AGI EZ Sentinel Series User manual
Read this manual before using product. Failure to
follow instructions and safety precautions can
result in serious injury, death, or property
damage. Keep manual for future reference.
Part Number: 11242
Revised: September 2023
Original Instructions
EZ Sentinel Series
HAZMON Operator Interface
User Manual
This manual applies to:
EZS128
New in this Manual
The following changes have been made in this revision of the manual:
Rev Description Date
First release October 17, 2010
AUpdate for Version 1.20 software release. March 24, 2011
BUpdate for Version 1.22 software release. December 1, 2011
C
• Update for Version 1.25 software release.
• Add hour counters screen.
• Add Tripper machine type.
January 20, 2012
D
• Update for Version 1.27 software release.
• Special case low alarms added.
• Screen displays updated.
March 22, 2012
EUpdate for version 1.27 software release. June 03, 2012
FReady for rebranding December 03, 2022
G
Manual converted to AGI format.
General formatting changes
Added new safety section.
Added various diagrams and text.
August 2023
EZ SENTINEL SERIES –
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CONTENTS
1. Overview ................................................................................................................................................. 4
2. Safety....................................................................................................................................................... 5
2.1 Safety Alert Symbol and Signal Words...................................................................................... 5
2.2 General Safety Information....................................................................................................... 5
2.3 HAZMON Safety......................................................................................................................... 5
2.4 Drives and Lockout/Tagout Safety ............................................................................................ 6
2.5 Electrical Equipment Safety ...................................................................................................... 7
2.6 Electric Motor Safety................................................................................................................. 7
2.7 Safety Equipment ...................................................................................................................... 8
2.8 Personal Protective Equipment................................................................................................. 8
3. Home Screen........................................................................................................................................... 9
3.1 Silencing Alarms ...................................................................................................................... 12
3.2 Security Verification ................................................................................................................ 13
3.3 Machine Displays..................................................................................................................... 15
3.4 System Status .......................................................................................................................... 19
3.4.1 I/O Status.................................................................................................................. 22
3.4.2 Hours ........................................................................................................................ 23
3.4.3 Lockout ..................................................................................................................... 24
3.5 Alarms...................................................................................................................................... 26
3.6 System Setup ........................................................................................................................... 28
3.6.1 Alarm Test ................................................................................................................ 29
3.6.2 Control Bypass.......................................................................................................... 30
3.6.3 Lock Out.................................................................................................................... 31
4. The SD Card........................................................................................................................................... 32
4.1 Removing the SD Card............................................................................................................. 32
4.2 Reading the SD Card in a PC.................................................................................................... 33
4.3 Formatting a New SD Card...................................................................................................... 35
4.4 Reading the SD Card Over the Ethernet Port ......................................................................... 37
5. Warranty ............................................................................................................................................... 39
5.1 AG Growth International Inc. – Form of Limited Warranty.................................................... 39
6. Digital Firmware License Agreement................................................................................................... 41
6.1 AGI SureTrack Digital Firmware License Agreement ............................................................. 41
4 11242
1. Overview
Operators of the EZS128 system must read and understand this document before
attempting to operate the system or machinery controlled by the system. Failure to
read and understand this document may result in damage to machinery, personal
injury or loss of life.
This manual describes the basic operation of the EZSentinel 128 (EZS128). EZS128 is a combination
HMI / Controller that provides comprehensive hazard monitoring for primary facilities. It supports up
to 128 field sensors for bearing temperature, belt tracking, belt speed vibration, and plugged chute.
The HMI consists of a 6” (15 cm) touch screen Graphical User Interface (GUI). All operations are
undertaken from the user interface. Users of the EZS128 shall read this manual before operating the
system.
EZS128 documentation comprises:
• EZSentinel 128 Installation and Configuration Manual (manual number 11240)
• EZSentinel 128 User’s Manual (manual number 11242)
• Installing HazMon in a Box (manual number 11258)
Alarms
•Display, Alarms, and Control. The system provides display, alarming, and control for conveyors,
bucket elevators, drag conveyors, tripper conveyors and other machinery in a grain processing/
storage facility or fertilizer plant. The system consists of a field sensing network that collects
temperatures of bearings and belt tracking rub points, belt speeds, vibration velocity and simple
switches. Sensors are typically installed on all bearings and belt rub locations. A speed pickup is
installed on the conveyor tail pulley.
•Temperature and Under Speed Alarms. Alarms are set to indicate over temperature and under
speed conditions. Two levels of alarms can be setup, one to warn the operator and a second to
stop the machine. A method is provided to test the alarm set points from the touch screen
interface.
•Alarm Logs. Alarms and other system events are logged to an alarm event log on the controller’s
microSD (Secure Digital) card. Logs are maintained in separate files for each day. In addition, a
trend log of all sensor values can be recorded on the memory card.
•Security System. A comprehensive security system is provided. The security system restricts access
to the setup and configuration portions of the controller. This system logs access to critical system
interaction such as alarm silence, alarm test, and alarm bypass.
•Alarm Bypass. A temporary bypass of faulted sensor alarms is possible which stops alarm horns, or
the machine. The sensor alarm annunciators will still indicate and record the alarm in the event
log.
1. OVERVIEW EZ SENTINEL SERIES –
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2. Safety
2.1. Safety Alert Symbol and Signal Words
This safety alert symbol indicates important safety messages in this manual. When you see
this symbol, be alert to the possibility of injury or death, carefully read the message that
follows, and inform others.
Signal Words: Note the use of the signal words DANGER,WARNING,CAUTION, and NOTICE with the safety
messages. The appropriate signal word for each message has been selected using the definitions below as a
guideline.
Indicates an imminently hazardous situation that, if not avoided, will result in serious injury or
death.
Indicates a hazardous situation that, if not avoided, could result in serious injury or death.
Indicates a hazardous situation that, if not avoided, may result in minor or moderate injury.
Indicates a potentially hazardous situation that, if not avoided, may result in property damage.
2.2. General Safety Information
Read and understand all safety instructions, safety decals, and manuals and follow them when operating or
maintaining the equipment.
• Owners must give instructions and review the information initially and annually with
all personnel before allowing them in the work area. Untrained users/operators
expose themselves and bystanders to possible serious injury or death.
• Use for intended purposes only.
• Modification of the ezsentinel 128 in any way without written permission from the manufacturer is not
covered by the warranty.
• Follow a health and safety program for your worksite. Contact your local occupational health and safety
organization for information.
• Follow applicable local codes and regulations.
2.3. HAZMON Safety
Follow safety procedures while starting and stopping the Hazard Monitoring system including
personnel notification, site permits, etc.
• Do not operate plant or equipment with compromised system.
• To prevent exposure to potential ignition source, do not open the IS Bus Converter cover in dust explosive
atmosphere while energized. Field Interconnect Boxes may be opened for troubleshooting purposes with
power applied when dust is settled – see next warning:
EZ SENTINEL SERIES – 2. SAFETY
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• Remove dust and condensation away from enclosure seals before opening to prevent contamination.
• Do not bypass alarm controls when operating the system. Follow safety protocols to verify there are no
hazards such as heat sources, blockages, lack of guarding, etc.
• Validate sensor positions after regular system maintenance, and immediately after installing replacement
parts before operating machines. Always test interlocks during commissioning and on a periodic basis
recording their functionality.
• Inspect sensors, associated wiring and enclosures for damage and proper installation on regular interval.
2.4. Drives and Lockout/Tagout Safety
Inspect the power source(s) before using and know how to shut down in an emergency.
Whenever you service or adjust your equipment, make sure you shut down your power
source and follow lockout and tagout procedures to prevent inadvertent start-up and
hazardous energy release. Know the procedure(s) that applies to your equipment from the
following power sources.
For example:
WARNING
• De-energize, block, and dissipate all sources of hazardous energy.
• Lock out and tag out all forms of hazardous energy.
• Ensure that only 1 key exists for each assigned lock, and that you are the only one that holds that key.
• After verifying all energy sources are de-energized, service or maintenance may be performed.
• Ensure that all personnel are clear before turning on power to equipment.
For more information on occupational safety practices, contact your local health and safety organization.
2. SAFETY EZ SENTINEL SERIES –
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2.5. Electrical Equipment Safety
Power Source
• Electrical equipment and controls shall be installed and
serviced by a qualified electrician and must meet all local
codes and standards.
• Locate main power disconnect switch within reach from
ground level to permit ready access in case of an emergency.
• All electrical equipment must be properly grounded.
• Covers and guards must be in place and secure.
• Ensure electrical wiring and cords remain in good condition;
replace if necessary.
Lockout
• Lockout power source before making adjustments, cleaning,
maintaining equipment or when not in use. Ensure that all
personnel are clear before turning on power to equipment
SERVICE DISCONNECT
ON
OFF
2.6. Electric Motor Safety
Power Source
• Electric motors and controls shall be installed and serviced by
a qualified electrician and must meet all local codes and
standards.
• Use a magnetic starter to protect the electric motor.
• You must have a manual reset button.
• Reset and motor starting controls must be located so that the
operator has full view of the entire operation.
• Locate main power disconnect switch within reach from
ground level to permit ready access in case of an emergency.
• Motor must be properly grounded.
• Ensure electrical wiring and cords remain in good condition;
replace if necessary.
SERVICE DISCONNECT
ON
OFF
Lockout
• The main power disconnect switch should be in the locked position during shutdown or
whenever maintenance is performed.
• If reset is required, disconnect all power before resetting motor.
EZ SENTINEL SERIES – 2. SAFETY
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2.7. Safety Equipment
Fire Extinguisher
Provide a fire extinguisher for use in case of an accident. Store in a highly visible and accessible
place.
First-Aid Kit
Have a properly-stocked first-aid kit available for use should the need arise, and know how to use it.
Emergency Exit
Locate the nearest exit(s) and know how to sound alarm in case of accident. Be aware of closest
muster station and alternate in case of evacuation.
Confined Space
Use personal carbon monoxide detector when entering Boot Pit and follow safety protocols for
determining whether safe to enter enclosed spaces using necessary equipment.
2.8. Personal Protective Equipment
The following Personal Protective Equipment (PPE) shall be worn when installing, operating, or maintaining the
equipment.
•Safety Glasses
Wear safety glasses at all times to
protect eyes from debris.
•Steel-Toe Boots
Wear steel-toe boots to protect feet from
falling debris.
•Coveralls
Wear coveralls to protect skin.
•Work Gloves
Wear work gloves to protect your hands
from sharp and rough edges.
•Hard Hat
Wear a hard hat to help protect your
head.
2. SAFETY EZ SENTINEL SERIES –
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3. Home Screen
The system starts up on the home screen which displays the machines that are configured in the
system. The machine is selected by the button next to each machine name. The buttons at the bottom
of the screen allow the selection of further system functions.
Figure 1. EZS128 Main Screen Showing Configured Machines
Screen Buttons Description
Button next to the
machine name
Displays a machine. See Section 3.3 – Machine Displays on page 15 for
more information.
Silence Silences alarm horn and acknowledges any existing faults. See Section 3.1
– Silencing Alarms on page 12 for more information.
Note
Alarms that are still active continue to be displayed and stop the
machinery after a Silence operation. The cause of the alarm must
be removed before machines can be restarted. The horn will be
silenced until further alarms are declared.
The silence function is protected by security settings. See Section 3.2 –
Security Verification on page 13 for more information.
Alarms Displays the alarms event log. See Section 3.5 – Alarms on page 26 for
more information.
Sensors Displays a list of sensors with current values and alarms.
EZ SENTINEL SERIES – 3. HOME SCREEN
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Screen Buttons Description
Status Displays the system status. See Section 3.4 – System Status on page 19 for
more information.
Setup Goes to System Setup. See Section 3.6 – System Setup on page 28 for
more information.
Setup
To enter System Setup, select the Setup button.
Note
Two error messages may display on this screen just above the row of buttons. The error
messages are:
•SD Card Fault. The Controller uses a microSD Card to store the alarm and sensor logs. If the
Controller cannot write to the memory card, this error message displays.
•Remote I/O Fault. The Controller can have an extended remote I/O. If remote I/O is
enabled but not communicating with the Controller, a Remote I/O Fault message displays.
In addition to the error messages, machine state messages are displayed. The possible
messages are:
Two additional messages may also display:
•Lockouts Present. Indicate that a machine has been locked out because more than five
start attempts have been made in the last five minutes.
•Night Mode On. Indicates the system is in Night Mode. In Night Mode all machines, and
the alarm horn, are disabled.
The system indicates the running status of the equipment. On the main screen, if enabled, the
equipment name in green indicates it is running. A blue name indicates the equipment is not running.
3. HOME SCREEN EZ SENTINEL SERIES –
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Figure 2. Main Screen Showing Machine Status with Fault
Software Version 2.0 and Above
For software version 2.00 and above, if programmed the machinery graphics screens show a STOPPED
or RUNNING annunciator at the bottom of the screen. North, West, South and East annunciators are
displayed to assist in locating sensors on the machinery.
Prev and Next keys allow the selection of machinery without returning to the Main screen. The
machinery screen number is displayed in the bottom right corner of the display.
EZ SENTINEL SERIES – 3. HOME SCREEN
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Figure 3. Machine Graphic Showing Stopped Status
3.1. Silencing Alarms
To silence an alarm:
1. Select the Silence button.
Note
Pressing Silence does not clear the alarm condition, it only turns off the horn.
2. Reduce the temperature or correct the speed fault before restarting the machine.
Note
The machine name must be displayed in blue or green on the selection screen before the machine
can be restarted.
3. Select Silence again to clear the alarm and allow the machine to restart.
The system sounds the horn and records an alarm event under the following conditions:
1. A high alarm is reached
2. A high warning is reached
3. A low alarm is reached
4. Low warning is reached
5. A rate of rise is exceeded
6. A sensor or other field component faults
7. A fault is found with the machine running input
3. HOME SCREEN EZ SENTINEL SERIES –
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Note
Not all of these fault conditions are enabled in a typical system configuration.
The system can also be programmed to stop machinery when alarm conditions are reached. Based on machine
running interlocks, an alarm condition on a machine may not only stop that particular machine but may stop a
machine that feeds the alarmed machine.
Alarms are indicated on the machine selection screen, red for alarms and yellow for warnings. They are also
shown in flashing red or yellow on the machine graphics screens.
If the machine stops shortly after starting, and a low-speed alarm is indicated, verify the following:
1. Start the machine and observe the STOPPED / RUNNING annunciator in the graphics. This feature is
optional so the annunciator may not be present on the system. If enabled the annunciator turns to
RUNNING when the machine starts.
2. Verify the speed sensor reading on the graphic screen is increasing to the correct RPM.
3. Monitor the speed to insure it does not fall below the low alarm setpoint.
4. If the speed drops below the setpoint, a low-speed alarm is recorded and the machine stops.
A special case alarm can be programmed that will stop the machine if the machine is moving, but no machine
running input signal is present. This alarm indicates as a low-speed alarm. If an attempt is made to start a
machine and the machine name does not change from blue to green, or the STOPPED / RUNNING Controller
changes to RUNNING on the graphics, the machine running input signal is not being received by the Controller.
This alarm will also be declared if the running signal is lost while the machine is running. There is an increased
delay for the loss of signal alarm to prevent false alarms while the machine stops normally.
3.2. Security Verification
Many functions on the EZS128 require user identification before proceeding. If the system has user security
enabled, it prompts to enter a username and PIN. Operations that require user identification are:
• Alarm silence and acknowledgment
• System setup
• Sensors setup
• Screen setup
• Alarm Test
• Alarm Disable
• Lockout Reset
If one of these functions is selected with security enabled, the following screen will be displayed:
EZ SENTINEL SERIES – 3. HOME SCREEN
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Figure 4. Security Main Screen Start
To verify security credentials:
1. Select the button next to the user.
2. Enter the PIN number by touching the entry box. Only numbers are permitted for the PIN. If an invalid PIN is
entered, an error message displays.
Figure 5. Security Screen Enter PIN
Figure 6. Security Screen Invalid PIN
3. HOME SCREEN EZ SENTINEL SERIES –
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3. If the error message displays, re-select the user and re-enter the PIN.
4. If access is denied because of an invalid PIN, select the Back button.
5. If a user is not authorized to execute the selected function, the system displays a Not Authorized message.
Figure 7. Security Screen Not Authorized
3.3. Machine Displays
The system displays graphics for up to 15 machines. Six types of machines are supported:
• Conveyors
• Gravity Take Up Conveyors
• Legs / Bucket Elevators
• Drags
• Motor Drives
• Fans
Pressing the button next to the machine name displays that machine. The graphics below illustrate a typical
conveyor, and indicate the locations where sensors are installed. This conveyor has four bearing sensors and
eight rub block sensors and a single speed sensor.
EZ SENTINEL SERIES – 3. HOME SCREEN
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Indicator Machine Graphic
RUNNING
All sensor values indicate
the sensors are working
normally
Figure 8. Home Screen Displaying a Conveyor Graphic in Running State
WARNING STATE
If a sensor on the conveyor
exceeds the warning set
point, the value display on
the graphic changes to
flashing yellow. The graphic
opposite displays a bearing
sensor (bottom left corner)
in a warning state.
Figure 9. Machine Graphic Showing Sensor in Warning State
3. HOME SCREEN EZ SENTINEL SERIES –
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Sensors in Alarm State
Important
Alarms and warnings can be configured to stop a machine.
• If an alarm is present, the alarm horn can be silenced by pressing Silence.
• If the alarm is no longer present, the value displayed returns to green after pressing Silence.
• If the alarm condition is still present, the value displayed remains yellow or red depending on the alarm.
• If machinery control is in use, the machine is stopped, and remains stopped, until the alarm condition is
removed.
If the Silence button is selected, and user security is enabled, the User Log In screen displays. Select the User
Name button and enter the PIN.
3.4. System Status
The EZS128 has screen displays for the field sensor network, and the machine control inputs and outputs. Enter
the diagnostic screens by pressing the Status key from the Main screen.
The Main Status screen displays the status of the system’s Bus Converters and firmware version. If any of the
annunciators are red, there is a fault in the field sensor network. The online annunciator is green if the Bus
Converter is communicating with the EZS128. There may be up to four Bus Converters on the network
depending on the number of field sensors installed. On version 1.22 and above, the Bus Converter watchdog
counter is also shown. This counter should increment at a one second rate.
The system status screen also shows status messages when machinery lockout or night mode are active. The
annunciators appear in the bottom right corner of the screen.
Figure 17. System Sensor Screen
EZ SENTINEL SERIES – 3. HOME SCREEN
20 11242
Figure 18. System Status Screen Showing a Sensor Alert
Table 1. Screen Button Descriptions
Screen Buttons Description
I/O Status Selects the machine controller inputs and outputs view screen.
Hours Goes to the machinery Hours Counter screen.
Lock Out Goes to the Lock Out screen to reset any lockouts.
Night Goes to Night Mode settings.
Back Returns to the previous screen.
Table 2. Annunciator Status Indictors
Annunciator Description Possible Cause
Data Shorted Low Bus Converter’s sensor field bus has
the data wire shorted to common.
Sensor Bus cable is damaged - a field
sensor is damaged and/or the bus
cable has not been properly
terminated in the field interconnect
enclosures.
Data Shorted High Bus Converters sensor field bus has
the data wire shorted to +5VDC.
Sensor bus cable is damaged - a field
sensor is damaged and/or the bus
cable has not been properly
terminated in the field interconnect
enclosures.
No Sensors on Bus Bus Converter cannot detect any
sensor on the sensor field bus.
Sensor Bus cabling is broken and/or
not terminated.
3. HOME SCREEN EZ SENTINEL SERIES –
Table of contents
