRs
Solid State Relays
Expanded
Olympic Board
Aux Outputs
(6) Open Collector
(6) Open Collector
(6) Open Collector
Expanded
Olympic Board
Event Outputs
(6) Open Collector
(6) Open Collector
(6) Open Collector
Expanded
Olympic Board
Ethernet
10/100 BaseT
10/100 BaseT
10/100 BaseT
10/100 BaseT
OS
5.0
5.0
5.0
5.0
Synergy Quattro
P/N TE1961-3
Processor: ARM
Floppy Drive: No
OS: P/N TE2162
economical Synergy Quattro and the compact ¼ DIN Synergy Nano.
The Synergy Nano is available in four different conf i gurat i ons.
Synergy Controller Technical Manual, Revision H
Page 12
Chamber Type Applications
The Synergy Controller supports many different test chamber types including one, two, three and four
channel systems. These standard configurations are as follows:
♦ Generic Temperature Only
♦ Generic Temperature/Temperature (Thermal Shock Chambers)
♦ Generic Temperature/Humidity
♦ Generic Temperature/Humidity Single Stage
♦ Generic Temperature/Pressure (Altitude and Space Chambers)
♦ Generic Temperature/Humidity/Pressure
♦ Generic Temperature/Humidity/Vibration (HALT/HASS Chambers)
♦ Generic Temperature/Vibration (HALT/HASS Chambers)
♦ Generic Pressure (Altitude and Space Chambers)
♦ Retro Temperature Only
See section 6.10
for the specifics of each application.
Contact Tidal Engineering for custom configurat ions.
Synergy Controller Technical Manual, Revision H
Page 13
1.3 Company Information and Assistance
Tidal Engineering Corporation
Tel: 973-328-1173
Web Site: www.tidaleng.com
Congratulations on purchasing the Synergy Cont roll er designed and manufactured by Tidal Engineering.
Headquartered in Randolph, New Jersey, Tidal Engineering designs and manufactures embedded hardwa re
and software for test & measurement and data acquisition products. Tidal also provides engineering
services, custom electronic product devel opment and provide turnkey distributed data acquisition and control
systems.
2 Emery Ave
Randolph, NJ 07869
Fax: 973-328-2302
Email: support@tidaleng.com
Please have the application version of your Syner gy Contr olle r available when conta cting u s.
Parts Replacement
The Synergy controller has been designed and m anufactured to provide years of reliable service. In the
event a system should fail, only OEM approved parts should be used as replacements. A list of replacement
parts appears at the end of this manual. Please contact the Tidal Engineering for component replacement ,
or repair.
Notice to Users
TIDAL ENGINEERING PRODUCT S ARE NOT AUTHORIZED FOR USE AS CRITICAL
COMPONENTS IN LIFE-SUPPORT DEVICES OR SYSTEMS UNLESS A SPECIFIC WRITTEN
AGREEMENT REGARDING SUCH USE IS OBTAINED FROM TIDAL ENGINEERING PRIOR
TO USE.
Life-support devices or systems are devices or syste m s intended for surgical implantation into
the body or to sustain life, and whose failure to perform, when properly used in accordance with
instructions for use provided in the labeling and use r’s manual, can be reasonably expected to
result in significant injury.
No complex software or hardware system is perfect. B ugs are always present in a system of any
size. In order to prevent danger to life or property, it is t he res ponsibility of the system designer
to incorporate redundant protective mechani sms appropriate to the risk involved.
All Tidal Engineering products are 100 percent functi onall y tested. Additional testing may include visual
inspections. Specifications are based on characterization of tested sample units rather than testi ng over
temperature and voltage of each unit. Additional te st i ng or burn-in of a system is available by special order.
Tidal Engineering reserves the right to make change s and improvements to its products without providing
notice.
TIDAL ENGINEERING IS A REGISTERED TRADEMARK OF TIDAL ENGINEERING CORPORATION
Synergy Controller Technical Manual, Revision H
Page 14
2.0 SPECIFICATIONS
2.1 Data Sheet
Synergy Controller Technical Manual, Revision H
Page 15
2.2 Block Diagrams
The Synergy Controller is a flexible multi-channel control system designed to handle virtually all t em perature
control applications. The block diagram in the following section identifies the major systems of the controller
and their relationships. Two small block diagrams in the two secti ons following the main block diagram
identify each block diagram section and provide a des cript i on of each.
Synergy Controller Technical Manual, Revision H
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Synergy Controller Block Diagram
(2) RTD
Inputs
(4) High Res.
Analog
(8) Low Res.
Analog
(64) UUT
Inputs
Channel 1
Channel 2
Channel 3
Channel 4
Channel 1
(30) Digital
(2) Alarm
(2) Analog
Channel 2
Channel 3
Channel 4
Channel
Primitives
User Alarm 1
User Alarm 2
User Alarm n
Logging Database
Channel
Primitives
Channel
Primitives
Channel
Primitives
Channel
Primitives
Set Points
Input
User Alarm System
Primitives
Retransmit
Touch Screen
Profile
Remote
Calibration
and Scaling
Calibration
Calibration
Calibration
Calibration
PIDs
PIDs
PIDs
PIDs
Outputs
Relay
Outputs
Synergy Controller Technical Manual, Revision H
Control
Selectable Log Interval, Log File Size, Etc.
Outputs
Page 17
Inputs
Channels
Application
RTD channels
2
Temperature Measurements
High Resolution
0-5VDC channels, 16-Bit
4
Humidity, temperature and other process
variables. 0.0001 Volt resolution
Low Resolution
0-5VDC channels, 10-Bit
8
For refrigeration pressure and process variables.
0.005 Volt resolution
UUT Temperature Inputs
T-Type Thermocouples
16 per Module
64 max
Temperature Measurements
2.1.1
Inputs
2.1.2
Scaling
2.1.3
Calibration
2.1.4
PIDs
2.1.5
Primitives
Process
Input Cal.and
Channel
2.1.1 Process Inputs
The Synergy Controller has multiple inputs. (See detail above) These are listed in the table below.
Channel
Channel
Note: All of these inputs can be logged and checke d using the user programmable alarm system.
2.1.2 Input Calibration and Scaling
Each Input can be calibrated for the physical measurement, Ohms, Volts or Degrees C.
Each Input can also be scaled to appropriate engi neering units. (See the Calibration section
2.1.3 Channel Calibration
Each Channel is assigned an input. In addition, channel data can be scaled and offset to accommodate
Channel errors caused by sensor position, t hermal gradients, etc.
2.1.4 Channel PIDs
Each Channel has a set of PID constants and variables. Each channel implements a PID control algorit hm
that determines its Heat and Cool outputs. The PI D variables can be logged for documentation and tuning
purposes.
2.1.5 Channel Primitives
The channel primitives are the algorithms that cont rol each output device such as fans, compressors,
heaters, etc. The Synergy Controller supports mult iple instances of the same primitive. For example in the
thermal shock application there are two hot chambers and one cold chamber and thus uses two Heat output
primitives. Each primitive output is displayed in t he E vents/Digital Outputs folder.
Synergy Controller Technical Manual, Revision H
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2.1.6
Channel
2.1.8
2.1.7
Alarm System
2.1.9
Retransmit
Logging
User Program.
Analog
2.1.6 Channel Setpoints
Each channel has a setpoint. The setpoint can be a s teady-state value, a profile generated setpoint or a
remote setpoint from a computer or PLC.
2.1.7 User Programmable Alarm System
A user programmable alarm can be specified for one or more alarms using any input or channel value.
These alarms can be used for various purposes includi ng chamber protection, unit-under-test protection, or
chamber control. See the user programmable alarm Section 6.14
for details.
2.1.8 Logging System
The logging system is used to capture test results and chamber performance data as well as alarm
conditions. The logging system can acquire data from any controller input, channel or PID output. See the
logging section 6.11
of the manual for detailed setup instructions.
2.1.9 Analog Retransmit Outputs
The Analog Retransmit Outputs can be used to retransmit process or control variables as a proportional
voltage to chart recorders or proportional control valves. There are two retransmit outputs. See Analog
Retransmits in the Special Function Section 6.4
for more details,
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3.0 APPLICATIONS
The Synergy Controller support s a variety of systems including environmental test chambers, process
ovens, thermal platforms, and chillers.
3.1 Environmental Test Chambers
The Synergy Controller series can handle a variety of standard and special environmental test chambers
including:
• Multiple Communications options
• WebTouch Remote ™ for r em ote control with any browser
• Cascade control loops
• Data logging and printi ng.
• Bar code reader featu res for error proof setup.
• Temperature Humidity Cha mber s
• Temperature Humidit y Altitude Chambers
• Thermal Vacuum Oven s
• Thermal Vacuum Chambers (Space Simulation)
• HALT/HASS Chambers
• HAST Chambers
• Thermal Shock, 2 Zone and 3 Zone
3.2 Process Ovens
Cascade control loops, data logging and printing, and bar code reader features provide a lot of value in
process oven applications in manufacturing operations.
• Data logging and printi ng.
• E-mail alarms and chart data delivery
• Bar code reader featu res for error proof setup.
3.3 Thermal Platforms
Thermal platforms are used in testing applications where thermal conduction is the most efficient way to
control the test temperature of the Unit-Under-Test (UUT). These are popular in RF component testing
application as well as transducer applications. Controller features that add value in these applicati ons are:
• Cascade control loops
• Multi-Channel capability for dual platform applications
• Data logging and printing.
• Bar code reader featu res for error proof setup.
3.4 Chillers
The remote control and remote sensing features of t he S ynergy Controller are beneficial in chiller
applications.
• Multiple Communic ations options; Ethernet and RS-232
• WebTouch Remote ™ for remote co ntrol with any browser
• Cascade control loops
• Data logging and printi ng.
• Bar code reader featu res for error proof setup.
3.5 Other Equipment
Plant growth chambers, Wind Tunnels, and food processing.
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4.0 EQUIPMENT SAFETY AND CONTROLLER ALARMS
No complex software or hardware system is perfect. Defects are always present in a
software
responsibility of the system designer to incorporate redunda
appropriate to the risk involved.
Make sure you completely understand the operation and function of the chamber and the
Synergy Controller before you begin
Dangerous voltages are present in this eq
and tag circuit out before servicing or replacing components.
Do not use the Synergy Controller in any manner not specified in this manual. Improper use
may impair the safety features employed and
warranty. Failure to follow the proper operating procedures listed throughout any of the
information provided could cause damage to your equipment, personal injury or death.
system of any size. In order to prevent danger to life or property, it is the
nt protective mechanisms
The Synergy Controller offers multiple built-in alarms to protect the equipment (test chamber, process oven,
thermal platform etc.) and the unit-under-test from conditions outside their ratings. The al arms should be
carefully set to appropriate limits based on the capabilities of the equipment and the safe limits of product
exposure. In addition to these built-in alarms, a secondary controller should always be employed to offer
further protection in the case of sensor or controller failure.
using your test chamber.
uipment. Disconnect electrical service of source
may void your test chamber and controller
4.1 Standard Alarm Limits
The Synergy Controller features standard high and low absolute limits and high and low deviations limits for
each channel. Look for the alarms in the setup folder for each channel in section 6.2
SETUP/Calibration/Channel 1, 2, etc.
under
4.2 User Programmable Alarm Limits
In addition to the standard alarm limits, the Programmable User Alarm System can provide additional
protection against open or failed sensors and pro cess variable outside expected limits. User alarms can be
created using redundant sensors for any channel and provide shut down protection to reduce the probability
of machinery failure. See section 6.14
.
4.3 Secondary Controller Alarms
Redundant protective mechanisms such as a TempGard limit controller should be used to provide complete
protection against controller and/or sensor failure. When used with a separate sensor, secondary alarm
controllers reduce the probability that a singl e poi nt failure will cause damage to the chamber or to the
product inside. The secondary controller should be wired to remove power from all of the chamber’s
machinery in order to provide maximum protection.
4.4 Alarm System Testing
It is important that users periodically verify all alarm systems by test. As a minimum, it is important to confirm
that chamber shut down occurs and power is removed from heaters, compressor, etc. when standard alarm
limits, user programmable alarm limits and secondary controller li mits are reached.
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4.5 Alarm Notifications
Channel Alarm Notification
♦ When any channel alarm limit or deviation
limit is exceeded the Synergy Controller’s
conditioning outputs shut down and the
following indications are present:
♦ “ALARM” flashes in the upper right
corner of the touch screen.
♦ Alarm status is displayed in the lower left
hand corner of the touch screen.
♦ Alarms are listed in the Alarm folder in the
Maintenance Screen.
♦ Alarms are logged in the History File (Log
File).
See the Maintenance Screen Section
this manual for additional information
of
See Section 19.2 E-Mail Delivery to learn how the Synergy Controller can generate text messages and
alarm notification e-mails.
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5.0 FRONT PANEL AND CONTROLS
Comm. Activity
RS-485
Power On LED
Ethernet
Link LED
Ethernet
Activity LED
USB port for
Reset
LCD
Touchscreen
Function Keys
Screen Selection Keys
5.1 Front Panel Layout
The Synergy Controller features a color touch screen, a number of software keys and a front accessable
USB Host port..
The principal components of the Synergy Controller Interface P anel are identified in the layout below.
Synergy Controller– Front View
GPIB
RS-232
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5.2 User Interface
Calibration
Machine
RS - 232
Screen
Screen
Event
Graph
Screen
Temps.
Special
Channel
IEEE - 488
Digital
L - Values
About
Ethernet
Inputs
LCD
File Utilities
Web Server
Hi Res
Chamber
Setup
Date &
Time
TCP / IP
Server
Lo Res
Inputs
Logging
Macro
Panel Lock
Select Keys:
Turn Chamber
ON or OFF
Help Key: context
sensitive help.
BMP Key: take
screen shots.
Help with
entering data
and selecting
from lists &
groups
SCREEN NAVIGATION KEYS
SETUP MAINT COMM PROGRAM RUN EVENTS GRAPH MAIN
The Following Folders and Screen Editors Will Appear When Pressed
Screen
Large
Graphic
Display
Editor
Manual
Mode
Operating
Screen
w/ Small
Graphic
Display
PID
Settings
Functions
Settings
Languages
Inputs
Alarms
PIDs
Utilities
RS - 485
Editor
Create, edit,
or load
profile
Editor
Run Profile
Outputs
UUT
Outputs
Digital
Inputs
Note: Green cells highlight new folders in this Synergy Controll er software release.
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5.2.1 LCD Screen Touch Screen
Screen Title
System /
Program
Actual Values of both
Chamber Channels
Scroll Bar
Alarm Descriptions
Will Appear Here
“Alarm” Indicator Will Appear Here
Synergy Controller incorporates a 320 x 240 color LCD with a touch screen Windows graphical user
interface. The screen shot shown below identifies the common elements of the Synergy Controller display.
The title bar at the top and the status bar at the bottom of the window are found on most screens.
from Main
Folder /
Directory
Keypad Screen Example:
The screenshot below shows a typical keypad for numerical data entry.
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5.2.2 Function Keys
Help Key:
Screen Capture Key:
ON / OFF Keys:
Select Keys:
Press the Help key and then press a location on
the touch screen, a small Help window like the one
shown will appear with information to assist you.
Press OK to close the Help screen.
Press this key to capture a bitmap image of the
current screen and store it to a USB Hard Disk.
After pressing the key the window at the left will
appear. The picture will be saved in memory. To
export the bitmap to your storage media go to the
Maintenance screen and press the Export Screen
shots button.
Press OK to close the Capture screen.
These keys are used to turn the chamber On and Off.
The six keys to the right of the LCD are used to enter data and select from lists
and groups. The arrow keys move or scroll from item to it em. The Enter key
selects and enters data.
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5.2.3 Keypads
The number keypad at left is a
Synergy Controller User-Interface uses Numeric and Alpha-Numeric keypad for data entry. The screenshots
below provide a few examples.
Numeric Keypad Example:
typical keypad used to enter a
controller parameter.
Parameter Name
Valid Range
Present parameter value
New paramter value
Clear, Cancel, can Accept keys
Numeric Values
Alpha Numeric and Symbol Keypad Example
The Alpha Numeric keypad is based on the T-9 pad u sed on a cellphone. Use the mode radio-buttons as
shown below to select the way to sequence thru the key s. Use the Symbols selection to open the keypad on
the below right to enter the symbols used for example in e-mail addresses.
Use the Next -> button to accept a character value and enter another value on the same key.
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5.2.4 Screen Navigation Keys
Folder Path
Screen Name
The eight keys below the LCD are the Screen Navigation Keys (Soft keys). These are labeled: SETUP,
MAINT, COMM, PROGRAM, RUN, EVENTS, GRAPH, and MAIN. These keys provide easy navigation to the
controller’s setup, operating and programming features.
All the Synergy Controller screens retain their state so when you navigate away from a screen and return,
the folder remains in the state that it as in. For example, you can navigate to the MAIN screen while entering
a parameter in the SETUP screen and when you navi gat e back, the SETUP screen will be as you left it.
5.2.5 Navigating to a Screen Folder Path
Navigating to a specific controller parameter f rom a screenshot in the technical manual is straightforward
using the Screen name in the title bar and Screen Folder Path at the top of the screen. See the example
shown below for the Screen Folder Path: \SETUP\Logging\Profiles\Options.
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SETUP Screen
5.3 Screen Overview
This section provides a single page overview of the control ler’s eight screen navigation buttons and screens.
For in-depth information on each screen, go to the corres ponding manual section. Screen Navigation Keys:
5.3.1 Setup Screen
The Setup screen is used at various times by OE M s and technicians, administrators, and engineers.
The OEM and Chamber Technician will utilize a variety of Setup screens during the initial installation and
calibration including: PID Settings, Calibration, Logging, Special Functions, L-Values, Chamber Setup,
Resume Behavior, User Alarms, Main S creen Setup, and Event Screen.
The Administrator can use the Panel Lock and Languages screens to control access to the chamber and
setup the controller language.
The Engineer/Operator can use the Logging scre en to select the logger data, logging interval, and automatic
results delivery features. The L-Values are used to optimize the controller for a wide range of test conditions.
Provides access to 14 Setup folders.
♦ Calibration
♦ PID Settings
♦ Special Functions
♦ Logging
♦ L - Values
♦ Chamber Setup
♦ Graph Settings
♦ LCD Settings
♦ Panel Lock
♦ Languages
♦ User (Programmable) Alarms
♦ Resume Behavior
♦ Main Screen Setup
♦ Event Screen
Details are in Section 6.0 Setup Screen.
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5.3.2 Maintenance Screen
MAINTENANCE Screen
The Maintenance screen is generally used at by OEMs and technicians during setup and tuning and by
engineers and operators during operation.
The OEM and Chamber Technician will utilize the following Maintenance screens during the initial installation
and calibration: Channel PIDs, File Utilities, Data and Time, and Re start Screens.
The Administrator will typically use the File Utilities to Backup and Restore the controller settings and set the
Data and Time using that folder.
The Engineer/Operator will typically use the Alarm screen manage chamber alarms and the Channel PIDs to
monitor chamber performance...
These folders contain utilities that are used for
the operation and maintenance of the chamber.
♦ Alarms
♦ Channel PIDs
♦ About (Synergy Controller)
♦ File Utilities
♦ Date and Time
♦ Restart Controller
Details are in Section 7.0 Maintenance
.
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5.3.3 Comm Screen
COMMUNICATIONS Screen
The Communication screen is used at various times by OEMs and techni cians, administrators, and
engineers.
The four folders in the Communication Screen are u sed t o setup the controller’s communications ports. The
RS-232 folder is read-only and displays the fixed parameters for the RS-232. The RS-485 port is used to
setup the connection to the UUT Thermocouple mod ules.
The IEEE 488 folder is used for the setup of that port.
The Ethernet Network folder is used to setup the network properties as well as the network services and
Network printing.
For example, this folder is used to setup the WebTouch Remote ™ Webserver, the FTP Server, e-mail and
the Synergy Server.
Provides access to six different Communicatio ns
folders.
♦ RS - 232
♦ RS - 485
♦ IEEE 488
♦ Ethernet Network
Details are in Section 8.0 Communications
.
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5.3.4 Program Screen
PROGRAM Screen
The Program screen is used at various times by OE Ms and technicians, administrators, and engineer s to
load, save, create and edit controller programs.
♦ Create a New File
♦ Open and Existing File
♦ Save the Loaded File
♦ Edit a program step
♦ Add a program step
♦ Copy a program step
♦ Delete a program step
Details are in
Synergy Controller.
Section 9.0 Programming the
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5.3.5 Run Screen
RUN Screen
Synergy Controller: Running a Program.
The Run screen is used by engineers and operators to load, control, and m oni t or programs.
♦ Open File
♦ Run
♦ Run From (from a selected step)
♦ Run Off (program with outputs off)
♦ Stop
♦ Pause
♦ Dynamic Edit
Details are in
Section 9.7 Programming the
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5.3.6 Events Screen
EVENTS Screen
The Events screen is used at various times by OEMs and technicians, engineers and operators.
The OEM and Chamber Technician will utilize all of the Events screens during the chamber setup and
testing.
The Engineer/Operator uses the Events screen to m onitor and control the user defined Event Outputs.
UUT Temperatures folder is used to display up to 64 T-Type T hermocouple from the UUT Thermocouple
monitoring system.
The Digital Outputs folder is a visual display of all of the controller outputs and the Digital Inputs folder is a
visual display of all of the controller inputs.
The High and Low Resolution analog inputs screens display all of the controller sensor input; i.e. RTDs,
Pressure transducers, Humidity Sensors, V i brat i on, Pressure and altitude sensors.
Provides access to four different Events fol ders.
♦ Event Outputs
♦ UUT Temperatures
♦ Digital Outputs
♦ Digital Inputs
♦ High Resolution Analog (Inputs)
♦ Low Resolution Analog (Inputs)
Details are in Section 11.0 Events
Directory.
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5.3.7 Graph Screen
GRAPH Screen
The Graph screen is used at various times by all us ers; i.e. OEMs and technicians, engineers and operators
to monitor the operation of the equipment.
The Graph scaling, X and Y can be adjusted in the SETUP\Graph Settings folder.
Screen Information:
♦ Graph channel actual and setpoint values
over time.
Control Features:
♦ Access the Graph Setup Screen by
touching the graph. You can individually
enable and disable the plotting of the
setpoint and actual values for each of the
chamber variables.
Details are in Section 12.0 Graph Screen
.
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5.3.8 Main Screen
MAIN Screen
The Main screen is used at various times by all users.
The Main screen provide an On/Off push button and LE D and Setpoint for Steady State operation. The Ma i n
screen can be adjusted to display a Chamber Light Swit ch or Event Switch, up to 10 Sensor values, a
process graph, and various control channel arrangements from the SETP\Main Screen Setup Folder.
The Main screen is the first screen that appears
after power-up. Use this screen to operate the
chamber in steady state mode.
Screen Information:
♦ Actual values for each chamber channel
vs. time
(Product and Air Temperature in Cascade)
♦ Setpoint values for each chamber channel
vs. time.
Control Features:
♦ You can turn the chamber on and off by
pressing the On/Off button in the center of
the screen.
♦ You can adjust the steady state (manual)
setpoint for each channel by pressing on
the Setpoint field and entering the value in
the keypad that appears.
Details are in
Section 10.0 Steady State Operation
.
Synergy Controller Technical Manual, Revision H
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Key Pad Screen
Alphanumeric data is entered in the
Synergy Controller with the T9 Key Pad. When
Alpha is selected, pressing a key will cycle
through the letters on that key. For example, if
the first key pressed is “2” the text box displays
the letter “A”. When pressed a second time, the
text box will display the letter “B” and a third time
will show “C”. If the next letter is on a different
button, just press that button. However, if the
next letter is on the same button, press the
Next -> button to save the entry and then select
the next key.
When Numeric is selected, pressing a key displays the number on the key. When Alpha-Num(eric) is
selected, press the key to cycle through the let ters then the number on the key.
To clear one character, use the Back Space (Bk Sp) button. To clear all of the characters, use the Clear
button. When you are finished, press OK to accept the entry. To cancel, press Cancel.
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6.0 SETUP SCREEN
Setup Screen
The SETUP screen provides access to all of the controller setup parameters. The Setup screen is organized
into 14 folders as follows:
6.1 Setup Folder Root Menu
• Calibration
• PID Settings
• Special Functions
• L-Values
• Logging
• Chamber Setup
• Graph Settings
• LCD Settings
• Panel Lock
• Languages
• User Alarms
• Resume Behavior
• Main Screen Setup
• Event Screen Setup
.
Some of the parameters in the Setup Directory are preset by t he i nstaller or equipment
manufacturer. Under most circumstances thes e parameters should not be changed. They are
shown and described in the tables for reference only. Some are default set t i ngs or may not apply
to your chamber. Changes to some of the parameters may affect the chamber operation and void
your warranty. Please contact the chamber manufacturer or installer with any questions about
your specific chamber.
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6.2 Calibration
Setup\Calibration Folder
The SETUP\Calibration\ screen provides access to Setup and calibration parameters. This screen is
organized into 5 folders as follows:
• Calibration Channel n
• Altitude
• Guaranteed Soak
• Input
• Virtual Sensors
6.2.1 Channel Calibration
The SETUP\Calibration\Calibration Channel n\ Screen contains all of the setup and calibration parameters
for channel n. There is a Calibration Channel folder for each channel with the following 14 parameters:
♦ CHn Sensor Select
♦ Temperature Offset (b)
♦ Temperature Game %(m)
♦ High Alarm, Channel n
♦ Low Alarm, Channel n
♦ Ignore Alarm When Off
♦ Channel Alarm Delay
♦ Deviation High Alarm
♦ Deviation Low Alarm
♦ Deviation Alarms Enable
♦ Deviation Alarm Delay
♦ Waitfor CHn Tolerance
♦ High Limit, Channel n
♦ Low Limit, Channel n
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SETUP\Calibration\Calibration
Parameter
Description
CH1 Sensor Select
Channel Sensor Select
Temperature Offset (b)
Channel Offset and Gain (Span)
Hi Alarm, Channel 1
Channel Absolute Alarms
Deviation High Alarm
Channel Deviation Alarms
Waitfor CH1 Tolerance
Wait For Tolerance
High Limit, Channel 1
Channel Limits
Temperature Gain %(m)
Adjust the Channel Offset (b) and Gain %(m) to
accommodate channel specific sensor errors such as
Select the channel feedback Sensor
those caused by the sensor placement. Generally , sensor
setup and calibration adjustment should be made i n the
Input Calibration screens shown in the next secti on.
Low Alarm Channel 1
Ignore Alarm When Off
Channel Alarm Delay
The Synergy Controller can shut down the chambe r when
the PV goes outside the High and Low Limit Alarm v al ues.
The absolute alarm limits can be disabled automatically
when the Channel is off using the Ignore Alarm When Off
parameter.
Alternatively, the Absolute Alarms can be delayed using
the Channel Alarm Delay.
Deviation Low Alarm
Deviation Alarms Enabled
Deviation Alarm Delay
The Synergy Controller Deviation Alarms will trigger when
the Process Error (Process Varia b l e – Setpoint) is outside
the Deviation High and Deviation Low Limits.
The Deviation Alarms can be disabled or delayed usi ng
the Deviation Alarm Enable and Deviation Alarm Delay
parameters.
Low Limit, Channel 1
The Wait For Tolerance specifies a toleranc e window
around the Wait For setting. When executing a Wait For
step the program will not advance until the Process
Variables are within this tolerance.
The Channel Limits constrain the range of values allowed
when entering Setpoints.
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6.2.1.1 Channel Sensor Selection
Olympic (High Resolution Inputs)
RTD 1
RTD 2
Analog 1
Analog 2
Analog 3
Analog 4
TC 1*
TC 2*
UUT (Up to 64 T-type T/Cs)
Module 1 Thru 8
Sensor 1 thru Sensor 8
Machine Inputs (Low Resolution Inputs)
Low Res 1 thru 8
Digital Inputs
Dig. In. 1 thru 16
Channels (PV)
Act CH 1 thru Act CH 4
Setpoints (SP)
Setpt CH 1 thru Setpt CH 4
Virtual Sensors
Dual Press.
Wet Bulb/Dry Bulb
Virtual Kft
UUT Sensor Selection
Note: * Direct Thermocouple Inputs are not
if thermocouples are required.
The SETUP\Calibration\Calibration Channel n\Channel n Sensor Select parameter determines the
sensor for channel n. The sensor is selected from the Sensor Selection screen a s follows:
1. Select the Module f rom t he list in the first column.
2. Then select the sensor or the sub-module from the Sensor list.
3. When necessary, select the sensor from the sensor list in third column.
available on Synergy Micro 2.
Use the TE1908 Thermocouple Signal Conditioner
Synergy Controller Technical Manual, Revision H
♦ To select a sensor from the UUT
Thermocouple module, Select UUTs from
the Module column, and then select the
UUT Module (1 thru 8) and then the
Sensor (1 thru 8).
Page 41
6.2.2 Altitude Value
SETUP\Calibration\Altitude\Altitude Value\
ALT
SETUP\Calibration\Guaranteed Soak\
GS
SETUP\Calibration\ Input\High Res\RTD n\Type\
HIGHn_TYPE
SETUP\Calibration\Altitude\Altitude Value\ sets the scaling for the pressure channel. Set the altitude value
to 0 for linear scaling for regular pressure transducers. F or Granville-Philips transducers, set the parameter
to 10, 11 or 12 for exponential scaling. A Registration Key may be required to access this feature. See
additional details in the Altitude/Space Chamber Setup section
.
6.2.3 Guaranteed Soak
The Guaranteed Soak feature stops a program from advancing until the process variable is within t he
guaranteed soak limits. Range for this is 0 to 50 degrees. This value appl ies to each setpoint in the program.
As an example, for a setpoint of 100 degrees with a guaranteed soak of 1 degree, the program will wait until
a temperature between 99 and 101 degrees is reached bef ore advancing, regardless of the step time. When
enabled, the Guaranteed Soak feature will affect al l set point steps in any profile run on the chamber. An
alternative to the system wide Guaranteed Soak setting is the Wait For step which provides soaking on
specific steps of the profile. For example, to guarantee a soak at 100C add a Ramp step to 100C the n add a
Wait For step that waits for 100C. See the Program section
of the manual for more information.
6.2.4 Input Calibration
Each controller input is calibrated and scaled from t his folder and sub-folders. Raw calibration calibrates the
controller measurement, either Volts or Ohm s. The voltage and scale and engineering scale are set for each
sensor. The input type is selected from the list. The High Resolution Inputs are the most accurate inputs and
typically uses for process variables. The Low Res olution inputs are used for machine parameters like
pressure transducers, etc.
6.2.4.1 RTD Calibration
The Synergy Controller chamber accepts up to two P latinum RTD (Resistance Temperature Detector)
sensors. RTDs are the most linear, stable and reproducible temperature sensors available. Over the years,
both American and European RTD standards have been developed to ensure that RTDs are interchangeable
from manufacturer to manufacturer. Platinum RTDs are specified to standards such as DIN (Deutsch
Institute fur Normung) and JIS (Japanese Industrial Standard). These standards define the RTD
specifications.
Synergy Controller Technical Manual, Revision H
Each of the Synergy Controller’s two RTDs can be
set for four types:
RTD JIS 500
RTD JIS 100
RTD DIN 500
RTD DIN 100.
Note: In early software versions, the RTD curve
was set globally so one RTD curve was used for
both sensors.
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SETUP\Calibration\ Input\High Res\RTD n\Gain\
HIGHn_GAIN
SETUP\Calibration\ Input\High Res\RTD n\Offset\
HIGHn_OFF
SETUP\Calibration\Input\High Res\Analog n\Raw Calibration\Gain\
HIGHn_GAIN
SETUP\Calibration\Input\High Res\Analog n\Raw Calibration\Offset\
HIGHn_OFF
SETUP\Calibration\Input\High Res\Analog n\High Eng. Scale
HIGHn_HIGHEU
SETUP\Calibration\Input\High Res\Analog n\Low Eng. Scale
HIGHn_LOWEU
SETUP\Calibration\Input\High Res\Analog n\High Volts Scale
HIGHn_HIGHVOLTS
SETUP\Calibration\Input\High Res\Analog n\Low Volts Scale
HIGHn_LOWVOLTS
SETUP\Calibration\Input\High Res\Analog n\Type
HIGHn_TYPE
This screen is used to enter an Offset and Gain
(span) for the raw data in Ohms. This is used
to compensate for a difference in the reading
due to sensor position, wiring, etc.
Use the Two Point calibration calculation formul a
section 16 to calculate the Offset and Gain
(span).
6.2.4.2 Analog Voltage Calibration
Each of the controller’s analog inputs is calibrated an d sc al ed from this folder. The Raw Calibration
parameter is used to calibrate the physical voltage measurement. The voltage scale and engineering scale
are used to scale the value to engineering units. The se inputs can be scaled to select a wide range of signal
conditioners with 0-5VDC and 4-20mA outputs. In addition, when set to the Temperature Type, the Synergy
Controller converts inputs from C to F and vice versa. There are four High Resolution Analog inputs and
eight Low Resolution Analog inputs eight.
Set the Raw Calibration gain and offset to calibrate cont rolle r. Use the Two Point calibration calculation
formula section 16 to calculate the Offset and Gain (span)
Set the High Engineering Scale to the Full scale output of the sensor. For example 1000 Torr.
Set the Low Engineering Scale to the Zero scale ou tput of the sensor. For example 0 Torr
Set the High Voltage Scale to the full scale output of t he sensor. For example 5 VDC.
Set the Low Voltage Scale to the zero scale output of the sensor. For example 0 VDC.
Select the Sensor type from the list. Set the type to Temperature to automatically scale the value when the
temperature units of measure for the controller are ch anged from C to F and vice versa.
Set analog input to Vaisala HMM30C to temperature compensate the Vaisala humidity sensor. There are
different HMM30C types in the list to allow compensation from a variety of temperature sensors.
Synergy Controller Technical Manual, Revision H
Page 43
Vaisala HMM30C Temperature Compensation
Vaisala Constants
Temp Range (C)
a0
a1
-40…-20
-0.104980
-0.060009
-20…+15
0.469374
-0.031292
+15…+45
0.000000
0.00000
+45…+180
-1.536460
0.034144
Temp Range (C)
b0
b1
-40…-20
0.947370
-0.008510
-20…+15
1.050385
-0.003359
+15…+45
1.000000
0.000000
+45…+100
0.889657
0.002452
+100…+180
0.551922
0.005829
Vaisala Temperature Compensation
T RH
Raw
a0 a1 b0 b1 A B
Vaisala RH
Corrected
60
70
-1.53646
0.034144
0.889657
0.002452
0.51218
1.036777
73.105
60
80
-1.53646
0.034144
0.889657
0.002452
0.51218
1.036777
83.473
60
100
-1.53646
0.034144
0.889657
0.002452
0.51218
1.036777
104.209
70
40
-1.53646
0.034144
0.889657
0.002452
0.85362
1.061297
43.358
70
60
-1.53646
0.034144
0.889657
0.002452
0.85362
1.061297
64.584
70
80
-1.53646
0.034144
0.889657
0.002452
0.85362
1.061297
85.810
70
100
-1.53646
0.034144
0.889657
0.002452
0.85362
1.061297
107.036
80
30
-1.53646
0.034144
0.889657
0.002452
1.19506
1.085817
33.872
80
40
-1.53646
0.034144
0.889657
0.002452
1.19506
1.085817
44.730
80
60
-1.53646
0.034144
0.889657
0.002452
1.19506
1.085817
66.447
80
80
-1.53646
0.034144
0.889657
0.002452
1.19506
1.085817
88.163
80
100
-1.53646
0.034144
0.889657
0.002452
1.19506
1.085817
109.879
85
30
-1.53646
0.034144
0.889657
0.002452
1.36578
1.098077
34.442
85
40
-1.53646
0.034144
0.889657
0.002452
1.36578
1.098077
45.423
85
60
-1.53646
0.034144
0.889657
0.002452
1.36578
1.098077
67.384
85
80
-1.53646
0.034144
0.889657
0.002452
1.36578
1.098077
89.346
85
100
-1.53646
0.034144
0.889657
0.002452
1.36578
1.098077
111.307
100
60
-1.53646
0.034144
0.889657
0.002452
1.87794
1.134857
70.223
100
80
-1.53646
0.034144
0.889657
0.002452
1.87794
1.134857
92.920
100
100
-1.53646
0.034144
0.889657
0.002452
1.87794
1.134857
115.617
54
30
-1.53646
0.034144
0.889657
0.002452
0.307316
1.022065
30.976
Vaisala Relative Humidity sensors are available in t emperature compensated and uncompensated versions
(HMM30C) and the Synergy Controller is com patible with both types. In addition the controller ca n
accommodate sensors with 0-5VDC and 4-20mA outputs.
The Synergy Controller uses the Vaisala recommended temperature compensation algorithm for the
HMM30C. The algorithm is a second order polynomial defi ned over four temperature ranges by the following
table of coefficients.
Where: a0, a1, b0, b1 are constants with the values as determined in the table below:
And Where:
Offset compensation: A = a0 + b0 * T
Gain compensation: B = b0 + b1 * T
RH Compensated = (RH Raw + A) * B
The following is a table of example temperature read i ngs (T) and uncompensated raw relative humidity
readings (RH raw). The last column displays the compensated relative humidity reading (Vaisala RH
Corrected).
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6.2.5 Virtual Sensors
Virtual Sensors
The Synergy Controller supports a variety of V i rt ual Sens or f or a variety of applications. The virtual accepts
on or more sensors and calculates a new sensor value.
• Wet Bulb-Dry Bulb
• Virtuall Kft
• Virtual Pressure
6.2.5.1 Wet Bulb/Dry Bulb Virtual Sensor
The Virtual Wet Bulb/Dry Bulb sensor measures relative humidity using two temperature sensors as an
alternative to an electronic RH sensor. To make t hese measurements, a wet-bulb sensor infers the amount
of moisture in the air when the evaporation from a moist clot h wick placed over the sensor lowers its
temperature reading. When the air surrounding the wet-bulb sensor is dry, evaporation of moisture from the
wick is faster than when the air is moist. If the air is sat urat ed, no evaporation from the wick occurs and the
temperature of the wet-bulb sensor is the same as th e t em perature of the dry-bulb sensor.
The Wet Bulb/Dry Bulb Virtual Sensor folder includes all of the parameters that configure the sensor.
Synergy Controller Technical Manual, Revision H
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SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Wet Bulb Sensor
WETB_SENID
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Dry Bulb Sensor
DRYB_SENID
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Altitude – Torr\
WBDB_ALT
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Wet Bulb Input Fil ter\
WBIN_FLT_ENABLED
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Wet Bulb Filter Max Delta \
WBIN_FLT_MAXD
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Wet Bulb Filt er Weight\
WBIN_FLT_WT
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Dry Bulb Input Filter\
DBIN_FLT_ENABLED
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Dry Bulb Filter Max Delta\
DBIN_FLT_MAXD
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Dry Bulb Filter Weight\
DBIN_FLT_WT
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Wet Bulb Input Fil ter\
WBIN_FLT_ENABLED
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Wet Bulb Input Filter\
WBIN_FLT_ENABLED
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Wet Bulb Input Fil ter\
WBIN_FLT_ENABLED
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Wet Bulb Input Fil ter\
WBIN_FLT_ENABLED
SETUP\Calibration\Virtual Sensors\Wet Bulb Dry Bulb\Wet Bulb Input Filter\
WBIN_FLT_ENABLED
SETUP\Calibration\Virtual Sensors\Virtual KFt\Torr Sensor
VIRTKFTSEN
Virtual Pressure Sensor
threshold and hysteresis which)
Assign the sensor IDs for the two temperature sensor s.
The Altitude – Torr Sensor parameters sets the pres sure at the site to allow the controller to compensate the
humidity calculation for the pressure altit ude.
Wet-Bulb/Dry-Bulb Virtual Sensor Filter parameters
6.2.5.2 Virtual Kft Sensor
The Virtual Kft. sensor calculates Altitude in Kft (thousands of feet) from a pressure sensor scaled in Torr.
The Torr Sensor parameter is the sensor ID of t he Torr s ensor.
5.2.5.3 Virtual Pressure Sensor
The Virtual Pressure sensor combines the readi ngs from two pressure sensors into one sensor to increase
the accuracy of the reading over a wide range.
♦ Std. Range Pres. Sensor ID
♦ High Alt. Pres. Sensor ID
♦ Transfer Pres. Threshold
♦ Transfer Pres. Hysteresis
The Virtual Pressure sensor combines the readi ngs
from two sensors into one sensor to increase the
accuracy of the reading over a wider range than
possible with a single sensor.
These settings specify the two sensor IDs and
control when the virtual sensor switches between
the two input sensors. (the transfer pressure
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SETUP\Calibration\Virtual Sensors\Virtual Pressure\Std. Range Pres. Sensor ID.
VP_STDALT_SENID
SETUP\Calibration\Virtual Sensors\Virtual Pressure\High Alt. Pres. Sensor ID.
VP_HIALT_SENID
SETUP\Calibration\Virtual Sensors\Virtual Pressure\Transfer Pres. Threshold.
VP_TRANS_PRESS
SETUP\Calibration\Virtual Sensors\Virtual Pressure\ Transfer Pres. Hysteresis
VP_TRANS_HYST
These settings specify the two sensor IDs and control when the virtual sensor switches between the two
input sensors. (The transfer pressure thresh old and hysteresis which)
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6.3 PID Settings
The parameters for Heat and Cool PID are :
SETUP\PID Settings\PID Ch n\PID Ch n Heat\Prop. Band Ch n Heat\
PBnH
SETUP\PID Settings\PID Ch n\PID Ch 1 Heat\Reset Ch n Heat\
RSnH
SETUP\PID Settings\PID Ch n\PID Ch n Heat\Cycle Time Ch n Heat\
CTnH
Channel PIDs
The Synergy Controller implements the Proportional, Integral, and Derivative (PID) algorithm for each control
channel. The Synergy Controller PID algorithm s are designed to automatically adjust the output variables t o
hold the process variable at the setpoint while minimizing instability and error.
The PID Settings screen is used to edit the constant s that control the PID algorithms. In general, PID
adjustment should only be performed by a qualified technician. If you would like to know more about P I Ds
we have included a brief tutorial below. For PID tunin g procedures, see section 16.0
6.3.1 Heat and Cool
♦ Prop. Band Heating
♦ Reset Channel n Heating
♦ Rate Channel n Heating
♦ Cycle Time for Ch n Heating
♦ Rate Band for Ch n Heating
Where n is the Channel.
When the controller is running, the control action can be monitored from the Channel PIDs screen in the
Maintenance directory.
To help with tuning, the control variables for ea ch
channel are displayed in the Channel PIDs folder in
the Maintenance screen. Tap the Channel button
at the top of the screen to select the channel. The
following parameters are displayed:
Pn – Proportional Term
♦
In – Integral Term
♦
Dn – Not Used
♦
PID – PID Output
♦
Err – Current Error
♦
Last Err – Last Error
♦
Delta Err – Difference between current and last error
♦
P.B – Proportional Band Constant
♦
Reset – Reset Constant
♦
Rate – Not Used
♦
Synergy Controller Technical Manual, Revision H
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6.3.2 Cascade Control
Register Cascade
Cascade Folders
Cascade control is a control system method in whi ch the temperature setpoint and actual readings are tak en
from the both the air temperature and the unit-under-test. These settings and readings are combined in the
PID calculations and offer the user greater speed and more accurate UUT temperature control during the
test. Using the Cascade feature allows the operator to control the chambers processes to bring the UnitUnder-Test (UUT) to the desired temperature, rat her than just the air temperature. Cascade control provides
greater test accuracy in addition to faster and mo re efficient ramps and soaks.
Because the Cascade control is a powerful feature of the Synergy Controller, we have dedicated a separ ate
section for its discussion. See Section 14 Cascade Temperature Control
description of the Cascade feature.
The Cascade control feature requires a
Registration Key. Contact Tidal Engineering for the
Cascade Registration Key for your controller.
Tap in the Registration Key field to open the
number pad. Enter the Registration Key and tap
the Register button.
for a detailed and complete
The Cascade parameters are organized in the
following three folders:
Enable
♦
Settings
♦
PIDs
♦
Synergy Controller Technical Manual, Revision H
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Register Cascade
Cascade Settings
Cascade PIDs
The Cascade control feature requires a
Registration Key. Contact Tidal Engineering for the
Cascade Registration Key for your controller.
Tap in the Registration Key field to open the
number pad. Enter the Registration Key and tap
the Register button.
The Cascade parameters are organized in the
following three folders:
Sensor Select
♦
Cascade High Limit
♦
Cascade Low Limit
♦
Pos. Deviation Limit
♦
Neg. Deviation Limit
♦
Cascade
♦
The Cascade PID parameter control the PID tuning.
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6.4 Special Functions
Special Functions
The Cascade parameters are organized in the
following three folders:
Celsius/Fahrenheit
♦
12/24 Hour Time
♦
Output 11 Control Type
♦
Output 17 Control Type
♦
Output 18 Control Type
♦
Analog Retransmits
♦
PWM Retransmits
♦
On/Off Retransmits
♦
Remote Start/Stop
♦
Analog Programming
♦
Allow Multiple Stop Steps
♦
Celsius / Fahrenheit
The Celsius/Fahrenheit setting sets the tem perature units displayed by the Synergy Controlle r. The setting
is global. All temperature data are automatically displayed according to the C/F setti ng i ncluding currently
loaded program files.
12 / 24 Hour Time
The 12/24 Hour Time setting sets the Synergy Controller’s time display to either AM/PM format or 24 hour
format. The setting is global. All absolute tim e data is automatically displayed based on this format.
Output 11 Control Type (Ambient Coil)
This setting is used to set the output logic for the Ambient Coil (Output 11) to On/Off control or Time
Proportioning control. In On/Off mode the A m bi ent Coil is either on or off depending on the controller
demand. When in Time Proportioning mode the Ambient Coil output is between 0% and 100% depending on
the demand required. The default setting is On/Off control mode. On/Off control mode typically enabl es the
chamber to react faster, sacrificing accuracy. T i me P roportioning modes allow greater accuracy but may
slow temperature and humidity ramp.
Time Proportioning Mode (TPM) can be changed in a program on a step-by-step basis by selecting the OT11
checkbox when creating a program step (see Secti on 9.0 Programming the Synergy Controller
).
Output 11 or OT11 TPM (Time Proportioned Mode) ca n be m oni t ored from within the Events screen. To
monitor the state of the OT11 TPM setting, go to the Events\Event O ut put folder and observe the LED light
next to the OT11 TPM label. The light is red when O utput 11 is in time proportioning mode, gray when in
Synergy Controller Technical Manual, Revision H
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On/Off mode. You can monitor the Ambient Coil from the Events\Digital Outputs folder. The LED is gray
OT17 – Output 17 Control Type
Selects the control logic for the Vacuum
device. Can be either Vacuum or Purge
LEV 2
Controls Vacuum device when OT17 is set to
Purge
OT18
Selects the Control logic for the Vent – Boost
Cool device
L14 Time Delay Boost Cool
Time delay (in seconds) required before Boost
Cool is enabled
Note: Turn On Timer is reset when Channel 1 PID Cool < 100%
when off, red when on and yellow when in time proport ioni ng m ode.
Output 17 Control Type (Vacuum or Purge)
The Output 17 Control Type selects the type of cont rol logic for Vacuum/Purge output. When channel 2 is
Altitude, choose either the Vacuum mode or Purge mode. Use vacuum when channel 2 units are in Torr.
Output 17 (Vacuum) Logic Diagram
Output 18 Control Type (Vent of Boost Cool )
The Output 18 Control Type selects the type of cont rol logic for Vent/Boost Cool output.
Vent / Boost Cool Logic Diagram
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Analog Retransmit 1 and 2
Analog Retransmit 1 Folder
One of the optional features often specified with environmental chambers is the circular chart recorder. The
chart recorder is a graphing device used to record chamber data such as temperature, humidity and
pressure over time. An example of a Tenney Chambe r with a circular chart recorder is shown below.
Note that the Synergy Controller includes built in Logging features that can often eliminate the need for a
conventional chart recorder.
The Synergy Controller features two analog sig nals called Analog Retransmit 1 and 2 that can output
setpoints, actual process data and internal PID values. The outputs can either be graphed on the chart
recorder or, in some equipment; the PID output value s can be used to control external steam valve (heat),
chilled water (cool) or LN2 liquid nitrogen outputs.
To configure the outputs, press the SETUP button
on the Synergy Controller touch screen and go to
the Setup\Special Functions\Analog Retransmit 1
folder.
Select the Analog Retransmit 1 folder to open the
data output mapping options.
Synergy Controller Technical Manual, Revision H
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PWMs Retransmits
PWM Retransmit Folder
The parameters for each PWM are :
The parameters for each On/Off are :
The PWM Retransmit feature is similar to the
Analog Retransmit except the output is modulated
by varying the Pulse Width, thus the term Pulse
Width Modulation. This is also known as TimeProportioning.
To configure the outputs, press the SETUP button
on the Synergy Controller touch screen and go to
the SETUP\Special Functions\PWM Retransmits. .
Select the PWM Retransmit 1 folder to open the
data output mapping options.
♦ Retransmit Source
♦ High Eng. Scale
♦ Low Eng. Scale
♦ High Duty Cycle
♦ Low Duty Cycle
♦ Cycle Time
The Retransmit source is typically one of the PID
Variables; i.e. Channel 2 Heat PID Outputs.
On/Off Retransmits
Synergy Controller Technical Manual, Revision H
♦ Retransmit Source
♦ High Eng. Scale
♦ Low Eng. Scale
♦ Hysteresis Value
♦ Low Duty Cycle
♦ Active State
The Retransmit source is typically one of the PID
Variables; i.e. Channel 2 Heat PID Outputs. The
output is Active when the Retransmit Source
Variable is between the High and Low Eng. Scale
limits.
Page 54
Remote Start/Stop
The Remote Start/Stop Parameters:
The Analog Programming Feature parameters are:
Allow Multiple Stop Steps controls a programming
Analog Programming
♦ Remote Start/Stop Enable
♦ Start Input
♦ Stop Input
The Remote Start/Stop inputs can be connected to
remote switches and used to turn the controller On
and Off remotely.
♦ Programming Enabled
♦ Analog Input Select
When Analog Programming is enabled, the
controller setpoints can be set using an analog
input.
Allow Multiple Stop Steps
Synergy Controller Technical Manual, Revision H
option
When enabled, multiple Stop Steps are allowed i n a
Synergy Controller Program. Otherwise, only one
Stop step is allowed in each program.
Page 55
6.5 Settings List
Description
Command
Value
Calibration
Channel 1
Ch1 Calibration
CAL1
Ch1 Alarm Low Limit
A1L
Ch1 Alarm High Limit
A1H
Channel 2
Ch2 Calibration
CAL2
Ch2 Alarm Low Limit
A2L
Ch2 Alarm High Limit
A2H
Altitude
ALT
Guaranteed Soak
GS
PID Values
Channel 1
Proportional Band, Ch1 Heating
PB1H
Reset, Ch1 Heating
RS1H
Rate, Ch1 Heating
RT1H
Cycle Time, Ch1 Heating
CT1H
Rate Band, Ch1 Heating
RB1H
Dead Band, Ch1
DB1
Proportional Band, Ch1 Cooling
PB1C
Reset, Ch1 Cooling
RS1C
Rate, Ch1 Cooling
RT1C
Cycle Time, Ch1 Cooling
CT1C
Rate Band, Ch1 Cooling
RB1C
Channel 2
Proportional Band, Ch2 Heating
PB2H
Reset, Ch2 Heating
RS2H
Rate, Ch2 Heating
RT2H
Cycle Time, Ch2 Heating
CT2H
Rate Band, Ch2 Heating
RB2H
Dead Band, Ch2
DB2
Proportional Band, Ch2 Cooling
PB2C
Reset, Ch2 Cooling
RS2C
Rate, Ch2 Cooling
RT2C
Cycle Time, Ch2 Cooling
CT2C
Rate Band, Ch2 Cooling
RB2C
Synergy Controller Technical Manual, Revision H
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Description
Command
Value
Special Functions
Celsius / Fahrenheit
CF Output 11 Control Type
OT11
Output 17 Control Type
OT17
Output 18 Control Type
OT18
Ch1 Low Range
R1L
Ch1 High Range
R1H
Ch2 Low Range
R2L
Ch2 High Range
R2H
Ch 1 RTD Type
RTD
Vaisala Compensation Enabled
VCMP
Analog Retransmit 1
OUT_420_1
Analog Retransmit 2
OUT_420_2
L-Values
1L1 Ch1 Main Cooling Turn-On
1L1 1L2 Ch1 Main Cooling Turn-Off
1L2 1L3 Ch1 Setpoint Transfer Setting
1L3 1CTY Ch1 Chamber Type
1CTY
2L1 Ch2 Main Cooling Turn-On
2L1 2L2 Ch2 Main Cooling Turn-Off
2L2 2L3 Ch2 Setpoint Transfer Setting
2L3 2CTY Ch2 Chamber Type
2CTY
L3 Ch1 Main Cooling Turn-On
L3 L4 Ch1 Main Cooling Turn-Off
L4 L6 Ch1 Full Cooling Switch Over
L6 L7 Ambient Cooling Turn-On
L7 L8 Heat Ambient Cooling Turn-Off
L8 L9 Ramp-Up Cooling
L9 L11 Dehumidify / Vent On
L11 L12 Dehumidify / Vent Off
L12 L14 Time Delay Boost Cool
L14 L15 Compressor Turn-Off Delay
L15 LEV1
LEV1
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6.6 L – Values
L_Values
The L-Value parameters control the operation of t he chamber outputs.
The Cascade parameters are organized in the
following three folders:
Thermal Shock Chamber Parameters
1L1 Ch1 Main Cooling Turn-On
1L2 Ch1 Main Cooling Turn-Off
1L3 Ch1 Setpoint Transfer Setting
1CTY Ch1 Chamber Type
2L1 Ch2 Main Cooling Turn-On
2L2 Ch2 Main Cooling Turn-Off
2L3 Ch2 Setpoint Transfer Setting
2CTY Ch2 Chamber Type
Temperature Humidity/ Temperature Only
L3 Ch1 Main Cooling Turn-On
L4 Ch1 Main Cooling Turn-Off
L6 Full Cooling Switch-Over
L7 Ambient Cooling Turn-On
L8 Heat Ambient Cooling Turn-Off
L9 Ramp-up Cooling
L11 Dehumidify / Vent On
L12 Dehumidify / Vent Off
L14 Time Delay Boost Cool
L15 Compressor Turn-Off Delay
LEV1 Drier / Dehumidify Coil
Synergy Controller Technical Manual, Revision H
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L-Value Descriptions
L-Values are parameters for the programmable lo gi c that control processes in the Device Primitives. Flow
charts illustrating the Device Primitives are illustrated in Section 6.7 Device Primitives
of this manual. Please
refer to the Device Primitives flow charts in conjunction with the definitions below when editing L-Values.
Thermal Shock Parameters
1L1 Ch1 Main Cooling Turn-On
Cooling output required to turn on channel 1 cooling. (0 to 100%)
1L2 Ch1 Main Cooling Turn-Off
Heat output required to turn off channel 1 main cooling. (-100 to 100%)
1L3 Ch1 Setpoint Transfer Setting
Temperature threshold for the artificial load output. (-1 00 t o 100C, -148 to 212F)
1CTY Ch1 Chamber Type
Defines the controlling logic for channel 1. (CAP Tube System, Agree Logic, Burn-in Logic, XV Sys
Logic)
2L1 Ch2 Main Cooling Turn-On
Cooling output required to turn on channel 2 cooling. (0 to 100%)
2L2 Ch2 Main Cooling Turn-Off
Heat output required to turn off channel 2 main cooling. (0 to 100%)
2L3 Ch2 Setpoint Transfer Setting
Artificial load is enabled above this temperature threshold. (-100 to 100C, -148 to 212F)
2CTY Ch2 Chamber Type
Defines the controlling logic for channel 1. (CAP Tube System, Agree Logic, Burn-in Logic, XV Sys
Logic)
Temperature Humidity/Temperature Only
L3 Ch1 Main Cooling Turn-On
The low stage compressor is switched on above this PID Cooling output percentage. (0 to 100%)
L4 Ch1 Main Cooling Turn-Off
Percent heat required before turning off low sta ge compressor. (0 to 100%)
L6 Full Cooling Switch-Over
Full cooling is switched on at this temperature. (-100 to 100C, -148 to 212F)
L7 Ambient Cooling Turn-On
Percent cooling required that turns on the compres sor. (0 to 100%)
L8 Heat Ambient Cooling Turn-Off
Percent heat required to turn off the compressor. (0 t o 100%)
L9 Ramp-up Cooling
A temperature setpoint above this threshold t urns off the compressor when heating. (-100 to 100C, -
148 to 212F)
Synergy Controller Technical Manual, Revision H
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L11 Dehumidify / Vent On
Percent dehumidify required to enable dehumidif y device. (0 to 100%)
L12 Dehumidify / Vent Off
Percent humidify required to turn off dehumidify device. (0 to 100%)
L14 Time Delay Boost Cool
Time delay required before Boost Cool is enabled. (0 to 1200 seconds)
L15 Compressor Turn-Off Delay
Delay required before turning off a compressor. (0 t o 5 minutes)
LEV1 Drier / Dehumidify Coil
Selects Drier or the Dehumidify Coil for dehumidifi cat ion. (Dehumidify Coil, Drier). When equipped
with a drier, the chamber will typically be capable of achieving a lower humidity.
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6.7 Logging
Step #1:
Select the Data folder.
The Synergy Controller’s logging system periodically captures and stores user selected data at a user
specified interval to the Storage Card, the on board non-v olatile Flash memory. In addition the logging
system also records alarm activity and other abnormal events to the Storage Card. The log data (sometimes
called history) can be exported to removable memory for use in test documentation.
6.7.1 Logging Setup
This section describes the Log system setup options and steps.
Note: Before starting a test that requires loggin g you should consider whether you want to export and then
clear the data already stored in memory to minimiz e the possibility that the Storage Card will fill during the
test. Export the history using the Export History folder and then use the Clear History folder in either the
Maintenance\File Utilities directory or at Setup\Logging\Clear History. See Section 7.0 Maintenance
further information.
From the main setup directory, select the
Logging folder.
for
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The screen at the left appears. The following
data is available for logging.
♦ Channel Readings (Actual)
♦ Channel Setpoints
♦ Channel PIDs
♦ Machine Values
♦ UUT Values
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Example Log Printout:
Step #3: Select the Channel Setpoints Folder
Step #4: Select the Channel PIDs Folder
Date and Time, CH1Actual, CH2Actual, CH1Setpoint, CH2Setpoint
02/23/2001 11:35:56, 25.0, 51.8, 25.0 50.0
02/23/2001 11:33:56, 24.9, 48.0, 25.0 50.0
02/23/2001 11:34:56, 24.9, 50.0, 25.0 50.0
Step #2: Select the Channel Readings Folder
Use this screen to select the process values for
each selected channel for logging. Select the
channel, press the Change button, and select
Enable in the screen that follows.
♦ Return to the Logging / Data directory by
pressing the Back button.
Use this screen to enable setpoint logging for
each channel. Select the channel, press the
Change button.
Control the logging of the Heat and Cool PIDs
for Channel n from this screen. These values
can be viewed in the Channel PIDs screen of the
Maintenance directory.
After selecting the Channel PIDs folder, another
screen appears that has three folders labeled
PID CH1, PID CH2, and CH3 PID.
Select the desired channel folder. The screen at
the left appears. Select Heat or Cool, press the
Change button. Return to the Logging\Data
directory by pressing the Back button.
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Step #5: Select the Machine Values Folder
Step #6: Select the UUT Values Folder
Step #7: Start Logging Operation
and press the Change button.
Select the Machine Input process values of
Sensors 1 thru 8 for logging. These inputs
usually consist of compressor suction and
discharge pressures and temperatures. These
values can be viewed in real-time from the Low
Res. Analog Screen in the Events folder.
Select the sensor and press the Change button.
Scroll down to access sensors 6 - 8.
♦ Return to the Logging\Data directory by
pressing the Back button.
Use this screen to enable Units Under Test data
logging for UUT1 thru UUT8. These values can
be viewed in real-time in the UUT Temperatures
screen of the Events directory.
Select the UUT and press the Change button.
Scroll down to access UUTs 6 - 8.
♦ Return to the Logging directory by
pressing the Back button.
From the Logging directory, select the Setup
folder. The screen at left appears. Here you set
up and start the logging operation.
♦ To change the logging interval, select the
parameter and enter the time in seconds
on the keypad. The allowable range is 1 to
3600 seconds.
♦ To change the file size, select the
parameter. Press Change and enter the
size in the keypad that follows. Range is
from 0.25 to 5.0 Megabytes. The upper
limit is dynamically calculated based upon
available space on the internal Storage
Card.
♦ To enable logging, select the parameter
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Export Log to USB
Clear History for Logging Operation
The export process is monitored in the Export
History Status window. First the Synergy Controller
prompts for a USB Hard Disk. If your removable
storage media is not installed, install it and press the
OK button.
Once the media is detected the Synergy Controlle r
will automatically export the file. When the export is
complete it will confirm a successful export and
prompt to close the window by pressing the OK
button. Your export history file is automatically
named “exphst00.txt”.
Press the Clear History button to clear the history
file.
Note: The Clear History and Export History folder s
are also available with the Maintenance\File
Utilities folder. Once cleared the log data is not
recoverable.
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Synergy Controller Data Logging Capacity Calculations
As described above, the Synergy Controller records process data, setpoints and machine diagnost ics to its
Storage Card. This information can be exported at a later time to a USB Hard Disk or to the FTP server and
used in a test report or for system troubleshooting as explained in the previous section. Calculati ons below
estimate the Synergy Controller's logging capacity; i.e. the number of history samples that can be re corded
on the Storage Card.
The number of samples depends on the number of bytes av ai lable on the internal Storage Card and the
amount of data that is logged per sample.
SCINFO can be used to determine the number of byt es av ai lable on the Storage Card thru the TCP/IP, RS232 or IEEE communications interface.
Command Format: ? SCINFO.
Response example: “Total: 8128512 Free: 1048576”
To determine the amount of data that is logged, use the following table and formulas. The table below lists
the information that can be logged. Each data type requires a specific amount of storage space on the
Storage Card. In addition, there are a number of overhead bytes per sample for time and other
housekeeping data.
For example, assume that we want to record CH1 Actual (Temperature) and CH2 Actual (Humidity)
readings.
Capacity can be calculated as follows:
Samples=X/(Y+Z
1+Z2+Z3
)
Where:
X=2 MBytes available on Storage Card (Available Storage Card capacity)
Y=21 Bytes (Number of bytes of overhead per sample)
=(Number of bytes required for n samples)
Z
n
Thus, the number of samples that can be stored ar e calculated:
Samples=X/(Y+Z
1+Z2
)
Samples= 2,097,152/(21+6+6)
Samples=63,550
If we record 60 samples per hour we will have the capacit y to record for 1,059 hours.
Hours = Samples/Sample Rate
Hours = 63,550/60
Hours = 1,059
The actual time may be less than this since other data st ored on the machine including profiles will reduce
the number of available bytes. In addition, exi sti ng data stored in the history file will reduce the number of
samples that can be saved. Other data recorded in the file are alarm events and header information saved
when the Synergy Controller is restarted.
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Log Data Size
Data
Max. Size
Description
CH1 Actual
6 bytes
Temperature
CH2 Actual
6 bytes
Humidity
CH3 Actual
6 bytes
Pressure
CH1 Setpoint
6 bytes
Temperature
CH2 Setpoint
6 bytes
Humidity
CH3 Setpoint
6 bytes
Pressure
CH1 Heat PID
4 bytes
0 to 100%
CH2 Heat PID
4 bytes
0 to 100%
CH3 Heat PID
4 bytes
0 to 100%
CH1 Cool PID
4 bytes
0 to 100%
CH2 Cool PID
4 bytes
0 to 100%
CH3 Cool PID
4 bytes
0 to 100%
Machine Sensor 1
4 bytes
Low Stage Pressure, Low Side
Machine Sensor 2
4 bytes
Low Stage Temperature, Low Side
Machine Sensor 3
4 bytes
Low Stage Pressure, Hi Side
Machine Sensor 4
4 bytes
Low Stage Temperature, Hi Side
Machine Sensor 5
4 bytes
High Stage Pressure, Low Side
Machine Sensor 6
4 bytes
High Stage Temperature, Low Side
Machine Sensor 7
4 bytes
High Stage Pressure, Hi Side
Machine Sensor 8
4 bytes
High Stage Temperature, Hi Side
UUT Device 1
56 bytes
8 Thermocouple readings
UUT Device 2
56 bytes
8 Thermocouple readings
UUT Device 3
56 bytes
8 Thermocouple readings
UUT Device 4
56 bytes
8 Thermocouple readings
UUT Device 5
56 bytes
8 Thermocouple readings
UUT Device 6
56 bytes
8 Thermocouple readings
UUT Device 7
56 bytes
8 Thermocouple readings
UUT Device 8
56 bytes
8 Thermocouple readings
Note that the oldest 4% of the data in the log file will be lost wh en the log file exceeds the Log File Size set in
the Settings\Logging\Setup window. Therefore, the required log file siz e should be calculated using the
above technique before any lengthy test to be sure t hat it will not reach the Log File Size limit. In addition,
any data that already exists in the log file should be taken into account. You can export the History file and
then clear it using the Logging\Clear Histo ry f older before a long test to utilize the full capacity of t he S torage
Card.
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6.8 Chamber Setup
WARNING: Incorrect Chamber Type setti ngs may cause severe damage to your chamber.
The Chamber Setup Directory is used for factory s etup. The chamber type specified in the Synergy
Controller must match the chamber that it is controlling. The Chamber Type setting maps software outputs
to chamber hardware. Each chamber type has as specific map that is unique to that type of chamber. The
operator should NEVER change this setting. It should only be modified by a qualified technician.
Generic Temperature Only
Generic Temperature/Temperature *
Generic Temperature/Humidity *
Generic Temperature/Humidity Single Stage
Generic Temperature/Pressure
Generic Temperature/Humidity/Pressure
Generic Temperature/Vibration
Retro Temperature Only
The Chambers Types in the list above that are identifi ed with * support VersaTenn retrofit fit applications.
Chamber Output Mapping
The Synergy Controller can be configured for many c ham ber types. Each chamber type has a unique device
output mapping. For example, the fan is driven by Out put 1 on Temp-Humidity and Temp-Only chambers,
and by Output 10 for Temp-Temp chambers.
The following tables list the output mappings for th e supported chamber types including retrofit
configurations; i.e. when the Synergy Controller is installed on a chamber with a VersaTenn, VersaTenn II or
VersaTenn III.
Output Map Abbreviations:
♦ SM – Switching Module
♦ SSR – Solid State Relay
♦ P# - Olympic Board Connector Labels
♦ J# - Output Board Connector Labels
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Switching Module Configuration
1SM
1 Thru 8
Alarm
SSR
Outputs
2SM
1 Thru 6
3SM
1 Thru 6
1SM
9 Thru 10
1SM
11 Thru 12
The Olympic board drives all of the outputs for the chamber thru
solid state switches called Switching Modules (SM). In some
cases there is more than one way to connect a specif i c out put.
This provides flexibility when wiring the chamber to support new
and retrofit installations. The figure at the right shows the
different the ways Olympic board can be connected t o t he
various SM boards.
For example, note that the 3SM-Event outputs can be connected
two ways; directly to the Olympic board P6 connector or thru the
1SM- J5 connector as shown at the right
In addition, some chamber definitions provide t he same function
to more than one output. This is referred to as mirroring.
For example, in the Generic Temperature Humidity configuration
the “Humidify” output is available on 2SM-2 and SSR-2. The
SSR outputs emulate the VersaTenn III SS R out puts which
simplifies VersaTenn controller retrofits. T o further support
retrofits, the 5-Channel output board is wired to emulate the
wiring of the VersaTenn III SSR outputs.
Installation section 17.0
describes the SSR outputs for retrofit
configurations in greater detail.
The Screenshot below shows the position of each swit ching
module on the EVENTS/Digital Output Screen.
Relays
1 and 2
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6.9 Graph Settings
The Graph Settings Paramters Control both the
6.10 LCD Settings
The LCD Brightness feature changes the brightnes s of the LCD touch screen. If your Synergy Controller i s
at eye level or you work in very light conditions such a s a room with direct sunlight, you may want to set the
LCD screen to a slightly darker setting. If your Synerg y Controller is mounted in a location that requires the
operator to view the screen at a sharp angle or in a low light room, you can set the LCD to a brighter output.
Note that this function is controlled by a potentiomet er on Synergy Micro and Synergy Micro V units. See t he
figure in the installation section
of this manual.
6.11 Panel Lock
Panel Lock is a security feature that either partiall y or completely restricts access to the Synergy Controller.
This feature can protect a chamber from unauthori zed access. When Panel Lock is enabled, access is only
permitted when the operator enters the password.
User access to specific controller areas can be restricted appropriately for each user function.
The enhanced Panel Lock feature provides 5 level s of access security:
1. Administrator
2. Maintainer
3. Engineer
4. Operator
5. Unrestricted
The Synergy Controller user interface consists of the LCD Touch screen, eight Screen Selection but tons
below the LCD, and 10 Navigation and Control buttons to the right.
With the new Panel Lock features, each Screen Selec tion button is assigned a security level from the five
available levels. General Synergy controller screen f eatures and Default user levels are summarized in the
table below.
chart on the Graph Screen as well as the chart on
the Main Screen.
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Screen
Screen usage summary
Default Access
SETUP
Chamber Configuration, Settings and PID values
Administrator
MAINT
Time/Date, Monitoring
Maintenance
COMM
Communications setup, Network Setup
Engineer
PROG
Program creation and editing
Engineer
RUN
Program Run
Operator
EVENTS
Input and Output Monitor and User Event control
Operator
GRAPH
Process variable and Setpoint graphing
Unrestricted
MAIN
Steady State control setpoints, Graph, and On/off feature.
Operator
Screen
LCD
Navigation and
Touchscreen
Selection
Control
Panel Lock Feature Setup
To setup the Panel Lock feature follow these steps:
1. Specify the password for each user level.
2. Specify the user level for each of the 8 Screens.
3. Set the Panel On/Off Keys as re quired.
4. Set Unlock Duration t i me (in units of minutes).
5. Set Panel Lock to "Locked".
Once locked, access to your controller is now restricted.
Any user touch on a password protected screen, whether locally through the touch screen or via a web
browser will pop up a password entry dialog box. The user can enter the password to unlock that screen or
press Cancel and return to the Main screen.
The Panel Lock feature setup is done from the S etup screen’s Panel Lock Folder.
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In the \Panel Lock\ folder there are two subfolder s; A dm i n Settings and Screen Settings as shown below.
The \Panel Lock\Admin Settings\ folder is used to enable the Panel Lock feature and control Panel Lock
options and passwords. The panel lock options control the function of Panel Lock in two ways:
1. Panel On/Off Keys Enable/Disable.
2. Unlock Timer Duration
1. Panel On/Off Keys, when set to Enable, allow the use of the ON/OFF keys on the controller when the
panel is locked. Enabled is the recommend setting f or saf et y reasons.
2. Once unlocked, the touch panel will automatic all y re-lock after a period of inactivity. The Unlock Duration
setting specifies this period in minutes.
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The Panel Lock Passwords are listed in the \Panel Lock\Admin Settings\ folder in the order of access
privilege. The Administrator password has the highest privilege and can access all the controller screens.
The password can be up to 10 alpha-numeric characters. To change the password, select the user level a nd
press the Change button to open the T-9 pad, and th en enter the new password.
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The \Panel Lock\Screen Settings\ folder is used t o assign the user level for each screen. The suggested
Screen
Default Access
SETUP
Administrator
MAINT
Maintainer
COMM
Engineer
PROG
Engineer
RUN
Operator
EVENTS
Operator
GRAPH
Unrestricted
MAIN
Operator
user levels are listed in the table below.
Default User Levels
The \Panel Lock\Screen Settings\ folder is sho wn below:
(Note that the vertical scroll bar must be used to vi ew all 8 sc reens in the list)
When the Panel is locked, access is only permitted on screens assigned a user level other than “none” after
the user enters an appropriate password.
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When the “Enter Password” dialog appears, the use r m ust enter the password and then press OK to unlock
the panel.
Once unlocked, the touch panel will allow access t o any screens assigned that access level or any lower
level screens.
In addition, the panel will automatically re-lock afte r a period of inactivity. The unlock duration setting
specifies that period in minutes.
The user can go to the \Panel Lock\Admin Setup\ folder to clear the password without waiting for the Unlock
Duration inactivity timer to expire by unlocking and re-locking the panel.
6.12 Languages
The Synergy Controller can be configurable to many language formats. Please contact Tidal Engineering f or
more information.
Note: The Espanol setting is for demo purposes only.
6.13 User Programmable Alarm System
The Synergy Controller’s user programmable alarm system can create customer specific ala rms and
warnings and special factory applications. The user can create alarms for RTD temperatures, UUT
temperatures as well as voltage inputs, digital i nputs and auxiliary sensors such as Oxygen, pressure, etc.
For special applications, the chamber manufacturer or retrofit installer can program an alarm relay to operate
a system function. This section explains the user alarm setup procedures using two examples.
The User Alarm screen operates as a wizard like the profile wizard screen. This means that the setup
instructions are provided along with the entry fields and the user enters information and presses next or back
as required until the alarm is entered. The result alarm can be programmed to appear in the Alarm window if
required as shown below. The diagram below right s hows the electrical connection for the corresponding
user alarm.
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Module
First Selection
Second Sel.
Choices
Olympic Board
RTD1&2, Analog 1-4
N/A
6
UUT Module Inputs
UUT Module
Sensor
64
Machine Inputs
Low Resolution Channels 1 thru 8
N/A 8 Digital Inputs
Inputs 1 thru 16
N/A
16
Channels
Channels 1 thru 4
N/A
4
Setpoints
Setpoints 1 thru 4
N/A
4
Comparison
Application
Input Open
Digital Inputs only
Input Closed
Digital Inputs only
Greater than Threshold
All inputs except Digital, Raw or Scaled.
Less than Threshold
All inputs except Digital, Raw or Scaled.
There are 102 inputs/variables that can be monit ored for user alarm conditions (see the table below)
The Input options are:
There are four Comparison options available.
The User Alarm Wizard steps are as follows:
1. Open the Setup S cr een and browse to the User Alarms folder.
2. Select the Sensor, Setpoint or Channel.
3. Define the comparison type and the scaling, i.e. Input Open, Closed, Great er than (>), etc.
4. Select the Alarm Threshold. (Not required for Digital Inputs).
5. Assign a name for t he al arm. This name appears in the alarm screen when the alarm occurs and in
the User Alarm list.
6. Select the desired alarm responses.
7. Confirm your choices to finish.
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Open the Setup Screen and browse to the
User Alarms folder
Select the Sensor, Setpoint or channel.
Define the comparison type and the scaling,
The Comparison choices are:
1. Input Open.
2. Input Closed.
3. Greater than. >
4. Less than. >
The Data Scaling choices are:
1. Raw Value.
2. Scaled Value.
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Select the Alarm Threshold.
This step is not required for Digital Inputs.
Enter a name for the alarm. This name
Select the desired alarm response.
appears in the alarm screen when the alarm
occurs and in the alarm list.
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The Options are :
1. Show Alarm.
2. Log Alarm.
3. Disable Chamber.
4. Activate Alarm Relay 1.
5. Activate Alarm Relay 2.
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Confirm your choices and finish.
Open the User Alarm folder and press the Add
Oxygen
Oxygen
User Alarm Example 1:
Create an alarm that senses Digital Input 5 and Display s “Ox ygen Sensor Warning” when the input is Open.
Sensor
Warning
Normal
State
Sensor
Warning
Alarm State
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Alarm button on the Setup screen shown at left .
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Press the Sensor text box as shown at left to
start the Sensor Selection process.
Select Digital Input 5 as shown in the figure at
The wizard displays the code for this sensor.
left and then press accept.
Press Next -> to continue.
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Select the Comparison from the drop down
window. In this case Input Open.
Enter a name for this alarm.
Enter the name for this alarm.
Note: Data Scaling doesn’t apply for digital
inputs
Then press Next ->.
Press the text box to open the Alpha Numeric
Keypad.
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Then press Next ->.
Select the Alarm Actions.
Confirm your choices and press Finish to
In this case, the “Show Alarm” and “Log Alarm”
options are selected.
Then press Next ->.
complete the Alarm entry process.
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The User Alarm Setup screen shows the new
entry.
In operation, the Alarm Screen in the Maintenance folder indicates a normal state when the Input is closed
as shown in the figures below:
The Alarm Screen in the Maintenance folder Indicates the alarm condition when the Input is open as shown
in the figure below:
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User alarms in the Maintenance/Alarm screen are cleared and acknowledged like built-in High and Low limit
alarms. The alarm entry indicates Yes in the Ack colum n af ter an alarm is acknowledged. The alarm
indicates Yes in the Cleared column after it has been cleared, i .e. the alarm condition is no longer present.
As with built-in alarms, user alarms can be acknowledged before or after they have cleared but the alarm is
removed from the list only after the alarm condition has cleared and it has been acknowledged by the
operator.
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For example, in the screenshot below, the Alarm has been acknowledged but the alarm condition still exi st s.
Once the Alarm has been acknowledged and the alarm condition has cleared the alarm entry is removed
from the list as shown below.
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Example 2
Open the User Alarm folder and press the
Select the Olympic Module and Analog 1, the
This screen shows the Sensor code for the
Since we want the alarm to trigger when the
pressure is less than 30 Torr, we select the
At low atmospheric pressures, the heaters in mo st al titude chambers are turned off so they don’t overheat
when convection cooling capacity is reduced. In this example we will create an alarm that senses Hi Res
Input 3 (Torr) and opens Relay 2 when the value is less tha n 30 T orr. This alarm is named “Heater Safety
Shutoff” and displays “Heater Safety Shutof f ” when t he threshold is reached.
Add Alarm button on the Setup screen shown
at left.
Hi Resolution Analog input.
Olympic Module and Analog input 1.
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Less Then comparison type. We also select the
Scaled Value for Data scaling because we want
Next we enter the Alarm Threshold.
Enter the Alarm Threshold and press Accept to
to check the scaled Torr value as opposed to the
Raw 0-5 Volt input value.
Then we press Next-> to continue.
Press the Alarm Threshold text box to open the
number pad.
continue.
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Confirm the Alarm Threshold.
Here we enter the Alarm response.
And finally, we confirm our settings and then
Then we press Next-> to continue.
In this case we only want to Activate Relay 2.
Then we press Next-> to continue.
press Finish.
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The User Alarm Setup screen lists our new
alarm as shown at left.
In operation, when the Torr value is greater than
When the Torr value is less than 30 Torr, as
30 Torr, as shown here, Relay 2 (Event 24) is
Activated (Grey).
shown here, Relay 2 (Event 24) is normal (Red).
Note that as we specified, this alarm only
operates Relay 2. It doesn’t appear in the title
bar, in the alarm screen or in the log file.
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6.14 Resume Behavior
The Resume Behavior parameters control the
behavior after the controller power is restored.
Steady State parameter controls the behavior
when the controller power is lost while the
controller is on and in Steady State mode.
Profiles parameter controls the behavior when
the controller power is lost while the controller is
running a Program.
Restart Delay parameter is used to delay the
chamber restart to limit the current inrush if a
facility operates multiple chambers.
6.15 Main Screen Setup
Main Screen Setup options include:
• Large, Medium, and Small Channel Text sizes.
• Process Graph
• Sensor Readings; up to 8 additional display sensors on the Main Screen.
• Optional Chamber Light Switch.
6.15.1 Channel Displays
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Large Display Channel Text
Medium Display Channel Text
Large, Medium, Small Channel Text sizes
Small Display Channel Text
Small Display Channel Text with Graph
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6.15.2 Sensor Displays
Up to 8 Sensors
Medium Display Channel Text
Sensor 3
Sensor 6
Sensor 5
Sensor 4
Sensor 7
Sensor 8
Sensor 9
Sensor 10
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6.15.3 Chamber Light
Main Screen Setup Folder
Chamber Light Folder
Chamber Light with Large Display Text
Chamber Light with Medium Display Text
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Event Screen parameters that pertain to Humidity
6.16 Event Screen Setup
control features can be hidden, allowing Event 7,
Event 8, and Event 9 to be displayed.
The Event Screen can be customized to display
user-friendly names rather than just the Event
number. These names would typically be based
on the functions that the events control.
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7.0 MAINT SCREEN
Alarms
exists.
7.1 Operator Interface
The Maintenance Directory provides a set of uti l ities used during the operation and maintenance of the
chamber.
Maintenance Screen
Press the MAINT button to access the following
functions.
♦ Alarms (View and Clear Alarms)
♦ Channel PIDs (PID variables in real-time)
♦ About (Versions and Serial Numbers)
♦ File Utilities (Copy Files, Export History)
♦ Date and Time (Set)
♦ Restart Controller
The alarm screen displays current Synergy
Controller alarm conditions. Access this screen
to view and clear a chamber alarm. When an
alarm occurs, the following attributes are listed.
♦ Time of Alarm
♦ Alarm Type
♦ Ack: (User acknowledgement).
♦ Cleared: (Indicates if the alarm condition
has cleared).
The word ALARM will flash in the upper right
corner of all screens while an alarm condition
Select an alarm and press the Ack Alarm button t o ack nowledge it. This will set the Ack column value to
Yes. When the Alarm condition clears the Cleared column will automatically be set to Yes. When both the
Ack and Cleared column read Yes (When the user ha s acknowledged the alarm and the alarm condition has
cleared), the alarm is removed from the list. Specific alarms are covered in greater detail i n the following
section. Alarms always create an entry in the log f i l e.
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7.2 Alarm Functions
SYNERGY CONTROLLER ALARMS AND ACTIONS
Relay 1
Relay 2
Turn OFF
This section contains information on: Low Storag e Alarms, Low Memory Alarms and Alarm Actions (Relays,
Alarm Indications, and Outputs). Note: Alarm Relays are normally energized.
# Alarm Name
1 Low Space Storage Card (Flash)
2 Low Program Memory (RAM)
3 Temp-guard
4 Open Sensor Ch1 (RTD 1)
5 Open Sensor RTD 2
6 Voltage Sensor Ch 2 (Humidity)
7 Voltage Sensor
8 Voltage Sensor
9 Voltage Sensor
10 Hi Temperature
11 Low Temperature
12 Hi Humidity
13 Lo Humidity
14 Internal Comm. (B ad Dat a)
15 Internal Comm. (Connection)
16 Olympic Board Re set
ALARM RESPONSES
Alarm
Closed Closed YES No
Closed Closed YES No
Closed Closed YES No
OPEN Closed YES YES
Closed Closed No No
Closed OPEN YES YES
Closed Closed No No
Closed Closed No No
Closed Closed No No
OPEN Closed YES YES
OPEN Closed YES YES
Closed OPEN YES YES
Closed OPEN YES YES
Closed Closed No No
OPEN Closed YES YES
Closed Closed YES No
Alarm
Alarm On
Screen Flashes
All Outputs
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Synergy Controller Low Program Memory & Low Storage Alarms
When an alarm occurs, the word “ALARM” flashes
To clear the alarm condition, export the logging
There are two types of local storage on the Synergy Controller: Storage Card (Flash) and RAM. The Storage
Card holds all the application programs, programs, and log files. RAM is used exclusively by the Operating
System (OS) and Synergy Controller software. The S ynergy Controller monitors both storage areas for low
memory.
Low Program Memory Alarm
In the event that the RAM memory runs low, the Synergy Controller operating system will no longer run
efficiently. If a Low Program Memory condition exi sts a pop up window warns "The Synergy Controller is
running low on memory. Please reboot at your earliest convenience" and the Maintenance Alarm s creen will
display the message “Low Program Memory”. Reboot the Synergy Controller to clear this error.
Low Storage Alarm
The Synergy Controller monitors the space remaining on the Storage Card Flash memory device, and
generates an alarm condition when the space remaining is less than 160K. When this occurs, you can clea r
the log file, export screenshots or remove program s f rom the Storage Card to free up Storage Memory to
correct this condition.
A Low Storage Alarm can occur when the log file has grown too large. When your chamber is properly setup
the Synergy Controller will log until the file gets to a specifi ed maximum size and then begin overwriting the
oldest records, thus limiting it to the specified size. The maximum size specified for t he l og file should be
less than the physical space available. Step-by-step instructions for clearing the alarm and adjusting the
chamber settings to prevent this alarm from reo ccurring are illustrated below.
Removing a Low Storage Alarm Condition
in the title bar of the Synergy Controller screen. To
determine if your alarm condition is a Low Storage
alarm, go to the Maintenance\Alarms folder and
read the alarm description.
history data and clear the file according to the
following steps:
Go to Setup Screen folder and scroll down to select
the Logging folder.
Synergy Controller Technical Manual, Revision H
Page 98
Select Export History if you would like to save the
history file. This step can be skipped if you don’t
Open the Actions Folder.
Select Export Log to USB to save the history file.
need the data in the log file. See
Section 7.1
Maintenance: Operator Interface for more
information on exporting history files.
WARNING: Once deleted, logging data cannot be
recovered.
Go to the Setup Screen and select the
Logging\Clear History folder. Press the Clear
History button to delete the current hist ory file and
free its space on the Storage Card. The chamber
should now be free of the Low Storage alarm
condition
Synergy Controller Technical Manual, Revision H
This step can be skipped if you don’t need the data
in the log file. See
Section 7.1 Maintenance:
Operator Interface for more information on
exporting history files.
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Select Clear Log and press the Execute.
Acknowledge the Low Storage Alarm Condition.
WARNING: Once deleted, logging data cannot be
recovered.
The chamber should now be free of the Low
Storage alarm condition
Once you have cleared the alarm condition, y ou can
acknowledge the alarm to remove it from the
Alarms folder list.
To acknowledge the Low Storage alarm, go to the
Maintenance Screen and select the Alarms folder.
The Low Storage alarm should say “Yes” in the
Cleared Column.
Press the Ack Alarm button. The Alarm condition
is now acknowledged and cleared and is removed
from the list.
Synergy Controller Technical Manual, Revision H
This “alarm acknowledge” procedure ensures that
the user sees the alarm event before it is cleared.
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Preventing the Low Storage Alarm condition
Go to the Setup screen and select the
The Synergy Controller determines the upper limits
The maximum Log File Size is now set to 1.40 MB.
You can eliminate the recurrence of a Low Storage Alarm Condition by adjusting the Log File Size to a value
less than the space available on the Synergy Cont roller Storage Card. Follow the steps below:
Logging\Setup folder. Select Log File Size and
press the Change button.
of the valid range automatically. Change the Log
File Size to a number below the maximum value. I n
this case 1.40 MB is a valid value.
Synergy Controller Technical Manual, Revision H
Now the chamber will not generate a Low Storage
Alarm condition. If the history file reaches the Log
File Size limit in the Logging Setup folder, new
logging information is added to the file and the
oldest data is removed in a FIFO (First In First Out)
basis.
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