Tidal Engineering Synergy Series Manuel utilisateur

Synergy Controller Technical Manual, Revision H

Nano, Micro 2, and Quattro

For One to Four Channel Systems

Tidal Engineering Corporation

2 Emery Ave

Randolph, NJ 07869

[email protected]om

www.tidaleng.com

Document Number TE1813, Revision H: October 18, 2016

Synergy Controller Technical Manual, Revision H

Page 2

Revision History

Rev.

Date

Revision

June 16,2005

First Release

June 27, 2006

Added revision page

Updated chapter numbering for sections 8.1.1, 9.7, 11.4

October 17, 2006

Updated for Synergy Controller application version 2.0.8.

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

Revised Synergy Controller Compact Interface Panel Layout figures

January 10, 2008

Updated for Synergy Controller application version 2.6.10.

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

Added bookmark hyperlinks to document

October 5, 2015

Updated for Synergy Controller application software version 3.0.7 Build 893.

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

Replaced CCFT Lamp replacement with LED upgrade procedure.

October 18, 2016

Unified Technical Manual Covers Synergy Controller Software and programming for all

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

Synergy Controller Technical Manual, Revision H

Page 4

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

Synergy Controller Technical Manual, Revision H

Page 5

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 Data 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 Option...........................................................................167

14.4.1 Setup Procedure................................................................................................................................169

14.5 Alarm Logging........................................................................................................................................172

15.0 INSTALLATION AND TROUBLESHOOTING......................................................................................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, Altitude 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

Synergy Controller Technical Manual, Revision H

Page 6

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 Software for 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 Controller 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

Page 7

1.0 INTRODUCTION

Welcome to the Synergy Controller line of touch 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 efficiency and simplify test programming

and documentation tasks.

The Synergy Micro 2 Controller employs features that maximize the capabilities of your test chamber. It is

designed to take complete command of the chamber’s conditioning systems with total programming of

process variables such 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 controllers 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 Server which

permits control of the equipment from anywhere in 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 format is

Windows™ compatible, and program, logging and 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 access to all areas in the system; i.e. the controller is easily

switched between setup, programming, and diagnostic 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 permit 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 released in 2001 and has been steadily improved through a

continuous process. Numerous software versions have been released in an effort to improve the usability,

reliability and features of the controller. This manual refers to the features in the newest major upgrade of

the Synergy Controller application, version 3.0.7. Some of the features described in this manual were not

available in previous versions. Check the Tidal Engineering website (www.tidaleng.com) for information 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 you 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 Build 893x, offers some powerful new features and capabilities

including:

•E-mail

oAlarms

oLog Files

oPlots

•Network printing features.

oPDF plots

oPrint directly to a network printer.

•User alarms

oCustom alarms for pressure transducers, Basket jam

•Main screen layout features

oDisplay additional sensor values for user information

oChamber light switch

oToggle switch

oFont size options; Large, Medium, Small

oFTP Server

•New Output Primitive Types

oPWM – General purpose time proportioning output (Up to 8)

oON/OFF – Thermostatic Primitive. (Up to 8)

•Updated Help System

oSpanish Language

oEdited for clarity

•Graph

oImproved graph timing accuracy and resolution

oAdditional Graph Scaling features; Time Scale and Vertical Scale

•Events Screen

oNew parameter turns off Humidity events and displays 9 total User Events

oDisplay friendly event names like GN2 Purge or LN2 Enable

•Alarm Screen

oAlarm information enhanced; i.e. Alarm shows source of Digital Input DIN 1

•Improved Cascade Control Algorithm

oControl Boost Heat and Boost Cool explicitly

•Command Set

o200 new commands

•Logging Feature

oProfile Logging

oProfile log Auto-Removal

oExport file naming

oWarn when full

oStop logging or Overwrite option when full.

oAdded Header to all logs and settings that includes chamber information

oLogging PID Values, constants and variables

•Programming

oAdded Pause Step

oChange Setpoint while paused

oAdded a “Wait For Tolerance” Parameter for each channel.

oDisplay Program Name in the Title Bar of all screens

•Standard Alarms

oAdded Deviation Alarm Feature

oAdded Alarm Delay

oCustom Behavior capability

•Added Chamber Name feature to allow each chamber to be uniquely identified in chamber in logs & e-mails

•Virtual Sensors

oVirtual Pressure

oWet-Bulb/Dry Bulb

oVirtual 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 Controller” added to highlight the various ways the controller

can format and deliver test results.

Synergy Controller Technical Manual, Revision H

Page 9

1.2 Controller Configurations

This technical manual supports the Synergy Micro 2 and the legacy Synergy Micro and Synergy Micro V

configurations. In many cases the features of these 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 identified in this document with the appropriate icons.

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

x86

Floppy Drive

Yes

5.0.E1

5.0

2.11 and 4.2

The following table shows each of the above configurations with the corresponding image.

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

OS: P/N TE1860

Synergy Controller Technical Manual, Revision H

Page 10

The Synergy V and Synergy Compact configurations below are supported by prior technical manuals; Rev F.

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

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