GSi PLC Owner's manual

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

2PNEG-2170 PLC Controller
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
PNEG-2170 PLC Controller 3
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

Table of Contents
4PNEG-2170 PLC Controller
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

PNEG-2170 PLC Controller 5
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.
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 make 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.Intersystemsrecommendsthatyoucontactthelocalpowercompanytohavearepresentativesurvey
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.
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.

1. Introduction
6PNEG-2170 PLC Controller
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 109th Ave
Omaha, NE 68142
Phone: [phone]
FAX: [phone]
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.
Replacement Parts
The InterSystems, Inc. sampler is a quality built piece of machinery. As with any machine, parts do wear
outandfail.ItisInterSystem’srecommendationthat a smallsupplyof spare partsbe kept on handtocover
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 any special or custom components
utilized on this equipment.

PNEG-2170 PLC Controller 7
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
signalis use the 30seconddelayis not used. Whenthecontrolisin automatic, the delay betweensamples
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.

8PNEG-2170 PLC Controller
3. Safety
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,whichmustbecarefullyfollowedinallcases.Authoritieshavingjurisdictionmust 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.
ST-0001-3

3. Safety
PNEG-2170 PLC Controller 9
Cautionary Symbol Definitions
Cautionary symbols appear in this manual and on product decals. The symbols alert the user of potential
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
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

3. Safety
10 PNEG-2170 PLC Controller
Safety Cautions
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

3. Safety
PNEG-2170 PLC Controller 11
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

3. Safety
12 PNEG-2170 PLC Controller
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
PNEG-2170 PLC Controller 13
Safety Sign-Off Sheet
Below is a sign-off sheet that canbe used to verify thatall 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
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
ST-0007

14 PNEG-2170 PLC Controller
4. Installation
Receiving Inspection
Carefully inspect the sampler control for damage as soon as it is received. Also, verify that the quantity of
parts or packages actually received corresponds to the quantity shown on the packing slip. Report any
damage or shortage to the delivering carrier as soon as possible. InterSystem’s responsibility for the
equipment ended with acceptance by the delivering carrier. Refer to the bill of lading.
Pre-Installation Preparation
NOTE: Before starting the sampling system installation, study this manual, the certified drawing(s)
furnished with the system and other applicable documents (including, but not limited to OSHA
regulations, the National Electrical Code and all other applicable federal, state and local codes
and regulations).
Controller Location
1. Use vibration isolation pads when mounting the control enclosure or mount the controller in a
vibration free location.
2. Unless ordered for severe duty, locate controller so it is protected from water and dust.
3. Unless an explosion-proof rated controller was specifically ordered, DO NOT locate the controller in
a hazardous area.
4. Most applications require that the sampler be in easy view of the controller.
System Wiring
Refer to the certified electrical drawing(s) for specific wiring requirements. The 19-position barrier
terminal strip located inside the bottom right corner of the control enclosure is the connection point for
ALL external circuitry.
The controller was completely assembled and tested with the sampler before it left the factory. The
electrical installation must comply with OSHA Regulations, the National Electrical Code and all other
applicable federal, state and local codes and regulations.
If wiring between the controller and the sampler unit is run through rigid conduit, use a short length of
flexible conduit to connect wiring to the sampler. This will isolate the rigid conduit from any vibration
originating in the product conveying line and sampler.
Controller Electrical Power Requirements
110/120 VAC 50/60 Hz, Single Phase, 20 Amp Maximum Service.
Optional - 220/240 VAC 50/60 Hz, Single Phase, 10 Amp Service.
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 15
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.

5. Operations and Adjustments
16 PNEG-2170 PLC Controller
Power OFF/ON Switch S-1
The Power OFF/ON switch controls all electrical power to the controller and the sampler unit.
Power Pilot Light
This light is illuminated as long as power is available to the controller and the POWER switch (S-1) is set
to ON.
Sampling Pilot Light
This light will illuminate when a sampling cycle has been initiated and will stay lit until CR-1 has been
turned OFF for controller series 550800. On control series 550803 the sampling lights are associated
with the traverse direction of the pelican. The light will stay illuminated until the solenoid has been
de-engerized.
PanelView 300 Operator Interface
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.)
This machine starts without warning. Moving parts can cause severe
injury. Clear area prior to controller start-up.

5. Operations and Adjustments
PNEG-2170 PLC Controller 17
Figure 5B Operator PanelView Flow Chart

5. Operations and Adjustments
18 PNEG-2170 PLC Controller
Description of Operator Screens
Function keys F1, F2, F3 and F4 Used to select desired control function or
parameters.
Up/Down arrow keys Used to enter numeric numbers by incrementing
digits.
Left/right arrow keys Used to change numeric number position.
Enter key
F1 MANUAL SAMPLE Used to initial a manual sample cycle when in
manual mode.
F2 MANUAL INDEX Used to initial a manual index of sample cabinet in manual mode when a cabinet is connected to the
control.
F3 IN MANUAL F3 toggles between manual mode and automatic
mode.
F4 SETTINGS Allows user to select other control options.
F1 VIEW SETTINGS
Used to view sample duration timer.
F1 TIME BETWEEN SAMPLES
F2 SAMPLES DONE
F3 CURRENT JAR
F4 INPUT STATUS and TURN OUTPUT ON
F2 SAMPLE TIMER Password required for changing time between
samples.
F3 SAMPLE SELECTION Allows operator to select program mode and option
settings.
F1 PROGRAM MODE
Changes between the different sampler programs
in the controller.
F1 toggles through sampler programs.
F2 sets timer values for that specific sampler.
F2 OPTION SETTINGS Allows operator to change mode of operation, turn ON and set-up index cabinet and turn on sample
purge.
F1 OPERATION MODE
Changes control operation from timer based to
counter and timer/counter.
Also contains the Timer Settings to allow for the
adjustment of the specific sampler timer values.
F2 INDEXER SETUP Used to turn the indexer ON or OFF, enter the total number of jars per cabinet and enter the number of
samples per jar.
F3 PURGE OFF Turns sample purge ON/OFF.
F1 MANUAL SAMPLE
F2 MANUAL INDEX
F3 IN MANUAL
F4 SETTINGS
F1 VIEW SETTINGS
F2 SAMPLER TIMER
F3 SAMPLE SELECTION
F4 MAIN SCREEN
F1 PROGRAM MODE
F2 OPTION SETTINGS
F4 MAIN SCREEN
F1 OPERATION MODE
F2 INDEXER SETUP
F3 PURGE OFF
F4 PASSWORD SCREEN

5. Operations and Adjustments
PNEG-2170 PLC Controller 19
Terminal Strip
This 19-position barrier terminal strip is located inside along the bottom right corner of the control
enclosure. It serves as the controller’s interface and connection point for all external circuits and for the
components mounted in the enclosure. Refer to the certified electrical drawing(s).
Power Transformer
The control is equipped with a transformer which converts 120/240 volt incoming power to 24 VDC for the
operation of the PLC, PanelView, display lights, input signals and operation of the control relays. Refer to
the certified electrical drawing(s). The transformer is internally protected against overloads.
Control Relays
The control is equipped with four control relays, which are driven by the PLC output signals. Each relay
has a mechanical flag indicator showing the relay is energized. The relay coil is operated using 24 VDC
while the relay contacts are wired for 120/240 volts. Refer to the certified electrical drawing(s).
Main Fuse F1
This fuse is located along the top edge of the control next to the base of the ON/OFF switch. The fuse
rating will change depending on the type of sampler being used. This fuse protects the controller and
sampler components against overloads and short circuits.
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 10point 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. This control is design only to run InterSystems equipment.
This control is to be operated only on the voltage designated on the certified
electrical drawing. Fire or explosion may result, which can cause death, serious
injury and extensive damage to equipment.

20 PNEG-2170 PLC Controller
6. Operations Mode and Description
Operation Modes
The PLC control can operate under three different operation modes: Timer, Counter, Counter/Counter,
Timer/Counter. Operation mode determines when the sampler starts a sample cycle when in the
automatic mode. The controls are factory set in the Timer operation mode.
Counter Mode
Whenin theCOUNTER modethesamplerislooking forpulsesfrom externalequipment (i.e.baggingline).
When the sampler reaches the desired counts a sample cyclewill be initiated. To setthe control to operate
in COUNTER mode:
1. Turn power ON.
2. Press F4 key for Settings.
3. Press F3 for Sample Selection.
4. If prompted for the User enter 1followed by enter key .
5. EnterPasswordscreen will appear. Using the Up/Downarrowkeysonthe right side to adjustnumber
values and the Left/Right arrow keys on the left side to change position enter 1500 followed by the
enter key .
6. Caution Changing Sampler Parameters press F3 for OK.
7. Press F2 for Option Settings.
8. Press F1 for Operation Mode.
9. Press F1 to toggle through to counter.
10. Press F2 to change the number of counts between samples.
11. Enter desired value using the Up/Down arrow keys on the right side to adjust number values andthe
Right/Left arrow keys on the left side to change position. Then press the Enter key .
12. Press F4 to return to Main Screen.
To initiate the input pulse the factory installed REMOTE ENABLE jumper needs to be removed. In its
place, install a normally open contact. The normally open contact should be a dry contact rated for
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.
Signal Start-Multiple Cycle Mode
When in the Signal Start-Multiple Cycle mode the sampler is looking for a pulse from external equipment
(i.e. bagging line). When the enable signal is initiated the sampler will cycle for a pre-determined number
of cycles. To set the control to operate in Signal Start-Multiple Cycle mode:
1. Turn power ON.
2. Press F4 key for Settings.
3. Press F3 for Sample Selection.
4. If prompted for the User enter 1followed by enter key .