Prime Controls ECLIPSE EP200 Manual de usuario

EP200 Multi-Lane End Leak Detection System

Operating Instructions

202920 Revision E

4/13/2022

Prime Controls, Inc.

DESCRIPTION

The EP200 End Leak Detection System (ELDS) uses Prime Controls LH200H and SL100H

featuring Eclipse Leak Detection Technology to provide up to four lanes of light-based end leak

detection for conversion presses. The system can operate at up to 1000 ends per minute while

detecting holes and cracks as small as 0.5µm.

EP200 Multi-Lane End Leak Detection System

This document is confidential and proprietary. No part of this document may be disclosed in any manner

to a third party without the prior written consent of Prime Controls, Inc.

202836 i Revision E

Revision History

Revision Date Description Author

A 2021-05-03 Initial Release RMC

B 2021-05-21 Updated LH200H-3 Mechanical Drawings RMC

C 2021-06-21 Updated terminal block numbers 2401 -> 24X1 RMC

D 2021-11-02 Replaced LH200H-3 with LH200H-202 and LH200H-300.

Added SL100H-2

RMC

E 2022-04-13 Updated Troubleshooting sections, expanded installation

sections

©Prime Controls, Inc.

EP200 Multi-Lane End Leak Detection System

This document is confidential and proprietary. No part of this document may be disclosed in any manner

to a third party without the prior written consent of Prime Controls, Inc.

202836 ii Revision E

Table of Contents

1 INTRODUCTION ................................................................................. 1

2 SYSTEM COMPONENTS .................................................................... 1

2.1 EP200 Chassis .................................................................................................. 1

2.1.1 Indicators ................................................................................................... 1

2.1.2 Interconnects ............................................................................................. 1

2.2 MI200 Touch Screen .......................................................................................... 1

2.3 SL100H-D LED Driver ........................................................................................ 2

2.4 PS506 Power Supply ......................................................................................... 2

2.5 CAP001 Power Filter ......................................................................................... 3

2.6 PLC001 Programmable Controller ..................................................................... 3

2.7 ET230 Ethernet Gateway (Option) ..................................................................... 4

2.8 LH200H or LH200H-opt Light Detector .............................................................. 4

2.9 SL100H-1 or SL100H-2 Remote LED Illuminator .............................................. 5

2.10 Cable Set ........................................................................................................... 6

2.11 Sensors and Actuators ....................................................................................... 7

3 INSTALLATION ................................................................................... 7

3.1 EP200 Chassis Mounting ................................................................................... 7

3.2 LH200H, LH200H-opt Mounting ......................................................................... 7

3.3 SL100H-1, SL100H-2 Mounting ......................................................................... 7

3.4 Wiring and Cabling............................................................................................. 7

3.4.1 Introduction ................................................................................................ 7

3.4.2 General Terminal Block Connections ...................................................... 12

3.4.3 AC Power ................................................................................................. 12

3.4.4 Press Controller Connections .................................................................. 12

Input Logic Signals .......................................................................................13

Output Logic Signals .....................................................................................13

Signal Polarities ............................................................................................13

3.4.4.3.1 Drop-In Replacement Wiring Configuration ................................................14

3.4.4.3.2 Fail Safe Wiring Configuration (Preferred) .................................................15

3.4.5 External Rejector Signals ......................................................................... 15

3.4.6 Internal Signals ........................................................................................ 15

3.4.7 Configuring System Parameters .............................................................. 16

4 OPERATION ..................................................................................... 21

EP200 Multi-Lane End Leak Detection System

This document is confidential and proprietary. No part of this document may be disclosed in any manner

to a third party without the prior written consent of Prime Controls, Inc.

202836 iii Revision E

4.1 Power-Up Sequence ........................................................................................ 21

4.2 Power Troubleshooting .................................................................................... 21

5 USER INTERFACE ........................................................................... 23

5.1.1 MI200 Touch Screen Interface ................................................................. 23

5.1.2 MI200 Screen Elements ........................................................................... 23

5.1.3 Introduction .............................................................................................. 23

5.1.4 Menu Buttons ........................................................................................... 24

5.1.5 Toggle Buttons ......................................................................................... 24

5.1.6 Indicators ................................................................................................. 24

5.1.7 Changing Values ..................................................................................... 24

Numeric Keypad ...........................................................................................25

5.2 MI200 Screens ................................................................................................. 26

5.2.1 Main Screen ............................................................................................. 26

System Operating No Status Messages........................................................26

5.2.1.1.1 Communication Status ...............................................................................26

5.2.1.1.2 System Status ...........................................................................................27

5.2.1.1.3 Measurement Results ................................................................................27

5.2.1.1.4 Lane Status ...............................................................................................28

5.2.1.1.5 Menu Login ................................................................................................28

5.2.1.1.6 Password Entry .........................................................................................29

5.2.1.1.7 Menu Select ..............................................................................................29

5.2.1.1.8 Menu Log Out ............................................................................................30

5.2.1.1.9 Help ...........................................................................................................30

5.2.1.1.10 Main Screen with Status Message ...........................................................31

5.2.1.1.11 Main Screen with Leak Reset ..................................................................31

5.2.2 Leak Log Screen ...................................................................................... 32

5.2.3 Measurement Log Screen ........................................................................ 33

5.2.4 System Status Screen ............................................................................. 33

5.2.5 System History Screen ............................................................................ 34

5.2.6 Lane Status Screen ................................................................................. 35

5.2.7 Lane History Screen ................................................................................ 36

5.2.8 Main Menu ............................................................................................... 37

Setup ............................................................................................................38

5.2.8.1.1 Limits .........................................................................................................38

5.2.8.1.2 Phasing .....................................................................................................39

5.2.8.1.3 Configure IO ..............................................................................................41

Default Settings ...................................................................................41

IO Enable/Disable Switch ....................................................................41

IO Polarity ...........................................................................................41

IO Drive Type ......................................................................................42

Lane Reject (Result) Mode ..................................................................42

5.2.8.1.3.5.1 ELTP Drop-In-Replacement Settings ............................................44

5.2.8.1.3.5.2 ELDS Fail-Safe Signal Settings ....................................................44

EP200 Multi-Lane End Leak Detection System

This document is confidential and proprietary. No part of this document may be disclosed in any manner

to a third party without the prior written consent of Prime Controls, Inc.

202836 iv Revision E

5.2.8.1.4 Rejector .....................................................................................................45

5.2.8.1.5 Parameters ................................................................................................45

5.2.8.1.6 Configure PLC ...........................................................................................46

IO Enable/Disable Switch ....................................................................46

IO Polarity ...........................................................................................47

5.2.8.1.6.2.1 ELTP Drop-In-Replacement Settings ............................................48

5.2.8.1.6.2.2 ELDS Fail-Safe Signal Settings ....................................................48

Diagnostics ...................................................................................................49

5.2.8.2.1 Lane Force IO ............................................................................................49

IO Force Enable/Disable Switch ..........................................................50

IO Polarity ...........................................................................................50

IO Signal State ....................................................................................50

5.2.8.2.2 Configure Internal IO .................................................................................50

IO Enable/Disable Switch ....................................................................51

IO Polarity ...........................................................................................51

IO Drive Type ......................................................................................51

5.2.8.2.2.3.1 ELTP Drop-In-Replacement Settings ............................................52

5.2.8.2.2.3.2 ELDS Fail-Safe Signal Settings ....................................................52

5.2.8.2.3 Version ......................................................................................................53

5.2.8.2.4 Measurement Screen ................................................................................53

5.2.8.2.5 Statistics Screen ........................................................................................54

5.2.8.2.6 Force PLC001 IO Screen...........................................................................55

IO Force Enable/Disable Switch ..........................................................55

IO Polarity ...........................................................................................55

IO Signal State ....................................................................................56

Utility Menu ...................................................................................................56

5.2.8.3.1 Load Defaults ............................................................................................57

5.2.8.3.2 Modbus Address ........................................................................................57

5.2.8.3.3 Modbus Counts .........................................................................................58

5.2.8.3.4 Internal Diagnostics ...................................................................................60

5.2.8.3.5 Set Date ....................................................................................................60

5.2.8.3.6 Set Time ....................................................................................................61

5.2.8.3.7 Limits .........................................................................................................61

6 MODBUS COMMUNICATION ........................................................... 63

6.1 Serial Interface ................................................................................................. 63

6.2 LH200H Commands ........................................................................................ 63

6.2.1 Discrete Coil Outputs (000001) ................................................................ 64

6.2.2 Discrete Inputs (100001) .......................................................................... 66

6.2.3 Register Inputs (300001) ......................................................................... 67

6.2.4 Holding Registers (400001) ..................................................................... 68

6.3 PLC001 Commands......................................................................................... 69

6.3.1 Discrete Coil Outputs (000001) ................................................................ 69

6.3.2 Discrete Inputs (100001) .......................................................................... 72

6.3.3 Register Inputs (300001) ......................................................................... 73

6.3.4 Holding Registers (400001) ..................................................................... 73

EP200 Multi-Lane End Leak Detection System

This document is confidential and proprietary. No part of this document may be disclosed in any manner

to a third party without the prior written consent of Prime Controls, Inc.

202836 v Revision E

7 MAINTENANCE ................................................................................ 74

7.1 Light Head Gasket and Bushing Replacement ................................................ 74

8 TROUBLESHOOTING ....................................................................... 75

8.1 Basic Guide ..................................................................................................... 75

8.2 Diagnostic Messages ....................................................................................... 76

8.3 Indicators ......................................................................................................... 78

8.3.1 PS506 ...................................................................................................... 78

8.3.2 LH200H .................................................................................................... 79

8.3.3 SL100H-D ................................................................................................ 79

8.3.4 PLC001 .................................................................................................... 80

8.3.5 Rejector Relays ....................................................................................... 82

8.4 Detailed Instructions ........................................................................................ 82

8.4.1 #x NOK .................................................................................................... 82

8.4.2 DMA COMP NOK – DMA START NOK ................................................... 82

8.4.3 #X Timing NOK ........................................................................................ 82

8.4.4 #x Watchdog NOK ................................................................................... 83

8.4.5 Strobe NOK ............................................................................................. 83

8.4.6 Modbus Communication Troubleshooting................................................ 84

Incorrect or Broken Wiring (Individual Lane with HMI) ...................................84

Duplicate Modbus Address ...........................................................................84

Incorrect Modbus Address ............................................................................84

8.4.6.3.1 HMI Detecting Method ...............................................................................85

8.4.6.3.2 Serial Terminal Method ..............................................................................85

9 REPLACING ECLIPSE SYSTEM COMPONENTS ............................ 86

9.1 Power Down Prior to Maintenance .................................................................. 86

9.2 LH200H/LH200H-opt Replacement ................................................................. 86

9.3 SL100H-1 or SL100H-2 Remote LED Illuminator Replacement ...................... 86

9.4 SL100H-D Replacement .................................................................................. 87

9.5 PLC001 Programmable Controller Replacement ............................................. 87

9.6 CAP001 Replacement ..................................................................................... 87

9.7 PS506 Power Supply Replacement ................................................................. 88

10 FACTORY ASSISTANCE .................................................................. 88

11 OPERATING SPECIFICATIONS ....................................................... 89

12 ELECTRICAL SPECIFICATIONS ..................................................... 90

13 LIMITATIONS AND EXCLUSION OF WARRANTIES ....................... 91

14 ACRONYMS ...................................................................................... 92

EP200 Multi-Lane End Leak Detection System

This document is confidential and proprietary. No part of this document may be disclosed in any manner

to a third party without the prior written consent of Prime Controls, Inc.

202836 vi Revision E

15 GENERAL TERMINAL BLOCK CONNECTIONS ............................. 94

15.1 Wiring and Cabling........................................................................................... 94

15.1.1 Introduction .............................................................................................. 94

15.1.2 LH200H, LH200H-opt Connections ......................................................... 99

15.1.3 SL100H-1, SL100H-2 Connections ........................................................ 100

16 DRAWINGS ..................................................................................... 101

EP200 Multi-Lane End Leak Detection System

This document is confidential and proprietary. No part of this document may be disclosed in any manner

to a third party without the prior written consent of Prime Controls, Inc.

202836 vii Revision E

Table 1 – Cable Set ................................................................................................................... 6

Table 2 – Signal Drive Types ....................................................................................................16

Table 3 – Internal Signal Polarities ............................................................................................16

Table 4 – System Status List .....................................................................................................34

Table 5 – System History List ....................................................................................................35

Table 6 – Lane Status List ........................................................................................................36

Table 7 – Lane History List........................................................................................................37

Table 8 – Signal Polarities ........................................................................................................42

Table 9 – PLC IO Signals ..........................................................................................................46

Table 10 – Signal Polarities.......................................................................................................47

Table 11 – Internal IO Polarities ................................................................................................51

Table 12 – Result Bit Meanings ................................................................................................54

Table 13 – Modbus Counter Descriptions .................................................................................59

Table 14 – Modbus Counters Normal Operation .......................................................................59

Table 15 – Modbus Counters Trouble Shooting ........................................................................59

Table 16 – Modbus PSIO Terminal Block Connections .............................................................63

Table 17 – Modbus Command Codes .......................................................................................63

Table 18 – Modbus Discrete Coils.............................................................................................64

Table 19 – Modbus Discrete Inputs ...........................................................................................66

Table 20 – Modbus Register Inputs ...........................................................................................67

Table 21 – Modbus Holding Registers ......................................................................................68

Table 22 – Modbus Command Codes .......................................................................................69

Table 23 – Modbus Discrete Coil Outputs .................................................................................69

Table 24 – Modbus Discrete Inputs ...........................................................................................72

Table 25 – Modbus Register Inputs ...........................................................................................73

Table 26 – Modbus Holding Registers ......................................................................................73

Table 27 – Maintenance Parts ..................................................................................................74

Table 28 – PLC001 Indicators ...................................................................................................80

Table 29 – PSIO Terminal Block External Connection List ........................................................94

Table 30 – LHSL Terminal Block Connection List .....................................................................95

Table 31 – LH200H/LH200H-opt Connection List ......................................................................99

Table 32 – SL100H-1, SL100H-2 Connection List ................................................................... 100

EP200 Multi-Lane End Leak Detection System

This document is confidential and proprietary. No part of this document may be disclosed in any manner

to a third party without the prior written consent of Prime Controls, Inc.

202836 viii Revision E

Figure 1 – MI200 Touch Screen ................................................................................................. 2

Figure 2 – SL100H-D LED Driver ............................................................................................... 2

Figure 3 – PS506 Power Supply ................................................................................................ 3

Figure 4 – CAP001 Power Filter ................................................................................................. 3

Figure 5 – PLC001 ..................................................................................................................... 4

Figure 6 – ET230 Ethernet Gateway .......................................................................................... 4

Figure 7 – LH200H ..................................................................................................................... 5

Figure 8 – LH200H-202 or LH200H-300 .................................................................................... 5

Figure 9 – SL100H-1 Remote LED Illuminator ........................................................................... 6

Figure 10 - SL100H-2 Remote LED Illuminator .......................................................................... 6

Figure 11 – MI200 Screen Elements .........................................................................................23

Figure 12 – MI200 Menu Buttons ..............................................................................................24

Figure 13 – Numeric Keypad .....................................................................................................25

Figure 14 – Main Screen ...........................................................................................................26

Figure 15 – Main Screen System Status ...................................................................................27

Figure 16 – Main Screen Measurement Results ........................................................................27

Figure 17 – Main Screen Lane Status .......................................................................................28

Figure 18 – Main Screen Menu Login .......................................................................................28

Figure 19 – Password Entry Screen ..........................................................................................29

Figure 20 – Main Screen Menu Select ......................................................................................29

Figure 21 – Main Screen Menu Select ......................................................................................30

Figure 22 – Main Screen Help ...................................................................................................30

Figure 23 – Main Screen Status Message .................................................................................31

Figure 24 – Main Screen Leak Reset ........................................................................................31

Figure 25 – Main Screen Leak Reset Active .............................................................................32

Figure 26 – Leak Log Screen ....................................................................................................32

Figure 27 – Measurement Log Screen ......................................................................................33

Figure 28 – System Status Screen ............................................................................................33

Figure 29 – System History Screen ...........................................................................................34

Figure 30 – Lane Status Screen ................................................................................................35

Figure 31 – Lane History Screen ...............................................................................................36

Figure 32 – Main Menu Screen .................................................................................................37

Figure 33 – Setup Screen .........................................................................................................38

Figure 34 – Limits Screen .........................................................................................................38

Figure 35 – Phasing Screen ......................................................................................................39

Figure 36 – Phasing Screen Detail ............................................................................................40

Figure 37 – Configure IO Screen ..............................................................................................41

Figure 38 – ELTP Drop-In IO Configuration ..............................................................................44

Figure 39 – ELDS Fail Safe IO Configuration ............................................................................44

Figure 40 – Rejector Screen .....................................................................................................45

Figure 41 – Parameters Screen ................................................................................................45

Figure 42 – Configure PLC Screen ...........................................................................................46

Figure 43 – ELTP Drop-In IO Configuration ..............................................................................48

Figure 44 – ELDS Fail Safe IO Configuration ............................................................................48

Figure 45 – Diagnostics Menu Screen ......................................................................................49

Figure 46 – Lane Force IO Screen ............................................................................................49

Figure 47 – Configure IO Screen ..............................................................................................50

Figure 48 – ELTP Drop-In IO Configuration ..............................................................................52

Figure 49 – ELDS Fail Safe IO Configuration ............................................................................52

Figure 50 – Version Screen.......................................................................................................53

EP200 Multi-Lane End Leak Detection System

This document is confidential and proprietary. No part of this document may be disclosed in any manner

to a third party without the prior written consent of Prime Controls, Inc.

202836 ix Revision E

Figure 51 – Measurement Screen .............................................................................................53

Figure 52 – Statistics Screen ....................................................................................................54

Figure 53 – Force PLC001 IO Statistics Screen ........................................................................55

Figure 54 – Utility Menu Screen ................................................................................................56

Figure 55 – Load Defaults Screen .............................................................................................57

Figure 56 – Modbus Address Screen ........................................................................................57

Figure 57 – Modbus Counts Screen ..........................................................................................58

Figure 58 – Internal Diagnostics Screen....................................................................................60

Figure 59 – Set Date Screen .....................................................................................................60

Figure 60 – Set Time Screen ....................................................................................................61

Figure 61 – Gain Bias Screen ...................................................................................................61

Figure 62 – PS506 LED Indicator ..............................................................................................78

Figure 63 – LH200H Indicators .................................................................................................79

Figure 64 – SL100H-D Indicators ..............................................................................................79

Figure 65 – PLC001 Indicators ..................................................................................................80

Figure 66 – Rejector Relay Indicator .........................................................................................82

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