Prime Controls SD220 Operating Instructions Manual

OPERATING INSTRUCTIONS

SNGL

COM

+24V

CAL1+

NOTAB

CAL2+

MODEL SD220 SHELL/TAB DETECTOR

DESCRIPTION

The Model SD220 Shell Detector for conversion press applications is a rugged but sensitive dual channel instrument designed specifically to detect and report missing blanks or double blanks at the infeed to a conversion press and to detect and report ends that exit the press without tabs.

A complete system for one lane of a press comprises a control module housed in an aluminum enclosure and four probes. One transmitting and receiving probe pair senses doubles at the press input while the second transmitting and receiving pair senses the presence or absence of tabs at the press output.

March 13, 2019

TABLE OF CONTENTS

DESCRIPTION Control Module………………………………………………….………... Page 3 Calibrate Pushbutton Operation………………………………………... Page 3 Probes………………………………………………………………….…. Page 4

OPERATION Calibration …………………………………………………………….….. Page 4 Fault Message Interpretation ……………………………………….….. Page 5

INSTALLATION Installing the Probes ……………………………………………….….… Page 5

Mounting the Control Module ………………………….………….…….Page 6 Wiring the Contro l Mod ule ………………………………………..……..Page 6 Setting Switch Options ………………………………………….………. Page 7

Sensing Aluminum Ends ……………………………………….. Page 8 Sensing Steel Shells ……………………………………………. Page 8 Sensing Al Tabs on Al Ends ……………………………….……Page 8 Sensing Al Tabs on Steel Ends ………………………………. . . Page 8 Sensing Steel Tabs on Stee l Ends ………………………….… Page 8 Set Sinking or Sourcing Outputs ………………………………. Page 8 Set Outputs for Failsafe or Compatibility …………………….. Page 8 Enable or Disable Tab Profiling ………………………………...Page 9

Setting Options Through the Front Panel…………………………..…. Page 9 Adjusting the Tolerance……………………………………….… Page 9 Set Display Direction………………………………………….…. Page 10 Parameter Value Ranges……………………………………….. Page 11

Special Functions………………………………………………………… Page 11 Remote Calibration…………………………………………….… Page 11 Quick Calibration Changeover………………………………….. Page 11 Determining Firmware Version…………………………………. Page 12

DOCUMENT APPLICABILITY…………………………………………….……. Page 12 ELECTRICAL SPECIFICATIONS……………………………………………… Page 13 CONTROL MODULE DIMENSIONS…………………………………………... Page 14 WIRING RECOMMENDATI O NS………………………………………………. . Page 15 OUTPUT SIGNAL DIAGRAMS………………………………………………….Page 16 SUMMARY OF DIFFERNCES BETWEEN SD200 AND SD220…………… Page 17 SD200 TO SD220 MIGRATION…………………………………………………Pa ge 1 8 LIMITATION AND EXCLUSION OF WARRANTIES………………………….Page 19

Control Module

The control module allows for fast and easy setup and for quick diagnosis of system errors or problems. Setup is achieved through the simple press of a push-button switch or an external contact closure. Faults are reported on digital displays on the control module and through FAULT outputs that may be connected to a PLC or system controller.

The DOUBLE, SINGLE, NO TAB, TAB and FLT outputs may be switch selected as sinking or sourcing drivers. An eight position DIP switch, accessible on the front panel, allows the installer to select a number of operational options as described in the installation section of this document.

The AUX inputs provide a means to switch between two different setups, such as sensing steel shells and sensing aluminum shells, without recalibrating or changing the DIP switch settings.

When the unit first powers up, if probes are properly connected, the digital displays indicate the operational mode of the unit, i.e. whether set up for sensing Aluminum, Steel, or Aluminum on Steel by displaying the characters "Al", "St" or “AS” for a period of approximately two seconds. Which mode comes up is determined by the setup of the unit through the DIP switches and the state of the AUX input. See setup later in this document.

Calibrate Pushbutton Operation The push-button switches on the front panel of the control module serve to initiate the

calibration process and to make adjustments for system setup. The pushbuttons may be used to adjust the gauge tolerances (tL) and set the display option to invert the digital display (do).

To initiate calibration, simply press the appropriate pushbutton and release it within 3 seconds.

To view the current value of a parameter, press the pushbutton and hold it for more than 3 seconds until the appropriate parameter identifier (tL or do) appears on the digital display. After the parameter identifier appears, release the pushbutton and the current value of the parameter displays for 5 seconds. To retain the current value of the parameter, simply allow the 5 second display interval to elapse. The display reverts to displaying the gauge signal.

To change the value of a parameter, press the pushbutton and hold it for more than 3 seconds until the appropriate parameter identifier appears on the digital display. After the parameter identifier appears, release the pushbutton and the current value of the parameter displays. Press the pushbutton while the parameter is displaying and the value increments, first slowly then more rapidly. For more precise control of the value adjustment, simply tap the pushbutton repeatedly until the desired value is displayed. All parameters roll back to their minimum values after reaching the maximum value. To retain the adjusted value of the parameter, simply allow the 5 second display interval to elapse. The display reverts to displaying signal strength.

Probes

The SD220 may be used with any P15 or P70 series two wire probes or with older model three wire probes including AV, AY, AZ, AZA, and CB probes. When used with older 3 wire probes, the white wire in the probe cable is not used and must remain disconnected.

OPERATION Operation of the SD220 Shell/Tab Detector involves only two processes, calibration and

fault message interpretation. These processes are described below.

Calibration Calibration requires the following steps:

1. Stop the press in the dwell portion of the cycle with a single end between the infeed probes and a good tabbed end between the discharge probes.

2. Observe that no error conditions are being reported on either display of the SD220 control module.

3. Press and release the CALIBRATE pushbutton on channel 1 of the SD220 control module and observe the SINGLE and DOUBLE LEDs flashing alternately and “CAL” on the digital display. If the calibration is successful, the LED flashing stops in less than three seconds and the digital display shows a number between 48 and 52.

If the display flashes alternately “CAL” and “Lo”, the calibration was unsuccessful due to insufficient signal at the receiving probe. This can be an indication that the probes are too far apart or that the unit is not set to the appropriate frequency for the material being sensed, e.g. frequency set to aluminum when steel ends are present. If the display flashes alternately “CAL” and “Hi”, the receiver signal is too strong indicating nothing between the probes.

If the calibration problem is not resolved and the calibration switch is not pressed

again within 30 seconds, calibration mode is aborted and the previous calibration values are reinstated.

4. Press the CALIBRATE pushbutton on channel 2 of the SD220 control module and observe the TAB and NO TAB LEDs flashing alternately and ”CAL” on the digital display. If the calibration is successful, the LED flashing stops in less than 3 seconds and a number between 28 and 33 is displayed.

If the display begins to alternately flash “CAL” and “Lo”, the calibration was unsuccessful due to insufficient signal at the receiving probe. This can be an indication that the probes are too far apart or that the unit is not set to the appropriate frequency for the material being sensed e.g. frequency set to aluminum when steel ends are present.

If the calibration problem is not resolved and the calibration switch pressed again

within 30 seconds, calibration mode is aborted and the previous calibration values are reinstated.

If both channels calibrate successfully, calibration is complete. The calibration process may also be initiated through an external switch or signal controlling the CAL+ and CAL- inputs to the SD220. Activation of this input performs the same function as pressing the CALIBRATE push-button switch for the corresponding channel.

Fault Message Interpretation

The SD220 monitors the probe connections on a continuous basis and reports what it detects to be disconnected or malfunctioning probes. The probe faults are reported as follows:

Alternately flashing "PR" and "1" - transmitter probe disconnected or failing. Alternately flashing "PR" and "2" - receiver probe disconnected or failing. Alternately flashing "PR" and "3" - both probes disconnected or failing

During calibration: Alternately flashing “CAL” and “Lo” indicates a low signal at the receiving probe.

Alternately flashing “CAL” and “Hi” indicates the signal at the receiver is too strong, likely no end between the probes.

The SD220 performs extensive self diagnostics at power up and more limited diagnostics while running. Most fatal faults, if not involving the display subsystem, are reported on the digital displays through the alternate flashing of "Err" and "nnn" where "nnn" is a one to three digit number indicating the source of the fault. These faults are not field repairable and require the change-out of the control module.

Any detected fault causes the FLT output to be turned OFF until the fault is cleared.

INSTALLATION Installation comprises four basic steps: 1) Installing the probes, 2) Mounting the

control module, 3) Wiring the unit, and 4) Setting system options. Each of these steps is further expanded below.

Installing the Probes

1. Mount the double detecting infeed probes, one above and one below the centerline of the track carrying the ends into the press. The probes must be positioned such that they are centered on the can end during the dwell portion of the press cycle. In the vertical, the track should run midway through a gap of approximately 5/8 inch (16mm) between the probes.

2. Positioning of the tab detecting probes is more critical than the positioning of the infeed probes. For most tabbed ends, the optimum position for the probes is above and below the ring of the tab, not centered on the rivet. Centering on the rivet only works on some older tab designs where the tab formed a ring around the rivet. If positioning of the tab sensing probes is uncertain, contact Prime Controls for help.

Mount the tab detecting probes, one above and one below the tabbed ends as they are carried on the track from the press. The probes must be positioned such that they are centered on the tab ring during the dwell portion of the press cycle. In the vertical, the track should run midway through a gap of approximately 5/8 inch (16mm) between the probes.

3. Run the probe cabling through conduit back to the cabinet housing the control module. Do not run the sensor cables through conduit carrying high level or noisy signals.

Mounting the Control Module Mount the control module on the back panel of an industrial enclosure. The footprint is

8.25 inches (210 mm) by 6.25 inches (159 mm) with mounting slot locations on a

rectangle 7.625 inches (194 mm) in the horizontal and 4.0 inches (102 mm) in the vertical. Insure that the mounting screws make good electrical contact between the module housing and the control enclosure back panel. See drawing at the end of this document.

Wiring the Control Module

1. Connect 24 volt dc power between both sets of the +24V and COM terminals of the control module. The left and right side modules are electrically independent and must be powered independently. The two +24V terminals are NOT internally connected. The supply must be capable of delivering 0.250 amps continuously with a startup surge of 0.5 amps for 2 milliseconds.

2. Connect the double detecting transmitter probe wires to the two TMTR terminals on the channel 1 side of the control module and the double detecting receiving probe wires to the two RCVR terminals on the channel 1 side of the control module. The probe connections are not polarized Connect the shield wires to the terminal labeled SHLD.

Though both the transmitting and receiving probes are identical, it is preferred

practice to choose the transmitting probe as the one that will remain farthest from the track as it moves and stretches.

Note: Prime Controls assures compatibility with PN: CBL101-XX cables and the

cabling pre-attached to certain probes. Other types of cabling, and also, cable lengths above 30 meters (approx 100 ft) are not advised.

On retrofit installations where older three wire probes are installed, cut back and

do not connect the third (white) wire. If in doubt about which wires to use, measure the resistance between the wires in pairs, and then use the pair that produces the highest resistance reading (typically 24 ohms).

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