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GSi PLC Installation And Operation Manual

PLC Controller
PNEG-2170
Installation and Operation Manual
PNEG-2170
Version: 1.0
Date: 12-07-17
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.
Table of Contents
Contents
Chapter 1 Introduction ..........................................................................................................................................5
General Safety Statements ................................................................................................................... 5
Scope ..................................... ............................................................................................................... 6
Ordering Parts ....................................................................................................................................... 6
Replacement Parts ....................... .... ... ... ... ... .... .......................................... ... ... ... .... ... ... ........................ 6
Chapter 2 General Information .............................................................................................................................7
System Description .......................................................... ... ... .......................................... ..................... 7
Optional Features ................... ... ... .... .......................................... ... ... ... .................................................. 7
Chapter 3 Safety .....................................................................................................................................................8
Safety Guidelines .................................................................................................................................. 8
Cautionary Symbol Definitions ............................................... .... ... ... ... ... .... ... ... ..................................... 9
Safety Cautions ................................... ... ... .......................................... ... .... ... ...................................... 10
Safety Sign-Off Sheet ......................................................................................................................... 13
Chapter 4 Installation ..........................................................................................................................................14
Receiving Inspection . ... ... .................................................................................................................... 14
Pre-Installation Preparation .................................... .................... ................... ................... ................... 14
Controller Location .............................................................................................................................. 14
System Wiring ..................................................... ... ... .... ... ... ... ............................................................. 14
Chapter 5 Operations and Adjustments ............................................................................................................15
Control Components and their Functions ............................................................................................ 15
Chapter 6 Operations Mode and Description ............................. ...................................................... .................20
Operation Modes .................... ... ... .... ... .......................................... ... ... ... ............................................. 20
Chapter 7 PLC Settings for PS, PS-XP and HD-PP Sampler Operation ..........................................................24
Sampler Operation Description ........................................................................................................... 24
PS, PS-XP and HD-PP Sampler Operating Components ................................................................... 24
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) ............................. 26
PT, PTG, LF, GS, GP and PDP Sampler Program Mode ................................................................... 26
PT, PTG, LF, GS, GP and PDP Sampler Timer Settings ........... ................... ................... ................... 27
Chapter 9 PLC Settings for GSS and GSS-U Sampler Operation .......................... ............................. .............28
Sampler Operation Description ........................................................................................................... 28
GSS and GSS-U Sampler Operating Components ............................................................................. 28
GSS and GSS-U Sampler Main Fuse (Refer to Certified Drawing) .................................................... 28
GSS and GSS-U Sampler Program Mode .......................................................................................... 28
GSS and GSS-U Sampler Timer Settings ........................................................................................... 29
Chapter 10 PLC Settings for GT, GRES and RS Sampler Operation ....................... ... ... .... ... ... ... ... .... ... ..........30
Sampler Operation Description ......................................................................................................... 30
GT, GRES and RS Sampler Operating Components ........................................................................ 30
GT, GRES and RS Sampler Main Fuse (Refer to Certified Drawings) .............................................. 30
GT, GRES and RS Sampler Program Mode ..................................................................................... 30
PNEG-2170 PLC Controller 3
Table of Contents
Chapter 11 PLC Settings for PRT and HD-PRT Sampler Operation ................................................................31
Sampler Operation Description ....................................... ... ... .... ... ... ... ... .... ... ... ... ............................... 31
PRT and HD-PRT Sampler Operating Components ......................................................................... 31
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 .............................................................................. 33
GRA and GCA Sampler Main Fuse (Refer to Certified Drawing) ...................................................... 33
GRA and GCA Sampler Program Mode ............. ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ........................ 33
Chapter 13 PLC Settings for GPE Sampler Operation (550804) ......................................................................34
Sampler Operation Description ....................................... ... ... .... ... ... ... ... .... ... ... ... ............................... 34
GPE Sampler Operating Components .............................................................................................. 34
GPE Sampler Program Mode ............................................................................................................ 34
Chapter 14 PLC Settings for Index Cabinet and Other Options ................................ ... ... .... ... ... ... ... .... ... ... ......35
Setting Controller to Operate Index Cabinet and Setting Up Index Cabinet ...................................... 35
Index Cabinet Delay Before Indexing ................................................................................................ 35
Sample Purge Option ........................................................................................................................ 36
Remote Enable .................................................................................................................................. 37
Chapter 15 Maintenance and Repair ..................................................................................................................38
General Maintenance ........................................................................................................................ 38
Periodic Inspection ............................................................................................................................ 38
Chapter 16 Troubleshooting ...............................................................................................................................39
PLC Control Troubleshooting ................ ... ... .... ... ... ... .... ... ... ... .... ......................................... .... ........... 39
Chapter 17 Warranty ............................................................................................................................................41
4 PNEG-2170 PLC Controller
1. Introduction
This equipment is to be obtained only on the voltage designated on the certified electrical drawings. Fire or explosion may result, which can cause death, serious injury and extensive damage to equipment. Do not connect to voltages other than designated.
Compressed air can cause severe injury. Shut off and lock out compressed air source to the sampler and bleed off any and all present compressed air within the sampler pneumatics before attempting any service on this sampler.
This manual covers the installation and operation for the PLC Con troller. 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.
InterSystems reserves the right to improve its product whenever possible and practical to do so. We reserve the right to change, improve and modify products at any time without obligation to ma ke changes, improvements and modifications on equipment sold previously.
General Safety Statements
1. The PLC Controller is designed and manufactured with operator safety in mind. However, residual hazards remain due to the nature of material handling, and specific material hazards. Use extreme caution at all times.
2. Modifications to equipment may cause extremely dangerous situations that could result in damage to the equipment as well as serious injury or death. Never modify the equipment.
3. Intersystems recommends that you contact the local power company to have a representative survey the installation to ensure wiring is compatible with their system and adequate power is supplied to the unit.
4. Consult Intersystems before making any changes to the sampler or its operating environment. Careless changes could result in death or serious injury to people and reduce the performance and service life of the equipment.
5. Never perform any service on this equipment or any powered equipment until all power has been shut off and locked out so that it cannot be restored without the consent and knowledge of the person who interrupted power. Power includes electrical, fluid, mechanical or pneumatic energy.
6. Never perform any service on this equipment without utilizing the required PPE (Personal Protective Equipment). Refer to the MSDS (s) (Material Safety Data Sheet (s)), on all products to which this equipment is in contact to determine what PPE is required.
PNEG-2170 PLC Controller 5
1. Introduction
Scope
The certified drawings list the non-standard components that have been incorporated into the equipment. InterSystems, Inc. normally stocks non-fabricated parts and non-custom OEM parts. Replacement parts for any other components, including fabricated parts and custom OEM components can be supplied upon request.
Ordering Parts
Direct parts orders or requests for technical assistance to your sales representative or to:
InterSystems, Inc.
9575 No 109 Omaha, NE 68142 Phone: (402) 330-1500 FAX: (402) 330-3350
Please have available the MODEL NUMBER, SERIAL NUMBER and CUSTOMER ORDER NUMBER of the equipment in question as well as the location where the sampler is INSTALLED.
th
Ave
Replacement Parts
The InterSystems, Inc. sampler is a quality built piece of machinery. As with any machine, parts do wear out and fail. It is InterSystem’s recommendation that a small supply of spare parts be kept on hand to cover any minor breakdowns. 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 a ny special or custom components utilized on this equipment.
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.
Sampler start-up, setting and operator interaction are easily navigated through the menu screens on the PanelView screen. Once the control is set-up and the desired timer values entered, the control can be set to run in automatic or manual operation. When in automatic mode, the control will upon initial power up wait 30 seconds before beginning the automatic sequence. This is designed to allow the operator time to decide if they want automatic or manual operation. If the control has been ON and the remote enable signal is use the 30 second delay is not used. When the control is in automatic, the delay between samples timer will start to time down, upon reaching 0 the control will begin the desired sampling sequence. When the control is set for manual operation, the delay between samples timer is ignored and upon press the “F1” key, the sampler will begin the sampling sequence.
Optional Features
The certified drawings indicate which, if any, optional features are included with a sampler control. Some of the more frequently specified optional features are briefly described in the following list.
1. Controller arranged to initiate a sampling cycle based on quantity or volume of material passing through conveying line rather than upon elapsed time periods.
2. Explosion Proof Controller. There are several major differences in an explosion-proof control as compared to a standard control. An explosion proof control will typically have the following features.
The explosion proof sampler control is available in two enclosure classifications. a. The NEMA 9 control with the rating of:
Class 2, Groups E, F and G, Division 1 and 2
b. The NEMA 7 control with the rating of:
Class 1, Groups C and D, Division 1 and 2 Class 2, Groups E, F and G, Division 1 and 2
3. Enclosure components of special materials, such as 304 stainless steel.
PNEG-2170 PLC Controller 7
3. Safety
ST-0001-3
Safety Guidelines
Safety guidelines are general-to-specific safety rules that must be followed at all times. This manual is written to help you understand safe operating procedures and problems that can be encountered by the operator and other personnel when using this equipment. Save these safety guidelines for future reference.
As owner or operator, you are responsible for understanding the requirements, hazards, and precautions that exist and to inform others as required. Unqualified persons must stay out of the work area at all times.
Alterations must not be made to the equipment. Alterations can produce dangerous situations resulting in SERIOUS INJURY or DEATH.
This equipment must be installed in accordance with the current installation codes and applicable regulations, which must be carefully followed in all cases. Authorities having jurisdiction must be consulted before installations are made.
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.
3. Safety
This symbol indicates an imminently hazardous situation which, if not avoided, will result in serious injury or death.
This symbol indicates a potentially hazardous situation which, if not avoided, can result in serious injury or death.
This symbol indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury.
This symbol is used to address practices not related to personal injury.
This symbol indicates a general hazard.
This symbol indicates a prohibited activity.
This symbol indicates a mandatory action.
ST-0005-2
Cautionary Symbol Definitions
Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potentia l safety hazards, prohibited activities and mandatory actions. To help you recognize this information, we use the symbols that are defined below.
DANGER
WARNING
CAUTION
NOTICE
PNEG-2170 PLC Controller 9
3. Safety
Use Personal Protective Equipment
Eye Protection
Hearing Protection
Hand Protection
Head Protection
Respiratory Protection
Foot Protection
Fall Protection
• Use appropriate personal protective equipment:
• Wear clothing appropriate to the job.
• Remove all jewelry.
• Tie long hair up and back.
ST-0004-1
Follow Safety Instructions
• Carefully read all safety messages in this manual and safety signs on your machine. Keep signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from the manufacturer.
• 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
Safety Cautions
3. Safety
Maintain Equipment and Work Area
• Understand service procedures before doing work. Keep area clean and dry.
• Never service equipment while it is operating. Keep hands, feet, and clothing away from moving parts
• Keep your equipment in proper working condition. Replace worn or broken parts immediately.
ST-0003-1
Stay Clear of Hoisted Equipment
• Always use proper lifting or hoisting equipment when assembling or disassembling equipment.
• Do not walk or stand under hoisted equipment.
• Always use sturdy and stable supports when needed for installation. Not following these safety precautions creates the risk of falling equipment, which could crush personnel and cause serious injury or death.
ST-0047-1
Sharp Edge Hazard
• This product has sharp edges, which can cause serious injury.
• To avoid injury, handle sharp edges with caution and always use proper protective clothing and equipment
ST-0036-2
Install and Operate Electrical Equipment Properly
• Electrical controls must be installed by a qualified electrician and must meet the standards set by applicable local codes (National 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
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3. Safety
Stay Clear of Moving Parts
• Stay clear - machine can start without warning.
• Entanglement in gate will cause serious injury.
• Keep all shields and covers in place at all times.
• Lock-out power source before making adjustments, cleaning, or maintaining equipment.
ST-0070-1
Stay Clear of Rotating Parts
• Do not service equipment while it is in operation.
• 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
3. Safety
Flying Material and High Pressure Air Hazard
• Flying material and/or high pressure air can cause severe eye injury or blindness.
• Wear safety glasses around operating equipment.
ST-0071-1
Safety Sign-Off Sheet
Below is a sign-off sheet that can be used to verify that all person nel 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
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