EC0x heat/cool issues - Sun Electronic Systems

SUN ELECTRONIC SYSTEMS
EC0X HEAT/COOL TROUBLESHOOTING GUIDE
062013
COVERS MODELS EC0x REV E , REV F
SUN ELECTRONIC SYSTEMS, INC.
Tel: 321-383-9400
1845 Shepard Drive
Fax: 321-383-9412
Titusville Florida
Email:info@sunelectronics.com
32780
Web: www.sunelectronics.com
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TROUBLESHOOTING AN EC0X (REV F AND LATER) CHAMBER WITH HEATING AND COOLING ISSUES
Note: EC0X chambers mfg after 2000 will have the REV F style controller. This is a 2-stack controller that uses an I/O
board mounted on the chamber’s firewall. Check the serial label on the back of the chamber to determine controller Rev.
See page 8 for troubleshooting an EC0X with a REV. E and earlier controller.
TROUBLESHOOTING A CHAMBER NOT HEATING
Separate control section from chassis by removing screws along top/bottom of right side of chamber.
Separate control section from rest of chamber and verify that the gray ribbon cable from motherboard to I/O board
is securely seated on both ends.
Verify that red/black twisted pair from bottom terminal strip labeled HEAT is connected securely to the 25A heater
SSR installed on firewall next to I/O board.
With the red heat LED on, the DC voltage to 3&4 of the 25A heater SSR should be between 3 and 5 VDC.
If this voltage is present on the heater SSR, then with voltmeter set to AC, the AC voltage measured on terminal 1 &
2 across heater SSR should be close to 0VAC.
If the voltage across 1&2 of the 25A heater SSR is not approximately 0VAC when the RED heat LED is on, then SSR
could be faulty or there could be an open heater element or poor connection to one or more heater elements.
To verify that heater elements are OK, you can measure the total equivalent resistance at the points listed in the
table. The value measured should be within a few ohms of the value listed in the table.
MODEL
VOLTAGE
MEAST. TERMINALS
OHMS
HEATER ELEMENTS
EC0A/01
110 VAC
11 & 9 ON I/O BOARD
10
(2) 600 WATTS
EC0A/01
220 VAC
11 & 10 ON I/O BOARD
40
(2) 600 WATTS
EC02/12
110 VAC
11 & 9 ON I/O BOARD
8
(2) 800 WATTS
EC02/12
220 VAC
11 & 10 ON I/O BOARD
32
(2) 800 WATTS
EC03/13
220 VAC
11 & 10 ON I/O BOARD
20
(4) 600 WATTS
If a much higher resistance is measured, then a poor connection to a heater element exists or there is an open
heater element.
To determine if a poor connection exists:
Remove the chamber back plate and set aside fiberglass insulation. Inspect wiring to heater elements and check that
nuts are tight, there are no charred connectors, or cracked/broken ceramic insulators. Repair as needed.
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To determine if a heater element is open:
Remove wiring to heater element and use ohmmeter to measure resistance of each heater element.
TROUBLESHOOTING A CHAMBER HEATING ALL THE TIME
With chamber powered on and the RED heat LED off, the chamber should not heat up at a fast ramp rate. The residual
heat from motors, however, will cause a very slow increase in temperature of the chamber.
If the chamber is heating at all times:
Separate control section from chassis by removing screws along top/bottom of right side of chamber.
Measure the DC voltage across 3&4 of the 25A heater SSR. It should be approximately 0vdc when RED heat LED is
off.
If a voltage is present, then either there is short in gray I/O ribbon cable or main motherboard is faulty. You can rule
out the ribbon cable by temporarily using the ribbon cable used by the front panel. If problem clears, then problem
is a faulty ribbon cable. If problem persists, then controller is faulty and should be sent in for repair. Call Sun for an
RMA number.
If no voltage is present on 3&4 of the 25A heater SSR, then measure the AC voltage across 1&2. With the red heat
LED off, the voltage should be approximately that of the line voltage. If the voltage measured is close to zero, the
SSR is most likely shorted internally. Otherwise, there is most likely a heater terminal shorted to ground via a broken
ceramic insulator or has opened up and making contact with chamber (ground).
To determine if a short from terminal to ground exists, remove the backplate of the chamber and set aside fiberglass
insulation. Inspect for broken ceramic insulators, charred or loose wiring. Measure the resistance from each
terminal to ground (inner chamber). It should read a very high resistance. If not, then heater element is faulty and
should be replaced. Contact Sun for part numbers or assistance.
TROUBLESHOOTING AN EC0X REV F CHAMBER WITH A DC VALVE THAT IS NOT COOLING
If the green cool LED IS coming on and the chamber is not cooling:
The chamber requires a LIQUID supply for the chamber to cool. It will not cool with gas. Verify that the correct coolant
is being used for the chamber. This information is located on the serial label listed on the back of the chamber. If you
are using an LN2 or LCO2 Dewar (tank), verify:
The supply hose is connected to the LIQUID port.
The tank is not empty.
The supply pressure is within 25 psi of the stated pressure listed on the label located on the back of the
chamber.
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The supply hose should be as short as possible (6’ is ideal) and insulated to minimize vaporization of the liquid
before it gets to the chamber.
If you are using 850 psi LCO2, verify that you are using a SIPHON cylinder to ensure that liquid CO2 is drawn and that the
tank is not empty.
If you are confident that the chamber is receiving a liquid supply:
Separate control section from chassis.
Verify that the gray ribbon cable from motherboard to I/O board is securely seated on both ends.
The coil resistance of the DC valve can be measured. To do this, remove the black valve wires from terminals 15&16.
Set meter to measure resistance. The value should be approximately 18 OHMS. If an open resistance is measured,
the coil is faulty and needs to be replaced.
If the resistance is OK, reconnect valve wires to 15 and 16.
Set chamber to cool. When the green cool LED is on, the driver board sends out a 20-25 volt pulsed signal that can
be viewed on a scope OR the average DC voltage of this can be measured with a voltmeter.
Set the voltmeter to measure DC volts and measure the voltage to 15 & 16. The voltage should be between 4 Vdc
and 7 Vdc.
If this voltage is not present (0Vdc measured) then the valve driver board could be bad. To verify if driver board is
faulty, verify that the 3-5Vdc cool control voltage from the controller is getting to this driver board. This control
signal is present between the pins labeled + and – (on the I/O board) next to the leads on the cool driver board . If
this signal present and no voltage is present on 15 & 16, then most likely the cool driver board is faulty.
If a voltage IS present on 15 & 16 of the I/O board, verify LN2 supply pressure is within 25 psi of the rated pressure
listed on back of chamber. If the valve continues to not open, valve is most likely faulty and should be replaced or
sent in on RMA. Contact Sun at 321-383-9400 for assistance.
TROUBLESHOOTING AN EC0X REV F CHAMBER WITH AN AC VALVE THAT IS NOT COOLING
If the green cool LED IS coming on and the chamber is not cooling:
The chamber requires a LIQUID supply for the chamber to cool. It will not cool with gas. Verify that the correct coolant
is being used for the chamber. This information is located on the serial label listed on the back of the chamber. If you
are using an LN2 or LCO2 Dewar (tank), verify:
The supply hose is connected to the LIQUID port.
The tank is not empty.
The supply pressure is within 25 psi of the stated pressure listed on the label located on the back of the
chamber.
The supply hose should be as short as possible (6’ is ideal) and insulated to minimize vaporization of the liquid
before it gets to the chamber.
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If you are using 850 psi LCO2, verify that you are using a SIPHON cylinder to ensure that liquid CO2 is drawn and that the
tank is not empty.
If you are confident that the chamber is receiving a liquid supply:
Separate control section from chassis.
Verify that the gray ribbon cable from controller to I/O board is securely seated on both ends.
Set chamber to cool. When the green cool LED is on, the cool SSR should send out an AC voltage approximately
equal to the line voltage supplied to chamber (110VAC or 220VAC) on terminals 15 and 16 of the I/O board.
If no voltage is present, then the SSR, controller or gray I/O ribbon cable could be at fault. To verify if which one is at
fault, verify that the 3-5Vdc cool control voltage from the motherboard is getting to the cool relay. This control
signal is present between the SSR + and – leads. If the signal is present, then cool SSR is most likely at fault. If this
signal is not present, then replace ribbon cable to see if problem clears. If not, the controller is most likely at fault
and should be sent in on an RMA. Contact Sun to get an RMA number.
TROUBLESHOOTING AN EC0X REV F CHAMBER WITH A VALVE STUCK OPEN
If the green cool LED is off, the chamber’s valve should not allow coolant into the chamber. If it is off and continues to
allow coolant into the chamber, UNPLUG the chamber from the outlet. If coolant continues to rush into the chamber
with no power applied to the chamber, then the valve is at fault (Contact Sun for replacement part). If problem clears
then the electronics is at fault. To determine if problem lies with controller, I/O flat ribbon cable or DC driver board (AC
SSR):
Separate control section from chassis.
Swap out ribbon cable with known good ribbon cable. The ribbon cable used by the chamber’s front panel may be
used. If problem clears, ribbon cable was faulty. Contact Sun for replacement part. If problem persists:
Verify that NO voltage is present on terminals 15 & 16 (or on optional valves, terminal strip is labeled). For DC valves
you should measure close to 0VDC and for AC valves, close to 0VAC. If a voltage is present, then either the DC driver
board (SSR) or the motherboard is at fault. To determine if the controller is erroneously sending out a voltage to the
driver board (SSR), measure the DC voltage to the input of the driver board (SSR) )See I/O photo below).
Measurement should be taken from the (+,-) pads for the driver board in question. The measurement may also be
taken from the 26-pin gray connector. Use any of the (+) leads along with the output in question. If no voltage is
present from motherboard then the driver board (SSR) is at fault. If a voltage is present at the input to the DC driver
board (or AC SSR), then the controller is at fault. Contact Sun for an RMA or replacement part (s).
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Input Voltage to the driver board
(from motherboard). Should be
approximately 3-5 Vdc ONLY when
the green cool LED is ON.
Meas’ts can be
taken here as well.
Use any of the (+)
terminals along
with the output in
question.
I/O board used for DC valves
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Output Measurement such as cool,
heat may be measured here to
determine if motherboard is at fault.
Any of the (+) terminals may be used
with output in question (cool, heat
etc.). 3-5 Vdc present when output
should be on, 0 Vdc when off.
I/O board used7 for AC valves
TROUBLESHOOTING AN EC0X CHAMBER (REVE AND EARLIER) WITH HEATING AND COOLING ISSUES
Note: EC0X chambers mfg before 2001 will have the REV E style controller. This is a 3-stack controller that uses a 16
position terminal strip mounted on the chamber’s firewall. Check the serial label on the back of the chamber to
determine controller Rev.
TROUBLESHOOTING AN EC0X REV E CHAMBER NOT HEATING
Separate control section from chassis by removing screws along top/bottom of right side of chamber.
Verify all wiring to terminal strips are secure.
With the RED heat LED on, verify line voltage is present on terminals 11 and 9 (110 VAC) and 11 & 10 (220
VAC) of terminal strip on firewall.
If no voltage is present, check F2 25A fuse (located on top power supply board to left of transformer) for
continuity/corrosion and replace if faulty/corroded. Check fuse holder for corrosion and clean if necessary.
If fuse is ok, then 25A heater triac is most likely at fault. Contact Sun for RMA or replacement part.
To verify that heater elements are OK, you can measure the total equivalent resistance at the points listed in the
table. The value measured should be within a few ohms of the value listed in the table.
MODEL
VOLTAGE
MEAST. TERMINALS
OHMS
EC0A/01
110 VAC
11 & 9 ON TERMINAL STRIP
10
(2) 600 WATTS
EC0A/01
220 VAC
11 & 10 ON TERMINAL STRIP
40
(2) 600 WATTS
EC02/12
110 VAC
11 & 9 ON TERMINAL STRIP
8
(2) 800 WATTS
EC02/12
220 VAC
11 & 10 ON TERMINAL STRIP
32
(2) 800 WATTS
EC03/13
220 VAC
11 & 10 ON TERMINAL STRIP
20
(4) 600 WATTS
HEATER ELEMENTS
If a much higher resistance is measured, then a poor connection to a heater element exists or there is an open
heater element.
To determine if a poor connection exists:
Remove the chamber back plate and set aside fiberglass insulation. Inspect wiring to heater elements and check that
nuts are tight, there are no charred connectors, or cracked/broken ceramic insulators. Repair as needed.
To determine if a heater element is open:
Remove wiring to heater element and use ohmmeter to measure resistance of each heater element.
8
TROUBLESHOOTING AN EC0X REV E CHAMBER HEATING ALL THE TIME
With chamber powered on and the RED heat LED off, the chamber should not heat up at a fast ramp rate. The residual
heat from motors, however, will cause a very slow increase in temperature of the chamber.
If the chamber is heating at all times:
Separate control section from chassis by removing screws along top/bottom of right side of chamber.
Set meter to AC and measure voltage across heater elements (terminal 11 and 9 of terminal strip).
If the red heat LED is off, there should be ~ 0VAC across elements. If line voltage is measured, then 25A heater triac
on control stack’s power supply is most likely internally shorted.
Otherwise, there is most likely a heater terminal shorted to ground via a broken ceramic insulator or has opened up
and is making contact with chamber (ground).
To determine if a short from terminal to ground exists, remove the backplate of the chamber and set aside fiberglass
insulation. Inspect for broken ceramic insulators, charred or loose wiring. Measure the resistance from each heater
terminal to ground (inner chamber). It should read a very high resistance. If not, then heater element is faulty and
should be replaced. Contact Sun at 321-383-9400 for part numbers or assistance.
TROUBLESHOOTING AN EC0X REV E CHAMBER THAT IS NOT COOLING
If the green cool LED IS coming on and the chamber is not cooling:
Separate control section from chassis.
Verify wiring from valve to terminal strip and from terminal strip to control stack are secure.
Set chamber to cool. When the green cool LED is on, the cool triac should send out an AC voltage approximately
equal to the line voltage supplied to chamber (110VAC or 220VAC) on terminals 13 and 16 of the terminal strip.
If no voltage is present, then cool triac is most likely faulty. Contact Sun for RMA or replacement part.
If a voltage IS present on 13 & 16 of the I/O board, verify LN2 supply pressure is within 25 psi of the rated pressure
listed on back of chamber. If the valve continues to not open, valve is faulty. Contact Sun for an RMA or replacement
part.
TROUBLESHOOTING AN EC0X REV E CHAMBER WITH A VALVE STUCK OPEN
If the green cool LED is off, the chamber’s valve should not allow coolant into the chamber. If the green cool LED is off
and continues to allow coolant into the chamber, UNPLUG the chamber from the outlet. If coolant continues to rush into
the chamber with no power applied to the chamber, then the valve is at fault. If problem clears then the cool triac is at
fault. Contact Sun for replacement part.
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If you would like an RMA, need replacement parts, or assistance of any kind with troubleshooting your chamber, please
contact us at:
Sun Electronic Systems, Inc.
1845 Shepard Dr.
Titusville, FL. 32780
Email: info@sunelectronics.com
Phone: 321-383-9400
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