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Sanyo Thermometer 550 User's Manual

1. L HAHAHA hook eet tte pog wep epee rai ee ARA s P rh rr rs rF Pitari le AAA rb A D e mr ds aum tag ee e AAA PN AE A la 1 los ee oo HA FAA rs A op ram ma a np Errar A ir r n Farvrms 1 t 1 L a heb eee REF MO TOI A C274 67 CONTACT INFORMATION SANYO Gallenkamp PLC 50 Bishop Meadow Road Loughborough Leicestershire England LE11 ORE Telephone 0509 266366 Telefax 0509 269770 Contact Environmental Service Department
2. ine LES J Paste 1 Fig 5 The Program Data Entry Window When preparing a program for entry into the FORMAT programmer it is recommended that the provided programming sheets are used Copies of programming sheets are available from Sanyo Gallenkamp part number Z01442 A library of pre prepared programming sheets and disks is also available covering many of the popular standard tests 4 2 How to use FORMAT programming sheets Draw out the graphic representation of the required test on the graph area of the pro gramming sheet This needs to indicate the changes ramps in temperature and hu midity if being programmed From the graph determine all data segments the changes in the temperature and hu midity data often called corners A data segment is a point in ime when a change in the data on which the programmer is acting upon is required For example change in temperature humidity from a ramp to a dwell in programmed temperature ramp rate Switching on or off user digital channel s A segment can reflect any number of changes providing they are required at the same time The first segment of any program starts at time 00 00 00 00 days hours minutes seconds This corresponds to the instant the chamber starts running at which time the condition inside the chamber is ambient The segment time is from the start of the program not from the previous segment The last s
3. Enabled Threshold Disabled Fig 11 The Alarm Setpoints window 6 2 Setting Alarms To set the alarm triggers select the Alarm option on the Main Menu This brings up a sub menu from which you can select either Temperature or Humidity After selecting either temperature or humidity FORMAT presents a data entry window as shown below There are Alarm Setpoint data entry windows for both temperature and humidity alarms Set the alarm triggers by Enabling the relevant type of triggers and then enter the threshold values for the triggers You can have any combination of triggers enabled If an alarm is triggered then Alarm is shown in the Status window and if logging is selected then the alarm condition is logged to disk 7 COMPUTER INTERFACING 7 1 7 2 INTRODUCTION Using the RS232 port on the chamber the Format 550 can be interfaced to PC compatible computers Primarily there are at present two methods available to the user However this area of application continues to develop rapidly If this manual does not fully address your application please contact SANYO Gallenkamp PLC or your dealer 7 1 1 HOST SYSTEM This is a software package that can be installed onto the hard disk of a personal computer It enables the connection of up to 8 Format 550 controllers Each can be addressed individually to allow uploading and downloading of programs It can be ordered from SANYO Gallenkamp PLC or your dealer
4. Important It is important that the master should wait for a reply from the Controller up to the 12 second time out before issuing any more Command Packets If this precaution is not observed a packet clash could take place on the RS485 bus Even if the master software is only intended to run in a single Controller configuration using RS232 observing this precaution will ensure compatibility with the RS485 configuration Packet Flow Summary master transmits Command Packet to Controller ifthe Controller fails to receive the packet in full or one of the check sums is wrong the packet is ignored amp the Controlier takes no further ac tion In this case the master would realise that the packet was lost after the time out period amp would be able to re transmit the Command Packet ifthe Controller receives a correct Command Packet from the master it acts on the command and issues the appropriate Reply Packet as soon as it can usually within 15 but always within 125 7 3 4 FUNCTIONAL LAYER DEFINITION Types of Packets Description CONTROLLER CONFIGURATION REQUEST Type Command Source master Header 128 Data Block No This packet instructs the Controller to reply with information as to its type and configuration Description CONTROLLER CONFIGURATION Type Reply Source Controller Header 128 Daia Block 22 bytes The data bytes of the Controller Configuration Reply are as follows in the order in which they appea
5. When a program is being editted or displayed on the Edit Program window after loading a visual representation of program may be displayed as a line graph by pressing F2 Condition C 41 ee eee 5 Data Logging This section describes how to start and stop logging and how to import data into industry standard spreadsheet packages Condition C RH Siatus Runcicg program Logging Control Program SEIRENA Main Menu Logging Menu _ Start Logging Now Synchronise Start Start On Alarm Halt Logging Now Load Log From Disk lose this Menu Shut Chamber Down Fig 10 The Logging Menu 5 1 Introduction to Data Logging Data Logging is selected from the Mam Menu There are three different ways data logging can be initiated Start Logging Now Synchronised Start and Start on Alarm Whichever method you choose you will be prompted for a file name for the data log 5 2 Starting Data Logging The simplest method to start data logging is to select the Start Logging Now menu option This starts logging as soon as you have entered a file name You can also set logging to start at the same time that a program 15 run Select Synchronise Start for this If you only want to start logging when an alarm condition occurs select Start On Alarm The logging field in the status banner at the top of the screen changes to reflect the start mode you have chosen 42 9 3 Stopping Data Log
6. employed to ensure fool proof operation 1 2 Format digital channels The FORMAT programming system fitted to the cabinet has up to eight digital channel functions The digital channels are cabinet dependent A number of the channels are for the control of the cabinet but require selecting on or off to achieve certain conditions If applicable other user designated channels are fitted such as voltage free contacts for switching the test load The selection of cabinet dependent digital channels is predicted by FORMAT and its suggestions will in most cases be adequate The digital channels can however be operator selected to match particular requirements The digital channels descriptive names are listed on applicable windows screens of the FORMAT display Full details of the function of the digital channels fitted are given in Part 1 Section 2 4 of this manual oo LE Li o 1 3 How to use these instructions These instructions are written for the end user and is not intended to be an engineering manual For this reason itomits unnecessary detail concerning how the controller works and concentrates on information the operator needs in order to make the best use of FORMAT s powerful capabilities Some users will find they are familiar with the system after only a short time For such users these instructions may be used as a reference guide the sections are split into controller functions If you prefer a methodical approach to
7. 1 OE ES 0 10 190 65 00 00 04 10 1H 35 OO 40 40 00 00 03 40 i 65 00 00 01 164 15 loep to 1 00 04 20 M0 35 00 00 60 40 01 04 04 29 iM 65 05 00 41 ON 00 04 40 70 15 100p to 3 00 10 5 00 00 0 40 09 00 05 90 3t H 00 99 05 214 EU M 08 00 01 24 0 06 65 18 MY 15 09 60 61 40 E 00 06 M 309 Y loop to 1 90 00 01 0 0 00 54 14 38 35 bas 08 00529 00 90 4 24 5 35 00 00 08 4b 06 00 06 40 421 65 80 60 21 08 08 00 07 00 un loop to 1 00 06 01 Od 40 61 30 15 00 50 41 460 65 0 96 91 09 04 90 07 40 9 15 to 3 00 40 01 30 A i 4 0608 00540 sho 65 9 03 01 PETERE 35 Ure 00 00 06 0 4 45 06 00 99 560 5 00 64 04 23 4 25 00 50 02 30 00 10 39 40 APPENDIX 3 FORMAT 550 PROGRAMMING FORMAT 550 PROGRAMMING SHE CENVIRONMENTAL TEST NO OF CYCLES DIGITAL CHANNELS USER NOTES LS LOD STORT SEGMENT Reo HUMBER DF REPESTS SANTO Gallenkeme PLO UE Service Depor Prone 44 03507 266366 4 05507 263770 D 1994 SANYO Galtenkame Plc ES SHEETS CONDITION SEGMENTS esl DIGITAL CHANEL HE Y ROU MINS 0 00 00 00 m E 9 7 EE zu Pie ear TE 14 wil tidad mr bse 4 vu pra E iacta eio 0r rd dam Fi 1 1 t tamm ta
8. 5 S 0 4 5 D Data Block 0 to 127 6 54D XOR Checksum 0 to 127 6 5 D Additive Checksum 0 to 127 Minimum packet size is 8 bytes Maximum packet size is 260 bytes The same packet structure is used for both transmissions from the master Command Packets and transmissions from the Controller Reply Packets A dialogue is always initiated by a Command Packet from the master Header This byte which must have bit 7 set i e value between 128 and 255 identifies the purpose of the packet a full description of ail the different types of packet is given later Packet Count This byte may take a value between 0 and 127 and should be incremented by 1 for each Command Packet transmitted by the master except when the packet is a retransmission due to the fact that no reply was received to the last Command Packet in which case the Packet Count should remain at the value of the original Command Packet When the Packet Count reaches 127 the Packet Count of the next Command Packet Should be 0 When the Controller replies the Packet Count byte in ihe Reply Packet 15 set to the same value as in the corresponding Command Packet This allows the master to positively associate Reply Packets with Command Packets The Controller does perform validation of the Packet Count field in some circumstances For example when transferring a file from the master to a Controller the file is split into packets and transmitted one packet ata tim
9. Selecting this menu option brings up a sub menu New Program Clears program in Host memory and enters Edit mode Edit Program Allows program in Host memory to be edited Load Program from Host Disk Loads program from Host disk library to memory Save Program to Host Disk Saves program in memory to Host disk li brary Delete Program from Host Disk Deletes program from Host disk library Load Program from Controller s Disk Load program from Controller s local library to memory Save Program to Controller s Disk Save program in memory to Control ler s local library LOGGING Selecting this option brings up a menu with the following options Transfer Log from Controller Copy data log from the controller to the Host disk After selecting the data file to copy the user is given the op tion to have the file deleted from the controller after copying LoadLog from Host Disk Displays the data log traces on the Host PC This is for verification of trends only no scales are displayed A sepa rate spreadsheet package may be used for detailed analysis and display of the logged data 7 25 PRINTOUTS You can print out hard copies of programs from your Host PC Call up the required program program load from disk ESC edit program With the required program displayed in Edit mode press Print Screen A formatted listing will be produced see sample In the sample please note that the Seg men
10. a program When you choose Run Program from the Program Menu provided the current program is valid you will be presented with a data entry screen for run options The options are NUMBER OF CYCLES This is the number of times the program is repeated This facility is of use for repetitive programs GUARANTEED SOAK This option when enabled haits the program run time at each segment until the specified condition is reached TIME IN TO PROGRAM This specifies at what time into the program you want the run to start Note A mid cycle start can only be initiated during the first cycle ie at a time which is valid for the program COUNTDOWN TO RUN START This specifies a delay before the chamber starts running A delayed start to a program run can often be a very useful feature for example starting a test at some point during the weekend so it finishes on monday moming Number Of Cycles E o i Guaranteed Soak 1 0n 0 oif 9 Day Hour Min Program Start Fima fa qs Jo Day How Min Sec Countdown To Start Fig 7 Run Program Parameters window 39 A aac 4 6 Program Monitor Window When the run has started you can observe the progress of the program by selecting the Monitoring option from the Main Menu In addition to the information displayed for a Steady State run FORMAT displays the time into program run number of program cycles left and the Time Hold mode The Time Hold mode can be Soak if theGuar
11. channel enables the switching of external devices such as measuring equipment and the test load The system comprises of a voltage free termination of the programmer s digital channel number 8 which is wired through the cabinet s safety thermostat The final termination isasocketon the side orrear of the instrument compartment a suitable plug is provided The termination 15 rated at 240v S maximum and requires a suitable circuit for switching higher current loads Program this channel ON whenever the voltage free termination 15 required to be closed contact 3 DESCHIPTION 3 1 PRINCIPLE AND AIRFLOW direct cooling cod The well insulated cabinet interior is divided into working and treatment chambers as shown in the diagram fig 1 Airis circulated by a fan from the treatment conditioning chamber into the working chamber through the right hand wall plenum in which the wet and dry bulb sensing elements are situated in the optimum position for rapid response The conditioned air passes through the working chamber in a turbulent manner ensuring minimum temperature gradients before returning to the treatment chamber through the left hand wall plenum performance tolerances are to within 50mm of the walls of the working chamber This is the working envelope in which the test load is not affected by heat sources such as fans heaters or cooling coils The temperature and relative humidity of the air are maintained a
12. dept or your dealer Applications currently being explored include simple routines to interrogate the chamber in terms of temperature amp humidity potentially to be available in B A S LC source code and as compiled EXE files APPENDIX 1 TECHNICAL SPECIFICATION Temperature amp Humidity Programmer Controller with inbuilt Logic chamber intelligence mapping amp Data Logging Operator interface dataentry on chamber dedicated numeric keypad display on chamber green monochrome CRT Operating temperature 5 C to 60 C Analogue inputs Two 4 wire PRT inputs Range 150 C to 350 C Accuracy 0 1 C Dedicated to measuring temperature and humidity relative humidity is de rived by wet amp dry bulb by psychrometric computation Calibration of the analogue inputs performed in software there are no presets 10 ad just Control Loops Temperature Three term P 1 D digital control using trapezoidal approximation to in terpolate between samples Input sample and control period is 4 seconds Output of control algorithm is heat digital mark space ratio with 100 to 100 dead band adjustment Set point resolution 0 10C Relative Humidity Three term P 1 D digital control using trapezoidal approximation to interpolate between samples Input sample and control period is 4 seconds put of control algorithm is humidify digital mark space ratio with 100 to 100 dead band adjustment Set point resolut
13. of the Host PC LEARN CFG DIG CHAN CFG If you are unsure about this please contact SANYO Gallenkamp PLC Service Dept Once installed on the PC the Host Software has two modes of operation On line Mode connected via RS232 port to Format 550 controller Off line mode Host Software in stand alone mode 7 2 2 STARTING THE SOFTWARE Torun the Host Software ensure that the security key is fitted and the enter the foliowing at the DOS prompt CD HOST enter 47 HOST lt enter gt The Host Software will then start up in Network Monitoring Mode see below 7 23 NETWORK MONITORING MODE When the Format 550 Host software is executed it scans the network for a Format 550 controller which is switched on and connected to the Host and enters Network Monitoring Mode In this mode the condition of up to 8 Format 550 Controllers may be seen on the screen of the Host PC there are no Controllers on the network e g Host PC off line the condition panels are blank Underneath each condition display panel is the serial number Underneath one of the condition panels is a flashing cursor The arrow keys may be used to move this between panels With the cursor on the serial number of the connected Controller any if off line press ENTER io enter the main menu for the selected controller Press Esc from the main menu to cause the Host software to return to Network Monitoring mode Press Esc from the Network Mo
14. part number 503554 In fact this package can network a mixture of Format 500 amp Format 550 controllers The following notes deal with only a single connection to a single Format 550 7 1 2 COMPUTER INTERACTIVE In this situation software is written by the user to enable his chamber to be slaved to some other intelligent device Typically this might be a system controller that is managing a test procedure being conducted on the test piece within the chamber The system controller can make decisions and direct the operation of test device and or chamber Ata simple level this can take the form of the system controller requiring data about the chamber condition to add toa log already being acquired A substantial protocol supports these interactions amp is described in section 8 2 INSTALLING amp USING A SINGLE CONNECTION HOST SYSTEM HOST PC SYSTEM REQUIREMENTS Hardware IBM PC compatible computer with 3865X processor or better VGA display adapter Hard disk with at least 2MB free 3 5 1 44MB floppy disk drive RS222 serial port COM Parallel Printer Port LPT1 Operating system MSDOS 5 0 or higher Additionally recommended Maing Filter Unit R5232 null modem cable to connect Host PC to Format 550 RS232 port Software Physical Components Installation disk Security key 7 2 1 INSTALLATION Insert the Installation Disk in drive A of the Host PC and at the DOS prompt enter the following e
15. surfaces of the mild steel are protected with rubberised paint and sealed against the ingress of moisture Insulation Minimum of 75mm of polyurethane foam giass wool Access Full sized insulated outer door with silicone rubber seal Lf fitted full sized inner glass door with silicone rubber seal One or more 66mm diameter silicone rubber cable entry port in left hand wall Shelf One solid stainless steel shelves with three shelf positions All models have a double skinned working chamber base which can be used for test samples False roof Provided to prevent condensate droplets from falling on the test samples Castors Nylon castors are fitted to floor standing models front castors are lockable Drain Provided for drainage of excess moisture Vent Provided in the rear of the cabinet to allow for expansion and contraction during temperature changes Can also be used in conjunction with the cable port to provide air exchange to prevent the build up of humidity or contaminating gases from test samples 2 2 SPECIFICATION PERFORMANCE Model reference CFI CF4 Temperature range 10 C to 180 C 40 C to 180C 70 to 180 C models HCC009 CB1 and HCC060 CF1 have a T max of 100 C Temperature rise rate not specified Temperature fall rate not specified Temperature fluctuation with time 0 3 C Temperature variation gradient LOC Humidity range rh 20 C 30 C 60 C 50 95 30 95 15 95 Humidity fluctuation w
16. the Program Menu If you wish to keep the program use the Save Program menu option see section 4 4 Note Programs written on screen are lost when the chamber is switched off or when there is a mains power interruption Programs required for repeated use should always be saved 4 3 1 Selecting digital channels when you know best On some occasions the selection of digital channels suggested by Format550 is not the best for the particular circumstances you wish to control Generally these cases involve loads which represent a significant thermodynamic load on the climatic systems They could be active loads which dissipate heat within the chamber Or they might be loads with significant mass which need to be taken through a rapid temperature change Finding the best selection for digital channels in these circumstances may need trial and error but as simple guidelines 37 wherever the thermodynamic load looks large increase the cooling power typically from aux to main or indirect to direct cooloing wherever the required temperature fall rate is high increase the cooling power wherever high humidity is required with a load that tends to dehumidify increase the humidifier power Usually this involves selecting first the high RH channel Then the vpg instead of the atomiser In extreme cases it involves switching them both on together loads that tend io dehumidify are those dissipating heat remember that a large mass descendin
17. this procedure terminates the FORMAT program the cabinet should also be switched off by pressing the mains power pushbutton 4 Programs This section describes how to write edit and run programs on the FORMAT 550 GENERAL OPERATING SEQUENCE ENTERING A NEW PROGRAM Write out the program using the FORMAT program preparation sheets Select Program from the Main Menu Select New Program from the Program Menu Enter the program segment by segment Save the program to disk tho UG Rx GENERAL OPERATING SEQUENCE RUNNING A PROGRAM Select Program from the Mam Menu Select the Load from Disk from the Program Menu Select the name of the program to be run Enter the number of cycles to be run and if required the mid cycle start time and de layed start time 5 Start the program running select Monitoring from the Main Menu to display the pro gram running 6 When the program has completed return the programmer to the main menu If no fur ther programs are to be run then switch off the cabinet AYR Condition C 95RH Status RENNIN steady Logging Inactive l Control i Program Edit Current Program New Program Load From Disk eee ee ss Shut Chamber Down Fig 4 The Program Menu 35 4 1 Writing a Program steady state Temp Hum Rep Digital Channels ann oon Ho o rim E sm M LIE ILE TES LOU LUC WU
18. 0 00 02 10 95 0 010 00 00 04 00 25 0 67 EFFECTS ON THE RUNNING TIMEBASE DISPLAY The timebase display in Monitor mode no longer counts up time from start of cycle after the system starts to loop Once it passes the pomt from which it must loop back it displays the time flow within each loop Once it has finished looping it continues io count up time from the beginning of the last loop The need for calculation can be removed by changing the basis of timing to a segmental one but itisno panacea However if you would like to explore this system variant please contact Service Dept or your dealer NESTED LOOPS The following shows an example of the use of nested loops When this program is run it canses the temperature to return to 25 C point 8 in the diagram at 9 minutes 40 seconds after the start of the cycle not at 2 minutes 20 seconds as listed Seg Time Temp Hum L5 Rep Digital Channels dd hh mm ss 000 00 00 00 00 001 00 00 00 01 25 0 65 002 00 00 00 20 85 0 003 00 00 00 40 35 0 004 00 00 01 00 650 005 00 00 01 20 15 0 3 2 2 reps original 006 00 00 01 40 45 0 007 00 00 02 40 5 0 2 2 2 reps original 008 00 00 02 20 25 0 65 CALCULATION FOR SUCCEEDING EVENTS event statement time event actual time total looping time The total looping time is the time to execute the loops as defined by LS amp Rep In the above example it comprises segment 2 is the first segment looped back TO segment 5 i
19. 6 94 1 Introduction This section of the Operator s Handbook introduces you to the FORMAT controller and also suggests how to use this handbook to best effect 1 1 Introduction to FORMAT The FORMAT 550 SERIES programmer controller is a powerful chamber control system offering advanced features such as data logging and program editing The FORMAT 550 programmer represents the ultimate level of user friendliness in a dedicated test chamber controller programmer Such ease of use has been achieved by specialised software providing easily comprehensible data entry and information display All information and data are displayed on a 6 inch CRT screen Data is entered to the computer via a keypad or through the communications interface At all times the actual cabinet conditions are displayed in large figures at the top of the screen All of the command sequences are extremely simple to follow and hardly necessitate the in depth learning of key sequences and alternatives Although the FORMAT will make programming the test cabinet a simple task it will not make the test sequences themselves any less complex For this reason Program Sheets for many of the popular standard tests and blank sheets for your own programs have been produced s a service if requested when the cabinet was ordered the FORMAT will be supplied with selected standard tests prestored As with any other high level system many error trapping and security systems are
20. DIGITAL CHANNEL 1 COOLING MAIN SYSTEM CHANNEL This channel switches the inain cooling mode on see section 3 2 The main cooling mode is used to enable programmed temperature pull down from 70 C ie the fall rate is controlled enable freefall temperature pull down from the cabinet s maximum temperature ie the fall rate is as fast as possible enable temperature dwells below 40 C auxiliary cooling is used between 40 C and 15 C if high humidity control is required extract heat dissipated from the test load between 70 C and the minimum operating temperature enable the cooling coil s low surface temperature to dehumidify the cabinet between 5 C and 70 C DIGITAL CHANNEL 2 COOLING AUXILIARY etes SYSTEM CHANNEL This channel switches the auxiliary cooling mode on The indirect cooling mode is used to control temperature dwells with high humidities between approx 15 C and 60 C extract heat dissipated from the test load during temperature dwells The capacity of the auxiliary cooling mode to extract heat from the test load is limited DIGITAL CHANNEL 4 HUMIDIFIER VPG SYSTEM CHANNEL This channel determines when steam injection from the vapour phase generator system is available to the program controller This channel is always enabled when a humidity setting is programmed into the Format 550 programmer DIGITAL CHANNEL 8 VOLTAGE FREE TERMINAL USER PROGRAMMABLE CHANNEL This
21. L to an OPEN DRAIN Drainage restriction could cause an airlock and consequent flooding of the treatment chamber Two small black plastic pipes are also fitted to the right hand side or rear of the cabinet These are overflows from the wick reservoir and vpg humidification system self levelling header tanks If a float valve develops a fault the respective overflow will operate preventing flooding of the instrument compartment 4 7 DISTILLED WATER SUPPLY EITHER Connect the distilled water supply to inlet connector situated on the right side or at the rear of the cabinet Maximum allowable head is 1500mm 58 above the inlet Itis safe for a container to stand on top of the cabinet but ideally any reservoir should n have its own support to one side of the cabinet OR If the cabinet is supplied with a water re circulating system fill the reservoir as instructed and connect the water connections to the cabinet water inlet and drain as shown 4 8 WET WICK S See Section 6 2 4 wet wicks Wet bulb sensor s must be fitted with wet wick s Anchor the wick in the water reservoir and then push it over the sensor The wick should be taut but not stretched The sensor must be completely covered If any part of the sensor is uncovered or protrudes through the weave then accuracy will be impaired Keep wick material clean Contamination affects absorbency and hence RH control 4 9 TEST LOAD PROTECTION A safety thermostat should be
22. NING 42 1 Cabinets not requiring on site commissioning Place the cabinet on a level site or suitable surface in the case of bench standing models in such position that air is free to circulate around it The cabinet should be placed at least 450mm 18ins away from any obstruction eg a wall or workbench For floor standing models lock the front castors to prevent movement Stand the cabinet in its operating position for 24 hours before switching on to allow oil in the refrigeration system to return to sump 1f the cabinet is moved allow it to stand again If required we can arrange for one of our engineers to commission the cabinet Should you feel that his services are required please telephone us at Loughborough to make the necessary arrangements During his visit our engineer will run the cabinet and check that its systems are functioning correctly and enable you assure that your staff are fally acquainted with the cabinet and its operation 4 2 2 Cabinets requiring on site commissioning Cabinets supplied with a separate or remote refrigeration unit should be positioned to enable the pipe and cable connections to be made by our service engineer Positioning must be on a level site such that the cabinet and refrigeration unit are at least 450mm 18 ins away from any obstruction eg a wall or workbench Lock the front castors to prevent movement During his visit our engineer wil run the cabinet and check that its systems ar
23. SANYO GALLENKAMP ENVIRONMENTAL CHAMBER INSTRUCTION MANUAL Customer B de Ronde Programming system Format 550 Programmer Cabinet model supplied HCCO65 PF4 J Cabinet reference 7904 Handbook date July 1994 Handbook reference 9G7904 201456 CONTENTS PART ONE THE CABINET Section INTRODUCTION 11 Health amp Safety at Work 12 Commissioning U K Customers only 13 Sanyo Gallenkamp service amp maintenance facilities GENERAL DATA 21 Specification Physical 22 Specification Performance 23 Optional facilities 24 Format 550 digital channels DESCRIPTION 3 1 Principle and airflow 32 Temperature control 33 Relative humidity INSTALLATION 41 Accessories amp spares 42 Positioning 4 3 Ambient temperature 44 Power supply 45 Mains interrupt bridge 46 Drain 4 7 Distilled water supply 48 Wet wick s 49 Test load protection 4 11 Cable port 4 12 Vent 4 13 Glass inner door 4 14 RS232 connector OPERATION MAINTENANCE 6 1 Maintenance schedule 6 2 Maintenance methods APPENDICES Parts list Recitculating pure water system optional facility FORMAT 550 CONTROLLER OPERATING INSTRUCTIONS Full instructions for operating the Format 550 controller are given in the second part of this manual The contents list is provided at the beginning of that part 1 INTRODUCTION Great care has been taken in the specification design and manufacture of your cabinet to provide a system that will give long dependabl
24. Seimens cm is indicated by a dark blue colour The deioniser cartridge requires replacement if the indicator window colour changes to light brown The anticipated life of the deionisers in both systems is at least 6 months when used with distilled water and in clean test conditions Maintenance It is recommended that the water in the system is changed monthly or after a test if longer with distilled water If the system is contaminated with inorganic products or substances likely to promote algal or bacterial growth the water should be changed every 14 days If contaminated with organic products change the water after every test AA System draining Switch off the main power Disconnect the pipe connected to the cabinet distilled water inlet and place in suitable vessel or floor drain Switch on the system the pump operates and pumps out the reservoir water When the water ceases switch off the power and reconnect the outlet pipe to the cabinet distilled water inlet the reservoir with distilled water to the level shown on the sight tube Deioniser replacement Disconnect from mains power drain the system as described above and open the front panel of the unit Both types of cartridges are then disconnected from the water pipes and a new cartridge connected Refit the front panel and fill the system The meter type system cartridge is returnable for regeneration The colour change type cartridge is disposable Refer to the Part
25. able either as diagnostic advice or on site attendance Sanyo Gallenkamp Service Department operates nationally from our Loughborough factory where all stocks of spares are held In additton to training of customers own engineers for first line maintenance we offer l Exiended warranty 2 years 2 Contract maintenance schemes T 3 24 hour responsefcall out A loan or hire of units can be arranged in circumstances where an immediate repair is not possible ooo EEE ae 2 CABINET DATA 2 1 SPECIFICATION PHYSICAL model size 90 195 310 600 650 1100 2000 Internal working dimensions mm width 450 650 680 650 900 1100 2000 depth 450 500 650 650 900 1000 1000 height 450 600 700 1400 800 1000 1000 External dimensions mm excluding protrusions width 1144 1304 1334 1320 1554 1904 2654 depth 710 840 90 850 1240 1340 1340 height 113 1730 1875 1960 1975 1845 1975 Capacity litres 90 195 310 600 650 1100 2000 Shelf loading maximum kg 10 10 15 0 20 30 30 Cabinet loading maximum kg 30 30 45 NHN 60 090 90 Distilled water usage litres hr not specified Gross weight approx kg 180 280 310 320 360 750 900 Electrical requirement as stated on the cabinet rating plate 380 440V 50Hz 3ph or 216 264 V 50Hz 1ph Refrigeration gas CFC free 2 1 1 Construction Interior High quality stainless steel welded and vapour sealed Exterior finish Zinc coated mild steel with a stoved acrylic textured finish The interior
26. ame time the higher ambient temperature transfers heat more quickly into the cabinet through the insulation giving the refrigeration unit more work to do to maintain low temperature conditions Excessively high ambient temperatures and poor ventilation will cause the refrigerator compressor to overheat and inevitably reduce its working life possibly even causing it to burn out 4 4 POWER SUPPLY Cabinets designed for operation from a 13A supply are supplied with a 13A plug fitted Cabinets not supplied with a 13 plug are required to be hard wired by a competent electrician to an adequate power supply by connection to the front panel power contactor Power requirements are shown on a plaque on the rear of the cabinet The supply frequency is 50Hz unless stated otherwise An EARTH connection is essential to all chamber In addition if the chamber requires a 3 phase supply NEUTRAL is required WARNING If the cabinet requires on site commissioning do not switch on until it has been fully commissioned see section 4 2 2 4 5 MAINS INTERHUPT BRIDGE 4 6 DRAIN If the power supply to the cabinet fails for up to 30 seconds the cabinet will restart and continue the program from where it left off However if the power supply interruption lasts longer than approx 30 seconds the cabinet will fail safe An outlet nipple usually copper pipe is fitted to the cabinet right hand side or back Connect a pipe to give a CONTINUOUS FAL
27. anteed Soak option was enabled at the Program Run window and the temperature and humidity are not within the preset limits Bexternal through a signal external to the controller if fitted or Manual Manual Time Hoid is effected by pressing the F2 key The effect is to instantly freeze the program run time until it is pressed again You can stop a program run before it is completed by pressing the F10 key Set Point cu Sot Point Humidit Soak disabled wena TI Dav Hour Sec CudesLef o oo Js o Je af ser idee Hold se Esos ES Efso Dow Fig 8 The Monitor Chamber window 4 7 Holding a program To hold a program press F2 from the Monitor Chamber window The effect of holding the program will be immediately apparent as the time elapsed count timebase will stop When a program mun is held the temperature and humidity levels are controlled at the values of the calculated setpoints at the time the hold was initiated digital channel output status is also held as determined at that point in the program To remove the hold press F2 again and the program timebase will count again from where it was held 4 8 Program completion When a program has been completed the Main Menu is displayed showing the program status as idle 4 9 Program deletion Permanently deletes a single program Select Delete Program select the program to be deleted and press lt enter gt 4 10 View program graph
28. ator fitted to the front control panel to ON The MAINS pushbutton on the front control panel will become illuminated green b Power is now available to the Format 550 controller and settings for required test or cycle are entered see Part 2 of this manual for the Format 550 instructions c Start manual control or the desired program d Press and hoid the RESET pushbutton until the cabinet starts The reset orange indi cator light will extinguish when the cabinet starts The Format 550 will now control the cabinet 5 3 CABINET AND PROGRAM SHUT DOWN TO SHUT DOWN THE CABINET NORMAL SEQUENCE a To terminate steady state or two setpoint cycling control see Format 550 instruc tions b When control by Format 550 has been completed or terminated switch the 5 red yellow mains isolator to OFF The cabinet conditions will now drift slowly to ambient EMERGENCY SHUT DOWN Switch the MAINS red yellow isolator fitted to the front control panel to OFF aes oe 6 MAINTENANCE AND CARE WARNING Before entry into the instrument compartment refrigeration compartment or treatment chamber ISOLATE THE CABINET FROM MAINS POWER unless otherwise stated The cabinet has been designed and built for a long life and requires minimal attention and maintenance However regular attention to the few points will ensure a long and trouble frec life If the cabinet does fail the expertise of our service engineers is r
29. byte No 023 starts byte No 024 ends byte No 026 starts byte No 27 ends byte No 029 starts byte No 030 ends byte No 036 staris byte No 037 ends byte No 043 starts byte No 044 ends byte No 050 starts byte No 051 ends byte No 053 starts byte No 054 ends byte No 056 starts byte No 057 ends byte No 063 starts byte No 064 ends byte No 070 starts byte No 071 ends byte No 077 statts byte No 078 ends byte No 080 starts byte No O81 ends byte No 083 Starts byte No 084 ends byte No 091 starts byte No 092 ends byte No 97 starts byte No 098 ends byte No 100 6 bytes Temperature Setpoint No 2 in degC eg 150 0 1500 only starts byte No 101 ends byte No 106 3 bytes Relativ umidity Setpoint No 2 in 90 eg 050 600 only starts byte No 107 ends byte No 109 8 bytes Time time Inte gning program in starts byte No 110 1 ends byte No 117 4 bytes Cycle Baber Cycles raining in running program eg 0001 Starts byte No 118 Ji ends byte No 121 byte Hold St E during program run only O not held mg hold 2 held 14 to guarantee the soak period starts byte No 122 4 soak ends byte No 122 1 byte lt enable Status during program run only 0 disail 1 enabiit Starts byte No 123 ends byte No 123 Description SHUT CHAMBER DOWN Type Command Source master Header 130 Data Block No This pa
30. c instructs the Controller to shut the chamber down Description S CHAMBER DOWN Source Controller Header 130 Data Block No This from the Controller confirms that the chamber was shut down Description OPEN FILE FOR READING Type Command Source master Header 131 Data Block 13 bytes This instructs the Controller to prepare a file for reading by the master The data ites are as follows i 2 Drive to search IM 0 system drive A 1 data drive 12 lyies File Name String left justified A cz LOGIC cfg no leading spaces no included spaces pad to 12 characters with trailing spaces Only ONE file may be opened at a time The master should take some special precautions before issuing this command Firstly to ensure thatno file activity takes place on the Controller during the file transfer the master should send a Set Controller to Remote Access Mode command packet see below This locks out the keyboard on the Controller Next the master should use a Status Request command to ascertain the data entry mode of the Controller If the Controller is in Engineering opening a CFG file should not be allowed If the Controller is in Program Edit opening a PRG file should not be allowed If logging is active opening a LOG file should not be allowed Only after checking these criteria should the master proceed to Open the file on the Controller for reading After the file is read and closed the ma
31. cess window Description SET CONTROLLER TO REMOTE ACCESS MODE Type Reply Source Controller Header 136 Data Block No This packet is sent by the Controller to confirm to the master that the Controller is switched to Remote Access Made Description SET CONTROLLER TO LOCAL ACCESS MODE Type Command Source master Header 137 Data Block No This instructs the Controller to allow key presses on its local keyboard and dis play Local in the Access window Description SET CONTROLLER TO LOCAL ACCESS MODE Type Reply Source Controller Header 137 Data Block No This packet is sent by the Controller to confirm to the master that the Controller is switched to Local Access Mode Description SETACHANGE STEADY STATE CONDITION Type Command Source master Header 138 Data Block 20 bytes This command instructs the Controller to run a steady state set point The data block parameters are as follows 6 bytes Temperature Set Point in C eg 150 0 There should be no spaces in this string zeros should be used to pad the string e g 10 C should be represented as 010 0 4 3 C should be represented as 0004 3 3 bytes Relative Humidity Set Point in eg 100 There should be no spaces in this string e g O RH should be represented as 000 8 bytes Digital Channels eg 10010011 Description SET CHANGE STEADY STATE CONDITION Type Repiy Source Controller Header 138 Data Block i byte Data byte set to 1 if set poin
32. ch FORMAT is being controlled It may take the value local or remote Under normal circumstances this field will indicate local which means that the keyboard connected to FORMAT is controlling it If the value is remote FORMAT is under the control of remote RS232 communications Note FORMAT uses the following rules When running in steady state control mode Temperature is in C humidity is in For digital channels 0 means OFF 1 means ON In manual mode control is continuous until stopped by the operator 30 Conon o Oe When running in program mode Temperature is in C humidity is in GRA A data segment is a point in time when a change in the data on which the programmer is acting upon is required Times are specified as DAYS HOURS MINUTES SECONDS Each segment s time is from the start of the program The first segment of a program has zero time Each segment thereafter must be sequential with time The maximum number of segments m each program is 150 For digital channels 0 means OFF 1 means Programs cannot be linked together The mid cycle start facility can operate at any time in the program s first cycle 31 NY 9 pot n n 3 Steady state control wh A CA This section describes how to make the controller maintain a steady state condition GENERAL OPERATING SEQUENCE STEADY STATE MODE select Steady State operation from the Main Menu En
33. der Data Block GET SUGGESTED DCS Command master 142 0 bytes Obtains the recommended digital channel selections for a given temperature RH setpoint pair Data block is arranged as follows The same rules about spaces amp zeroes apply to these fields as with command 138 6 bytes temperature in C eg 2 150 0 3 bytes Relative Humidity in eg 100 Description Type Source Header Data Block GET SUGGESTED DCs Reply Controller 142 8 bytes 8 data bytes contain the recommended digital channel selections for a given temperature RH setpoint pair eg 01001100 If there is not an entry in the Controller s intelligence table the string NNNNNNNN is returned The same rules about spaces amp zeroes apply to these fields as with command 138 7 4 Cable connections Format 550 communications require a cable of the following connections to be fitted between the cabinet and the communicating PC Computer 5232 9 pin D type 9 amp Un bu 8 link to 7 7 link to 8 Computer RS232 Format 550 socket 25 pin D type 25 pin D type 22 8 CDR 2 3 RXR 3 2 TAR 6 20 TR 1 amp 7 7 20 6 SR 5 link to 4 4 RTS 4 link to 5 5 CTS 8 22 7 5 Support software Because this is a rapidly developing aspect of the applications of Format 550 SANYO Gallenkamp PLC continue to expand the range of support available for these systems If your application is not covered here please contact our Service
34. dow press the F4 function key to start the chamber running The Status field at the top of the screen will change from idle o running to indicate that the chamber has started running If at any point while entering information in the data entry window you decide that you do not want to start the chamber you can press Esc io cancel This takes you back to the main menu 3 3 Condition monitoring When the chamber is running a steady state condition you can observe its settings by selecting the Monitoring option from the Main Menu This brings up a Monitor Chamber window as shown in Fig 3 Note the status bar shows the measured conditions In addition to the set point values for the steady state condition the Monitor Chamber window displays the selected digital channels Information When running a steady state condition if you need to change to another condition it is not necessary to shut the chamber down first You can go straight to the Steady State option on the Main Menu and enter the new condition and or digital channels while the chamber is running The changes will not take effect until you press the F4 function key Condition Dunning sicady saie Control r Set Point Temperature Set Point Humidity Figure 3 Monitoring a Steady State Condition 33 3 4 Ending manual control To end steady state control press Fi0 A safety catch message will ask you Are you sure you wish to shut down Note
35. ds Often wicking quality can be restored by boiling for a few minutes in clean distilled water Figure 4 RECORDER CONTROLLER WET RT WETRT DRYRT Temperature sensor positions as viewed from inside working chamber 20 6 2 4 Lubrication Most moving parts are lubricated and sealed for life except the inner door catches if glass inner door is fitted These components should be oiled once per month 6 2 5 Check safety thermostat Adjust the safety thermosiat sited inside the instrument compartment through prevailing cabinet iemperature Check that the safety thermostat fails the cabinet safe In the event of a fault RECTIFY AT ONCE 6 26 Clean the refrigeration condenser It is essential that the refrigeration condenser is kept clean dirty condensers adversely affect the performance of the cabinet and reduce the working life of the refrigeration unit 1 Isolate from M AINS 2 Remove the front louvre and back mesh panels from refrigeration compartiment or ventilation panels in the case of a separate refrigeration module 3 Gently brush blow vacuum dust etc from the fins and tubes of the refrigerator condenser Initially check and clean condenser monthly actual frequency will depend upon the cleanliness of the surroundings 6 2 7 Distilled water filter This is located below the distilled water inlet nozzle and can be inspected through the viewing liole in the cabinet s side or back panel The clear pla
36. e As the Controller receives each packet it acknowledges this to the master It is possible however that the acknowledgement is lost e g due to noise and the master has no way of knowing whether the Controller ever received that packet or not as far as the Controller is concerned the transaction was completed successfully In this case after the time out period has elapsed see below Packet Timing when the master re transmits the Command Packet the Packet Count will be the same as in the preceding Command Packet The Controller upon receiving this duplicate packet which it can identify by the Packet Count simply acknowledges the packet but does not store the data Serial Number Length In Command Packets this is set to the length in characters of the serial number of the Controller to which the packet is intended In Reply Packets this is set to the length in characters of the serial number of the Controller which is transmitting the reply Data Block Length This is set to the number of data bytes which follow in this packet The minimum value is 1 so if there are no data bytes this should be set to 1 and the data block should contain a single null byte value 0 Serial Number In Command Packets this field contains the sertal number of the Controller to which the packet is intended encoded in ASCII In Reply Packets this field contains the serial number of the Controller transmitting the Reply Packet NB this refe
37. e functioning correctly Take advantage of the commissioning visit to ensure that your staff are fully acquainted with the cabinet and its operation Connect a suitable power supply to the cabinet see section 4 4 The maximum power ratings are shown on the cabinet rating plate and refrigeration unit rating plate if applicable DO NOT SWITCH ON THE CABINET UNTIL IT HAS BEEN COMMISSIONED Figure 2 Figure 3 Distilled water inlet instrument compariment cabinets 13 4 3 AMBIENT TEMPERATURE IMPORTANT To achieve the guaranteed performance figures the maximum acceptable laboratory ambient temperature is 25 C At higher ambient temperatures the minimum operating temperature and rate of fall will be affected All refrigeration equipment from home freezers to air conditioning plant performs a heat exchange operation in which the refrigeration compressor acts as a heat pump to transfer heat from the cooling coil called the evaporator because this is where the gas evaporates and absorbs hear to the condensing coil where the gas condenses and gives up heat The condensing coil is air cooled and assisted by a fan All air cooled condensers need air movement around them in order to be able to give up to the air the heat extracted from the cooling coil and hence the cabinet If the ambient temperature is high above 25 C more air will be required around the condenser to take up the same amount of heat At the s
38. e the humidity present relative to the humidity possible The latter varies with temperature hence RH measurements are related to their prevailing temperature Air at 100 relative humidity is saturated and cannot absorb any more water If air at 100 rh is heated the amount of water the air can hold increases and therefore the rh will drop unless more water is introduced If air at 10095 rh is cooled water will be lost through condensation on to the cooling surface For each atmospheric RH temperature relationship there is another relevant temperature known as the dew point Surfaces at or below this temperature chill the water vapour sufficiently to cause condensation 3 3 1 RELATIVE HUMIDITY DETERMINATION Air with a relative humidity less than 100 flowing over a wet surface causes evaporation of water from that surface and causes a temperature drop at the surface The actual drop in temperature compared with the temperature of a similar dry surface subjected to the same air flow can be used to measure and conirol relative humidity The technique is known as wet amp dry bulb psychrometry and the difference in temperature is referred to as the wet bulb depression Psychrometric tables give interrelated values for temperature relative humidity and wet bulb depression In the cabinet conditioned air flows over two resistance thermometer RT sensors one dry and one kept permanently wet by a wick fed from a constant level water reser
39. e service This handbook is an integral part of that policy Please use it to help you obtain continued good performance and reliability If it fails please let us know 1 1 Health amp Safety at Work Section 6 4 of the above act requires manufacturers to advice their customers on the operating and handling precautions to be observed when installing operating maintaining and servicing their products Accordingly the following points should be noted 1 The relevant sections of these instructions should be carefully read before proceeding 2 Intallation maintenance and servicing should only be carried out by suitably trained personnel 3 Normal safety procedures must be taken to avoid the possibility of an accident occur ring 1 2 Commissioning U K Customers only If required we can arrange for one of our engineers to commission the cabinet In many cases this is not necessary but should you feel that his services are required please telephone us at Loughborough to make the necessary arrangements During his visit our engineer will run the cabinet and check that its systems are functioning correctly Take advan tage of the commissioning visit to ensure that your staff are fully acquainted with the cabinet and its operation 1 3 Sanyo Gallenkamp service amp maintenance facilities Sanyo Gallenkamp s Service Engineers and their colleagues have many years of experience in this equipment This expertise is readily avail
40. e working chamber base Any accumulation of contaminants from the test sample can cause the treatment chamber to block The drain should be checked regularly to ensure that particles are not collecting around it 6 23 inspection and replacement of the wet wick s Access to the sensors and wicks is through the sliding panel in the right hand wall of the working chamber See fig 4 for the position of the wet and dry bulb sensors The accuracy of all wet and dry bulb systems for the control of relative humidity is totally dependent on the wet wick The rate of evaporation from the wick determines the cooling of the sensor and hence the temperature differential wet bulb depression of the control or recording instrument Adherence to the following notes is recommended for all serious work at controlled relative humidities a Wick must be ciean handle with care and clean hands store in a clean place change regularly once a month b Wick must covet the entire exposed length of the sensor ie extend well beyond the sensitive tip and fit tightly to the sensor c Wick must be the correct length to fit over the sensor and well down into the rubber wick reservoir to prevent the high speed necessary for correct evaporation from blowing the wick out of the reservoir d If wicking quality of the material is suspect test by cutting off 1 cm of dry material and dropping into acup of distilled water Sample should wet and sink within 2 secon
41. eadily available for either diagnostic advice or on site attendance Service contracts are available after the One year guarantee period finishes and details are available from our Service Department This section contains a maintenance schedule to follow and a methods section giving instructions relating to the schedule Note if the cabinet is going to be left unused for more than a month we suggest that the cabinet is started up and run through all its functions on a monthly basis This will ensure that the cabinet is in perfect runming order for when it is required 6 1 MAINTENANCE SCHEDULE Weokly or between tesis Clean the cabinet s mterior and exterior surfaces Clean drain s Clean atomiser s Check wicks Month Renew wicks Lubricate moving parts Check safety thermostat Clean refrigerator condenser Check distilled water filter 19 6 2 MAINTENANCE METHODS 6 2 1 Interior and exterior cleaning The cabinet interior and exterior should be kept clean and free from deposits The exterior surface is easily cleaned with warm soapy water When cleaning any stainless steel surface do not use any cleaning agent containing chloride or hypochiorite ions as these will cause corrosion 6 2 2 Cleaning of cabinet drain s Either one or two drains are situated centrally in the base of the treatment chamber Access to the treatment chamber involves the removal of the working chamber base Remove the front cover and slide out th
42. egment s time must be the desired finish time of the program Enter onto the program sheet the corresponding changes that occur at each segment For future reference record on the sheet the program name used to store the program on floppy disk and the number of program cycles to be used when the program is run The following page shows a sample completed Programming Sheet 4 3 Entering the data into the programmer select the New Program option from the Program Menu This brings up the program editing window Following the FORMAT programming sheet enter the time and conditions into each segment line As you enter conditions pressing enter between each field you will notice that the digital channel fields are automatically populated by FORMAT These are suggested digital channel values If you wish to override the suggested values move to the you wish to change You can then freely edit the digital channels You can perform line cut and paste editing on your program In order to cut a line i e remove from program but remember it for future pasting Simply move the cursor to the line for cutting and press the F5 key To paste the line again move the cursor to the line where the cut information is to be pasted and press F6 Future releases of the FORMAT software will also enable block cut and paste options To make space for a new line in a program press F7 When you have finished editing press F4 This takes you back to
43. familiarising yourself with the FORMAT programmer controllet it is recommended that you read all sections in order trying out the topics described hands on as you go along As a minimum you should read sections 2 and 3 of the handbook which describe the basics of using the controller 27 2 Getting started This section describes the basics of using the controller and the meaning of the various items of information presented on the screen 2 1 The menu system FORMAT uses a menu system to allow the operator to select what function the controiler should perform This approach will be familiar to users with experience of using personal computers Wher the chamber is first switched on FORMAT goes through its startap sequence which lasts approximately 1 minute and then displays the initial Main Menu screen The Main Menu displays a list of options which are available to you one of which is highlighted Steady State in Figure 1 By using the up and down arrow keys the highlight bar can be moved through the menu options Condition C Control arabe ager Main Menu Steady State Monitoring Alarm Setpoints Program Logging Fio Shut Chamber Down Fig 1 The Main Menu Screen To select a menu option move the highlight bar to the option you require then press the Enter key Selecting some of the menu options for example Alarm Setpoints and Program causes another sub menu of options to appea
44. fitted to all equipment being powered inside the cabinet The thermostat should switch off equipment power if the air temperature in the cabinet rises above safety level The thermostat will protect both the equipment and the cabinet against damage in the event of failure or shut down of the cabinet s temperature control system Equipment dissipating only a few hundred watts inside the weil insulated cabinet with no cooling will heat sufficiently to cause severe damage Advice on suitable thermostats is available from our Technical Department SANYO GALLENKAMP will not be held responsible for any damage to either equipment or cabinet during or after the cabinet guarantee period caused by heat dissipation from unprotected equipment If the cabinet is fitted with a glass inner door and the load being tested in the cabinet is liable to dissipate excessive heat the glass inner door must be protected from absorbing this heat by radiation effect Failure to protect the inner door could result in the glass cracking 15 _ _ mm 4 10 CABLE PORT 4 11 VENT One or two cable portis are fitted to the left hand side of the cabinet to enable wires leads etc to pass into and out of the cabinet The port has two plugs one inside one outside the cabinet and both plugs must be fitted when the cabinet is in operation to maintain the cabinets excellent insulation The plugs can be slit or holes bored to enable wires leads to pass through
45. g in temperature dissipates heat even though not powered One area where Format550 cannot suggest selection is that concerning user digital channels those other than system channels No rules are pre stored for them other than that they are biased to off Program them on when you want them on A typical example is channel 8 v f t Here you will need to program 1 to switch it on and 0 to switch it off These instructions can share a program line with a condition corner or they can have a line of their own 4 4 Loading and saving programs When you save a program or load a program you must specify a file name to FORMAT This must consist of 8 characters As the Format 550 panel mounted keypad is numeric only you are restricted to numeric identifiers When loading you can select the program yon want to load from a list rather than type the file name if you wish Use the up and down atrow keys to select the file name of the program you want to load When saving if you want to replace i e update a program that already exists you can use the up and down arrow keys to select the file name of the program you want to replace Condition C RH Status RE 5 Logging contro FEET Program Main Man Load Program E Run Cur Edit Cur New Pre Load Fix Free entries 224 Free space 125K Fig 6 Load Program window AA ee ee ee eee ee ee 2 m A AA AA 4 5 Running
46. g system already being used The document describes in detail what a master computer should do to comply with the protocol This makes no assumption about the functionality of the master software A particular Host Software package is available separately The protocol is defined in four layers Physical Layer defining electrical connections between controller amp master Frame Layer defining byte frame structure Packet Layer defining information flow between controller amp master Information Layerdefining syntax of information passed 731 PHYSICAL LAYER DEFINITION The medium used to connect Controller s to master depends on the distance between master amp Controller the number of Controllers Master to single Controller Up to 50 feet RS232 Up to 1000 feet RS485 Master to several Controllers RS485 bus The Chamber itself has a 25 pin RS232 port connector D type DTE which is used for communicating with the master R5232 to 485 adapter is used when a RS485 hook up is required The adapter uses the RS232 s RTS line to control the data direction of the RS485 port 7 3 2 COMMUNICATIONS FRAME DEFINITION 19 200 baud 1 start bit 8 data bits parity bits 1 stop bit 51 7 3 3 PACKET LAYER DEFINITION Data Packet Structure Byte Description Byte Value range 1 Header 128 to 255 2 Packet Count 0 to 127 3 Serial No Length S l to 127 4 Data block length D 1 to 127 5 to 4 5 Serial No 32 to 127
47. ging stop FORMAT data logging select the Halt Logging Now option from the Logging Menu 5 4 Displaying Results You can obtain a trend display of the data log from FORMAT using the Load Log From Disk option This only displays the data in low detail 5 5 Loading into Spreadsheets Data Logs in FORMAT are stored as comma separated fields Most industry standard spreadsheet packages support this data format for importing into them Although the method varies between spreadsheet packages the basic technique is similar The order of the second and third points in the list below may be interchanged Select the import option from your spreadsheet package Specify the floppy disk drive and file name of the data log and use the LOG extension Specify the type as comma separated values 6 Alarms This section deals with setting alarms on the FORMAT controller 6 1 Introduction to Alarms FORMAT provides a comprehensive array of alarm triggers Alarms are available on fixed high and low setpoints or on deviation from control set point The same alarm functionality is provided for both temperature and humidity channels Alarms can trigger several events Shuts the chamber down If you have set logging to start on alarm data logging of the condition will start If your controlier has been configured to use an alarm output an external event may be triggered program Condition C Logging E Control
48. he start of the cycle not at 1 minute 40 seconds as listed This is because the looping interferes with Format 550 s timekeeping Due to the disruption of the intemal timekeeping the listing of events that succeed loops is no longer derived directly from the start of the cycie A simple calculation is required to determine when to program the statement for each succeeding event CALCULATION FOR SUCCEEDING EVENTS Cail the target time for the succeeding event the event statement time Call the time when the event is required the event actual time Both times are from the start of the cycle event statement time event actual time total looping time The total looping time is the time to execute the loops as defined by LS amp Rep I in the above example it is required to end the cycle at 3 40 event statement time 3 40 1 20 2 20 EXAMPLE 2 in the following example the temperature is required to reach 95 C at 4 minutes 55 seconds into the cycie event statement time 4 55 1 45 lt 3 30 4 55 event actual time when you want it to occur 1 45 total looping time Rep multiplied by the time from the start of the loop to its end To do this you would program Seg Time Temp Hum LS Rep Digital Channels dd hh mm ss C 000 00 00 00 00 001 00 00 00 01 25 0 65 00 00 00 20 85 0 003 00 00 00 40 35 0 00 00 01 00 65 0 005 00 00 01 20 15 0 3 3 006 00 00 01 40 25 0 007 00 00 02 40 10 0 008 00 00 02 20 25 0 009 0
49. ion 1 Controller Intelligence For all regions of the chamber performance envelope a table pre stores a map of appropriate housekeeping facilities a map of appropriate P I D controller coefficients Maps are not displayed on the controller Housekeeping Digital channel selection by autosuggestion from intelligence at setpoint entry Over ride available at keypad Internal Defrost Clock Invoked automatically if required from intelligence Steady State Control The controller allows set point values to be entered for tempera ture and humidity With autosuggested or manually input digital channel seiections Programs Library capacity 20 programs nominal leaves space for 1 week log program size 150 lines segments max per program 10 kbytes approx per program segment line con tent time any of temperature humidity digital channei loop time basis time from program start time units days hours minutes seconds editing facilities line cut paste block copy loop facility to repeat program sections nesting loops within loops supported file facilities save load delete precondition line 000 omits after 1st cycle Program Run Options Repeats up to 9999 cycles Guaranteed Soak Run start facilities Monitoring displays Steady state Facilities Alarms Data Logging Storage media Digital outputs Digital input active at start of each program segment arming preset at run start
50. ith time at max rh 396 rh at min 5 rh Air velocity average empty working chamber 0 2 m sec turbulent Tolerated cabinet loadings to maintain specified performance Static load ie the test load not specified Dynamic load watts ie dissipating loads not specified Fluctuation is the maximum difference temperature or humidity measured at the chamber centre over a period of time after the cabinet has reached stability Variation is ihe maximum temperature difference at any time between the centre of the chamber and the extremes of the working envelope 2 3 OPTIONAL FACILITIES Where optional facilities are fitted to the cabinet instructions for their use if necessary are detailed in the appendices of this manual Alternatively additional information sheets are inserted in the front of this manual rem mr cre 2 4 FORMAT 550 DIGITAL CHANNELS a b c d b The Format 550 programming system fitted to the cabinet has the following digital channel functions A number of the channels are for the control of the cabinet and are usually automatically selected on or off by the programmer as required to achieve particular conditions If applicable other user designated channels are also detailed below Alldigital channels are shown on the monitor and program screens of the Format 550 programmer Full operating instructions for the Format 550 programmer are given in Part 2 of this manual
51. nd Packet see below 15 not operational Controller has priority over master starts byte No 002 ends byte No 002 1 byte Logging Status 0 inactive 1 active starts byte No 003 ends byte No 003 1 byte Temperature Alarm Status 0 in limit 1 alarm starts byte No 004 ends byte No 004 1 byte Humidity Alarm Status 0 in limit 1 in alarm starts byte No 005 ends byte No 005 6 bytes Temperature in degC eg 150 0 starts byte No 006 ends byte No 011 3 bytes Relative Humidity in eg 095 6 bytes Temperature Setpoint in degC eg 150 0 3 bytes Relative Humidity Setpoint in eg 095 3 bytes Third Variable setpoint in eg 050 3 bytes Intelligence Table Line eg 001 7 bytes Temperature P term eg 123 45 7 bytes Temperature I term eg 123 45 7 bytes Temperature D term eg 123 45 3 bytes Heating Effort in eg 100 3 bytes Cooling Effort in eg 100 7 bytes Relative Humidity P term eg 123 45 7 bytes Relative Humidity 1 term eg 123 45 7 bytes Relative Humidity D term eg 123 45 3 bytes Humidification Effort in 95 eg 100 3 bytes Dehumidification Effort in eg 100 8 bytes Running Digital Channels eg 10110010 6 bytes Temperature Setpoint No 1 in degC eg 150 0 500 only 3 bytes Relative Humidity Setpoint No 1 in eg 050 500 only starts byte No 012 ends byte No 014 starts byte No 015 ends byte No 020 starts byte No 021 ends
52. ndows When the controller needs information from you it presents a data entry window FORMAT has data entry windows for a multitude of different situations e g asking you for a steady state condition or alarm setpoints so they vary in appearance Common to all of them however is a standard method of data entry and navigating the fields in the window 2 4 1 Moving between fields The enter or right arrow keys are used to move the input cursor to the next field of a data entry window The key to move the input cursor to the previous field is the left arrow Keying past the last field causes a wrap round effect which moves the input cursor to the first field ee nn Information however you do wish to edit the digital channels you should use the lt and gt keys These keys do not skip the digital channel fields When editing a program if you use the enter key to move to the next field the Digital Channel fields are skipped This is because in most cases you would want to accept the suggested values prompted by the controller 2 4 2 Types of data entry field There are two types of data entry field The most common is a value field When the input cursor is on a value field the operator should simply enter the appropriate value e g temperature digital channel state file name etc The other type of data entry field ts a selection list When the cursor is on a selection list you should use the u
53. nitoring screen to exit the Host system and return to DOS 7 2 4 MAIN MENU Pressing Esc from the main menu causes ihe Host software to go back to network monitoring mode The MAIN MENU options are as follows Steady state control Monitoring Program downloading uploading Logging STEADY STATE CONTROL This option brings up a window which is identical to the Steady State Control window on the controller itself The condition and digital channels can be entered exactly as on the controller While this window is being displayed on the Host the Access window on the controler contains the message Remote indicating that the Host temporarily has controt and that the chamber keypad is temporarily barred Any attempt to select brings up a message Access Denied Host has Priority If Steady State Control is selected on the Host whilst the controller is in any of the following modes a message will be displayed stating Access Denied Controller has Priority Press Esc to pass control back to the main menu Steady State Control entering setpoints Ron Program entering program run options Countdown to Run Start delay before starting a program Monitoring The latter brings up a window which is identical to the monitoring window on the controller if the controller stops running i e the end of a program run or if Shut Down is pressed on the controller keypad control passes back to the main menu PROGRAM
54. nter INSTALL lt enter gt The Host Software installation process will then begin During installation the Host Software is copied on to the Hard Disk to a directory named HOST INSTALLING THE SECURITY KEY Before the Host Software can be used the security key must be fitted Insert the security key into the parallel printer port LPT1 of the Host PC If you have a printer connect this to the back of the security key The security key is completely transparent to normal printer operation CONFIGURING THE HOST SOFTWARE Before the Host Software can be used the serial number of the Controller must first be written in a configuration file called HOST CFG Use a standard text editor such as EDIT supplied with DOS 5 0 6 0 to create and edit the HOST CFG file in the C HOST directory on the Host PC Enter the serial number of the Format Controller on a single line of the file The serial number must be that of the CONTROLLER This number must be entered literally taking note of the case of the characters Include SN eg SN2 94001234 SETTING UP OFF LINE CHAMBER INTELLIGENCE Before installing the Host Software it is recommended that two files from the Controller System disk are first copied to the Host Directory This enables the Host system to use their information without having to interrogate the controller each time The following files should be copied from the root directory of the Format 550 System Disk to the HOST directory
55. of the same name on the disk the master can use the Open for Reading command to check if a file of the same name is present first and then closing ihe file straight away The data bytes are as follows 1 byte Drive 0 system drive 1 data drive 12 bytes File name string left justified eg LOGIC CFG Exactly the same precautions as with Open File for Reading apply to this command Description OPEN FILE FOR WRITING Type Reply Source Conirolier Header 134 Data Block 1 byte 1 af file was opened successfully or Q if the Controller failed to open the file for writing file in use disk write protected etc Description WRITE BLOCK TO FILE Type Command Source master Header 135 Data Block Even number up to 126 bytes send a block of data to the Controller for writing to a file opened with Open File for Writing Data block contains up to 63 hextuples representing the next block of data to write to the file For example the sequence of bytes 4Ah 80h 25h 30h would appear in the data block as the string 44802530 Descnption WRITE BLOCK TO FILE Type Reply Source Controller Header 135 Data Block No The Controller sends this packet to the master to confirm that the block of data has been written Description SET CONTROLLER TO REMOTE ACCESS MODE Type Command Source master Header 136 Data Block No This instructs the Controller to ignore key presses on its local keyboard and display Remote in the Ac
56. or manually during program run criteria temperature error 0 50C or relative humidity error 190 action program time base is arrested until the condition returns inside limits in cycle start specify time into first cycle delayed start allows unsupervised start setpoints digital channel status running program setpoints digital channel status soak status hold status time into program run number of cycles remaining turn on off timebase hold turn on off guaranteed soak parameters temperature humidity type high low deviation range chamber range Log content actual temperature actual humidity time setpoint temperature synch start setpoint humidity synch start Log interval one minute Log information source control probes Log entry size 100 bytes Log triggers manual synchronised alarm Log preview simple trend graphic File facilities load delete Log format comma separated values import to industry standard spreadsheets internal floppy diskettes 2 one system and one program log data disk 50 way connector interfaces inside chamber to SSR drives dedicated to the External Hold facility internal access only contact SANYO Gallenkamp PLC or your dealer for applications Data communications port on chamber RS232 25 pin D support software available separately hard copy program printouts are available using the above software APPENDIX 2 PROGRAM LOOPING AND NESTED LOOPS You can prog
57. p and down arrow keys to move the highlight bar to the appropriate selection 2 5 he status bar The status bar is the window of information displayed at the top of the screen It is visible at all times The data items displayed on the status bar are CONDITION The temperature and relative humidity if the controller is configured for humidity inside the chamber is constantly displayed Tbe values displayed are updated every second If the controller is configured for open loop control of a third channel e g light level this is not displayed since the actual level is equal to the set point which is displayed in the Monitor screen STATUS This field describes what the controller is currently doing It can take the value idle or running LOGGING This field describes the current status of logging It may take one of the following values inactive sync alarm or active sync indicates that logging will start when the chamber is run and alarm indicates that logging will start when an alarm condition occurs PROGRAM This field describes the state of the currently loaded program 1f there is a program loaded the name and description appears here In addition if it is running the word active appears to the right of the description if editing has started on a new program but that program has not yet been saved the message Not Named appears in this field CONTROL This field indicates the method by whi
58. r The highlight bar then appears on the sub menu To remove a sub menu returning the highlight bar to the parent menu press the Esc key 2 2 Using the on line help FORMAT has a context sensitive on line help system activated by the Fi key You can press the F1 key at any time while using the controller to obtain an information window summarising what actions are possible from the current position The on line help system is not intended to be a replacement for this handbook but provides a useful reminder for keystrokes and menu options If you find you are unsure of what to do next your first action should be to call for the on line help In most cases this will give you sufficient information to let you carry on 2 3 Function keys Function keys are keys which cause the controller to immediately action a task FORMAT has two kinds of function keys namely global and local 2 3 1 Global function keys These are keys which serve one fixed purpose and are operational all the time An example is the F10 key which shuts the chamber down This can be thought of as an emergency stop button Itis active all the time whatever the controller is doing Global function keys are shown at the bottom of the screen see Figure I 2 3 2 Local function keys These are keys whose function may change from one task to another They are shown at the bottom of the window that the user is currently interacting with 2 4 Using the data entry wi
59. r in the data block 4 bytes Controller type string 2000 for Format 550 4 bytes Controller software version string 100ths with leading zeros eg 0144 represents V1 44 1 bytes humidity enabled l enabled Q temperature only chamber 1 byte third variable enabled 1 enabled third variable normaily 0 for Genus chambers 12 bytes Third Variable description string eg Light This string contains trailing spaces to pad to 12 characters Description STATUS REQUEST Type Command Source master Header 129 Data Block No This packet instructs the Controller to reply with information as to the status of the Controller Description STATUS REQUEST Type Reply Source Controller Header 29 Data Block 123 bytes The data bytes of the Status Request Reply are as follows in the order in which they ap pear in the data blocks 1 byte Running status 0 idle 1 running steady state 2 N A 3 running a program 4 counting down to program start starts byte No 001 ends byte No 001 1 byte Controller Data Entry Activity Value when the Controller is displaying any of the following data entry screens Steady State 1 2 SP Format 500 only 2 Program Run Format 550 only 3 Countdown to Program Start Format 550 only 4 Program Edit Format 550 only 5 Engineering Format 550 only 6 Byte set to 0 for all other screens When this byte is not set to 0 the Set Change Steady State Condition Comma
60. r the master has completed transmission of a packet the RTS line should be dropped within 0 05s but not before the stop bit of the last byte has been transmitted The Controllers normally have their RTS lines unasserted so that their RS485 ports are in Input mode waiting for transmissions from the master When a Controller is about to transmit a reply packet its RTS line is asserted driving its RS485 port to Output mode After the Controller has completed transmission of a packet the RTS line is dropped within 0 055 This means that the master must wait at least 0 05s before raising RTS to transmit the next Command Packet Packet Timing In most instances the Controller will issue a Reply Packet in response to a Command Packet from the master within 1 second The Controller has buffered interrupt driven communications This ensures that Command Packets from the master cannot be lost even if the Controller s processor is preoccupied with another task If the Controller s processor is preoccupied however e g accessing the disk or repainting an area of the screen the Controller will not issue the Reply Packet immediately The master should allow the Controller up to 12 seconds to reply no reply is received 12 seconds after the Command Packet was issued it can be assumed that communications have been lost with that Controller e g noise caused Command Packet to become corrupted Controller switched off or disconnected etc
61. ram loops in format550 In addition you can program loops within loops nesting This section tells you how with simple examples LOOP INSTRUCTIONS The loop instructions are achieved using the LS amp Rep columns that appear on the program preparation sheet amp on the program window of the system In the line from which you want to loop back incolumn LS you specify which line you want the program to loop back to incolumn Rep you specify how many times you want the program to re peat this part of the program The program loops back from the time line in which the loop is listed to the first line in the loop EXAMPLE 1 Taking a simple example You require the temperature to cycle from 25 C to 85 C then to 35 C then to 65 C then to 15 C before retuming to 25 C But you want to cycle through the 35 65 15 part three times in all before emerging at the final 25 To do this you would program Seg Time Temp Hum L5 Rep Digital Channels dd hh mm ss C 000 00 00 00 00 001 00 00 00 01 250 65 002 00 00 00 20 85 0 003 00 00 00 40 35 0 00 00 01 00 65 0 005 00 00 01 20 15 0 3 2 reps original 006 00 00 01 40 250 65 the times are unrealistic for environmental test purposes but they provide a program that can be cycled quickly to see the effects 2 7 x 66 When you run this program you will see that it causes the temperature to return to 25 C point 6 in the diagram at 3 minutes after t
62. ration at working chamber temperatures up to 70 C Cabinets with a 70 C lower temperature limit CF7 models use cascade refrigeration systems The main and auxiliary cooling modes are automatically selected by the control system to enable freefall temperature pull downs from the cabinets maximum temperature ie the fall rate is as fast as possible down to 70 C or below temperature dwells below 40 C auxiliary cooling is used between 40 C and 15 C if high humidity control is required of heat dissipated from the test load between 70 C and the minimum op erating temperature the cooling coils low surface temperature to dehumidify the cabinet between 5 C and 70 C Refrigeration unit control The refrigerator is controlled by the switching of solenoid valves which pass refrigerant to pressure switches which in turn energise the refrigerator compressor motor There is a short delay between switching and motor start up Similarly pressure switches act as safety devices preventing excessive pressure which might arise when the refrigerator is not selected and the refrigerant is heated by the cabinet In such cases the pressure switches detect the incipient pressure rise and switch on the compressor to pump down 3 3 RELATIVE HUMIDITY RH Relative humidity is a measure of the ratio of the amount of water vapour present in ari atmosphere to the amount of water vapour that atmosphere could hold i
63. rs to the serial number of the CONTROLLER not the chamber Data Block This field is used mainly in Reply Packets from the Controller to pass back the information requested in Command Packets from the master although some Command Packets also have data associated with them In general the data bytes contained in the Data Block are printable characters encoded in 7 bit ASCI values 32 to 127 The bytes may contain any 7 bit value 0 to 127 XOR Checksum This is an exclusive OR checksum calculated from all bytes from the Header to the last byte in the Data Block inclusive The checksum is calculated as follows A byte variable C is initialised to 128 As each byte in the packet is transmitted each bit in C is XORed with the corresponding bit in the byte being transmitted After all bytes have been transmitted up to and including the last data byte C contains the result of the checksum calculation and is transmitted Additive Checksum This is a sum of all bytes transmitted in the packet up to and including the last data byte modulo 128 i e the remainder after dividing by 128 the sum of all bytes transmitted Compatibility with RS485 Multi Controller Configuration The RTS signal on the RS232 port controls data direction on the RS485 bus Normally the RTS line should be left unasserted by the master Just before the master transmits a packet it should assert the RTS line to drive the master s RS485 port to Output mode Afte
64. s List for details eee rc PART 2 FORMAT 550 INSTRUCTIONS CONTENTS Introduction 11 introduction to the FORMAT programmer controller 12 Format digital channels 13 How to use these instructions Getting Started 21 The menu system 2 2 Using on line Help 23 Function Keys Appendix 1 Appendix 2 2 3 1 Global function keys 2 3 2 Local function keys 24 Using the data entry windows 2 4 1 Moving between fields 24 2 Types of entry field 25 The status bar Steady state control 3 1 Condition setting 32 Resetting steady state setpoints 33 Condition monitoring 34 Ending steady state control Programs 4 1 Writing a program 42 How to use Format programming sheets 43 Entering the data into the programmer 44 Loading and saving programs 45 Runningaprogram number of cycles guaranteed soak mid cycle start delayed program start 4 6 Program monitoring window 4 7 Holding a program 48 Program completion 49 Program deletion Data logging 5 1 Introduction to data logging 52 Starting data logging 5 3 Stopping data logging 54 Displaying results 53 Loading into spreadsheets Alarms 6 1 Introduction to alarms 6 2 Setting alarms Communications 7 1 Introduction 7 2 Installing and using a single connection host system 7 3 Computer interactive interfacing main protocol 74 Cable connections 7 5 Support software Technical specification Program looping and nested loops Sample programming sheet Appendix 3 Part number 201456 Issue
65. s the first segment looped back FROM time from segment 2 to segment 5 1 20 60 seconds loop 1 from 5 to 3 time from 3 0 5 40 seconds loop 2 from 5 to 3 time from 3 to 7 80 seconds loop A from 7 to 2 time from 2 to 5 60 seconds loop La from 5 to 3 time from 3 to 5 40 seconds loop 2a from 5 to 3 time from 3 to 7 80 seconds loop B from 7 to 2 time from 2 to 5 60 seconds loop 15 from 5 to 3 time from 3 to 5 4 seconds loop 2b from 5 to 3 time from 3 to 5 40 seconds total 500 seconds 7 20 Because in the above example it is required to end the cycle at 9 40 then event statement time 9 40 7 20 220 Point 8 must be programmed at 540 seconds 9 minutes 40 seconds from the start of the cycle and point 7 at 9 minutes 20 seconds The figure below shows the whole program list ng as performed EXAMPLE OF NESTED LOOPS as performed 0 200 400 800 seconda PROGRAM AF di tie tag on Beda display tiat GASHI HS d 1 i5 00 04 46 0 00 00 00 81 00 H0 H 5 09 00 00 29 00 M 0 20 nei i5 i RSR H 08 04 00 0 31 06 H 5 t 65 9H i 00 00 01 5 M 15 loop te 3 65 HH 5 06 01 28 00 40 41 34 E 34 H 5 00 00 00 6 9 21 i5 100 gf 05 50 41 41 00 93 40 00 00 14 00 l 135 M 100 to 2 00 02 08 LAA E 5 B 134 1 00 8 M 16 04 08 42 40 Hi is 08 00 01 48 163 15 40 40 01 10 40 90 82 40 184 45 i 05 04 03 00 14 loop te
66. ster should then issue a Set Controller to Local Access Mode command packet to restore the Controller s local keyboard operation Description OPEN FILE FOR READING Type Reply Source Controller Header 131 Data Block 1 byte 0 if there was an error opening the file e g file in use does not exist etc 1 if the file was opened successfully Description CLOSE FILE Type Command Source master Header 132 Data Block No Closes a file opened for reading or writing Description CLOSE FILE Type Reply Source Controller Header 132 Data Block No The Controller sends this packet to the master to confirm that the file was closed Description READ DATA Type Command Source master Header 133 Data Block No the Controller 10 read the next b ock of data from the file and send to the master Description READ DATA Type Reply Source Controller Header 133 Data Block Even number up to 126 bytes Data block contains up to 63 hextuples representing the next block of data from the file For example the sequence of bytes 4Ah 80h 25h 30h would appear in the data block as the string 44802530 If the Controller has no more bytes to send data block of one null byte is transmitted by the Controller Description OPEN FILE FOR WRITING Type Command Source master Header 134 Data Block 13 bytes This packet instructs the Controller to prepare to write a file to the Controller s disk This will overwrite any file
67. stic bowl and filter can be removed for cleaning 1 ISOLATE ELECTRICS 2 If recirculating water system is not fitted disconnect the distilled water supply 3 Open instrument compartment door 4 Unscrew the bowl and remove the filter Clean or replace 5 Reassemble in reverse order 21 APPENDIX 1 PART NUMBERS Part numbers will be provided separately Note some of the parts may not apply to your cabinet FAN MOTOR BUNG 66mm diameter BUNG 100 diameter ELEMENT v p g heater ELEMENT cabinet heater primary ELEMENT cabinet heater secondary if fitted MCB MCE MCB MCB RELAY Delay RELAY Solid state 2 5 amps RELAY Solid state 25 amps FILTER Distilled water SERVICE KIT For air compressor SOLENOID VALVE Distilled water system SENSOR WICK For wet bulb controller WICK For wet bulb recorder SAFETY THERMOSTAT Mechanical TTT Ce ee APPENDIX 2 REC W WATER SYSTEM The recirculating water system is a self contained unit The system purifies waste water from the working chamber and recirculates it back to the cabinet inlet removing the need for a continuous supply of distilled water It consists of a reservoir tank water pump deioniser cartridge and a purity indicator Waste water is piped to the reservoir tank then pumped through a deioniser cartridge and back to the cabinet inlet The purity of the water in the system is indicated by either a conductivity meter or a colour change indicator window on
68. t number has been incremented by 1 throughout that there is an additional column 3rd This ensures compatibility with Sanyo Gallenkamp s plant growth products which control lighting via a third channel PROGRAM 2011db55 No Description Seg Temp Hum 3rd LSeg Rep Digital Channels dd hh mm ss C RH 12345678 001 00 00 00 00 0 0 01101000 002 00 00 00 01 25 0 97 0 0 01101000 003 00 02 50 00 533 97 0 0 01101000 004 00 03 00 00 55 0 95 01101000 005 00 03 10 00 55 0 93 0 0 01101000 006 00 11 50 00 550 93 0 0 01101000 007 00 12 00 00 55 0 9 0 0 01101000 008 00 12 10 00 533 99 0 0 01101000 009 00 13 30 00 400 99 0 0 01101000 010 00 16 30 00 25 0 99 0 0 01101000 011 00 16 31 00 250 98 0 0 01101000 012 01 00 00 00 25 0 98 0 0 01101000 Key for Digital Channels iz cooling 1 main 2 cooling 2 aux 3 4 v 5 T 50 7 3 Computer interactive interfacing main rotocol This section defines fully the serial communications protocol implemented in the Format 550 Controller used on Sanyo Gallenkamp chambers and rooms This protocol allows a master computer System Master to communicate with one or more Controllers on a network Typical applications include where the chamber is required to operate mteractively with the test proce dure being applied to the test load within the chamber where simple record of the conditions of the chamber is required di rectly into a loggin
69. t changed successfully or if access is denied controller has priority Description DIGITAL CHANNEL DESCRIPTION Type Command Source master Header 139 Data Block l byte This instructs the Controller to reply with the description of a digital channel The data byte is a numeric string from I to 8 representing the digital channel in question Description Type Source Header Data Block DIGITAL CHANNEL DESCRIPTION Reply Controller 139 30 bytes The data block of this packet contains the digital channel description Description Type Source Header Data Bloc ENABLE DISABLE GUARANTEED SOAK Command master 140 1 byte This instructs the Coneroller to enable or disable the Guaranteed Soak option while running Data byte set to 1 to enable to disable Description Type Source Header Data Block ENABLE DISABLE GUARANTEED SOAK Reply Controiler 140 1 byte Data block contains 1 if successful 0 if not eg chamber not running Description Type Source Header Data Block ENABLE DISABLE MANUAL HOLD Command master 141 1 byte This instructs the Controller to enable or disable the manual timebase hold Data byte set to L to enable 0 to disable 61 Description Type Source Header Data Block ENABLE DISABLE MANUAL HOLD Reply Controller 14 1 byte Data block contains 1 if successful 0 if not eg chamber not running Description Type Source Hea
70. t the conditions set by the operator via the control system A sloping false roof is fitted to the working chamber to prevent condensation dripping onto the test load The base of the working chamber is double skinned to prevent hot and cold spots forming due to radiated heat cold from the treatment chamber If required the base of the working chamber may be used as another shelf working chamber temperalure Sensors drain vapour phase 3 2 TEMPERATURE CONTROL a b c d Accurate repeatable temperature control levels are achieved by continuously balancing heat loss with intermittent modulated heating controlled by electronic controllers The conditioned air flows over a dry platinum resistance temperature sensor B31904 100chms at C which feeds signals back to an electronic controller The actual temperature is compared with the operator set temperature and errors are corrected by switching the heaters via relays on a time proportioning basis to achieve smooth accurate control 3 2 1 HEATING One or more inconel sheathed electrical heating elements are situated in the treatment area These elements normally operate only at black heat for a long life and avoidance of excessive heater surface temperatures 3 2 2 COOLING All models have CFC free mechanical refrigeration units with a direct cooling coil to achieve the minimum temperature specified All refrigeration compressors are protected for ope
71. tdown automatically N B this thermostat monitors the cabinet only see also 4 9 Test load protection 16 5 OPERATION WARNING This cabinet is capable of temperatures well outside ambient If the door is opened during such conditions there could be a temperature HAZARD from cabinet air or contents 5 1 CONTROL PANEL INSTRUMENTATION Full details of the Format 550 programmer controller fitted 10 the cabinet are given in Part 2 If there are any further controls not mentioned here refer to 2 3 Additional facilities fitted 5 1 1 INDICATORS PUSHBUTTONS Mains Green Indicator lamp The mains indicator is illuminated green when mains power is supplied to the cabinet and the mains power switch red yellow rotary switch is switched on Reset Amber pushbutton Internal lamp glows whenever the cabinet is powered but not reset Press to reset and start the cabinet The reset button is not illuminated when the cabinet is running 5 1 2 RECORDER If a recorder is fitted it should be set up and operated in accordance with the manufacturer s instructions packed either with this manual or inside the instrument itself 17 5 2 CABINET AND PROGRAM START UP Ensure that The interior of the cabinet is clean and dry b You know how to SHUT DOWN the cabinet see section 5 4 c Distilled water level is adequate d Clean wicks are fitted to the wet bulb sensor s TO START THE CABINET a Switch the MAINS red yellow isol
72. ter the required temperature setpoint Enter the required humidity setpoint FORMAT will suggest the correct digital channel selection Set the digital channels for non chamber dependent digital channels VFTs etc as required Reset sug gested settings for the chamber dependent digital channels only if previous experi ence shows a need to Start steady state control and start the cabinet Run the cabinet under manual control for the desired length of time Stop manual control and switch off the cabinet Condition C WRH Status Logging Program Set Point Temperature Set Point Humidity Digital Channels Fig 2 Steady State Data Entry Window 3 1 Condition setting _ To set a condition on the controller select the Steady State menu option You will then be presented with the Steady State Data Entry Window Type in the required temperature in C and press enter If you make a mistake while typing use the backspace key to strike out erroneous digits Type in the humidity in RH in the same way 3 2 Resetting steady state setpoints After you have entered a condition FORMAT will suggest digital channel settings If you want to alter the suggested digital channel selections press enter or arrow right key until the input cursor reaches the required field and press 1 or 0 Entering 1 switches a digital channel ON and 0 switches it OFF When you are satisfied with the data m the win
73. the deioniser cartridge Installation 1 Place the recirculating water system below cabinet level preferably beneath to enable the water waste to drain back to the reservoir 2 Connect the recirculating water unit inlet to the cabinet drain then connect the recirculating water unit outlet to the cabinet water supply inlet Suitable lengths of plastic tubing are provided There must be a CONTINUOUS fall from the cabinet to the system inlet otherwise the cabinet will flood due to air locks in the pipe 3 Remove the white filler cap and fill the reservoir with DISTILLED water Use distilled water because distillation kills algae spores 4 Connect the mains lead to a 220 240 volt 50Hz single phase minimum 5 supply Operation Switch on the mains power to operate the recirculating water system To cease operation switch off mains power If the level of water in the reservoir falls to the minimum mark top up with distilled walter For units with the water purity indicated by a conductivity meter calibrate the meter by pressing and holding in the button left of the meter and turning the knob right of the meter to adjust the meter to read infinity A satisfactory reading for water conductivity is below 10 micro mho cm Above this level the deioniser cartridge requires replacement For units indicating water purity by a colour change indicator do not require calibration satisfactory water conductivity of below 10 micro
74. the port Wires ieads should enter the cabinet via the top of the outside plug and the bottom of the inside plug to prevent condensation accumulating between the plugs Extra or replacement plugs can be obtained see PART NUMBERS An air vent 1s situated at the rear of the cabinet The hole in the vent must always be kept clear as it prevents pressurisation of the cabinet 4 12 GLASS INNER DOOR When fitted a glass inner door enables observation of the test without unduly disturbing the cabinet s climatic conditions The door is held closed by sash fasteners which should be hand tight and not forced If the test load dissipates heat the glass door must be protected from absorbing heat by radiation effect see section 3 8 Test load protection 4 13 RS232 CONNECTOR On the right hand side of the instrument compartment is the 25 pin D type RS232 serial communications connector of the Format 550 programmer Further details of the pin connections are given in Part 2 of this manual 4 14 SAFETY THEHMOSTAT A factory preset safety thermostat is fitted inside the instrument compartment to protect against overheating of the cabinet in the event of failure of the temperature control system The thermostat is set to a temperature 10 C above the maximum operating specification of the cabinet The thermostat must not be reset Should the cabinet air temperature exceed that set on this thermostat it will cause the cabinet to fail safe i e shu
75. voir The are connected to the programmer The relative humidity is determined from the psychrometric difference between the wet and dry RT s The reference temperature for humidity control is compensated for the actual chamber temperature Errors are corrected by actuating the vapour phase generator vpg 3 32 RELATIVE HUMIDITY CONTROL Relative humidity levels are maintained by balancing continuous minimised extraction of water by condensation with intermittent injection controlled by an electronic controller 3 33 RELATIVE HUMIDITY INCREASE All cabinets are fitted with a vapour phase generator VPG Vapour phase generation Water vapour produced in the vpg is introduced into the treatment chamber and is absorbed by the air The vapour phase generator is provided humidification from 15 to 95 th at 60 C to 50 to 95 at 20 C 10 3 34 RELATIVE HUMIDITY DECREASE Dehumidification is achieved using the cooling coil to form a dew point to remove water vapour from the air in the working chamber The direct cooling mode has a low surface temperature cooling coil which enables dehumidification of the cabinet air between 5 C and 70 C Ti 4 INSTALLATION 4 1 ACCESSORIES amp SPARES Check that the following items have been supplied with the cabinet a Wick for the wet bulb sensor s b A set of psychrometric tables for the recorder if fitted C Instructions and wick for recorder if fitted 4 2 POSITIO

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