Simco scorpION3 Instructions Manual

INSTRUCTIONS

Operation/Maintenance

Simco Ionization for Electronics Manufacture

Publication 5200943, June 2007

2257 N Penn Rd - Hatfield , PA 19440

215-997-0590 - 1-800-538-0750 (in USA)

Email: [email protected]

Simco Ionization for Electronics Manufacture 1 Publication 5200943

Simco Ionization for Electronics Manufacture Publication 5200943

Section 1 Introduction

4

Section 2 scorpION3 CI Computer Interface

6

2.1 Description 6

2.2 Specifications 6

2.3 Systems Connections 7

2.4 Ethernet Equipped Models 8

2.5 Internal Address Configuration 8

2.6 The scorpION3 Bus and Connections 9

2.7 The RS-485 Bus and Connections 10

2.8 The User Interface and Connections 10

Section 3 Account Types

12

3.1 User Account 12

3.2 Manager Account 12

3.3 Interface Layout 13

Sectio

n 4 Status Panel

14

4.1 Active Errors 14

4.2 History 14

4.3 Legend 14

4.4 Causes Tab 15

4.5 Solution Tab 15

Section 5 History Tab

16

Section 6 Graphic Panel

18

6.1 Full Screen Graphic View 18

Section 7 Error Logging

20

7.1 Daily Error Logging 20

7.2 Active Error Logging 20

7.3 An Example with Error Conditions 21

7.4 Context Sensitive Error Analysis 22

7.5 Expanded Historic View 23

Table of Content

2

Section 8 Bar Modification

24

8.1 Custom Grouping History 24

8.2 Modifying a Controller 25

8.3 Programming a Bar 26

8.4 Diagnosing a Bar 28

8.5 Changing the Role of Bar 29

8.6 Changing the Address of Bar 30

Notes

Data Log

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Features Include:

• Tool Interface Integration

• "Peak Reduction" Technology

• Bi-directional Intelligent MMI

• Full Digital Platform

• Active Monitor and Control

• SiC Emitters (US and International patents pending)

The scorpION3 ionizing bar utilizes SIMCO's innovative and
effective microcontroller intelligent ionization technology.
The system provides rapid neutralization of static charges
over a localized work area or in a mini environment. It is the
most flexible and efficient system available, capable of elim­inating electrostatic discharge (ESD) and preventing electro­static attraction (ESA) of particles to surfaces.

Section 1

Introduction

Introduction

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SECTION 1- Introduction

Simco Ionization for Electronics Manufacture Publication 5200943

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Simco Ionization for Electronics Manufacture Publication 5200943

SSCCOORRPP

ION3 CI Computer Interface

2.1 Description
The scorpION3 CI (Computer Interface) was designed to allow multiple ion bar systems to be connected
and controlled from a single personal computer through dedicated hardware. This connection allows ion
bar performance and settings to be monitored, configured and diagnosed. The computer interface contin­uously polls the condition, settings and diagnostic information of connected ion bars. Using this device
allows the construction of a scorpION3 network consisting of multiple CI units each with multiple ion bars
connected.

Each CI supports up to 10 connected ion bars on a dedicated scorpION3 communication / power distri­bution bus. Multiple CI's can be 'networked' via a true RS-485 communication bus used to supplying data
to a PC. Ethernet capable models convert the RS-485 bus to Ethernet allowing
connection of multiple systems via a single IP address. This architecture allows calibration and monitoring
of scorpION3 based systems. The computer interface also provides a user interface, which provides an
auxiliary power input and relay contacts for system level fault detection.

scorpION3 CI Features:

- Ethernet option

- Two RS485 interconnect bus connections

- 24VDC input, with power indicator

- Two scorpION3 bus connections

- Stainless steel case with mounting options

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SECTION 2

scorpION3 CI
Computer Interface

SECTION 2- scorpION2 CI Computer Interface

2.2 Specifications:

Unit Part Number: without Ethernet with Ethernet
without Software 5051411 5051412
with Software 5051413 5051414

Power:

24 VDC, 100 mA
Power may be input at the scorpION3 BUS connector (from the scorpION3
bar system) or at the USER INTERFACE connector (see connections sections
of instructions).

scorpION3 Bus:

RJ-11 modular connector x 2

User Interface:

Terminal socket block. Plug-in connector supplied with unit. (Weidmuller P.N.

1792890000)

RS-4485 Bus

RJ-11 modular connector x 2

Ethernet: (optional)

RJ-45 modular connector x 1

Ind

icators:

Power - green LED
Fault - red LED

Enclosure:

Stainless Steel

Weight:

0.64 kg (1.4 lbs)

Mounting:

User supplied M3 or M4 screws (#6 or #8)

Ethernet

RS485 BUS

scorpION2 BUS

2.3 System Connections
The following figure depicts connections typical to a system with multiple CI units and multiple ion
bars. Connections of scorpION3 bars to the CI are made using the scorpION3 bus. Connections
between scorpION3 CI units are made using the RS-485 bus. Connection to the PC is via
Ethernet.

ADDR

ADDR

ADDR

ADDR

ADDR

ADDR

ADDR

ADDR

ADDR

ADDR

ADDR

ADDR

scorpION2 Computer Interface

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SECTION 2- scorpION2 CI Computer Interface

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2.4 Ethernet Equipped Models
Ethernet equipped models of the scorpION3 CI convert RS-485 to Ethernet directly by using an
embedded device server (EDS). The EDS reliably converts the RS-485 to Ethernet using a single IP
address. Utilities from the EDS configure the PC to use a directly assigned virtual COM port that
remaps the serial port drive to the IP address. In most cases this configuration can be easily
achieved following the quick installation guide. This information as well as detailed user guides can
be located on the CD provided with the hardware.

The Network Enable Administrator runs on Windows based systems, allowing a broadcast search
for EDS devices to be performed. This utility finds EDS's based on their MAC addresses and allows
the assignment of IP addresses. It may be necessary to obtain an IP address for this assignment
from administrators of the network. Options for the COM assignment allow a 'virtual' COM port to
be configured using the mapping functions. After configuration the PC based hardware will use this
virtual COM port to communicate with the scorpION3 system and the PC will automatically retain
this configuration.

By entering the IP address of the EDS directly into the address line of a web browser such as
Internet Explorer, the EDS Web console can be accessed. Many of the same parameters can be
adjusted from the Web console. COM port configuration must have the following settings:
The Ethernet connection on the computer interface is clearly label and follows standard pin out
configurations for Ethernet.

2.5 Internal Address Configuration
A dipswitch internal to the scorpION3 CI is used to configure the address. In installations where
multiple CI units will be connected back to a single PC, each CI must have a unique address. The
dipswitch has 8 positions but switch 1-4 only are used to configure the address. The address equals
the binary number configured by the switches. The following table explains the configuration of
switches 1-4, where 0=off and 1=on, the PC based software subsequently refers to the CI units by
letter.

MOXA NE-4110A CONFIGURATION

PARAMETER

SETTING

Baud Rate

9600
Data Bits

8
Stop Bits

1
Parity

None
Flow Control

None
FIFO

Enable
Interface

RS485 4 Wire
Operation Mode

Real COM Mode
TCP Alive Check Time

99
Max Connection

4

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SECTION 2- scorpION2 CI Computer Interface

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SWITCH SETTINGS (1-4)

ADDRESS

SOFTWARE LABEL

0000

0

A

0001

1

B

0010

2

C

0011

3

D

0100

4

E

ETC….

2.6 The scorpION3 Bus and Connections
The scorpION3 bus provides power and communication lines to connected scorpION3 bars. Two
RJ-11 style connectors on the CI provide the ability to connect and power ion bars with this bus.

For some installations 24 VDC power can be supplied via the RJ-11 modular connector. Connect
pins 1 & 6 to the +24 volt supply voltage and connect pins 3 & 4 to ground (ground serving as the
return for the supply voltage), see table below. Users connecting to the scorpION3 in this way
should be ready to supply 200mA per ion bar connected and about 100mA for the CI. Note that
the scorpION3 CI is internally fused to protect the user's power supply during this type of setup.
Connections or grounding of the other pins (2 & 4) on the modular connector is not permitted and
may result in malfunction or damage to the system.

scorpION2 bus (N.C. = no connection permitted)
PIN NUMBER 1 2 3 4 5 6
CONNECTION +24VDC N.C. GND GND N.C. +24VDC

+/-10%

Because of the connection scheme used on the scorpION3 bus there is no need to be concerned
with the orientation of interconnection wiring. Cables that are 'flipped' or 'straight' will function iden­tically.

For installations of up to 3 ion bars and a CI, Simco's AC adapter can be utilized. Install all ion
bars and interconnect wiring before applying power. Plug the adapter power cord into a grounded
electrical outlet of 100 to 240 VAC, 50 or 60 HZ. Connect the adapter to the scorpION3 CI and
to the ion bars with modular cables, power will automatically be distributed to the other ion bars
on the 'chain'. The scorpION3 bar has no on/off switch so application of the 24VDC to the unit
will turn it on, and ionization will begin. The adapter and wiring can be located as desired by the
user.

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Note: a CI that is powered this way will provide power to ion bars that are connected to it via the
modular connector, and in this configuration the SIMCO adapter can power a maximum of 3 ion
bars.

2.7 The RS-4485 Bus and Connections
The RS-485 bus is a 4 wire, full duplex RS-485 connection. Two connections on the CI are provid­ed for connections to this bus. This bus is used specifically for interconnection of multiple CI units
back to an Ethernet enabled CI. With this construction a single IP address can collect data from
multiple scorpION3 systems. Note that there is no power distribution via these bus connections, so
each CI in the systems must be powered independently.

RS-485 bus

PIN NUMBER 1 2 3 4 5 6
CONNECTION TX+ TX- GND GND RX+ RX-

Cabling that interconnects multiple CI units must be of the 'flipped' or 'parallel' construction, where
by pin 1 is connected to pin 1 on the next connection, etc. This configuration connects all wires in
parallel with one another.

2.8 The User Interface and Connections
The User Interface provides a terminal strip for supplying power to a scorpION3 system. Wiring
connections are made to stripped wires, using clamping screw. This permits direct connection of
the CI and ion bars to existing power in tool or mini-environment applications. The specific pin
outs are provided below. Power supplied to pins 1 and 2 should conform to the following: pin 1
must be earth ground; pin 2 should be 24VDC+/10%. Users who provide power to the system in
this way should budget 200mA per scorpION3 bar and 100mA for the CI itself. The CI has an
internal fuse in series with the power distribution to the ion bars; this protects the power supply due
to wiring (24V) short circuits.

User Interface
PIN NUMBER 1 2 3 4 5
CONNECTION GND +24VDC NC COM NO

+/-10%

10

1 2 3 4 5

SECTION 2- scorpION2 CI Computer Interface

Simco Ionization for Electronics Manufacture Publication 5200943

The User Interface also provides a relay contact output that toggles based on fault conditions. The
normal relay positions are indicated in the table above. The CI detects status and conditions from
all connected ion bars. On a fault condition from any ion bar in the system the relay is activated,
changing the state of the relay relative to the common. The fault relay has a contact rating of 30V
at 1A maximum; this should not be exceeded as damage to the unit may result.

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SECTION 2- scorpION2 CI Computer Interface

Account Types

Before an operator can use the
scorpION3 Monitoring System they
need to login. You may login to the
GEMINI Profile Monitoring System in
two ways, as a User or Manager.

3.1 User Account
As a User an operator can:
Monitor the scorpION3 system.
Review both active and corrected
error conditions.
Login without using a password.

3.2 Manager Account
As a

Manager

an operator can:

• Do everything a User can.

• Edit a Controller's location.

• Modify the frequency of
Preventive Maintenance.

• Update the date of last
Preventive Maintenance.

• Modify the frequency of
System Calibration.

• Update the date of last
System Calibration.

• Change the manager login
password.

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SECTION 3

Account Types

SECTION 3 - Account Types

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3.3 Interface Layout

The scorpION3 monitor software is laid out in two primary areas:

Status Panel

and the

Graphic Panel

; separated by a Horizontal divider. A status bar at the bottom
of the screen displays the current date and time, two status areas display the time the Historic Error
log was written to, and when the Active Error log was written to.

The above system is composed of 3 controllers A, B, and C correspondingly having 9, 6, and 5
emitters each. Preventive Maintenance for controller A is due in 135 days and System Calibration is
due in 179 days.

Currently there are two active errors in the Active Errors list. The ErrorLog.csv was last updated at
5:23:30 PM.

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SECTION 3 - Account Types

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Status Panel

4.1 Active Errors
The top part of the Status Panel shows all
active error conditions. Each error is color
coded, identifies the Controller and the
Emitter experiencing the error, and the time
the error occurred.

4.2 History
A History tab next to the Active Tab lists all
corrected errors that have transpired.

4.3 Legend
In the lower part of the panel there is a
Legend that identifies error codes by ID
and by color.

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SECTION 4 - Status Panel

SECTION 4

Status Panel

Simco Ionization for Electronics Manufacture Publication 5200943

4.5 Solution Tab
The Solution Tab displays possible
Solutions/corrective measures that can be
taken to eliminate an Error. The information
displayed is updated based on the error
selected in the Active Error list.

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4.4 Causes Tab
The Causes Tab displays possible Causes of
an Error. The information displayed is updat­ed based on the error selected in the Active
Error list.

SECTION 4 - Status Panel

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History Tab

The History tab displays a detailed history of corrected errors including the time of occurrence,
where they occurred (Controller / emitter), what type of error occurred and the duration of the error.

By including information regarding the next preventative maintenance and next system calibration
we can gauge the need for servicing the system. Notice that controller B's System Calibration indi­cator is red. This happens because controller B should have had a System Calibration 5 days ago.

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SECTION 5 - History Tab

SECTION 5

History Tab

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Graphic Panel

6.1 Full Screen Graphic View

By maximizing the Horizontal Divider or by dragging the divider to the left you can get a full screen

This view takes full advantage of the graphical capabilities of the application.

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SECTION 6 - Graphic Panel

SECTION 6

Graphic Panel

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Error Logging

The status bar at the bottom of the screen informs the user of the error logging status.

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7.1 Daily Error Logging

At midnight all errors are added to the HistoricErrorLog.csv file.

7.2 Active Error Logging
Active errors are monitored in memory in real time. A change in the state of the system; new error
or error cleared notifies the system that it should update the active error file ErrorLog.csv. The
active error file is updated at a maximum frequency of once a minute.

SECTION 7 - Error Logging

SECTION 7

Error Logging

Simco Ionization for Electronics Manufacture Publication 5200943

7.3 An example with Error Conditions
The following image illustrates Controller A having an active error condition and Controller B having
an active error condition. Each error occurred at 12:00:29 APM.

A full screen graphic view
of the above scenario is
illustrated to the right.

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SECTION 7 - Error Logging

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7.4 Context Sensitive Error Analysis
Selecting an active error triggers the Causes and Solution panels to dynamically update their
content providing appropriate Case/Solution information.

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SECTION 7 - Error Logging

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7.5 Expanded Historic View
By dragging the horizontal scroll bar to the right we expand the view of the History tab while also
maintaining an active graphical view.

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SECTION 7 - Error Logging

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Bar Modification

8.1 Custom Grouping History

By dragging a column header you may create dynamic groupings. In the example illustrated below
History events are grouped by Date and Controller.

SECTION 8 - Bar Modification

SECTION 8

Bar Modification

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8.2 Modifying a Controller
If you are logged in as a Manager you may modify a controller's information by clicking on the con­troller's ID button (labeled 'B' here).

You may modify the location, Preventative Maintenance or System Calibration values of a controller.
If for example, you have just performed a System Calibration use the drop down calendar to
update the Last performed field to today's date.

SECTION 8 - Bar Modification

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8.3 Programming a Bar
You may wish to make adjustments to a bar's settings. In order to perform this operation you could
right click on the bar of interest and select Program from the list of available operations.
Since programming a bar is the default operation for a bar, you could simply click on the bar to
select the Program operation.

SECTION 8 - Bar Modification

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Click to highlight the bar you wish to program. Click Download from Bar to see the current set­tings. Make adjustments as desired and click Upload to Bar. When you are satisfied with the set­tings click Save Bar Settings. Close the application without saving to revert to the original settings.

Power Off on Fault causes the bar to stop producing ions any time a fault condition is encountered
by the bar.

Highlighting a bar address and then checking the Blink box causes the scorpION3 bar mounted
power indicators to blink rapidly. This is useful as a means to identify a particular bar address and
location.

SECTION 8 - Bar Modification

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8.4 Diagnosing a Bar
You may wish to Diagnose a bar. In order to perform this operation you would right click on the bar
of interest and select Diagnose from the list of available operations.

To diagnose the selected bar you must click Sample to retrieve the current bar performance level
and Program Current settings.

SECTION 8 - Bar Modification

Simco Ionization for Electronics Manufacture Publication 5200943

8.5 Changing the Role of a Bar
You may wish to make adjustments to a bar's Role. In order to perform this operation you could
right click on the bar of interest and select Role from the list of available operations.

The first bar (Bar 0) is always a Master. All other bars can be set to Independent or Slave. Master
and Slave Roles are illustrated with the "M" and "S" and Independent bars are unmarked.

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SECTION 8 - Bar Modification

Simco Ionization for Electronics Manufacture Publication 5200943

8.6 Changing the Address of Bar

You may wish to make adjustments to a bar's Address. In order to perform this operation you could
right click on the bar of interest and select Change Bar Address from the list of available operations.

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SECTION 8 - Bar Modification

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Notes:

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Simco Ionization for Electronics Manufacture Publication 5200943

SSyysstteemm SSeettttiinnggss DDaattaa LLoogg

Controller ID:
Pulse Time System Setting:

Recorded By:

Emitter

Address

Balance

Setting

Ion Output

Setting

Mode

Setting

Power

Setting

Date:

Temperature:
Humidity:

Test Results

Discharge Time

Offset
Voltage

-2.0 volts

12.5 sec

8.4 sec

Example

50/50 1.00 Pulse On

33

Controller ID: Date:
Pulse Time System Setting: Temperature:
Recorded By: Humidity:

Emitter

Address

Example 50/50 1.00 Pulse On 8.4 sec 12.5 sec -2.0 volts

Balance

Setting

Ion Output

Setting

Mode

Setting

Power

Setting

Test Results

Discharge Time

+ -

Offset

Voltage