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