GL Service Manual
[TOC]
This document describes the procedures for configuring the GL service menu and is intended solely for ESPEC technicians and engineers with advanced expertise in GL system settings.
| CAUTION | CAUTION |
|---|---|
| PROHIBIT | Do not use this [Service page] |
| Only ESPEC service representatives use this function to adjust the setting parameters. Altering settings without authorization at your own discretion can cause accidents. ESPEC is not responsible for damages or injuries caused by user-adjusted parameters. |
The Service page is located in the Setup menu, under the Configuration submenu. The default localhost user on the HMI can access the Service page via the Setup option in the menu bar or through the system menu (hamburger button).
If a user logs in remotely via a Web browser from a PC on the local network, they must have read/write privileges for the Setup menu in order to access the Service page. If the Service page is grayed out, that user lacks the write privilege for the Setup menu (see figure below).
The Service page is password protected. Contact ESPEC customer service for assistance regarding the password to the Service page. The following procedure outlines the steps to access the Service page via the Menu bar.
Procedure:
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Select Setup on the menu bar (or the Setup button on the home page)
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Select Configuration
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Select Service (see arrow)
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Enter the password and select Submit
Once authentication is successful, the Service page appears as shown below, with its configuration settings organized into three categories.
- General Service configuration options
- Server Setup options
- PLC and Chamber Setup Actions
Each group will be outlined and explained in the following chapters.
Note: The figure above shows the Service page on the HMI. In contrast, the final category (Item 3) appears differently when the Service page is accessed through a Web browser on a local PC, as shown below. In this view, the Dev button in the Actions group is not displayed.
This chapter provides an overview of the general configuration options available for all components and devices in the GL chamber.
Calibration and configuration for all devices in the chamber are managed on this page. Each device is presented in a row format and requires both an input value and a calibration type, which must be specified in the designated fields. The remaining parameters include maximum and minimum input values, scaled values, alarm values, as well as offset, delay and filter settings.
To configure or modify the settings on other devices on the list, apply the paging buttons or scroll bar (described in the following table) to locate the desired device.
| Number | Name | Description |
|---|---|---|
| 1 | Scroll bar | D rag the scroll bar up/down to move the page up/down; tab on the top/bottom arrow to gradually move up/down |
| 2 | Top Page | Apply this button to get to the top page |
| 3 | Paging Up | Apply this button to scroll up the list per page |
| 4 | Up | Apply this button to scroll up the list per entry line |
| 5 | Down | Apply this button to scroll down the list per entry line |
| 6 | Paging Down | Apply this page button to scroll down the list per page |
| 7 | Bottom Page | Apply this button to get to the bottom page |
The Control Loop PID page comprises one or more configuration panes supporting temperature-only or combined temperature and humidity control, etc. Each pane (see figure below) allows parameter settings for PIDs related to temperature-only, temperature/humidity, and other available configurations. The following figure depicts a typical chamber equipped with PID control loops for temperature and humidity.
The Digital Input Configuration page provides a table of selectable alarm triggers. The checkboxes in the second column can be selected to suppress or deselected to allow alarm trigger for each device. When the checkbox for a device is enabled, as depicted in the table, the corresponding alarm is suppressed. The unchecked boxes allow alarms to trigger. When an alarm is triggered, it displays Alarm ID and a brief description of the cause.
The Miscellaneous Settings page contains a table of the selectable setting values for miscellaneous items used during GL operation. These items are identified as tags and are displayed in the first column. The setting values in the Value field designate their threshold operation value. For instance, as indicated in the description (last column), when the temperature set point is lower than the threshold value specified in the Value column, the refrigeration system will run in cascade mode (if possible).
The High Side Refrigeration Configuration page provides separate panes to adjust control settings on ELV, Super Heat and Pressure. Different options of refrigerant type for the high-side system can be selected from the refrigerant list in the ELV pane. Maximum and minimum values of ELV can be adjusted by entering new values in the designated fields, along with the startup pulse and startup temperature.
The Superheat pane allows adjustment of the set value, as well as PB, Ti, and Td parameters by entering new values in the corresponding fields.
The Pressure pane provides controls for configuring the maximum and minimum set values, as well as PB, Ti, and Td parameters, through entry of new values in the corresponding fields.
The Misc. pane provides an option to configure the startup delay by entering the desired delay time in seconds.
The Low Side Refrigeration Configuration page provides dedicated panes for configuring ELV, superheat, and pressure control parameters. The refrigerant type for the low-side system can be selected from the refrigerant list within the ELV pane. Maximum and minimum values of ELV can be adjusted by entering new values in the designated fields, along with the startup pulse and startup temperature.
The Superheat pane allows adjustment of the set value, as well as PB, Ti, and Td parameters by entering new values in the corresponding fields.
The Pressure pane provides controls for configuring the maximum and minimum set values (psi), as well as PB, Ti, and Td parameters, through entry of new values in the corresponding fields.
The Misc. pane provides an option to configure the startup delay by entering the desired delay time in seconds.
The Humidity Control Configuration page contains a table of the selectable values for humidity related features during GL operation. These features are identified as tags and are displayed in the first column. Each item’s (or feature’s) behavior is determined by its value (or its checkbox) in the Value column. Each entry in the Value column can be adjusted.
For example, under the HumiDevEnable entry (see arrow), a value of 2 °C defines the allowable deviation between the temperature setpoint and the actual process temperature before humidity control is activated. A different deviation value can be used to set the condition for enabling the humidity control.
The description column provides the detail of this action.
The Humidity Gain page provides setting options for the temperature setpoint configuration and the PB multiplier. Humidity PIDs can be adjusted by applying the multiplier to the PB on the specific entry in the table (see figure below).
The Power Saver Dehumid Limit page provides setting options for the heater control power (%) and the maximum dehumidification power (%). This function defines the dehumidification power limit relative to the heater control power. As shown in the figure below, values in both columns (heater control power and maximum dehumidification power) can be adjusted by entering new values.
The Power Saver Humid Limit page provides setting options for the cooling control power (%) and the maximum humidification power (%). This feature limits the humidification power based on the selected cooling control power. As shown in the figure below, values in both columns (cooling control power and maximum dehumidification power) can be adjusted by entering new values.
The Dehumid SSR Output Limit page provides setting options for the temperature set point and maximum SSR dehumidification power(%). This function defines the SSR dehumidification power limit relative to the temperature set point. As shown in the figure below, values in both columns (temperature set point and maximum SSR dehumidification power) can be adjusted by entering new values.
This chapter provides an overview of the services on the GL system.
The System Logs page keeps track of and displays various logs during the GL operation.
The selection button in the Level dropdown list, as depicted in the following figure, provides different options to display the current logs on the GL system. Display options are available: ALL, NOTSET, DEBUG, INFO, WARNING, ERROR, and CRITICAL. Select one to filter the display. Further filtration is available through the selection of Logger Name, Trace ID, and a date and time range.
The following procedure outlines the steps to list the current users who are logged in the GL system.
Procedure:
- Click the Level field
- Select INFO from the dropdown list
- Click the Logger Name field
- Select especapi.auth from the list
- The Message column displays username and IP address the user device used to log in to the GL system.
As depicted in the following figure, a user who has logged in to the GL system can be traced.
The Chamber Interface Setup page consists of two chamber interface configuration options: Simple and Expert. Chamber configuration involves selecting the right unit from the Chamber Category list, along with the correct model, size, communication and optional features.
Note: The dropdown menu of the Chamber Category includes interface options available in the legacy ESPEC Web Controller (EWC). The setup is only operational on EWC connected to one of the legacy ESPEC controllers (P300, SCP200, ES102), T-series Allen Bradley PLC or Watlow F4 or F4T controller.
The figure below illustrates a typical Simple Mode chamber interface setup for a GL Platinum J chamber.
This setup page also provides information on the chamber serial number, model, and series code. The following figure illustrates configuration option associated with different types of chamber and features.
| Item | Description |
|---|---|
| Chamber Category | Category selection option |
| Model Type | Chamber model type: U, L, Z or X |
| Size | Chamber size selection |
| Communication Option | Remote access communication option via RS232 or RS485 |
| Control Range Option | Available options for Wet bulb/Dry bulb, solid state control range |
| Purge Option | Available in dry air purge (DAP) or nitrogen gas purge (NGP) |
Note: The Communication option in the Optional Features column differs from the chamber communication interface in the middle column, which defaults to an OPC-UA URL. The chamber communication interface specifies the protocol used to establish and manage communication between the GL system and the PLC. Access to the GL system and its user interface is provided via the endpoint URL opc.tcp://localhost:4840 (i.e., Ethernet communication). Additionally, the chamber is equipped with a CM2 or CM4 communication port for optional serial communication via RS-232C or RS-485, allowing the operator to control the chamber directly, either independently of or alongside Ethernet communication.
In Expert Mode, configurations are applied based on settings defined in Simple Mode. All settings initially configured in Simple Mode are stored in the Expert settings list. Once these settings are applied and stored, the values displayed in Simple Mode may no longer accurately reflect the actual configuration of the chamber. Therefore, to verify the current interface and chamber settings, users should refer to the Expert settings list. A typical Expert Mode configuration is shown below:
The Expert option enables customization of the interface configuration to match the intended chamber. Modifications must only be performed by operators with expertise in PLC configuration and YAML syntax. Proper configuration of the GL system requires a thorough understanding of PLC functionality and associated I/O modules.
Here is a closer look of the YAML configuration file: It begins with the sample rate and back trace configuration, followed by the type of interface used for communication (specified under the gl_protocol mapping key). The list continues with the relay (time signals), OPCUA endpoint URL specifications, etc. The Chamber Interface Setup page with Expert Mode enabled is depicted in the following figure.
| No. | Name | Description |
|---|---|---|
| 1 | Setup | Setup menu |
| 2 | Expert Mode | Expert configuration file |
| 3 | Save | Save the current setting |
| 4 | Export | Export the current configuration file |
| 5 | Import | Import the current configuration |
| 6 | Back | Return to previous menu or page |
Custom configuration may be performed using one of the following two methods:
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Content Modification: Modify the contents of the YAML file based on YAML syntax and data structure. For the new settings to take effect, click the Save button (3).
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Exporting YAML file: To back up the current setting, apply export via (4) and save the file on a PC.
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Uploading YAML File: Click the Import button (5) to upload the YAML configuration file from the local computer. The contents of this file must follow the syntax and data structure of YAML.
The Setting Database page provides three dropdown menus for configuring chambers: Chambers, Chambers Vars (Chamber Variables), and System Vars (System Variables), as illustrated in the figure below.
| No. | Name | Description |
|---|---|---|
| 1 | Chambers | Provides dropdown menu with options to delete or create new chamber configuration |
| 2 | Chambers Vars | Provides dropdown menu with options to create or configure optional chamber operations |
| 3 | System Vars | Provides dropdown menu with options to configure system settings (e.g., email server, users, network, etc.) |
Note: The Save and Delete buttons at the bottom of the menu bar can be used to save the edited or current configuration file or delete it. The back button can be used to return to the previous page.
The Chambers dropdown menu allows the operator to add a new chamber by composing a new configuration file in YAML. Each chamber configuration is identified by its ID number. The default chamber has ID 1.
The Chambers Vars dropdown menu provides more options on how to configure the parameters for the selected chamber. The figure blow depicts a macros configuration in YAML to send alert emails when an alarm is tripped.
| No. | Name | Description |
|---|---|---|
| 1 | Chamber ID | Displays ID of the current or selected chamber |
| 2 | Chamber Name | Displays the name or ID of the selected chamber for this configuration |
| 3 | Configure Type | Displays the type of selected configuration; e.g., macros |
| 4 | Type Name | Displays the name of the macros configuration file |
| 5 | Type Name List | Displays a list of different files associated with the selection type (macros) |
Other configuration options—such as settings, template, app_settings, and profile_gl—can be constructed in the same manner. Implementing these configurations requires in-depth expertise in GL PLC operation.
The System Vars dropdown menu includes options for configuring system settings, API (Application Programming Interface) options, and frontend configuration (such as registration-related settings). The default configuration options of this menu are depicted in the following figure.
| No. | Name | Description |
|---|---|---|
| 1 | settings | Displays a list of configuration options for email server, user account and privileges, network settings and override option |
| 2 | api | communication protocol for the GL system, specifying assigned port (10001), baud rate (19200), data transmission protocol |
| 3 | frontend | factory configuration options on registration, factory setup status and configuration wizard page |
Note: The Save and Delete buttons at the bottom of the menu bar can be used to save the edited or current configuration file or delete it. The back button can be used to return to the previous page.
The Server page is the operations center of the host OS (operating system) for the GL system, providing centralized monitoring and management of all system operations and processes. By default, it displays the services and hardware resources of the host OS, showing information of Up Time, Processor (CPU), Memory, Storage and Processes, as illustrated in the following figure.
Note: The appearance of the Service page may vary depending on the display. For example, on the HMI, the Processes pane appears at the bottom of the page and requires scrolling to access.
| No. | Name | Description |
|---|---|---|
| 1 | Up Time | Amount of time the GL system has been in operation |
| 2 | Processor (CPU) | Displays CPU current utilization (%), its clock speed and operating temperature |
| 3 | Memory | Displays current status of physical memory being used by the host OS and GL system services |
| 4 | Storage | Displays information of the storage configuration and utilization (%) |
| 5 | Process Tab | Displays different process tab for monitoring specific processes |
| 6 | Processes | Displays all running processes, who initiated them, and how much CPU and memory each one is using. |
Information about the embedded system (hardware and OS) that supports the GL system is displayed in the Storage pane (Item 4) which lists the partitions and their current usage. Information includes the type of security being used to protect the host OS and the GL system. For instance, the root partition (designated as / under the Mount column) is secured by configuring it as read-only, indicated by RO in the Mode column. The first root partition being used by the host OS is /dev/mmcblk0p2 (listed under the Device column). The second root partition, which is inactive and therefore not listed, is assigned the device name /dev/mmcblk0p3. This partition is used to perform system updates, enabling the host OS to switch to it upon successful completion. The update process alternates between /dev/mmcblk0p2 and /dev/mmcblk0p3 as required to ensure the system/chamber is up and running at all time.
Data collected from the chamber will be stored on a separate storage device with roughly 10GB of storage capacity mounted as /appdata (under the Mount column). This information enables the operator to determine when logged data will exhaust available storage and when deletion is required to reclaim space. The GL system (and underlying host OS) continuously monitors data file size to ensure adequate storage capacity is maintained.
The Processes pane displays a list of all running program instances. Each process includes details such as the associated user, CPU and memory usage, process ID, and the command that initiated it. Processes are generally initiated by the root user or by system services. The list provides detailed information on each process, enabling the operator to monitor system behavior, track all running processes, and identify those consuming excessive CPU time, which may indicate a potential issue.
The Service Monitor page provides detailed information about the operating conditions and capacity of the chamber and its hardware components, as depicted in the following figure. The content of this page can be compared to that displayed on the page under the Monitor menu (refer to the Chamber Operation Manual for details). This page shows details of the refrigeration system.
Here is the Service Monitor page when the chamber is in Standby mode.
The Service Monitor page of the Trend Graph provides detailed plots of the operating components. The content of this page can be compared to that displayed on the Trend Graph page under the Monitor menu (refer to the Chamber Operation Manual for details).
The Service Monitor page on I/O (Input/Output) Overrides provides detailed information regarding the inputs and outputs of Digital, Analog, SSR and ELV. Use the scroll bar to view the remaining input/output for these components.
This chapter provides an overview of the behavior of the Actions buttons in the lower section of the Service page. The following figure shows these buttons grouped into three categories: PLC Actions, Chamber Setup and Actions.
Once the PLC configuration is complete, it can be secured using the Lock button. To make changes, select Unlock. Use the Commit button to save changes, and Restore to revert the PLC configuration.
The chamber setup file can be downloaded as a backup using the Export button. On the HMI, when a USB storage device is connected to the external USB port on the side of the monitor, selecting Export saves the setup file to the USB drive. When accessing the GL system through a web browser on a local computer, selecting Export downloads the setup file to the computer’s Downloads folder.
The backup file can be restored to the GL system using the Import button. When a USB drive is connected, selecting Import opens a file manager that lists all devices connected to the system. Use this list to locate the USB drive and select the setup file for upload. When accessing the GL system through a web browser, selecting Import opens the file manager, allowing you to choose a setup file from the local computer.
The Actions buttons in the final category are intended for technicians who have completed GL system configuration, chamber setup, and testing. The Ship button resets the GL system and chamber to their factory default settings, preparing the unit for shipment.
The Dev button enables inspection mode in the HMI display software (Electron), providing access to development and debugging tools.
The Logout button logs the user out of the Service page. When selected, the system returns to the Configuration page, as shown below.
When the Logout button is applied, accessing the Service page again requires entering the password. In contrast, using the Back button (at the bottom of the menu bar) simply returns to the previous page while keeping the Service page logged in. Therefore, to ensure security and to protect the GL system and its configuration, the Logout button should be used.