Prime Controls SD220 User manual

OPERATING INSTRUCTIONS
MODEL SD220/SD230 TRISENSE SHELL/TAB/LEAK DETECTOR
2019.12.19
ORIGINAL INSTRUCTIONS

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Table of Contents
DESCRIPTION .....................................................................................................................................1
Control Module ......................................................................................................................................... 1
Calibrate Pushbutton Operation ............................................................................................................... 1
Probes........................................................................................................................................................ 2
OPERATION .......................................................................................................................................2
Calibration ................................................................................................................................................. 2
Fault Message Interpretation................................................................................................................ 3
INSTALLATION ...................................................................................................................................4
Safety......................................................................................................................................................... 4
Power..................................................................................................................................................... 4
Hazardous Locations.............................................................................................................................. 4
Installing the Probes.................................................................................................................................. 4
Mounting the Control Module .................................................................................................................. 4
Wiring the Control Module ....................................................................................................................... 5
Setting Switch Options .............................................................................................................................. 6
Selecting Metal Types............................................................................................................................ 7
Set Sinking or Sourcing Outputs ............................................................................................................ 7
Set Outputs for Failsafe or Compatibility .............................................................................................. 8
Enable or Disable Tab Profiling.............................................................................................................. 8
Setting Options Through the Front Panel ................................................................................................. 8
Set TriSense Mode (SD230 Only)........................................................................................................... 8
Adjusting the Tolerance......................................................................................................................... 9
Set Display Direction.............................................................................................................................. 9
Set Quick Calibration Changeover ....................................................................................................... 10
Parameter Ranges................................................................................................................................10
Parameter Value Ranges ..................................................................................................................... 10
Special Functions.....................................................................................................................................10

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Remote Calibration..............................................................................................................................11
Quick Calibration Changeover .............................................................................................................11
Determining Firmware Version ........................................................................................................... 12
MAINTENANCE ................................................................................................................................12
TROUBLESHOOTING.........................................................................................................................12
DECOMMISSIONING.........................................................................................................................13
DOCUMENT APPLICABILITY ..............................................................................................................13
ELECTRICAL SPECIFICATIONS ............................................................................................................14
SD220/SD230 CONTROL MODULE DIMENSIONS................................................................................15
SD230/TRISENSE WIRING DIAGRAM.................................................................................................16
SD220/SD230 PROBE WIRING RECOMMENDATIONS.........................................................................17
SD220/SD230 OUTPUT SIGNALS .......................................................................................................18
SUMMARY OF DIFFERENCES BETWEEN SD200 AND SD220/SD230 .....................................................19
SD200 TO SD220/SD230 MIGRATION................................................................................................19
MODBUS NETWORK (SD230 Only) ....................................................................................................21
Description .............................................................................................................................................. 21
Installation............................................................................................................................................... 21
Setup .......................................................................................................................................................21
Cabling.....................................................................................................................................................22
SD230/Pro-Face System Cabling.......................................................................................................... 22
SD230 To Pro-Face HMI Cable .............................................................................................................22
EthernetIP Gateway Interconnect .......................................................................................................23
ModBus Entities ...................................................................................................................................... 25
Discrete Coil Outputs (000001) (Read/Write) .....................................................................................25
Discrete Coil Inputs (100001) (Read Only)...........................................................................................27
Register Inputs (300001) (Read Only)..................................................................................................28
Holding Registers (400001) (Read/Write) ...........................................................................................33
LIMITATION AND EXCLUSION OF WARRANTIES.................................................................................36
NAME PLATE INFORMATION ............................................................................................................36

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EC DECLARATION OF CONFORMITY ..................................................................................................37

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DESCRIPTION
The SD220 Double Shell/Missing Tab Detector and the SD230 Double Shell/Missing Tab/Leak Detectors
for conversion press applications are rugged but sensitive dual channel instruments 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. The SD220 and SD230 units are identical except the
SD230 supports Modbus Networking capability and TriSense functionality.
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.
The SD230 when operating in TriSense mode, the controller interfaces to optional LH200 Light Leak
Detector and SL100 LED Strobe Lamp to add leak detection capability to the controller. Status and
configuration data passes through the controller’s Modbus interface through a serial link to the LH200
to provide complete control and monitoring of the Light Leak Detection functionality.
Multiple SD230 units, with or without TriSense functionality may be interconnected through a Modbus
network. See the Modbus Networking section (page 21) for details.
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 (fault) 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. This input may
also be used in TriSense mode to provide flash detection.
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 (page 6)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 including: set the TriSense mode (tr) (SD230 only),

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adjust the gauge tolerances (“tL”), set the display option to invert the digital display (do), and set the
function of the AUX input (“AU”).
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 (“tr”, “tL”, “do”, or “AU”) 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/SD230 controllers 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 three wire
probes, the white wire in the probe cable is not used and must remain disconnected.
OPERATION
Operation of the SD220/SD230 Double Shell/Missing 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/SD230
control module.
3. Press and release the CALIBRATE pushbutton on channel 1 of the SD220/SD230 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.

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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/SD230 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/SD230.
Activation of this input performs the same function as pressing the CALIBRATE push-button switch for
the corresponding channel.
Fault Message Interpretation
The SD220/SD230 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/SD230 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

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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.
Safety
Power
When performing installation, service or maintenance on the eqiupment, disconnect power to the
machine and Lock Out/Tag Out the power in accordance with your plant standard operating procedures.
Hazardous Locations
This equipment is suitable for operation in non-hazardous locations only.
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 a grounded industrial enclosure. Insure that the
mounting screws make good electrical contact between the module housing and the grounded control
enclosure back panel. Alternatively, connect a grounding wire to one of the mounting screws to provide
a ground. In the case of grounding the controller to a panel door, insure that the door is properly

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grounded in accordance with best practices. 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. See drawing at the end of this document. To avoid an electrical hazard while
operating the unit inside the enclosure, all live parts in the enclosure shall be IP2X or better.
If the control module is mounted external to an enclosure or on an enclosure door, an adequate cover
must be installed over the exposed connectors to achive IP4X protection or better. The door must be
permanently grounded and good electrical contact between the control module and grounded door
must be achieved.
Wiring the Control Module
Probe cable routing must follow best practices to isolate the sensitive probe signals from sources of
interference such as AC mains, variable frequency drives, digital switching signals and other high
current, high voltage or high speed signals. Power wiring to the unit should also follow best pratices to
isolate the low-voltage DC power from AC mains and other high voltage or high current wires. Where
paths must cross, their intersection should be perpendicular.
1. Connect +24V 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 0.500 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.
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).
3. Connect the tab detecting transmitter probe wires to the TMTR terminals on the channel 2 side
of the control module and the tab detecting receiving probe wires to the two RCVR terminals on
the channel 2 side of the control module. Connect the shield wires to the terminals labeled
SHLD.
The precautions regarding choice of transmitter probe are the same for the discharge side as for
the infeed. See above.

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4. Connect the SNGL, DBL, NO TAB, TAB, and FLT (fault) outputs to the system controller and/or
interlocking circuitry as required. These outputs may be sinking or sourcing as determined by
the setting of SW 5. See setting switch options (page 6).
The FLT outputs are always ON for no fault. The active states of the other outputs may be
affected by the setting of the compatibility DIP switch as described later in this document. The
outputs should not be wired to each other.
5. If calibration is to be activated remotely, connect the CAL+ and CAL- inputs appropriately.
Connect a sinking driver or contact to the CAL- terminal and connect CAL+ to the +24V power
source. Connect a sourcing driver to the CAL+ terminal and connect CAL- to COM.
6. If the application may involve switching between steel and aluminum blanks, the AUX inputs
may be wired to provide external control of the sensing mode of the SD230. Connect a sinking
driver or contact to the AUX- terminal and connect the AUX+ terminal to the +24V supply.
Connect a sourcing driver to the AUX+ terminal and connect the AUX- terminal to COM.
7. If TriSense mode is to be used, connect the LH200 serial signals to the controller using the
AC230-RJ breakout board and CBL230 cable. Connect the SL100 Flash Detect signal to AUX2+ if
used.
Setting Switch Options
To access the DIP switches in the middle of the front panel, swing the hinged plastic window to the side.
The left-most switch is SW1, the right-most is SW8. The switches are on when in the up position.
Channel 1 Switch Options
Switch
OFF
ON
SW1
Sense aluminum ends
Sense steel ends
SW2
On-press sensing
Off-press sensing (high speed)
SW3
Select fail-safe mode
Select compatibility mode
SW4
Fixed thresholds
Adjustable thresholds
SW5
Sourcing outputs
Sinking outputs
SW6
No overlap allowed
Overlap allowed if SW2 ON
SW7
Modbus Network Disabled
Modbus Network Enabled
SW8
Not used

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Channel 2 Switch Options
Switch
OFF
ON
SW1
Sense aluminum ends
Sense steel ends
SW2
Sense aluminum tabs
Sense steel tabs
SW3
Select fail-safe mode
Select compatibility mode
SW4
Fixed thresholds
Adjustable thresholds
SW5
Sourcing outputs
Sinking outputs
SW6
Enable tab profiling
Disable tab profiling
SW7
Modbus Network Disabled
Modbus Network Enabled
SW8
Not used
NOTE: DIP switch settings are only read on power-up of the unit. After changing switch setting, power
the unit down and back up again to activate the change.
Selecting Metal Types
SW1 and SW2 are used to inform the controller of the types of metals used in the manufacture of the
can ends and are generally set according to the metals used. However, metals with coatings, in
particular steels with coatings, may not produce significant differences in measured values between
tab/no-tab and single/double conditions. In these cases, it is acceptable to select a metal setting
different from the metals in use. Typically, this means, using the aluminum ends and/or tabs settings
when using particular coated steels.
Sensing Aluminum Ends
When sensing aluminum ends, insure that SW1 is off for both channels.
Sensing Steel Ends
When sensing steel ends, insure that SW1 is on for both channels. See paragraph above on Selecting
Metal Types.
Sensing Aluminum Tabs on Aluminum Ends
When sensing aluminum tabs on aluminum ends, insure SW1 and SW2 are off for both channels. See
paragraph above on Selecting Metal Types.
Sensing Aluminum Tabs on Steel Ends
When sensing aluminum tabs on steel ends, set SW1 on and SW2 off for channel 1. See paragraph above
on Selecting Metal Types.
Set SW1 on and SW2 off for channel 2.
Sensing Steel Tabs on Steel Ends
When sensing steel tabs on steel ends, set SW1 on and SW2 off for channel 1 and set both SW1 and
SW2 on for channel 2. See paragraph above on Selecting Metal Types.
Set Sinking or Sourcing Outputs
The setting of SW5 determines whether the output drivers are sinking or sourcing. SW5 off selects
sourcing, SW5 on selects sinking.

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Set Outputs for Failsafe or Compatibility
When SW3 is on, the sourcing outputs of the SD220/SD230 provide the same logic levels as the outputs
of older double shell units such as the DS33 and DS35, allowing for quick and easy retrofit installations.
When SW3 is off, the output states are defined to provide maximum protection against loss of
connection between the shell detector and the controlling PLC. The loss of connection is sensed as the
fault condition.
The table below defines the output states for all combinations of SW3 and the possible sensing states.
Also, see the SD220/230 Output Signal Drawings (page 18).
OUTPUT STATES
Switch
In Gap
SINGLE
DOUBLE
NO TAB
TAB
OFF
missing
OFF
ON
ON
OFF
OFF
single
ON
ON
OFF
OFF
OFF
double/tab
ON
OFF
ON
ON
ON
missing
ON
OFF
ON
OFF
ON
single
OFF
OFF
OFF
OFF
ON
double/tab
OFF
ON
ON
ON
Enable or Disable Tab Profiling
The SD220/SD230 uses two different methods for determining the absence or presence of tabs. The
most basic method is simple thresholding of the sensor signals. As the shape of the beverage ends and
tabs evolved and the speed of presses increased, it became necessary to implement a redundant test
that recognizes the profile of a tab as it moves through the machine. This feature, however, is not
compatible with larger and steel ends or with machines that have stainless steel belts. The stainless steel
belts can change the sensor signal sufficiently to interfere with the tab profiling algorithm and cause the
system to report self-check errors. Profiling is most effective in the detection of aluminum tabs on
aluminum ends on high-speed presses. SW6 enables and disables tab profiling.
Setting Options Through the Front Panel
Set TriSense Mode (SD230 Only)
By default, the system does not enable TriSense mode (tr= 0). In this mode, the SD230 operates stand
alone and presents Modbus entities related to its operation alone. TriSense mode is enabled by setting
the tr setting to 1or 2depending on if the Flash Detect input is used. Unused, TriSense mode is 1. Used,
TriSense mode is 2. To set the TriSense mode:
1. Press and hold the calibrate pushbutton until “tr”appears on the display.
2. Release the pushbutton and the display changes to “0”, “1”, or “2”.
3. At this point, with each press of the pushbutton the display increments up to 2and rolling over
back to 0. The 0disables TriSense, 1enables TriSense without Flash Detection, and 2enabled
TriSense with Flash Detection.
4. When the desired value is on the display, wait 5 seconds and the display reverts to displaying
the signal value in the selected mode.

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Adjusting the Tolerance
Adjust the double shell tolerance as follows:
1. Insure that SW4 is on. If necessary, change the switch position and power the unit down and
back up.
2. Press and hold the channel 1 calibrate pushbutton for at least 3 seconds until “tL”appears on
the display.
3. Release the pushbutton and observe the current value of the threshold (in percent).
4. If the current value is ok (typically 35), wait 5 seconds and the display reverts to displaying the
gauge value and retains the current tolerance.
5. To change the value, press and hold or tap the calibration pushbutton until the desired value is
displayed. After the value reaches 90, it rolls over to 10 and increases.
6. When the desired value is on the display, wait 5 seconds and the display reverts to displaying
the gauge value and retains the last displayed tolerance value.
Adjust the missing tab tolerance as follows:
1. Insure that SW4 is on. If necessary, change the switch position and power the unit down and
back up.
2. Press and hold the channel 2 calibrate pushbutton for at least 3 seconds until “tL”appears on
the display.
3. Release the pushbutton and observe the current value of the threshold (in percent).
4. If the current value is ok (typically 15), wait 5 seconds and the display reverts to displaying the
gauge value and retains the current tolerance.
5. To change the value, press and hold or tap the calibration pushbutton until the desired value is
displayed. After the value reaches 90, it rolls over to 10 and increases.
6. When the desired value is on the display, wait 5 seconds and the display reverts to displaying
the gauge value and retains the last displayed tolerance value.
Set Display Direction
By default, the digital display values follow the strength of the receiver signal, increasing for stronger
signal and decreasing for weaker signal. In this mode, the signal increases for thinner materials between
the probes and decreases for thicker materials. The display may be inverted so that the values are
proportional to material thickness rather than signal strength. To invert the display:
1. Press and hold the calibrate pushbutton until “do”appears on the display.

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2. Release the pushbutton and the display changes to “0” or “1”.
3. At this point, with each press of the pushbutton the display toggles between “0” and “1”. The 0
selects normal display mode, 1selects inverted mode..
4. When the desired value is on the display, wait 5 seconds and the display reverts to displaying
the signal value in the selected mode.
Set Quick Calibration Changeover
When TriSense is not enabled (tr = 0) the AUX input may be used to quickly change between sensed
metal types. By default (AU=0), Quick Calibration Changeover is disabled and the AUX input has no
effect on the metal sensing process. When enabled (AU=1), the AUX input works in conjunction with
SW1 (both channels) and SW2 (channel 2 only) to select the target tab and shell material combinations
as presented in the Quick Calibration Changeover section below.
To change the Quick Calibration Changeover setting:
1. Press and hold the calibrate pushbutton until “AU”appears on the display.
2. Release the pushbutton and the display changes to “0” or “1”.
3. At this point, with each press of the pushbutton the display toggles between 0and 1. The 0
selects normal display mode, 1selects inverted mode.
4. When the desired value is on the display, wait 5 seconds and the display reverts to displaying
the signal value in the selected mode.
Parameter Ranges
The range of values available for the SD220/SD230 adjustable parameters are as follows:
Parameter Value Ranges
ID
Function
Range of Values
tr
TriSense Operation
(SD230 only)
0No TriSense (default), 1TriSense without Flash
Detect, 2TriSense with Flash Detect (uses AUX input)
tL
Double Tolerance
10% to 90% for double (default is 35%)
tL
Tab Tolerance
10% to 90% for tab (default is 15%)
do
Display Direction
0for signal strength (default), 1relative thickness
AU
Aux Metal Select
0AUX does not control sensing mode (default), 1AUX
controls sensing mode
oL
Overlap Percentage
0% to 90% for off-press sensing only (SW2 On)
dL
Delta Tolerance
10% to 15% for off-press sensing only (SW2 On)
Special Functions
The SD220/SD230 offers two sets of optically isolated inputs on each channel that provide added control
over the unit. These are the remote calibration input terminals labeled CAL+ and CAL- and the sensing
mode inputs labeled AUX+ and AUX-.

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CAL Input Connections Sinking Driver:
Connect signal to CAL-, and +24V power source to CAL+
Sourcing Driver:
Connect signal to CAL+, and COM to CAL-
AUX Input Connections Sinking Driver:
Connect signal to AUX-, and +24V power source to
AUX+
Sourcing Driver:
Connect signal to AUX+, and COM to AUX-
Remote Calibration
The remote calibration inputs perform the same function as the CALIBRATE push-button switches on the
front panel of the control module.
Quick Calibration Changeover
The AUX input works in conjunction with SW1 (both channels) and SW2 (channel 2 only) to select the
target tab and shell material combinations as presented in the table below.
When the AUX input is activated or deactivated, the SD220/SD230 changes to accommodate the new
material combination and displays, for approximately 2 seconds, a two-character abbreviation indicating
the selected targeted materials. The display interpretation is as follows:
Al – aluminum tab on aluminum shell
St – steel tab on steel shell
AS- aluminum tab on steel shell
The two-character indication also displays at powerup indicating the current selection.
Channel 1 Material Selection
SW1
AUX
Shell Material
OFF
OFF
Aluminum
OFF
ON
Steel
ON
OFF
Steel
ON
ON
Aluminum

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Channel 2 Material Selection
SW1
SW2
AUX
Material Combination
OFF
OFF
OFF
Aluminum tab on aluminum end
OFF
OFF
ON
Aluminum tab on steel end
OFF
ON
OFF
Aluminum tab on aluminum end
OFF
ON
ON
Steel tab on steel end
ON
OFF
OFF
Aluminum tab on steel end
ON
OFF
ON
Aluminum tab on aluminum end
ON
ON
OFF
Steel tab on steel end
ON
ON
ON
Aluminum tab on aluminum end
If quick calibration changeover is to be activated remotely, connect the AUX+ and AUX- inputs
appropriately. Connect sinking drivers or contacts to the AUX- terminal and connect AUX+ to the +24V
power source. Connect sourcing drivers to the AUX+ terminal and connect AUX- to COM.
Determining Firmware Version
From time to time, as improvements are made to Prime Controls products, the firmware controlling the
units is revised. When setting a unit up or troubleshooting it may be necessary to determine the version
number for the firmware installed in your unit. The version numbers are of the form 1.00 and are
incremented either by tenths (1.01, 1.02, etc.) for small revisions or by the integer digit (1.00, 2.00, etc.)
for more significant revisions.
To determine the version of the firmware running in your unit, hold the calibration pushbutton in as
power is applied to the unit. The revision number is displayed directly on the digital display.
The two channels of the SD220/SD230 are independent and may be running different versions of
firmware. Each must be checked separately.
MAINTENANCE
The SD220/SD230 Controller requires no periodic maintenance beyond maintaining general cleanliness
of the controller, connections, and probes. Probes should be inspected and cleaned to prevent build up
of ferrous particles on the sensing surfaces. The frequency of inspection depends on the operating
conditions of the probes. Use a damp, not wet, cloth or sponge to clean the painted surfaces of the
controller. Mild soap or detergent may also be used. Dry with a soft rag.
TROUBLESHOOTING
If the display is not on, check the +24V DC power applied to the unit. Once the display is operational,
refer to displayed fault codes according to “Fault Message Interpertation” under Operation, Calibration
(page 2). If the displayed values rapidly change while the machine is static, check for loose or damaged
probe cables or improper routing of the these cables such as routing the cables with other high voltage,
or high current wires, power wires, or other noise sources.

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DECOMMISSIONING
If the machine or parts of the machine have to be permanently put out of service, laws and directives in
force at the time of the dismantling have to be strictly observed and complied with. In any case, check
which materials can be recycled. These must be sent to an appropriate waste collecting company.
DOCUMENT APPLICABILITY
This document applies to SD220/SD230 units running firmware Version 1.11 and greater.

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ELECTRICAL SPECIFICATIONS
Supply Voltage: +24V DC plus or minus 10%
Supply Current per Channel: 130 mA plus sourcing output load
Inrush Current at Startup: 500 mA for 3 milliseconds per channel
AUX and CAL Max Input Voltage: 30V
AUX and CAL Input Impedance: 3300 ohms
Sourcing Outputs: On voltage: Supply Voltage – 1.0 volt
Off voltage: 0 volts
Max current: 50 mA
Sinking Outputs: On voltage: 0 volts
Off voltage: Load pullup dependent
Max current: 50 mA
Output Overload Protection: Self-resetting thermal fuse
Input and Output Transient Protection: 30 volt transient absorber
NET Input and NET Output: Isolated 5V half-duplex RS485 Modbus transceiver
(SD230 Only)

15
SD220/SD230 CONTROL MODULE DIMENSIONS
Control module dimensions are the same for the SD220 and SD230 units. Only the SD230 control
module is shown.