PRO-201 PROFESSOR S CONTROLLER - Matheson · This document describes the installation, operation, and maintenance of the PRO-201 Siemens PLC semi-automated controller. ... The PRO-201

PRO-201 PROFESSOR SERIES CONTROLLER

OPERATION/MAINTENANCE/INSTALLATION MANUAL

Part Number S052-0105, Rev A

September, 2008

166 Keystone Drive Montgomeryville, PA 18936 Telephone: 215-641-2700 Fax: 215-641-2714 National Service Center: 800-850-6231 Internet Address: http://www.matheson-trigas.com

Copyright Notice

© 2008 Matheson Tri-Gas All rights reserved. Printed in USA

Trademark Information Centurion is a trademark of Matheson Tri Gas. Ethernet is a registered trademark of Digital Equipment Corporation, Intel, and Xerox Corporation. Other product and company names mentioned in this manual may be the trademarks of their respective owners.

Scope of this Document

This document describes the installation, operation, and maintenance of the PRO-201 Siemens PLC semi-automated controller.

For information about the installation, operation, and maintenance of the Centurion™ gas source manifold (GSM), refer to the appropriate manual.

Document Revision History Document Part No. Edition Status Issued

PRO-201 Professor Series Controller Operation, Maintenance, and Installation Manual

S052-0105 Rev A Released September, 2008

PRO-201 PROFESSOR SERIES CONTROLLER – OPERATION /MAINTENANCE/INSTALLATION MANUAL i

TABLE OF CONTENTS Table of Contents....................................................................................................................................... i

Figures................................................................................................................................................... ii Tables .................................................................................................................................................... iii

1. Product Description...............................................................................................................................4 1.1 PRO-201 Functionality ....................................................................................................................4 1.2 PRO-201 Features ..........................................................................................................................5

2. Engineering Data....................................................................................................................................6 2.1 Utilities Required .............................................................................................................................6 2.2 Analog Inputs...................................................................................................................................6 2.3 Digital Inputs....................................................................................................................................6 2.4 Relay Outputs..................................................................................................................................7 2.5 Solenoid Valves...............................................................................................................................7 2.6 Human Machine Interface (HMI) .....................................................................................................7 2.7 Siemens S7-224XP PLC .................................................................................................................8 2.8 Controller Enclosure........................................................................................................................8 2.9 Environmental Considerations ........................................................................................................9 2.10 Certifications..................................................................................................................................9

3. Safety.......................................................................................................................................................10 3.1 Safety Precautions ..........................................................................................................................10

General Precautions.................................................................................................................11 Operation Precautions..............................................................................................................11 Installation / Maintenance Precautions.....................................................................................11

3.2 Personnel Training ..........................................................................................................................12

4. Installation ..............................................................................................................................................13 4.1 Equipment Unpacking & Insurance Claims.....................................................................................13 4.2 Utilities .............................................................................................................................................13 4.3 Accessory Monitors & Controls .......................................................................................................14 4.4 NETWORK Communication Connections (Optional) ......................................................................14 4.5 Pneumatic Manifold Outputs ...........................................................................................................15 4.6 Post-Installation Start Up.................................................................................................................15 4.8 Post-Installation Tests .....................................................................................................................16

5. General Operation..................................................................................................................................17 5.1 User Interface ..................................................................................................................................17

5.1.1 Shutdown Switches................................................................................................................17 5.1.2 HMI Operational Basics................................................................................................................18

5.1.3 Main/Alarm Screen ................................................................................................................18 5.1.4 LED Indicators .......................................................................................................................19

5.2 Hierarchy of PRO-201 Screens.......................................................................................................20

6. Getting Started .......................................................................................................................................21 6.1 Viewing, Acknowledging, and Resetting Alarms .............................................................................21 6.2 Configuring The PRO-201 For Your Application .............................................................................22

6.2.1 Setting Product Weights ........................................................................................................22 6.2.2 Adjusting the Display Units ....................................................................................................24

TABLE OF CONTENTS

ii PRO-201 PROFESSOR SERIES CONTROLLER – OPERATION /MAINTENANCE/INSTALLATION MANUAL

6.2.3 Changing The Alarm Set Points ............................................................................................ 25

7. Changing The PRO-201 Panel Modes ................................................................................................. 27 7.1 Service Mode .................................................................................................................................. 28 7.2 Ready Mode.................................................................................................................................... 29 7.3 Purge Mode..................................................................................................................................... 29 7.4 Manual Mode .................................................................................................................................. 30 7.5 Offline Mode.................................................................................................................................... 32

8. Advanced Setup..................................................................................................................................... 33 8.1 Setting up your PRO-201 for Switchover or Non-Switchover Service............................................ 33 8.2 Setting up your PRO-201 for ESO Valves ...................................................................................... 34 8.3 Enabling Analog Signals ................................................................................................................. 35 8.4 Adjusting Analog Ranges................................................................................................................ 36

9. Viewing Administrative Information .................................................................................................... 37 9.1 Viewing the Siemens PLC Model and Version ............................................................................... 37 9.2 Cleaning the Keypad....................................................................................................................... 37 9.3 Viewing Software Version ............................................................................................................... 37

10. Troubleshooting .................................................................................................................................. 40 10.1 Alarm Messages ........................................................................................................................... 40

11. Limited Warranty & Service Policy .................................................................................................... 42 Limited Warranty: Hardware & Software .............................................................................................. 42 In-Warranty Repairs .............................................................................................................................. 42 Out-of-Warranty Repairs....................................................................................................................... 42 Shipments to Factory ............................................................................................................................ 42

Glossary ..................................................................................................................................................... 44

Acronyms ................................................................................................................................................... 46

Electrical Schematics................................................................................................................................ 49

FIGURES

Figure 1. PRO-201 Controller……………………………………………………………...........…….....4 Figure 2. PRO-201 Controller HMI……………………………………...………………………….…….....7 Figure 3. ON/OFF Circuit Breaker Switch on PRO-201 Controller………………………..…….....13 Figure 4. Main Screen of PRO-201 Controller....………………………………………………….....19 Figure 5. Alarm Screen of PRO-201 Controller…………………………………………………….....19 Figure 6. PRO-201 Screen Flow Chart…………………………………………………………………...20 Figure 7. Recommended Method for Clearing Alarms in the PRO-201 Controller……….….....22 Figure 8. Product Weight Screen…………………………………………………………………………..23 Figure 9. Cylinder Tare Screen………………………………………………………………………….....24 Figure 10. Unit Selection Screen………………………….………………………………………………….....25 Figure 11. LOW LOW Alarm Screen………………………………………………………………………….....26

TABLE OF CONTENTS

PRO-201 PROFESSOR SERIES CONTROLLER – OPERATION /MAINTENANCE/INSTALLATION MANUAL iii

Figure 12. Panel Mode Screen…………………………………………………………………………………27 Figure 13. Manual Mode Screen……………………………………………….……………………………...31 Figure 14. Manual Mode Valve Open/Close Screen…………………….………………………………….31 Figure 15. Switchover/Non-Switchover Configuration Screen……………………..……………………..33 Figure 16. ESO Enable Screen……………………………………………………..………………………....34 Figure 17. Analog Enable Screen……………………………………………………………………………...35 Figure 18. Analog Range Adjustment Screen……………………………………………………………....36 Figure 19. System Version Screen………………………………………………………………………….....38

TABLES

Table 1. PRO-201 Digital I/O Assignments………………………………………………...........…….....8 Table 2. PRO-201 Solenoid Valve Assignments…………………...………………………….…….....15 Table 3. Typical Alarm Conditions after Turning Controller ON…………………………..……....21 Table 4. LOW and LOW LOW Alarm Conditions....………………………………………………..25 Table 5. Summary of Alarms and Alarm Actions Based on Panel Modes……………….....28 Table 6. Alarm Messages & Operator Actions……………………………………………………...40

PRO-201 PROFESSOR SERIES CONTROLLER – OPERATION /MAINTENANCE/INSTALLATION MANUAL 4

1. PRODUCT DESCRIPTION The PRO-201 Professor Series Controller continuously monitors compressed and liquefied gas manifold operation, automatically shutting off gas flow and alerting the user when operating limits are exceeded. By eliminating the need for constant user attention, the PRO-201 Controller enables safer and more efficient delivery of compressed and liquefied gases. The PRO-201 Controller operates semi-automated Gas Source Manifolds (GSM) by monitoring up to 16 analog and digital inputs and controlling up to ten digital outputs.

The PRO-201 Controller can be purchased with new Centurion™ GSMs or purchased as a field upgrade unit for AT+, Vector, and Centurion™ systems using GSM-1A, GSM-4A, CS-350A, or AS-200 controllers. One PRO-201 Controller can replace up to two GSM-1/4A, two CS-350, and one AS-200 controllers.

Figure 1. PRO-201 Controller

1.1 PRO-201 FUNCTIONALITY

The PRO-201 Controller is designed for use with single or dual manifolds, and can monitor enclosure exhaust pressure, process gas cylinder pressure and/or weight, excess flow, high delivery pressure, and controller pneumatic supply pressure. There are dedicated facility terminal blocks within the enclosure for gas detection, fire detection, remote shutdown A/B, and EMO shutdown. Additionally, relay outputs are available for monitoring the status of the controller (Service/Warning/Alarm).

PRODUCT DESCRIPTION


The PRO-201 Controller can be configured to monitor up to two analog inputs: low cylinder pressure (LCP) or low cylinder weight. Users have the ability to configure alarm points, alarm time delays, display units, ranges, and offsets for each analog signal. Real time analog values are displayed on the MAIN/ALARM screen of the PRO-201 Controller.

The PRO-201 Controller can be configured by the user for switchover or non-switchover service. Switchover service facilitates continuous process gas delivery. Non-switchover service permits the use of two different process gases with a common PRO-201 Controller.

Users have the ability to reconfigure their PRO-201 Controller on the fly, without software upgrades. In a matter of minutes the PRO-201 Controller can be reconfigured if a process changes, a GSM is upgraded, or even if the process gas changes (i.e. compressed to liquefied gas).

1.2 PRO-201 FEATURES

The PRO-201 Controller is the nerve center for all manifold operations, both automatic and manual. The PRO-201 Controller provides the following functionality:

● Automatically monitors all manifold assembly sensors and switch states.

● Automatically or manually controls all pneumatically actuated valve state changes.

● Generates alarms to alert users of error conditions or faults.

● Manages either one or two process gas source manifolds.

● Manages process gas source automatic switchover equipment on dual source cabinets.

● Manages up to 14 digital inputs, ten digital outputs, and two analog input signals.

● Includes a circuit breaker ON/OFF switch with LOTO capability that shuts down the system and simultaneously closes all pneumatically actuated valves.

● Continuously updates analog input values as well as alarm status on the MAIN/ALARM screen.

● Can be reconfigured on the fly without software upgrades.

● Allows users to adjust alarm set points, alarm delay times, analog offset values, ranges, and units.


2. ENGINEERING DATA

2.1 UTILITIES REQUIRED Electric Power

Line voltage: 120-240 VAC, single phase

Voltage range: 85-264 VAC

Frequency: 50-60 Hz (47-63 Hz)

Full load current: 0.50 A @ 120 VAC; 0.25 A @ 240 VAC

Circuit breaker thermal overload protection: 1.5 A

Facility connection: ½” conduit hub to terminal block within the enclosure

Pneumatic Supply Gas Gas: Clean dry air or nitrogen

Purity: Filtered to 10µ or less

Pressure: 80 psig +/- 5 psig, regulated

Facility connection: Quick disconnect for ¼” OD by 1/8” ID polyurethane tubing

2.2 ANALOG INPUTS

The PRO-201 Controller can be configured for up to two analog inputs. The PRO-201 is able to monitor LCP transducers, cylinder scales, or a combination of the two. Analog input requirements are as follows:

• Excitation Voltage: 24 VDC

• Analog Output: 0-5 VDC

2.3 DIGITAL INPUTS

Any digital sensor with either a suitable dry-contact output or sinking transistor output can be interfaced with the PRO-201 Controller.

● Dry-contact output sensor requirements:

Logic, high: closed contact

Logic, low: open contact

Typical on (high) current: 10 mA DC

● Transistor output sensor requirements:

Logic voltage, high: 24 VDC

Logic voltage, low: 0 VDC

Excitation voltage: 24 VDC

Open-circuit supply voltage: 24 VDC, maximum

ENGINEERING DATA


● Sinking transistor output sensor requirements:

Logic, high: 3 VDC, 10 mA

Logic, low: 12V DC

Excitation: 24V DC, 20 mA

2.4 RELAY OUTPUTS

The PRO-201 Controller is equipped with four terminal block relays for facility monitoring of the controller status.

● Relay Type: SPDT

● Connection: Screw terminals within enclosure

● Relay Outputs: Alarm A (CR-1), Service A (CR-2), Warning A (CR-1 & CR-2), Alarm B (CR-3), Service B (CR-4), Warning B (CR-3 & CR-4)

2.5 SOLENOID VALVES Solenoid valves control the flow of actuation gas to individual pneumatically actuated valves.

● Voltage: 24 VDC nominal ±10%

● Power: 0.55 W

● Cv: 0.008

2.6 HUMAN MACHINE INTERFACE (HMI)

Operators interface with the PRO-201 via a Siemens’ TD-200 HMI. The Siemens TD-200 text and push button display allows users to change valve states, view active alarms, configure alarm set points, and change the operational mode of the controller.

Figure 2. PRO-201 Controller HMI

ENGINEERING DATA

8 PRO-201 PROFESSOR SERIES CONTROLLER – OPERATION /MAINTENANCE/INSTALLATION MANUAL

The TD-200 HMI is equipped with a backlit liquid crystal (LC) display with user adjustable contrast.

See Siemens’ Text Display (TD) System Manual A5E00765548-02 for additional information on operation and maintenance procedures for the TD-200.

2.7 SIEMENS S7-224XP PLC

The PRO-201 Controller utilizes a Siemens S7-224XP Programmable Logic Controller (PLC). The S7-224XP controller has the following features:

● Memory: 10 KB (Data); 16 KB (Program)

● Digital inputs on base PLC: 14 inputs; 24 VDC

● Digital outputs on base PLC: 10 outputs; 24 VDC

● Analog inputs on base PLC: 2 inputs; 0-5 VDC

The assignment of the PLC I/O is outlined in Table 1 below:

Table 1. PRO-201 Digital I/O Assignments

Byte.bit 14 Digital Inputs 10 Digital Outputs

0.0 Remote EMO Horn 0.1 Low Pneumatic Pressure Switch Alarm A LED 0.2 Exhaust ∆P Switch 1 Service A LED

0.21 Exhaust ∆P Switch 2 N/A 0.3 SPARE ESO A Solenoid Valve 0.4 Remote Shutdown A ASO A Solenoid Valve 0.5 Gas Detector Alarm B LED 0.6 EFS A Service B LED 0.7 HDP Switch A ESO B Solenoid Valve 1.0 LCP Switch A ASO B Solenoid Valve 1.1 Remote Shutdown B SPARE 1.2 Fire Detector N/A 1.3 EFS B N/A 1.4 HDP Switch B N/A 1.5 LCP Switch B N/A

Note: The PRO-201 Controller is capable of monitoring all the digital I/O listed in Table 1. Facility and GSM requirements at the time of order will dictate whether the I/O is enabled.

2.8 CONTROLLER ENCLOSURE The PRO-201 is constructed of rugged 0.090” thick aluminum with a light grey, corrosion-resistant powder coat finish.

● Dimensions: 9. 5” (W) x 9.25” (T) x 12” (D)

● Front display viewing angle: 70°

● Pneumatic connectors: 1-touch fittings for 1/8” OD tubing

ENGINEERING DATA


● Electrical connectors: 5 position M12 straight plugs

● Mounting hardware: Quantity four ¼”-20 screws

● ON/OFF switch: ON/OFF circuit breaker switch with LOTO capability

● AUX I/O and electrical power bulkhead: ½” conduit hub

● Pneumatic gas supply: Quick disconnect for ¼” OD by 1/8” ID polyurethane tubing

2.9 ENVIRONMENTAL CONSIDERATIONS The PRO-201 is rated for indoor use only. The PRO-201 should never be used in an outdoor environment. The PRO-201 is rated for the following climate conditions:

● Operational Temperature:

● Storage Temperature:

● Humidity Specification:

● Elevation Specification: Altitudes <1,000 m above sea level

2.10 TYPICAL MOUNTING INSTRUCTIONS The PRO-201 is rated for indoor use only. The PRO-201 should never be used in an outdoor environment. The PRO-201 is rated for the following climate conditions:

● Operational Temperature:

● Storage Temperature:

● Humidity Specification:

● Elevation Specification: Altitudes <1,000 m above sea level

2.11 CERTIFICATIONS The PRO 201 controller has the following certifications:

● EN60204-1

● CE

● S2-0706

● S8-0307


3. SAFETY

3.1 SAFETY PRECAUTIONS

Use the following safety precautions when installing, operating, or performing maintenance on the PRO-201 Controller.

CAUTION IMPROPER LIFTING OF HEAVY EQUIPMENT

CAN CAUSE SERIOUS INJURY AND DAMAGE EQUIPMENT

Only workers who have been trained in NIOSH-approved lifting techniques should be assigned to heavy equipment moving, installation, or removal efforts. Avoid personal injury and damage to equipment — use approved lifting techniques only.

CAUTION FAILURE TO OBSERVE SAFETY PRECAUTIONS CAN

RESULT IN SERIOUS INJURY

Never attempt to circumvent compressed gas equipment safety precautions. Compressed gases and associated equipment are potentially dangerous; they must be used only by persons that have been formally trained. Only by strictly adhering to all safety precautions can risk of personal injury or damage to equipment be avoided. Follow all safety precautions to the letter.

WARNING DANGER OF ELECTRIC SHOCK

Dangerous voltages exist on the PLC CPU, I/O modules, terminal block, and other components inside the controller enclosure. Accidental contact with controller internal electrical circuitry can result in severe injury, death, or damage to equipment.

Interrupt electrical power to the controller before attempting maintenance on controller internal electrical circuitry or components.

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SAFETY


General Precautions ● This manual cannot replace formalized training in compressed gas equipment safety practices;

accordingly, this section is intended only as a reminder for properly trained personnel that already understand and adhere to accepted safety practices.

● Only trained personnel should install, operate, and maintain gas control equipment.

● Follow all installation, operation, and maintenance instructions to the letter. Always replace all components, fasteners, labels, and other items exactly as originally installed; do not adjust, modify, install, or remove anything without authorization.

● Failure to follow recommended procedures may result in serious personal injury or death and equipment failure or contamination.

● Material Safety Data Sheets (MSDS) for all gases used in the facility should be available for consultation by all concerned personnel. These data sheets are obtainable from gas suppliers.

● Personnel working with hazardous gases or contaminated components must be provided with suitable protective gear.

● If fire, release of hazardous gases, or another potentially dangerous situation arises, latch the Local Shutdown switch if possible, then evacuate all personnel from the facility.

Operation Precautions ● Equipment not in proper operating condition should be shutdown immediately. Do not attempt to use

equipment that is not operating properly.

● Never attempt to defeat interlocks or other safety devices.

● Manual valve operation may override safety interlocks that would normally protect equipment and personnel during automatic valve operation. Be especially attentive when valves are operated manually (i.e., in manual valve operation mode).

● To avoid injury and discourage tampering, the manifold assembly door should remain closed and secured during typical operation. The door should be opened only when visually checking manifold assembly operation or making adjustments. If the facility exhaust equipment is not functioning, do not open the manifold assembly enclosure door.

Installation / Maintenance Precautions ● Disconnect electrical power prior to disassembly or replacement of electrical components and prior to

connecting or disconnecting wiring, including sensor output leads.

● Make sure the manifold assembly enclosure exhaust is functioning properly before starting a maintenance procedure. Accidental process gas release is more likely to occur during maintenance than during typical day-to-day operations.

● Whenever feasible, close the process gas delivery line isolation valve (PLI) before starting a maintenance procedure. If this practice is followed and an accidental gas release occurs, it will involve only a small volume of gas. Although this practice is strictly required for manifold assembly maintenance only, its general adoption is not without merit.

● Equipment used with hazardous gases must be thoroughly purged prior to disassembly.

● Vent all equipment prior to disassembly.

● Unexpected jet noise accompanying the release of a high-pressure gas can frighten workers and cause an accident.

● Even though equipment may have been properly purged, trace amounts of hazardous gases may remain. For this reason, components and piping that have been exposed to hazardous gases

SAFETY


should be carefully labeled with the names of the gases and either properly stored or discarded in accordance with pertinent safety ordinances and regulations.

● Mechanical or electrical maintenance should follow pertinent lockout/tagout procedures described in OSHA document 29 CFR 1910.147 (Control of Hazardous Energies, Lockout /Tagout) and 29 CFR 1910.331-335 (Electrical Safety-Related Work Practices, Chapter XVII, 7–1–92 Edition).

3.2 PERSONNEL TRAINING

Equipment should be operated only by personnel trained in the principles of gas control equipment operation. Equipment should be installed or repaired only by personnel who, in addition to the above training, are trained and experienced in electromechanical installation and repair techniques. Untrained personnel should not be entrusted with these responsibilities; they could injure themselves or co-workers and damage equipment, resulting in unexpected downtime and expense.

Before starting a job, all personnel responsible for equipment installation or operation must fully understand the specific procedures to be accomplished and all pertinent safety considerations. Because optional or non-standard components often exist, installation, operation, and maintenance details may differ substantially from the necessarily generic instructions provided in this manual.

If facility personnel are not confident in their abilities to install or operate the equipment, Matheson Tri-Gas Field Service should be contacted for assistance. Matheson specialists are available on request to assist equipment owners and provide authoritative training in all aspects of equipment installation, operation, and maintenance.


4. INSTALLATION NOTE: Refer to Chapter 3, Safety Precautions before performing any installation procedures.

4.1 EQUIPMENT UNPACKING & INSURANCE CLAIMS

If installation has been contracted with Matheson Tri-Gas, please do not unpack any equipment, as our field service engineers prefer to open the boxes themselves. However, you should carefully inspect the exteriors of all packages on arrival, as described below.

Because all shipments are FOB from the Matheson Tri-Gas factory, the title to purchased goods passes to the customer upon pickup by the carrier. Therefore, damage to the equipment sustained during transit is the responsibility of the carrier, with whom insurance claims for damage should be filed. Please inspect all shipping cartons immediately upon receipt. Should damage or stains be observed, immediately notify the carrier and request that an insurance claims agent be present when the carton is opened. Should any damage be discovered, retain the carton, contents, and all packing materials for inspection by the insurance claims agent.

4.2 UTILITIES

1. Connect ½” electrical conduit to the two ½” threaded conduit connectors on the rear of the controller enclosure.

2. Pull the electrical power supply conductors into the conduit. (line (L1): brown, neutral (L2/N): blue, ground: green/yellow). Connect L1 and L2/N lines to the circuit breaker ON/OFF switch utilizing 0.25” straight receptacles (MTG P/N S601-1048). Attach the ground wire to the green and yellow terminal block labeled ground ( ).

Figure 3. ON/OFF Circuit Breaker Switch on PRO-201 Controller

Note: The PRO-201 Controller is equipped with a 1.5A thermal overload circuit breaker switch. Fuses are not required with the PRO-201.

Facility Power Connection – L1

(Brown)

Facility Power Connection – L2/N

(Blue)

INSTALLATION


Note: The power supply in the PRO-201 Controller is auto ranging. No adjustments on the power supply are required for 120-240 VAC input.

Note: The customer’s power supply must have a branch circuit protection rated at a minimum of 10,000 AIC.

3. Using ¼” polyurethane tubing and the pneumatic actuation gas ¼” male inlet connector provided (MTG P/N S404-0101), connect a source of clean, dry, pressure-regulated nitrogen or air to the mating female pneumatic actuation gas inlet connector on the rear surface of the controller enclosure.

4.3 ACCESSORY MONITORS & CONTROLS

1. If required, connect exhaust probe tubing to the rear of the PRO-201 Controller. The PRO-201 Controller contains a differential pressure switch for facility exhaust monitoring.

Install the exhaust probe into the exhaust duct, and connect it to a hose barb fitting in EXH 1 using the provided ¼” polyurethane tubing. Do not connect anything to the atmospheric reference port (ATM REF). For dual exhaust systems, use EXH 2 for the second exhaust monitor probe.

2. Install hazardous-gas detection equipment as mandated by pertinent safety ordinances and regulations. Locate the GAS DET. terminal block and remove the jumper labeled “GAS DET.”. Connect the gas detection sensor to the +24V-5 terminal and the terminal labeled GAS DET. A normally closed contact (safe condition) is required.

3. For flammable process gases, install a fire sensor within the manifold enclosure. Locate the FIRE DET. terminal block and remove the jumper labeled “FIRE DET.”. Connect the fire sensor to the +24V-4 terminal and the terminal labeled FIRE DET. A normally closed contact (safe condition) is required.

4. The PRO-201 Controller can be wired for remote EMO shutdown. Locate the EMO terminal block and remove the jumper labeled “EMO.”. Connect a facility supplied relay to the +24V-1 terminal and the terminal labeled EMO. A normally closed contact (safe condition) is required.

5. The PRO-201 Controller can be wired for remote shutdown of the A side manifold. Locate the REM SD-A terminal block and remove the jumper labeled “REM. SD A.”. Connect a facility supplied relay to the +24V-2 terminal and the terminal labeled REM SD-A. A normally closed contact (safe condition) is required. The same procedure outlined above is followed if the REM SD-B feature is utilized.

6. The PRO-201 Controller can be wired for remote shutdown of the B side manifold. Locate the REM SD-B terminal block and remove the jumper labeled “REM. SD B.”. Connect a facility supplied relay to the +24V-3 terminal and the terminal labeled REM SD-B. A normally closed contact (safe condition) is required.

4.4 NETWORK COMMUNICATION CONNECTIONS (OPTIONAL)

Via an Ethernet network, the PRO-201 Controller can communicate with a host computer. With the optional Ethernet module, users can monitor analog output values and the system status (Alarm/Warning/Service).

INSTALLATION


Note: The facility IP address is required at the time of order. The IP address must be loaded into the PLC software prior to shipment.

4.5 PNEUMATIC MANIFOLD OUTPUTS

The PRO-201 is capable of controlling up to four solenoid valves. The solenoids are dedicated to ESO A, ASO A, ESO B, and ASO B pneumatic valves on the GSM. Table 2 shows the valve assignments on the solenoid valve manifold as well as the typical tubing color used for each pneumatic valve on the GSM.

Table 2. PRO-201 Solenoid Valve Assignments

Left Side Group (Manifold A) Right Side Group (Manifold B)

Port No. Color Valve Port No. Color Valve

1 Blue ESO 3 Blue ESO

2 Green ASO 4 Green ASO

Note: All the solenoid valves listed in Table 2 may not be present depending on the configuration of the GSM.

The PRO-201 Controller is equipped with a dedicated pneumatic supply for the VGS valve. The VGS pneumatic connection is clearly labeled on the bottom of the controller. If a manual VGS valve is present on the system, this bulkhead must be plugged (MTG P/N MPLU-0088-BO).

Note: The pneumatic supply line for the PRO-201 Controller supplies the solenoid manifold and the VGS valve. There is no shutoff valve inside the controller for the VGS supply. Do not turn on the pneumatic supply to the controller until the VGS pneumatic bulkhead has been plugged or is connected to the VGS valve. Otherwise, pneumatic supply gas will flow freely out of the controller.

4.6 POST-INSTALLATION START UP

WARNING TEST ALL EQUIPMENT BEFORE PLACING IN SERVICE

Operating this equipment without prior testing, modifying this equipment, or circumventing operating procedures recommended in this manual can result in injury or equipment damage.

Under no circumstances should this equipment be used for controlling a hazardous gas until suitability for service has been demonstrated. Matheson Tri-Gas assumes no liability for damages resulting from equipment operation. The user is ultimately responsible for equipment integrity and safety.

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INSTALLATION


Follow all installation and operation instructions to the letter. If questions arise, call a supervisor or contact the Matheson Tri-Gas Technical Service Department for advice.

After installing all equipment and prior to start up:

1. Turn on electrical power.

2. Calibrate all sensors (if applicable).

3. Test all energized circuits.

4. For each manifold:

Verify that all optional digital inputs are set as described in Table 1.

Verify that all optional digital outputs are set as described in Table 1.

Verify that all optional analog inputs are set as described in Section 4.5.2.

Verify that all alarm set points are correctly set as described in Table 6 (see 6.4 Setting Alarm Limits).

For network installations, provide each connected device with a unique network address.

4.8 POST-INSTALLATION TESTS 1. Verify that all alarm circuits function properly.

2. When indicated, test and verify enclosure exhaust pressures and volumetric flow rates.

3. Verify that all manifold assembly enclosure exhaust destination and duct construction materials are suitable for the intended process gas.

4. Verify that the manifold assembly enclosure exhaust pressure switch functions properly.

5. Verify that the ON/OFF switch functions properly.


5. GENERAL OPERATION NOTE: Refer to Chapter 3, Safety Precautions before operating the system.

IMMEDIATE ACTION FOR POTENTIALLY DANGEROUS SITUATIONS

If fire, release of hazardous gases, or another potentially dangerous situation occurs:

1. Press the front-panel red OFF button.

2. Immediately evacuate all personnel to a safe location.

DANGER OPERATING THROUGH AN OPEN ENCLOSURE DOOR

MAY INCREASE EXPOSURE TO HAZARDOUS GAS

If equipment fails when a hazardous process gas is used, the gas could be released inside the enclosure. When the enclosure door is open, exhaust performance is impaired, and personnel are at risk for exposure to this gas. For this reason, opening or closing valves and other manual operations on an operational manifold should be performed through the opened enclosure window only, and with the door closed. The enclosure door should be opened only when you cannot perform an operation through the window. Do not block closure of the door or window; when finished, allow it to close in the normal manner.

5.1 USER INTERFACE

All indicators and controls are on the front panel of the PRO-201 Controller. They provide manifold and controller status information and enable user interaction with the system. They include the Service and Alarm LED indicators, the main ON/OFF switch, and the TD-200 HMI.

5.1.1 SHUTDOWN SWITCHES

The ON/OFF switch mounted on the front face of the PRO-201 is a circuit breaker switch and a master ON/OFF switch. When the OFF button is actuated, the PRO-201 turns off and all solenoid valves return to their normally closed state.

The PRO-201 controller returns to the MAIN/ALARM screen when the ON button is activated. To return to gas delivery service, all active alarms must first be cleared. Section X.x outlines the

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GENERAL OPERATION


procedure for returning to gas delivery service after a complete system shutdown of the PRO-201 Controller.

5.1.2 HMI OPERATIONAL BASICS

The TD-200 HMI is the user’s primary interface the PRO-201 Controller. A two line text display and function keys help the user navigate through the screens.

As shown in Figure 2, the TD-200 is equipped with four function keys (F1-F8), one SHIFT key, one ENTER key, one ESC key, and ▲▼ keys.

Function Keys:

Function keys are used for a variety of tasks with the PRO-201 controller. For example, function keys are used to confirm alarms, change pneumatic valve states, and enable operational modes.

Shift Key:

In order to access function keys F5-F8, the SHIFT key must first be enabled. The SHIFT key does not have to be held down to enable it. Simply press the SHIFT key once. Users will be alerted the SHIFT key has been enabled by a flashing “s” in the lower right corner of the display.

When a carrot (^) symbol appears on the TD-200 display screen, the user must press the SHIFT key before pressing a function key.

ESC Key:

The ESC key is used to move to the previous screen or to call up the options menu from the MAIN/ALARM screen. See Figure X for a list of the PRO-201 screens.

In most cases, pressing the ESC key three times will bring the user back to the MAIN/ALARM screen.

Note: Pressing the ESC key twice brings the user to a Siemens’ Operator and Diagnostic menu. This is a default screen for the TD-200. There is no need during normal operation for the user to access this screen.

ENTER Key:

The ENTER key is used to confirm values that the user has input into the PRO-201 Controller.

▲▼ Keys:

The ▲▼ keys are used to toggle up and down within menus. The ▲▼ keys are also used to change numeric values within the PRO-201 software such as analog input ranges, offset values, and alarm set points.

5.1.3 MAIN/ALARM SCREEN The MAIN/ALARM screen is shown in Figure 4. During gas delivery service, users should make it a habit to display the MAIN/ALARM screen. This screen contains the most relevant information during gas delivery service:

● Operational mode of each manifold (SHUTDOWN, OFFLINE, PURGE, READY, SERVICE, or MANUAL).

● Cylinder content (pressure or weight) if analog sensors are used.

● Active alarms (press ▼ to view alarm screen).

GENERAL OPERATION


Figure 4. MAIN Screen of PRO-201 Controller

Figure 5 displays the active alarms screen. Line one of the ALARM screen displays the alarm name, or if no alarms are present, “NO ALARMS”. Line two of the ALARM screen displays four command options: acknowledge (ACK), reset (RST), UP, and DWN. The ACK (F1) key is used to silence the audible alarm. The RST (F2) key is used to reset the alarm once the alarm condition has been cleared. The UP (F3) and DWN (F4) keys are used to toggle through the active alarm listing.

Figure 5. ALARM Screen of PRO-201 Controller

Note: In most cases, pressing the ESC key three times will take the user back to the MAIN/ALARM screen.

5.1.4 LED INDICATORS

Red and green LED indicators for each manifold are located on the front panel of the PRO-201 Controller. These indicators reflect the current status of the left and right manifolds.

● Red LED Indicator: A shutdown alarm has been triggered. The red LED will extinguish when the alarm condition has been reset.

● Green LED Indicator: The GSM is in operation, flowing gas to an application.

● Red and Green LED Indicators: A warning alarm has been triggered.

● LED Indicator Not Lit: The GSM is not in Service mode. The GSM could be in Offline, Purge, Ready, or Manual modes.

GENERAL OPERATION


5.2 HIERARCHY OF PRO-201 SCREENS

Figure 6 outlines the hierarchy of the PRO-201 screens. To return to any main screen (mint color box), press the ESC key once.

Figure 6. PRO-201 Screen Flow Chart


6. GETTING STARTED The PRO-201 controller will default to the MAIN/ALARM screen whenever the unit is turned ON. Table 3 outlines the alarm conditions the user will encounter, as well as the recommended user action, after energizing the controller.

Table 3. Typical Alarm Conditions after Turning Controller ON

Component State Recommended User Action

Horn High Frequency Chirp In the ALARM screen, press ACK (F1)

LEDs ALARM A/B Illuminated All active alarms must be reset (RST) to disable the ALARM LEDs

System Status A: Shutdown

B: Shutdown

All active alarms must be reset (RST) before the panel mode can be changed

Solenoid Valve State Closed Valves will remain closed until Purge, Ready, Service, or Manual modes are

activated

Active Alarm(s) System EMO Triggered (others may be present) All active alarm(s) must be reset (RST)

6.1 VIEWING, ACKNOWLEDGING, AND RESETTING ALARMS

The user must go to the MAIN/ALARM screen to view active alarms. The alarm screen does not automatically display during an alarm condition. Reference Figure 4 for a screen shot of the MAIN/ALARM screen.

Follow the below procedure to view active alarms:

• In the MAIN/ALARM screen, toggle down (▼) once.

• Page through all of the active alarms by pressing the F4 key.

• When finished viewing the active alarms, press the down (▼) key to return to the MAIN/ALARM screen.

Figure 7 outlines the recommended procedure for clearing alarms. The procedure outlined assumes that the physical alarm has been corrected on the GSM or cylinder cabinet.

GETTING STARTED


Figure 7. Recommended Method for Clearing Alarms in the PRO-201 Controller

Note: The active alarms in the ALARM screen will not refresh until they have all been paged through.

6.2 CONFIGURING THE PRO-201 FOR YOUR APPLICATION

If the PRO-201 Controller is configured for analog signals, the user can adjust the product weight, display units, and alarm set points. The analog signal ranges and offsets will be configured from the factory. This section is not applicable if the GSM is equipped with switches only.

6.2.1 SETTING PRODUCT WEIGHTS

When the PRO-201 is configured for cylinder scales, it will be necessary for the user to set the product weight prior to gas service. The product weight can be entered in two ways: directly inputting the product weight or setting the cylinder tare weight. Figure 8 is a screen shot of the PRODUCT WEIGHTS screen and Figure 9 is a screen shot of the cylinder tare screen.

Setting Product Weights Using the Product Weights Function:

• Place the cylinder on the cylinder scale.

• In the MAIN/ALARM screen, press the ESC key and toggle down (▼) until PRODUCT WEIGHTS is highlighted. Press the ENTER key.

• Press the ENTER key. A cursor on the product weight will begin to flash.

• Use the ▲▼ keys to adjust the value to the product weight included with the gas cylinder. When the correct value is reached, press the ENTER key.

Note: For quicker entry of the cylinder tare weight, press and hold down the ▲▼ key.

GETTING STARTED


• If required, adjust the PANEL B PRODUCT WEIGHT following the procedure outlined above.

• When finished, press the ESC key three times to return to the MAIN/ALARM screen.

The PRO-201 comes preset from the factory to read in units of lbs. To adjust the display units, see Section 6.2.2.

Figure 8. Product Weight Screen

Setting Product Weights Using the Cylinder Tare Function:

• Place the cylinder on the cylinder scale.

• In the MAIN/ALARM screen, press the ESC key and toggle down (▼) until ANALOG CONFIG is highlighted. Press the ENTER key.

• Toggle down (▼) until the PANEL A/B TARE screen is displayed.

• Press the ENTER key. A cursor on the PANEL A TARE will begin to flash.

• Use the ▲▼ keys to adjust the value to the cylinder tare weight. When the correct value is reached, press the ENTER key.

Note: For quicker entry of the tare weight, press and hold down the ▲▼ key.

• If required, adjust the PANEL B TARE following the procedure outlined above.


The units will not display in the panel tare screen. The PRO-201 comes preset from the factory to read in units of lbs. To adjust the displayed units, see Section 6.2.2.

GETTING STARTED


Figure 9. Cylinder Tare Screen

6.2.2 ADJUSTING THE DISPLAY UNITS

The PRO-201 Controller is able to display the following units for weight and pressure: lbs or kgs and psi or MPa. The PRO-201 is capable of displaying any combination of these units. Reference Figure 10 for a screen shot of the unit selection screen.

Note: The user only needs to adjust the display units if analog sensors are being used. No units will display if only switches are used.

Follow the below procedure to change the display units on the PRO-201 Controller:


• Toggle down (▼) until the Panel A Units screen is displayed.

• Press the SHIFT key. Press the F5 key for “lbs”, the F6 key for “kgs”, the F7 key for “psi”, or the F8 key for “MPa”.

• To change the Panel B Units, press the ▼ key. Adjust the Panel B Units following the above procedure.

• Press the ESC key three times to return to the MAIN/ALARM screen.

Note: When a carrot (^) symbol appears on the TD-200 display screen, the user must enable the SHIFT key before enabling a function key.

GETTING STARTED


Figure 10. Unit Selection Screen

6.2.3 CHANGING THE ALARM SET POINTS

Users are able to adjust LOW and LOW LOW alarm set points with the PRO-201 Controller. Table 4 shows LOW and LOW LOW alarm conditions depending on the configuration and the operational mode of the GSM. Reference Figure 11 for a screen shot of the LOW LOW alarm set point screen.

Note: The user only needs to adjust the LOW and LOW LOW alarm set points if analog sensors are being used. Adjusting the alarm set points is not necessary if only switches are used.

Table 4. LOW and LOW LOW Alarm Conditions

PANEL MODE LOW ALARM LOW LOW ALARM

SERVICE Switchover Occurs

Warning Alarm Manifold Shutdown

READY Alarm Ignored Manifold Shutdown

PURGE Alarm Ignored Alarm Ignored

Switc

hove

r Ser

vice

MANUAL Alarm Ignored Alarm Ignored

SERVICE Warning Alarm Manifold Shutdown

READY Mode Not Configurable

PURGE Alarm Ignored Alarm Ignored

Non

-Sw

itcho

ver

Serv

ice

MANUAL Alarm Ignored Alarm Ignored

GETTING STARTED


The LOW and LOW LOW alarms are ignored in Purge and Manual modes so unnecessary alarms do not occur during cylinder changes or other purge routines. It should also be noted that the LOW alarm is ignored in Ready mode.

Follow the below procedure to change the alarm set points in the PRO-201 Controller:

• In the MAIN/ALARM screen, press the ESC key and toggle down (▼) until ALARM SET POINTS is highlighted. Press the ENTER key.

• Press the ENTER key. A cursor on the PNL-A LOW line will begin to flash over the LOW set point value.

• Use the ▲▼ keys to adjust the LOW set point to the desired value. When the correct value is reached, press the ENTER key.

Note: For quicker entry of the LOW alarm set point, press and hold down the ▲▼ key.

• If required, adjust the PNL-B LOW value following the procedure outlined above.

• To change the LOW LOW alarm set points, press the ▼ key.

• Press the ENTER key. A cursor on the PNL-A LOW-LOW line will begin to flash over the LOW-LOW set point value.

• Use the ▲▼ keys to adjust the LOW-LOW set point to the desired value. When the correct value is reached, press the ENTER key.

• If required, adjust the PNL-B LOW-LOW value following the procedure outlined above.


Figure 11. LOW LOW Alarm Screen


7. CHANGING THE PRO-201 PANEL MODES The PRO-201 Controller can be configured for six modes: Shutdown, Offline, Purge, Ready, Service, or Manual mode. Reference Figure 12 for a screen shot of the panel mode screen. Below is a brief summary of each mode:

Shutdown – Shutdown mode indicates that an alarm has been activated. All valves close in this mode. In order to exit Shutdown mode, all alarms must be cleared.

Offline – In order to enter Purge, Ready, Service, or Manual modes, the manifold must first be in Offline mode. In Offline mode, alarms are active. If a manifold is not ready for service, it is appropriate to place it in Offline mode.

Purge – Purge mode is used when a manual purge is required. In Purge mode, LCP, HDP, EFS, LOW, and LOW-LOW alarms are ignored. This prevents nuisance alarms during purge routines. The system must be in Offline mode before Purge mode can be enabled. The PRO-201 Controller allows the user to purge one manifold while the other is in service.

Ready – Ready mode is only used with a switchover configuration. In non-switchover service, Ready mode is not configurable. Ready mode places one manifold in standby while the other manifold is in service. Once a low cylinder pressure alarm is activated, the Ready manifold enters Service mode. The system must be in Offline mode before Ready mode can be enabled.

Service – Service mode is used when a manifold is ready for gas delivery service. In this mode, the PRO-201 controls pneumatically actuated valve positions and alarms are fully enabled. The system must be in Offline mode before Service mode can be enabled.

Manual – Manual mode gives the user complete control of the GSM. In Manual mode, the user can defeat all safety interlocks and open any pneumatic valve on the GSM. In Manual mode, LCP, HDP, EFS, LOW, and LOW-LOW alarms are ignored. Only highly trained personal familiar with compressed gas delivery equipment should enter Manual mode. The PRO-201 Controller must be in Offline mode before Manual mode can be enabled.

Figure 12. Panel Mode Screen

A summary of alarm and warning conditions is shown in Table 5.

CHANGING THE PRO-201 PANEL MODES


Table 5. Summary of Alarms and Alarm Actions Based on Panel Modes

Alarm Action Alarm Device

Purge Service Ready Manual Offline Manifold Alarms (A/B)

Excess flowc EFS IGb SD SD IGb SDb High delivery pressure (HDP)a HDP SW IG SD SD IG SD Low cylinder pressure (LCP)a LCP SW IG SD SD IG IG

Low cylinder weight/pressurea LCP XDCRCYL Scale IG SWOd

WN IGd WN IG IG

Low Low cylinder weight/pressurea LCP XDCRCYL Scale IG SD SD IG IG

Controller Alarms Fire detector FIRE DET SD EMO shut down EMO SD Exhaust failurea,c DPS 1/2 SD Gas detection GAS DET SD

Low pneumatic pressurea N2 pres. switch WN

Remote SD A REM SD A SD Remote SD B REM SD B SD Key: SD = Shutdown; WN = Warning; SWO = Switchover; IG = Ignored

a Configurable set point. b Triggers a Shutdown on the other manifold in a switchover configuration (i.e. Excess

flow triggered on Manifold A causes Shutdown on Manifold B). c Configurable alarm delay time. d Alarm action in switchover mode.

7.1 SERVICE MODE

Service mode is used when an operator is ready for process gas delivery. Service mode should not be entered until all safety procedures prior to gas delivery have been completed.

Note: Service mode is not configurable until all active alarms are satisfied.

Follow the below procedure to enter Service mode with the PRO-201 Controller:

• In the MAIN/ALARM screen, press the ESC key and toggle down (▼) once so PANEL MODE is highlighted. Press the ENTER key.

• Place the manifold in Offline (OFF) mode by pressing the F1 key.

• Place the manifold in Service mode (SVC) by pressing the F4 key.

Note: Once Service mode is activated, pneumatic valves will open.




7.2 READY MODE

Ready mode is only used when a GSM is configured for switchover service. In non-switchover, Ready mode is not configurable. Ready mode should not be entered until all safety procedures prior to gas delivery have been completed.

Note: Ready mode is not configurable until all active alarms are satisfied.

Note: Ready mode is not configurable if one manifold is not in Service mode.

Note: If no global alarms are present and one manifold is in Offline, Purge, or Shutdown modes, enabling Ready mode will automatically place the manifold in Service mode.

Note: In a Service/Ready configuration mode, pressing Ready again on the standby manifold will automatically switchover to that manifold (manual switchover function).

Follow the below procedure to enter Ready mode with the PRO-201 Controller:



• Place the manifold in Ready mode (RDY) by pressing the F3 key.


7.3 PURGE MODE

Purge procedures exhaustively dilute contaminant gas in a manifold space with purge gas. Purging typically is required to remove hazardous production gas in a manifold prior to performing maintenance, and to remove atmospheric contaminants in a manifold prior to introducing process gas. Purging is accomplished by cycling through repeatedly pressurizing the manifold with purge gas, then evacuating the manifold to a vent system.

The PRO-201 controller requires a manual purge of the GSM. Refer to manual S052-0091 or S052-0106 for manual purge procedures for 5V and 3V manifolds.

Purge mode is used when manual purge sequences are required. In purge mode, LCP, HDP, EFS, LOW, and LOW-LOW alarms are ignored. This prevents nuisance alarms during purge routines.

Note: Purge mode is not configurable until all active alarms are satisfied.

Note: Purge/Purge mode is not configurable (i.e. both process manifolds can not be purged at the same time).

Follow the below procedure to enter Purge mode with the PRO-201 Controller:





• Place the manifold in Purge mode (PRG) by pressing the F2 key.


7.4 MANUAL MODE

Manual operation allows the user to override automatic operation of pneumatically actuated valves on the GSM in order to perform troubleshooting, testing, maintenance or other special tasks. Manual mode can only be entered when the system is in Offline mode. During Manual mode, LCP, HDP, EFS, LOW, and LOW-LOW alarms are ignored.

WARNING ONLY TRAINED PERSONNEL

CAN OPERATE THIS EQUIPMENT IN MANUAL MODE

Operation of this equipment in manual mode by untrained personnel is hazardous and can result in injury or equipment damage.

If you have questions about any aspect of operation of this equipment, consult a supervisor or a Matheson Tri-Gas field service technician.

Note: Manual mode is not configurable until all active alarms are satisfied.

Note: Manual mode can only be accessed by Offline manifolds.

Note: Both A and B manifolds can be placed in Manual mode at the same time.

Follow the below procedure to enter Manual mode with the PRO-201 Controller:



• Press the ESC key once to return to the main menu screen.

• Toggle down (▼) until MANUAL MODE is highlighted. Press the ENTER key. To enter Manual mode, the PRO-201 must display the screen shown in Figure 13.

!



Figure 13. Manual Mode Screen

• Press the SHIFT key, then the F6 key. The HMI displays that the panel is now in Manual mode.

• Toggle down (▼) until the A Side and B Side valve listing is displayed. Reference Figure 14 for a screen shot of this window.

Figure 14. Manual Mode Valve Open/Close Screen

• To open the A Side ESO valve press F1.

• To open the B Side ESO valve press F3.

• To open the A Side ASO valve press the SHIFT key then the F6 key.

• To open the B Side ASO valve press the SHIFT key then the F8 key.

• Close all pneumatic valves that are opened during Manual mode before exiting the screen shown in Figure 14.




Note: Manually opening an ASO valve in switchover service may severely contaminate the manifolds or the process gas lines. It is highly recommended that users do not enter Manual mode during process gas delivery with a switchover system.

Note: The PRO-201 Controller will stay in Manual mode until a global alarm is activated or the user removes the manifold from this mode. Exiting the Manual Mode screens will not take the PRO-201 out of Manual mode.

7.5 OFFLINE MODE

It is recommended that any GSM not ready for service be placed in Offline mode. Additionally, when a PRO-201 Controller is used with a single GSM, the B manifold should be placed in Offline mode denoting the absence of this manifold.

Note: Offline mode is not configurable until all active alarms are satisfied.

Note: In Offline mode all alarms except LCP are active.

Follow the below procedure to enter Offline mode with the PRO-201 Controller:





8. ADVANCED SETUP PRO-201 Controllers purchased with a new GSM will come from the factory configured for the manifold. Users will not have to setup the PRO-201 for switchover service or ESO capability. This section will be helpful if the user changes their manifold configuration at a later time or upgrades an existing system to a PRO-201 Controller.

8.1 SETTING UP YOUR PRO-201 FOR SWITCHOVER OR NON-SWITCHOVER SERVICE

Switchover service facilitates continuous gas delivery to a process tool or other application. The PRO-201 can be configured for switchover service based on weight, pressure, or weight and pressure.

Non-switchover service is utilized when a continuous supply of gas is not required or if the PRO-201 is controlling two GSMs delivering different process gases.

Note: The PRO-201 Controller can be configured for switchover or non-switchover service while in any panel mode. The PRO-201 should always be placed in Offline mode before configuring the controller to avoid activating alarms or changing pneumatic valve states.

Follow the below procedure to configure the PRO-201 for switchover service:

• Place both panels (if applicable) in Offline mode. See Section 7.5 for instructions on placing a GSM in Offline mode.

• In the MAIN/ALARM screen, press the ESC key and toggle down (▼) until SYSTEM CONFIG is highlighted. Press the ENTER key.

• Toggle down (▼) once until the screen shown in Figure 15 is displayed.

• To change between switchover and non-switchover service, press the SHIFT key then the F8 key. The HMI will clearly display whether the PRO-201 is in switchover or non-switchover mode.


Figure 15. Switchover/Non-Switchover Configuration Screen

ADVANCED SETUP


Note: Switchover mode will not operate properly without ASO A and ASO B solenoid and pneumatic valves. If a controller and or GSM was not originally purchased for switchover service, a panel upgrade and controller upgrade will be required.

8.2 SETTING UP YOUR PRO-201 FOR ESO VALVES

Under alarm conditions, the PRO-201 Controller will close the ESO valve(s) on GSM, thereby stopping the flow of process gas from the cylinder. The user only needs to enable the ESO valve(s) if they are present on the GSM.

Note: The PRO-201 Controller can enable ESO valves while in any panel mode. The PRO-201 should always be placed in Offline mode before enabling ESO valves to avoid activating alarms and disturbing process gas delivery.

Follow the below procedure to configure the PRO-201 for ESO valves:



• Toggle down (▼) twice.

• To enable the ESO valve on Panel A, press the SHIFT key, then the F6 key. If the ESO valve is enabled the PRO-201 HMI will read “yes”. If the ESO valve is disabled, the HMI will read “no”. Reference Figure 16 for a screen shot of the ESO enable screen.

Figure 16. ESO Enable Screen

• To enable the ESO valve on Panel B, press the down (▼) key.

• Press the SHIFT key, then the F6 key. If the ESO valve is enabled the PRO-201 HMI will read “yes”. If the ESO valve is disabled, the HMI will read “no”.


ADVANCED SETUP


Note: Enabling the ESO valves without ESO A or ESO B valves present will not cause the controller or GSM to operate erratically. However, the user will notice that no operational change occurs. If a controller and or GSM was not originally configured with ESO valves, a panel upgrade and controller upgrade will be required.

8.3 ENABLING ANALOG SIGNALS

The PRO-201 is able to accept LCP transducers, cylinder scales, or any combination of the two. Analog signals are configured by the user via the PRO-201 HMI. Reference Figure 17 for a screen shot of the analog enable screen.

Note: The PRO-201 Controller can enable analog signals while in any panel mode. The PRO-201 should always be placed in Offline mode before enabling analog signals to avoid activating alarms and disturbing process gas delivery.

Follow the below procedure to enable or disable analog signals:



• To enable the A analog signal, press the SHIFT key, then the F6 key.

• To enable the B analog signal, press the SHIFT key, then the F7 key.

Note: Both the A and B manifolds do not have to have analog sensors.


Figure 17. Analog Enable Screen

If analog signals are enabled, prior to placing the PRO-201 Controller into service, verify the analog signal range(s), offset(s), and unit(s) are correct. If any of these settings are not correct, the PRO-201 Controller will generate faulty readings. See Section 6.2 and 8.4 for instructions on setting these parameters.

ADVANCED SETUP


8.4 ADJUSTING ANALOG RANGES

If purchased new with analog sensors, the PRO-201 will come from the factory set with the proper analog ranges. If analog sensors are part of a field upgrade, their ranges must be entered into the PRO-201 prior to gas delivery service. Reference Figure 18 for a screen shot of the analog range screen.

Note: The analog ranges can be adjusted in any panel mode. The PRO-201 should always be placed in Offline mode before making adjustments to avoid activating alarms and disturbing process gas delivery.

Follow the below procedure to adjust the analog signal ranges:



• Toggle down (▼) once.

• Press the ENTER key. A cursor on the ANALOG RANGE A valve will begin to flash.

• Use the ▲▼ keys to adjust the value of the analog sensor range. When the correct value is reached, press the ENTER key.

Note: For quicker entry of the analog range value, press and hold down the ▲▼ key.

• If required, adjust the ANALOG RANGE B following the procedure outlined above.


Figure 18. Analog Range Adjustment Screen


9. VIEWING ADMINISTRATIVE INFORMATION A series of menus are available to the user that are default Siemens TD-200 screens. Under normal operating conditions these menus do not need to be accessed. The following menus are password protected and users will not have access:

o SELECT LANGUAGE Screen

o TD200 SETUP Screen

o VIEW MESSAGES Screen

The remainder of Section 9 outlines the default Siemens TD-200 screens that users are able to access.

9.1 VIEWING THE SIEMENS PLC MODEL AND VERSION

Follow the below procedure to view the PLC model and version found in your PRO-201 Controller:

• From any screen, press the ESC key twice.

• Highlight the screen that reads OPERATOR MENU and press the ENTER key.

• Highlight the screen that reads VIEW CPU STATUS and press the ENTER key.

• The PLC model, version, and PLC mode will be displayed.


9.2 CLEANING THE KEYPAD

Follow the below procedure to clean the keypad of the PRO-201 Controller:

• From any screen, press the ESC key twice.

• Highlight the screen that reads OPERATOR MENU and press the ENTER key.

• Highlight the screen that reads CLEAN THE KEYPAD and press the ENTER key.

• You will now have 30 seconds to clean the keypad.

• When finished, press the ESC key twice to return to the MAIN/ALARM screen.

9.3 VIEWING SOFTWARE VERSION

Follow the below procedure to view the software version and date code:


• The software version and date will be displayed.

VIEWING ADMINISTRATIVE INFORMATION


Figure 19. System Version Screen



10. TROUBLESHOOTING

10.1 ALARM MESSAGES

Alarm messages inform the user of abnormal conditions. Interpretations of these alarm messages and some typical causes for alarm triggering are described in Table 6.

If you are having difficulty with equipment operation, first make sure that all interconnecting cables and pneumatic tubing assemblies are correctly installed, and that all electrical and pneumatic connectors are tight. Also, verify all alarm set points are correct. Reference Section 6.2.3 for adjusting alarm set points.

Manifold and sensor configurations often are specially configured to meet the requirements of specific installations. For this reason, troubleshooting is difficult to describe in a standard manner. Non-standard equipment may trigger alarm messages for reasons other than those described in this section. If questions arise, contact the Matheson Field Service Department for assistance.

Table 6. Alarm Messages & Operator Actions

Alarm Interpretation Possible Causes

Low Pneumatic Supply Inadequate Nitrogen supply pressure to controller detected by pneumatic supply pressure switch.

• Inadequate nitrogen supply pressure to controller.

• Improperly set low pneumatic switch. • Defective or disconnected pneumatic

supply pressure switch.

Gas Detection Gas detection device has detected a process gas leak above the preset alarm level.

• Inadequate seal at any connection in the system, such as the cylinder (CGA) connection.

• Poor wire connection on terminal block. • Incorrect, defective, or disconnected gas

detection sensor device.

System EMO Triggered System shutdown has occurred.

• OFF button activated. • Facility EMO shutdown triggered. • Power loss to controller. • Poor wire connection on terminal block.

Remote EMO Manifold A/B Manifold shutdown has occurred.

• Facility EMO Manifold A/B shutdown triggered.

• Poor wire connection on terminal block.

Fire Detection Fire detection device has detected a flame.

• Fire exists in gas cabinet. • Incorrect, defective or disconnected fire

detector. • Poor wire connection on terminal block.

TROUBLESHOOTING


Alarm Interpretation Possible Causes

System A/B Low & Low-Low Cylinder Weight/

Pressure

Inadequate process gas pressure or weight detected by LCP XDCR or cylinder scale.

• Empty cylinder. • Blocked process gas manifold between

source and manifold assembly. • Defective, obstructed, or maladjusted

sensor. • Incorrect analog signal range, tare, or

offset. • Alarm set point(s) incorrectly adjusted. • Defective analog input. • Faulty wiring on sensor.

System A/B High Outlet Flow

Excessive process gas flow detected by branch excess flow switch.

• Incorrect, defective, or disconnected EFS.

• Broken or disconnected process gas delivery manifold to process equipment.

• Improperly sized EFS. • Sensor plugged into wrong controller

bulkhead.

System A/B High Delivery Pressure

Excessive pressure detected by HDP switch.

• Defective, obstructed, or misadjusted HDP switch.

• Obstructed manifold filter. • Defective regulator. • Alarm set point incorrectly adjusted. • Faulty wiring on sensor. • Sensor plugged into wrong controller

bulkhead.

System A/B Low Cylinder Pressure Low pressure detected by the LCP.

• Defective, obstructed, or misadjusted LCP switch.

• Alarm set point incorrectly adjusted. • Faulty wiring on sensor. • Sensor plugged into wrong controller

bulkhead. • Manifold or pigtail leak.

Low Manifold Exhaust Differential pressure switch detected inadequate exhaust pressure in cabinet.

• Inadequate facility exhaust supply. • Main cabinet door opened during

operation. • Improperly adjusted flow regulator on

cabinet. • Improperly adjusted exhaust ∆P switch.


11. LIMITED WARRANTY & SERVICE POLICY Should a problem develop in operating any MATHESON TRI-GAS SYSTEMS equipment, we respectfully suggest reading the appropriate sections of the Operation Manual. Should the problem persist, please remember that Matheson field service engineers are available during normal business hours (Pacific Time) to answer questions.

The Matheson factory toll-free telephone number is 800-227-7468; the local telephone number is 408-971-6500; the National Service Center toll-free number is 800-850-6231.

Customer suggestions for service and product improvements are encouraged and always appreciated.

LIMITED WARRANTY: HARDWARE & SOFTWARE

Matheson warrants its equipment to be free from defects in materials and workmanship for a period of 12 months after installation or 18 months after shipment, whichever period first expires. This warranty, at Matheson’s option, is limited to incurred labor and repair or replacement of parts.

Warranty claims may be lodged with either the Matheson Field Service Department or authorized local sales representatives.

Not covered under this warranty are equipment failures caused by (1) misapplication, (2) improper installation or operation, (3) internal or external contamination, (4) abuse, and (5) failure of equipment not purchased from Matheson.

In no event shall Matheson liability include special, incidental, or consequential loss or damage, even though Matheson may have been apprised of the possibility of such potential loss or damage.

This warranty is in lieu of all other warranties of fitness and merchantability. Additional warranties of any kind are neither expressed nor implied.

IN-WARRANTY REPAIRS

Charges are waived; repaired equipment is returned freight prepaid.

OUT-OF-WARRANTY REPAIRS

Charges typically include parts, labor, freight, and insurance. Equipment that cannot be economically restored to satisfactory operating condition will be returned unrepaired freight collect or discarded at the owner's option.

SHIPMENTS TO FACTORY

Please contact your local Matheson field service engineer or the Matheson factory for consultation and advice prior to returning suspected defective goods for inspection and repair. All returns must be shipped with freight prepaid and accompanied by a RETURNED MATERIAL AUTHORIZATION (RMA) NUMBER.



GLOSSARY Alarm An event (e.g., activation of horn, shutdown) that results when equipment

operation deviates significantly from a predetermined safe or expected norm, causing an associated sensor value to surpass its associated alarm setpoint.

Manifold alarms refer to error conditions (e.g., high delivery pressure) that exist within one of the 2 manifolds.

Enclosure alarms refer to error conditions (e.g., fire. hazardous gas) that are not associated with a specific manifold, but to error conditions that exist elsewhere (e.g., within the manifold assembly enclosure).

Baud Rate Rate at which a device, such as a terminal, communicates on a network.

Check Valve An automatic valve that enables fluid flow in one direction only.

Field An entry on a display or window that contains alphanumeric characters that typically can be changed by authorized users only.

Manifold One of the 2 manifold assembly divisions that distribute pressure-regulated process gas to a destination.

Manifold Assembly All piping and associated components (e.g., valves, sensors) of the manifold assembly that are contained within the manifold enclosure.

Network A communication method that, via Ethernet protocol, enables host communication with other nodes on a network.

Network Address The unique numerical identifier assigned to each node on a network.

Pressure Switch An automatic switch that either opens or closes when the applied pressure surpasses a set point.

Pressure Regulator A mechanical device that converts a liquid or gas at an unregulated inlet pressure to an accurately regulated delivery pressure.

Purge Procedure An automated procedure for exhaustively diluting contaminant gas in a manifold space with purge gas. Purging typically is required to dilute a toxic process gas in a manifold prior to performing maintenance, and to dilute atmospheric contaminants in a manifold prior to introducing process gas. Purging is accomplished by repeatedly pressurizing and exhausting the manifold space with purge gas. Interruptions in the procedure enable maintenance operations, leak testing, etc. to be accomplished. Several types of purge procedures are available for accomplishing diverse tasks.

Sensor A pressure transducer, flow switch, pressure switch, or similar device that detects a change in physical conditions.

Set point A target value for a process operating parameter. When the actual process value is below or above the set point, it triggers a specific action, such as an alarm.

State With reference to a valve, either opened or closed.

Status Refers to manifold operation:

Service: Process gas is available at process equipment. This is normal operation.

Manual: An operator is manually controlling valves to allow process gas to be available at process equipment.

Shutdown: Process gas has been interrupted by HPI closure.

GLOSSARY


Stop: Process gas has been interrupted by the user pressing the Stop button on a display.

Standby: The manifold is ready to deliver process gas to process equipment. It will begin service upon a switchover.

Purge: A purge procedure has been started.

Manual/Purge: A purge procedure was started, then interrupted by the user so the user can manually control all pneumatically actuated valves.


ACRONYMS ACV Automatic Cylinder Valve. A pneumatically actuated version of the conventional cylinder valve.

AGC Auto-Guard Cover (4-port).

AS Automatic Switchover.

CCW Counter-clockwise.

CFG Conical Filter Gasket.

CGA Cylinder gas connection.

CW Clockwise.

EFS Excess Flow Switch.

EMO Emergency Machine Off switch, also known as the local shutdown switch.

FD Fire Detected by the fire sensor in the enclosure. When open, it shuts down the manifold.

GAG Pressure Gauge.

GD Gas Detected by the sensor in the enclosure. When the switch is open, it shuts down the manifold.

GSM Gas Source Manifold.

GDMC Gas Distribution Manifold Controller.

GSMC Gas Source Manifold Controller.

HDP High Delivery Pressure alarm. This alarm causes a warning.

HDPT High Delta Pressure Test alarm. This alarm causes the manifold to shutdown.

HHDP High-High Delivery Pressure alarm. This alarm can be configured as a shutdown or warning.

HHVP High-High Vent Pressure alarm. This alarm can be configured as a shutdown or warning.

HMI Human Machine Interface.

HMP High Manifold Pressure alarm. This alarm can be configured as a shutdown or warning.

HOF High Outlet Flow alarm. This alarm can be configured as a shutdown or warning.

HPA High-Pressure Access.

HPI High-Pressure Isolation Valve. When closed, it isolates the regulator and downstream components from the process gas source.

HPLT High-Pressure Leak Test.

HPP High Purge Pressure alarm. This alarm can be configured as a shutdown or warning.

HPT High-Pressure Transducer. The cylinder pressure.

HPV High-Pressure Vent Valve. When open, it vents high-pressure purge gas or high-pressure process gas via the vacuum generator. The check valve prevents backflow of vacuum generator supply gas or high-pressure process gas into the manifold assembly.

HVP High Vent Pressure alarm. This alarm can be configured as a shutdown or warning.

I/O Inputs/Outputs.

LCP Low Cylinder Pressure alarm. This alarm causes a warning.

LCW Low Cylinder Weight alarm. This alarm causes a warning.

LDP Low Delivery Pressure alarm. This alarm causes a warning.

ACRONYMS


LLCP Low-Low Cylinder Pressure alarm. This alarm can be configured as a shutdown or warning.

LLCW Low-Low Cylinder Weight alarm. This alarm can be configured as a shutdown or warning.

LLDP Low-Low Delivery Pressure alarm. This alarm can be configured as a shutdown or warning.

LLLCP Low-Low-Low Cylinder Pressure alarm. This alarm can be configured as a shutdown or warning.

LLLCW Low-Low-Low Cylinder Weight alarm. This alarm can be configured as a shutdown or warning.

LME Low Manifold Exhaust switch on the manifold enclosure. When open, it generates a warning.

LMP Low Manifold Pressure alarm. This alarm can be configured as a shutdown or warning.

LOTO Lockout / Tagout procedures for maintenance and installation.

LPA Low-Pressure Access.

LPI Low-Pressure Isolation Valve. When closed, it isolates the manifold from the process gas delivery line to process equipment.

LPP Low Purge Pressure. This alarm causes the manifold to shutdown during a purge, and it results in a warning during normal service.

LPS Low Pneumatic Supply by the pneumatic pressure switch. When open, it shuts down the manifold.

LPT Low-Pressure Transducer. The delivery pressure.

LPV Low-Pressure Vent Valve. When open, it vents low-pressure purge gas or low-pressure process gas via the vacuum generator. The check valve prevents reflux of vacuum generator supply gas or high-pressure process gas into the manifold assembly.

LZP Low Z-Purge Pressure switch. When open, it generates a warning.

MDP High Manifold Delta Pressure alarm. This alarm can be configured as a shutdown or warning.

MSDS Material Safety Data Sheet, containing information for chemicals.

PAC Password Access Controlled. Specific manifold functions that can be accessed, altered, or triggered by authorized users only.

PBV Purifier Bypass Valve.

PFI Purifier Inlet Valve.

PFO Purifier Outlet Valve.

PGB Purge Gas Bleed Valve. It allows full flow of purge gas when open, and it allows a small flow of purge gas when closed. It extends equipment life by allowing a small flow of purge gas at all times, thereby lessening the chance of corrosive obstruction.

PGI Purge Gas Inlet Valve. When closed, it isolates the regulator and downstream components from the purge gas source.

PGO Purge Gas Orifice.

PLC Programmable Logic Controller.

PLI Process (Gas Delivery) Line (to Manifold) Isolation Valve. When closed, it isolates the manifold from the process gas delivery line.

PPT Purge Pressure Transducer. The low purge pressure alarm can be configured as a shutdown or warning.

REG Pressure regulator.

REL Relief Valve.

RS Remote Shutdown alarm. Customer controlled dry contact which will shutdown the cabinet.

ACRONYMS


SCL Scale Transducer for the cylinder.

SD Shutdown.

SWO Switchover.

VAI Vacuum Access Isolation Valve. When closed, it isolates the low-pressure vent manifold from the leak test equipment vacuum source. The inlet port of this valve is connected to leak test equipment during leak testing only; the inlet port is closed with a protective cap during typical operation of the manifold assembly.

VAP Vacuum Access Port. An optional feature that includes VAI and VGI valves.

VGI Vacuum Generator Isolation Valve. When closed, it isolates the low-pressure vent manifold from the vacuum generator.

VGS Vacuum Generator Supply Valve. When open, it allows vacuum generator supply gas to enter the vacuum generator venturi, producing a vacuum.

VPT Vent Pressure Transducer. The high vent pressure alarm can be configured as a shutdown or warning.

VV Vacuum Venturi Generator.

WN Warning.

XDCR Transducer.

Z Z-Purge alarm. Triggered when a Z-Purge equipped controller loses purge gas pressure.


ELECTRICAL SCHEMATICS







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PRO-201 PROFESSOR S CONTROLLER - Matheson · This document describes the installation, operation, and maintenance of the PRO-201 Siemens PLC semi-automated controller. ... The PRO-201