Conspec Controls CS0352-MP User manual

CONSPEC CONTROLS
CS0352-MP
User Manual
1/24/2017
Rev. 3

Index
Purpose…………………………………………………………………………………………………..……………………………………………. 1
System Overview……………………………………………………………………………………………………….…………………......... 1
CS0352-MP Components……………………………………………………………………………………….............…………….…… 2
Panel View Screens…………………………………………………………………………………………………………………………....… 3
Modes……………………………………………………………………………………………………………………………....................... 6
Trouble Conditions……………………………………………………………………………………………………............................7
CO Sensor Calibration…………………………………………………………………………………………………………………........... 9
Flow Detector Calibration………………………………………………………………………………………………………..............10
See also……………………………………………………………………………………………………………………………………………..…10
Replacement Parts……………………………………………………………………………………………………………………….………10
Contact Information……………………………………………………………………………………………………………………….….…10

1
Purpose
Conspec atmospheric sample draw systems are designed to continuously monitor gas levels in areas
with extreme conditions. A gas monitor cannot be directly placed in areas of extreme heat, high
moisture levels and areas with large amounts of airborne debris. The remote probe design allows for
monitoring in such conditions without damaging the sensitive parts of the gas monitor. The PLC
controlled system is fully automated and allows for easy set up after installation.
The CS0352-MP is an extractive carbon monoxide monitoring system designed specifically to work in
conjunction with the MillPro mill protection system. It is designed to be able to handle the higher
temperatures and moisture levels of PRB coal burning systems. It is a single mill dual probe system. One
probe is located in the top of the mill near the exhaust ports and the second probe is inserted into the
underbowl of the mill.
System Overview
During start up, shutdown and normal running operations the sample is pulled from the top of the mill. A
sample is pulled from the underbowl only while the mill is offline to detect smoldering coal that may have
fallen to the bottom of the mill. The pump is disabled and sampling ceases during a deluge or spray down
of the mill to avoid the system from taking in too much water. The PLC determines the mill status by
several inputs from the MillPro system and acts accordingly.
The CS0352-MP performs scheduled high pressure blow backs to clear the sintered metal probes of any
blockage. The system is able to detect a low flow condition if the probe becomes clogged and will perform
an unscheduled blowback. Scheduled blow back intervals are user definable through the touch screen
interface.
Several sample conditioning elements are utilized to ensure accurate gas detection and sensor life. A
Vortec panel cooler and thermostat have been incorporated into the panel to lower the temperature of
the sample. Lowering the temperature to an acceptable level ensures sensor life and condenses any
excess moisture out of the sample air to be removed by a water catch and peristaltic pump.
A flow matching calibration process is used for more accurate gas detection. Using a 3 LPM regulator on
the calibration gas bottles and an adjustable flow regulator within the panel, the sampling flow rate and
calibration flow rate can be matched resulting in a more accurate gas reading

2
Figure 1: CS0352-MP Components
CS0352-MP Components –Labels, Descriptions, and Part Numbers
PLC
PS
UT
SN
FD
SP
SW1
DP
SW2
ETH
485A
S1
S2
S3
TH
TR
CR
FR
CF
CC
BV
CAL
EXH
ACin
SI
420mA
Allen Bradley 1400
Meanwell 24VDC 5A Supply
500PPM CO Detector Card
1000PPM CO Sensor
Flow Detector Card
120Vac 12 LPM Sample Pump
Sample Pump Switch
115Vac Peristaltic Drain Pump
Drain Pump Switch
Moxa Ethernet Switch
RS485 to Serial Adaptor
Probe Select Solenoid
Pressure Release Solenoid
H.P. Blow Back Solenoid
Thermostat
Trouble Relay
Cooler Solenoid Relay
.4-5.0LPM Flow Regulator
Coalescing Filter
Cooling Coil
3-way Ball Valve (Calibration)
Calibration Port
Exhaust Port
120VAC Supply Input
System Inputs
4-20mA CO Level Output
1766-L32BWA
SDR-120-24
900732-03
P2261-3
900724
AL-6SB
P1907-SL
SP101R.104
P1907-SL
EDS-205
1763-NC01
3CBX4S-Y-24VDC
3CBX4S-Y-24VDC
3CBX4S-Y-24VDC
Vortex 747 System
814-3028
814-3028
FL2013
2383T47
Non Inventory Item
46095K41
DMA3
DMA3
N/A
N/A
N/A

3
CM
Components not shown
PV
S4
VC
Cooling Muffler
Panel view Component C600
120Vac 2 way Cooler Solenoid
Vortec Cooler
Vortex 747 System
2711C-T6T
Vortex 747 System
Vortex 747 System
PanelView Screens
Main screen
The main screen contains a link to all the other screens. All the screens are accessible from the main
screen. The screens are:
Maintenance
Overview
PV Config
Alarm Log

4
PV Config
The Panel View Configuration screen is a user screen created by Allen Bradley Products to adjust screen
settings such a contrast, brightness, screen time out time, etc. The date and time are also set from this
screen as well as communication settings.
Overview
The Overview screen shows useful information all on one screen for easy viewing. The panel status, sensor
status, an approximated 4-20mA value, CO value, hour long trend window, MillPro status, Mill Status, and
logging information are all displayed. The logs keep track of operation times so the user can predict when
components will need maintenance or replacement. The About screen can be accessed from the overview
screen.
The about screen provides software version and contact information.
*When the log counts reach 10,000 they are reset to 0

5
Alarm Log
The Alarm Log screen logs alarms and error conditions. When an error occurs (such as a blocked probe
during start up mode) the PLC immediately goes into alarm and energizes the trouble relay. This error is
displayed on the panel view screen and needs to be cleared or acknowledged. A record of alarms and
errors is kept in this screen and can be cleared if desired.

6
Maintenance
The Maintenance screen gives the options to change the Panel Setup Times and modes. Under the Panel
Setup Times the user can adjust the Startup delay, High Pressure on time, number of blow backs, and the
time between blowbacks. The modes available are the calibration mode, off mode, maintenance mode,
and the startup mode. In maintenance mode the user can choose to turn on or off the High pressure
solenoid, pressure release solenoid, the pump, and choose the probe selection. The mode check alarm
time is adjustable in the maintenance screen as well.
Modes
Start Up Mode
Start up mode is the first mode that the sample panel goes into upon being enabled. Start up mode allows
pressure to be created within the lines and give the flow detector time to stabilize. The sample panel
enters start up mode every time that the pump turns on. If there is a low flow condition or the line is
clogged during start up mode the sample panel goes into an error condition and the PLC energizes the
trouble relay and sends a signal to the DCS signaling that maintenance is required.
Normal Mode
Normal mode occurs immediately after start up mode and is maintained during normal sampling
conditions. Normal mode is defined as: the pump operating correctly, the flow detector is within normal
range and the panel is not in maintenance or blowback mode.

7
Normal Blow Back Mode
Normal Blow Back Mode can only be accessed during Normal Mode and is an automated process which
occurs every 60 minutes. The time interval is user definable but is factory defaulted to occur every 60
minutes. Normal Blow Back Mode is used to blow high pressure air through the probe to clear it of any
dust or particles that could clog the sintered end of the probe and cause a low flow condition.
Low Flow Blowback mode
Low Flow Blow Back Mode can occur at anytime during Normal Mode. Low Flow Blow Back Mode begins if
the flow detector goes outside of its normal range and signals that there is a low flow condition. The Low
Flow Blow Back works just like the Normal Blow Back mode except that it is not a timed event and relies on
a low flow condition to start it.
Calibration Mode
Calibration Mode begins when the Universal Transmitter is put into Calibration by the user. All other
modes are disabled during this mode. The pump and solenoids are off and the flow detector reading is
ignored.
Maintenance Mode
Maintenance Mode should be entered by the user anytime that work is being performed on the system.
This will ensure that the scheduled blow back to occur every 30 minutes will not happen and the pumps
and solenoids will be turned off unless forced on by the user. Maintenance Mode is a useful tool for
trouble shooting and checking for proper operation of individual components. From this mode the pump
and solenoids can all be turned on individually. Other modes can also be selected from maintenance
mode to ensure they are working correctly. If the Sample Panel is left in Maintenance mode for longer
than 2 hours the (User selectable via HMI) PLC energizes the trouble relay and a signal is sent to the DCS
requiring that the error be acknowledged. This will ensure that the sample panel is not accidentally left in
maintenance mode.
Trouble Conditions
Low Flow alarm
The amount of gas flow to the sensor was too low and was not able to be restored to normal flow (2-
3LPM) after low flow blow back sequences.
Sensor fail
The calculated gas value has drifted negative by more than 3% of the monitors full range. A gas
calibration will typically correct this issue. If the sensor cannot pass calibration sensor replacement is
required.

8
Communication Error/Demoted
The PLC has lost communications to the gas transmitter board. Typically caused by a loose connection
or improperly configured communication settings in the Universal Transmitter.
Mode Check Error
The panel has been left in “Maintenance Mode” for longer than the user definable time frame. Error
will clear once panel is put into startup mode.
Alarm 1
The gas value has exceeded the alarm 1 user definable set point.
Alarm 2
The gas value has exceeded the alarm 2 user definable set point.
Temperature error
The internal temperature of the panel is outside of the -4F-120F range of the gas sensor.
Flow Cal Error
The pump is off but the flow detector still signals that flow is sufficient. Recalibration of the flow
detector will correct this issue.

9
CO Sensor Calibration
Required parts:
Zero gas (20.9% O2)
Span gas (250 PPM CO)
3/16” I.D. rubber hose
3LPM regulator
UP99 Universal IR programmer
These parts are included in the P1879-CO-250-NC-3 Calibration Kit.
To calibrate the sensor the panel door must be opened so the user can view the LCD display on the
Universal Transmitter and the adjustable flow regulator.
The UP99 Universal Programmer is used to put the Universal Transmitter into Calibration mode. To do so
point the programmer at the infrared sensor on the top of the Universal Transmitter, then the unlock code
must be entered. To unlock the Universal Transmitter press 25 (the unlock code will not be displayed on
the screen) then press enter (E) on the programmer. Next enter the password which is factory defaulted to
1 then press enter (E). When the monitor is unlocked enter 111 then press enter to access calibration
mode. When in calibration the PLC will shut off the pump so it does not interfere with the calibration. The
Universal Transmitter interface is also explained in the Universal Transmitter Manual.
Once in Calibration mode turn the handle of the ball valve on the right side of the enclosure to the upward
position and connect the 3/16” I.D. hose from the 3LPM regulator on the “zero gas”cylinder to the
calibration port on the right side of the enclosure. The status light on the bottom of the Universal
Transmitter will turn green when in calibration mode indicating that the zero gas should be applied to the
sensor. Open the valve on the regulator and apply the zero gas.
Make sure that the adjustable flow regulator inside the panel is fully open to allow maximum flow. Apply
the zero gas for two minutes. After two minutes or a stabilized reading, point the IR programmer at the
Universal Transmitter and press enter. The status light will now turn red indicating the monitor is ready to
have the “span gas” applied. Remove the zero gas and apply the span gas for two minutes.
Notice the LPM level on the flow regulator; it should be approximately 3 LPM. The sample flow rate will
have to be adjusted to match this flow for the most accurate sampling possible. After two minutes or a
stabilized reading, point the IR programmer at the Universal Transmitter and press enter. The monitor will
display if the calibration has passed or failed and go into standby mode for 60 seconds to allow the PPM
level to drop to avoid false alarms.
Immediately after you have finished the span gas calibration, while the monitor displays either “Cal Pass” or
“Cal Fail” quickly turn off and remove the span gas and turn the handle of the ball valve back to sample
mode. The PLC will automatically enter startup mode and turn the pump back on while the monitor is in
standby mode to lower the gas value.
At this point the adjustable flow regulator will need to be adjusted to match the 3LPM flow rate that the
sensor was calibrated at.
When the sample panel is in calibration mode the pump is turned off and all activities such as high pressure
blow back and low flow blow back are disabled. The Universal Transmitter calibration is also explained in
the Universal Transmitter Manual.

10
Flow Detector Calibration
To calibrate the flow detector go into the maintenance screen and put the system into maintenance mode.
Then turn the pump on and open panel door. Adjust the flow regulator so that the float is between 1.5-
2LPM.
On the Flow detector card is a small yellow button. Press and hold that button for one second until the
indicator light begins to blink green. This indicates that the card is ready to accept its low flow calibration
set point. With the flow regulator adjusted to approximately 1.5-2 LPM press and hold the yellow button
until the light stops blinking green then release it.
The indicator light will begin blinking red indicating that it is ready for the high flow set point. Adjust the
flow regulator to allow for full flow which should be approximately 4 LPM. Wait a few seconds to allow the
flow detector to stabilize then press and hold the yellow button again until the light stops blinking red and
then release it.
The indicator light should be solid green which indicates that the flow is within the calibrated parameters. If
the light is blinking green and red the calibration was not accepted. Repeat the process using a slightly
higher or lower low flow set point.
Once a successful calibration has been accepted lower the flow slowly to make sure the indicator light turns
red at approximately 1-1 .5 LPM and that you hear the relay energize and “click”. If the calibration worked
correctly raise the flow to approximately 3 LPM and close the door and put the panel back into run mode.
If the light does not turn red within .5 LPM of the low flow set point a calibration will have to be attempted
again. On the second attempt during the full flow calibration slightly restrict the exhaust port with a finger
to allow slightly more pressure to build in the system. Verify that the flow detector indicator light turns red
at approximately 1-1.5 LPM
See Also
Universal Transmitter Manual
CS0352-MP Pneumatic Drawing (DWG2014-099 RevA)
Replacement Parts
Damaged or questionable parts should be replaced immediately upon
detection. Damaged or inoperative parts could contribute to hazardous and/or unsafe conditions. Any
consumable parts should be replaced if the reliability is questionable or within the part’s specific
expected life. Consumable parts include any filters, pumps, sensors, solenoids….etc.
Contact Information
Questions / Technical Support…………….. [phone] Mon-Fri 8am-5pm
est. Conspec Sales…………………………....... [phone] Mon-Fri 8am-5pm
est. Fax…………………………………………………. [phone]
E-mail………………………………….…… …………[e-mail]
Web site…………………………………… …………..www.conspec-controls.com