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GSi PLC Installation And Operation Manual

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PLC Controller
Installation and Operation Manual
PNEG-2170
Version: 1.0
Date: 12-07-17
PNEG-2170

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  • Page 1 PLC Controller Installation and Operation Manual PNEG-2170 Version: 1.0 Date: 12-07-17 PNEG-2170...
  • Page 2 All information, illustrations, photos, and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. PNEG-2170 PLC Controller...

  • Page 3: Table Of Contents

    PS, PS-XP and HD-PP Sampler Program Mode ................24 PS, PS-XP and HD-PP Sampler Timer Settings ................. 25 Chapter 8 PLC Settings for PT, PTG, LF, GS, GP and PDP Sampler Operation ..........26 Sampler Operation Description ......................26 PT, PTG, LF, GS, GP and PDP Sampler Operating Components ............26 PT, PTG, LF, GS, GP and PDP Sampler Main Fuse (Refer to Certified Drawing) ......
  • Page 4 PRT and HD-PRT Sampler Main Fuse (Refer to Certified Drawing) ..........31 PRT and HD-PRT Sampler Program Mode and Solenoid Timer ............31 Chapter 12 PLC Settings for GRA and GCA Sampler Operation (550804) .............33 Sampler Operation Description ......................33 GRA and GCA Sampler Operating Components ................

  • Page 5: Chapter 1 Introduction

    1. Introduction This manual covers the installation and operation for the PLC Controller. This manual provides guidelines for installing the product. You must retain a qualified contractor to provide on-site expertise. INTERSYSTEMS IS NOT RESPONSIBLE FOR THE INSTALLATION OF THIS PRODUCT.

  • Page 6: Scope

    A separate priced spare parts list will be sent identifying the suggested spare parts. It is also necessary to check the certified drawings, which will list any special or custom components utilized on this equipment. PNEG-2170 PLC Controller...

  • Page 7: Chapter 2 General Information

    2. General Information System Description The PLC control is an Allen Bradley Micologix 10 point processor interfaced with a PanelView 300 operator display designed to control one sampler at a time. The control can handle the addition of a collection cabinet at installation or at a later date without replacing or upgrading the control. The controller was design with the intent to be user friendly using a minimum number of key strokes.

  • Page 8: Chapter 3 Safety

    When necessary, you must consider the installation location relative to electrical, fuel and water utilities. Personnel operating or working around equipment must read this manual. This manual must be delivered with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment. ST-0001-3 PNEG-2170 PLC Controller...

  • Page 9: Cautionary Symbol Definitions

    This symbol is used to address practices not related to NOTICE personal injury. This symbol indicates a general hazard. This symbol indicates a prohibited activity. This symbol indicates a mandatory action. ST-0005-2 PNEG-2170 PLC Controller...

  • Page 10: Safety Cautions

    Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. • If you do not understand any part of this manual or need assistance, contact your dealer. ST-0002-1 PNEG-2170 PLC Controller...
  • Page 11 Electrical Code for the US, Canadian Electric Code, or EN60204 along with applicable European Directives for Europe). • Lock-out power source before making adjustments, cleaning, or maintaining equipment. • Make sure all equipment is properly grounded. ST-0027-4 PNEG-2170 PLC Controller...
  • Page 12 • Entanglement in rotating parts or exposed belts will cause serious injury or death. • Keep all shields and covers in place at all times. • Lock-out power source before making adjustments, cleaning, or maintaining equipment. ST-0072-1 PNEG-2170 PLC Controller...

  • Page 13: Safety Sign-Off Sheet

    Below is a sign-off sheet that can be used to verify that all personnel have read and understood the safety instructions. This sign-off sheet is provided for your convenience and personal record keeping. Date Employee Name Supervisor Name ST-0007 PNEG-2170 PLC Controller...

  • Page 14: Chapter 4 Installation

    Refer to the certified electrical drawing(s) for specific wiring requirements. InterSystems strongly recommends that electrical service to the sampling system be an isolated line. Voltage fluctuations and line noise can affect the controller, thus causing the sampler to malfunction. PNEG-2170 PLC Controller...

  • Page 15: Chapter 5 Operations And Adjustments

    5. Operations and Adjustments Control Components and their Functions Figure 5A Standard Nema 4 Control Panel Detail Refer to the certified electrical drawing(s) for dimensions on control panels with optional features. PNEG-2170 PLC Controller...
  • Page 16 The operator interface is the source of all input necessary to operate the control. The operator PanelView is setup using linked menus to step through the operation of the control. The following flow chart depicts the layout of the operator menus. (See chart on Page 17.) PNEG-2170 PLC Controller...
  • Page 17 5. Operations and Adjustments Figure 5B Operator PanelView Flow Chart PNEG-2170 PLC Controller...
  • Page 18 Used to turn the indexer ON or OFF, enter the total F3 PURGE OFF F2 INDEXER SETUP number of jars per cabinet and enter the number of samples per jar. F4 PASSWORD SCREEN F3 PURGE OFF Turns sample purge ON/OFF. PNEG-2170 PLC Controller...
  • Page 19 For 120/240 VAC, 1 PH operation use ONLY a Buss Type FNM, 250 Volt Slo-Blo fuse or equal. Microview PLC The PLC for the control is a 10 point Allen Bradley Microview controller. The PLC operates on 24 VDC and is pre-wired to the proper terminal strip inputs and outputs. The processor program is protected to prevent any alterations to the existing program.

  • Page 20: Chapter 6 Operations Mode And Description

    120 VAC 0.5 Amps. This contact needs to be driven by the customer’s process (i.e. bagging line). When the contact closes the sampler PLC will register a count. They will count up until the desired count value is reached. When the count value is reached the sampling cycle will begin.
  • Page 21 120 VAC 0.5 Amps that is driven by the customer’s process (i.e: bagging line). When the contact closes the sampler PLC will start the sampling cycle. When the sample cycles are complete, the control will require another input pulse to start the cycle over.
  • Page 22 13. Enter desired value using the Up/Down arrow keys on the right side to adjust number values and the Right/Left arrow keys on the left side to change position. Then press the Enter key 14. Press F4 to return to Main. PNEG-2170 PLC Controller...
  • Page 23 9. Press F4 to return to Previous Screen. 10. Press F4 for Main Screen. When in automatic mode, the REMOTE ENABLE jumper needs to be installed. NOTE: When in manual mode, the sampler will only take one sampler per incident. PNEG-2170 PLC Controller...

  • Page 24: Chapter 7 Plc Settings For Ps, Ps-Xp And Hd-Pp Sampler Operation

    7. PLC Settings for PS, PS-XP and HD-PP Sampler Operation Sampler Operation Description The PS style sampler when operated in the timing mode and Automatic operates as follows. When the illuminated display reads all zeroes (000), the timer has “timed out” and initiates a sampling cycle. The sample probe extends and delays to collect a sample until T1 times out, the probe then retracts and actuates the limit switch LS-1.

  • Page 25: Ps, Ps-Xp And Hd-Pp Sampler Timer Settings

    7. PLC Settings for PS, PS-XP and HD-PP Sampler Operation 8. Press F1 for Mode (the current sampler mode should be showing). To change sampler mode, press F1 until a 0 is showing on this line. 9. Press F2 to change the sampler timer settings. (Extend timer and auger run timer.) The current value should be showing on the right side of this line.

  • Page 26: Chapter 8 Plc Settings For Pt, Ptg, Lf, Gs, Gp And Pdp Sampler Operation

    8. PLC Settings for PT, PTG, LF, GS, GP and PDP Sampler Operation Sampler Operation Description The PT style sampler when operated in the timing mode and Automatic operates as follows. When the AUTO mode is selected, the timer begins timing down. When the illuminated display reads all zeroes (000), the timer has “timed out”...

  • Page 27: Pt, Ptg, Lf, Gs, Gp And Pdp Sampler Timer Settings

    8. PLC Settings for PT, PTG, LF, GS, GP and PDP Sampler Operation 12. Press F4 to return to Password Screen. 13. Press F4 to return to Main Screen. PT, PTG, LF, GS, GP and PDP Sampler Timer Settings The PT, PTG, LF, GS, GP style sampler has one timer setting which must be set for proper operation. The timer setting is for the solenoid extend time (T1).

  • Page 28: Chapter 9 Plc Settings For Gss And Gss-U Sampler Operation

    9. PLC Settings for GSS and GSS-U Sampler Operation Sampler Operation Description The GSS style sampler when operated in the timing mode and Automatic operates as follows. When the AUTO mode is selected, the timer begins timing down. When the illuminated display reads all zeroes (000), the timer has “timed out”...

  • Page 29: Gss And Gss-U Sampler Timer Settings

    9. PLC Settings for GSS and GSS-U Sampler Operation 11. Using the Up/Down and Right/Left arrow keys to set the correct solenoid time. See Chart for the correct timer setting. Once the correct time value has been entered, press the enter key 12.

  • Page 30: Chapter 10 Plc Settings For Gt, Gres And Rs Sampler Operation

    The GT, GRES and RS style sampler only have one timer value which is not changeable in the PLC. This timer is to hold the starter contacts in until the limit switch has come off of the cam.

  • Page 31: Chapter 11 Plc Settings For Prt And Hd-Prt Sampler Operation

    11. PLC Settings for PRT and HD-PRT Sampler Operation Sampler Operation Description The PRT style sampler when operated in the timing mode and Automatic operates as follows. When the AUTO mode is selected, the timer begins timing down. When the illuminated display reads all zeroes (000), the timer has “timed out”...
  • Page 32 11. PLC Settings for PRT and HD-PRT Sampler Operation 9. Press F2 to change the sampler timer settings. (Solenoid timer and Motor run timer). The current value should be showing on the right side of this line. See chart for correct timer settings.

  • Page 33: Chapter 12 Plc Settings For Gra And Gca Sampler Operation (550804)

    12. PLC Settings for GRA and GCA Sampler Operation (550804) Sampler Operation Description The GRA style sampler when operated in the timing mode and Automatic operates as follows. When the AUTO mode is selected, the timer begins timing down. When the illuminated display reads all zeroes (000), the timer has “timed out”...

  • Page 34: Chapter 13 Plc Settings For Gpe Sampler Operation (550804)

    13. PLC Settings for GPE Sampler Operation (550804) Sampler Operation Description The GPE style sampler when operated in the timing mode and automatic operates as follows. When the AUTO mode is selected, the timer begins timing down. When the illuminated display reads all zeroes (000), the timer has “timed out”...

  • Page 35: Chapter 14 Plc Settings For Index Cabinet And Other Options

    Index Cabinet The PLC controller has the ability to operate a standard index cabinet with all samplers except the PRT and HD-PRT. If an index cabinet is to be used with a PRT or HD-PRT sampler a special control with more inputs and outputs are required.

  • Page 36: Sample Purge Option

    14. PLC Settings for Index Cabinet and Other Options 5. Enter Password screen will appear. Using the Up/Down arrow keys on the right side to adjust number values and the Left/Right arrow keys on the left side to change position enter 1500 followed by the enter key 6.

  • Page 37: Remote Enable

    14. PLC Settings for Index Cabinet and Other Options Remote Enable Each control is shipped with a jumper wire installed in the remote enable terminal strip (TB 1 and 2). The remote enable signal allows the end user when in automatic to start and stop the sampler in conjunction with the process system (i.e.

  • Page 38: Chapter 15 Maintenance And Repair

    9. Make sure that all guards are in place and that all warning labels are in place and legible. See Page 9, GENERAL SAFETY INFORMATION, explains the purpose and intended location of the warning signs. Warning signs are an important part of any safety program, replace any missing signs IMMEDIATELY. PNEG-2170 PLC Controller...

  • Page 39: Chapter 16 Troubleshooting

    16. Troubleshooting PLC Control Troubleshooting Symptom Possible Cause Corrective Action Correct. Refer to the certified Motor wired improperly. electrical schematic. Motor jammed. Inspect and replace. Motor fuse blows continuously. Inspect and replace. Refer to Sampler Auger seized up in sampler.
  • Page 40 NOTES PNEG-2170 PLC Controller...

  • Page 41: Chapter 17 Warranty

    INTERSYSTEMS, INC. NEITHER MAKES NOR AUTHORIZES ANY WARRANTY OTHER THAN AS HEREIN CONTAINED. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. PNEG-2170 PLC Controller...
  • Page 42 InterSystems 9575 N. 109 Ave. Omaha, Nebraska 68142 Toll Free: (800) 228-1483 www.gsiag.com InterSystems is a part of GSI, a worldwide brand of AGCO Corporation. Copyright © 2017 by Intersystems, Inc. Printed in the USA CN-331627...

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