ABB PGC2000 Operation manual

OPERATION AND SERVICE MANUAL
Process Gas Chromatograph PGC2000
2000-OSM F2: October 2008

NOTICE
Material contained within this manual is proprietary information of
ABB Inc.
and is to be used only for the purpose of understanding
and operating this product.
Specifications are subject to change without notice.
©2000 - 2008, ABB Inc.
ABB has no obligation with respect to any ABB equipment which:
(a) has been improperly installed, repaired or altered,
(b) has been subjected to misuse, negligence or accident, or
(c) has been used in a manner contrary to ABB’s instructions and
requirements.

2000-OSM, F2 i
LIST OF EFFECTIVE PAGES—PGC2000 MANUAL
DATE OF ISSUE FOR EACH VERSION OF THIS MANUAL:
A1 February 2000 B5 January 2002 E2 April 2006
A2 August 2000 C1 August 2002 E3 September 2006
B1 January 2001 C2 November 2002 E4 July 2007
B2 March 2001 D1 August 2004 E5 September 2007
B3 August 2001 D2 November 2004 F1 February 2008
B4 November 2001 E1 December 2005 F2 October 2008
REVISION STATUS OF EACH PAGE IN THIS MANUAL:
Page No. Revision Status
Title and Copyright F2
i F2
ii through ix F1
x and xi F2
xii through xviii F1
xix and xx F2
G-1 through G-6 F1
1-1 through 1-6 F1
2-1 through 2-38 F1
3-1 through 3-9 F1
4-1 through 4-75 F1
5-1 through 5-14 F1
6-1 through 6-44 F1
7-1 through 7-40 F1
8-1 through 8-41 F1
8-42 through 8-51 F2
8-52 through 8-75 F1
8-76 through 8-81 F2
9-1 and 9-2 F1
9-3 F2
9-4 through 9-9 F1
9-10 F2
9-11 through 9-15 F1
10-1 through 10-47 F1
11-1 F1
Back Cover F1
The revision status is noted at the bottom of each page of this manual.

ii 2000-OSM, F1
TABLE OF CONTENTS
Title Page
GLOSSARY ..............................................................................................................................................G-1
SECTION 1. INTRODUCTION
EQUIPMENT DESCRIPTION....................................................................................................................1-1
PGC2000 WITH FLAME PHOTOMETRIC DETECTOR ...........................................................................1-2
AIR PURGE SYSTEMS.............................................................................................................................1-2
SYSTEM VARIATIONS..............................................................................................................................1-3
SPECIFICATIONS.....................................................................................................................................1-3
Physical ...............................................................................................................................................1-3
Safety Area Classification....................................................................................................................1-3
Power...................................................................................................................................................1-4
Instrument Air ......................................................................................................................................1-4
Analytical Detectors.............................................................................................................................1-4
Isothermal Analytical Oven..................................................................................................................1-4
Gas Control (Analog)...........................................................................................................................1-5
Gas Control (Digital)............................................................................................................................1-6
SECTION 2. INSTALLATION AND START-UP
SAFETY CONSIDERATIONS....................................................................................................2-1
PREPARING FOR INSTALLATION...........................................................................................................2-1
Installation Tools and Equipment ........................................................................................................2-1
Plumbing Installation ...........................................................................................................................2-2
Gas Requirements...............................................................................................................................2-2
Calibration Sample ..............................................................................................................................2-2
Purge Air Alarm ...................................................................................................................................2-3
Liquid Sample Valve............................................................................................................................2-3
EQUIPMENT MOUNTING.........................................................................................................................2-4
CONNECTIONS.........................................................................................................................................2-4
Tubing..................................................................................................................................................2-4
Analyzer Air .........................................................................................................................................2-5
Carrier Gas..........................................................................................................................................2-5
Sample.................................................................................................................................................2-5
Hydrogen Gas......................................................................................................................................2-5
Vent .....................................................................................................................................................2-5
Electrical..............................................................................................................................................2-6
INITIAL SETUP OF EQUIPMENT .............................................................................................................2-7
Equipment and Supplies Required......................................................................................................2-7
Precautions .........................................................................................................................................2-7
Sample System Checkout...................................................................................................................2-8
GCC Pre-Checks.................................................................................................................................2-8
Analyzer Pre-Checks...........................................................................................................................2-8
Leak Check..........................................................................................................................................2-9
MATCHING COLUMN FLOWS................................................................................................................2-10
Manual Operation of Valves..............................................................................................................2-10
Checking Total Column Flow.............................................................................................................2-11
Checking Analytical Flow Adjust........................................................................................................2-12
Checking Backflush Flow ..................................................................................................................2-13
Checking Selector Flow Adjust..........................................................................................................2-14
Checking Selector Vent.....................................................................................................................2-14

2000-OSM, F1 iii
TABLE OF CONTENTS (continued)
Title Page
EQUIPMENT STARTUP..........................................................................................................................2-15
Initial Power On .................................................................................................................................2-15
Verify GCC Operation........................................................................................................................2-19
Calibration Run..................................................................................................................................2-21
Checking Streams .............................................................................................................................2-23
Chroma I/O PCB Setup.....................................................................................................................2-23
Analytical Operation ..........................................................................................................................2-26
Verify Zero Baseline on Chromatogram............................................................................................2-26
Time Cycle Check..............................................................................................................................2-28
Verify Reports....................................................................................................................................2-28
Benchmark Run.................................................................................................................................2-29
TCD Zero Adjust (Filament TCD Only)..............................................................................................2-31
Stopping the Analyzer .......................................................................................................................2-31
CONNECTING THE ANALYZER TO VistaNET ......................................................................................2-32
Initial Setup........................................................................................................................................2-32
Setting Access Levels .......................................................................................................................2-34
Subscriber List...................................................................................................................................2-35
Completing the VistaNET Connection...............................................................................................2-37
SECTION 3. OPERATION
CONTROLS AND INDICATORS...............................................................................................................3-1
Gas Chromatograph Controller (GCC)................................................................................................3-1
Regulator and Gauge Panels..............................................................................................................3-2
Oven Compartment .............................................................................................................................3-2
PREPARING FOR OPERATION...............................................................................................................3-2
Display Screen.....................................................................................................................................3-3
Checking Calibration ...........................................................................................................................3-3
Checking Streams ...............................................................................................................................3-5
ANALYTICAL OPERATION.......................................................................................................................3-5
Starting Analytical Operation...............................................................................................................3-5
Stopping Analytical Operation.............................................................................................................3-6
ALARMS.....................................................................................................................................................3-6
CHROMATOGRAMS.................................................................................................................................3-7
Displaying a Chromatogram................................................................................................................3-7
Recording a Chromatogram................................................................................................................3-7
SHUT DOWN PROCEDURES...................................................................................................................3-8
COMMAND TREE......................................................................................................................................3-9
SECTION 4. TECHNICAL DESCRIPTION
FUNCTIONAL DESCRIPTION...................................................................................................................4-1
DETECTORS.............................................................................................................................................4-2
Introduction..........................................................................................................................................4-2
Flame Ionization Detector (FID) ..........................................................................................................4-3
Thermal Conductivity Detector (TCD) .................................................................................................4-4
Flame Photometric Detector (FPD).....................................................................................................4-5
Intercolumn Detector ...........................................................................................................................4-5
Sequential Dual Detectors...................................................................................................................4-5
Simultaneous Dual Detectors..............................................................................................................4-6

iv 2000-OSM, F1
TABLE OF CONTENTS (continued)
Title Page
CIRCUIT BOARDS ..................................................................................................................................4-11
Power Supply PCB............................................................................................................................4-11
Chroma I/O PCB................................................................................................................................4-11
Single Board Computer (SBC) PCB..................................................................................................4-11
DC Solenoid Driver PCB ...................................................................................................................4-11
Front Panel PCB................................................................................................................................4-11
FID Amplifier PCB..............................................................................................................................4-11
TCD Amplifier PCB...........................................................................................................................4-12
FPD Amplifier and Interface PCBs....................................................................................................4-12
DTC Backplane PCB.........................................................................................................................4-12
AC Conditioning PCB........................................................................................................................4-12
DTC Zone PCB..................................................................................................................................4-12
EPC Multibus PCB ............................................................................................................................4-12
EPC Control PCB ..............................................................................................................................4-12
EPC Sensor PCB...............................................................................................................................4-12
LO COMM PCB (Option)...................................................................................................................4-12
Communications PCB (Option) .........................................................................................................4-13
VistaNET Interconnect PCB (Option)................................................................................................4-13
Ethernet PCB (Option).......................................................................................................................4-13
Analog Output PCB (Option).............................................................................................................4-13
Digital Input/Output PCB (Option) .....................................................................................................4-13
METHOD TABLES...................................................................................................................................4-13
Calibrating the Method ......................................................................................................................4-13
Preparing a Method Table.................................................................................................................4-15
Editing a Method Table......................................................................................................................4-18
Printing a Method Table ....................................................................................................................4-19
PEAK DETECTION..................................................................................................................................4-20
Forced Gating....................................................................................................................................4-21
Slope Detection: Introduction ...........................................................................................................4-21
Slope Detection: Basic Functions.....................................................................................................4-21
Slope Detection: Supplemental Functions .......................................................................................4-22
OTHER TIME-CODED FUNCTIONS.......................................................................................................4-26
Auto Zero...........................................................................................................................................4-26
Stream Step.......................................................................................................................................4-27
Valve On and Valve Off.....................................................................................................................4-27
Tic Mark.............................................................................................................................................4-27
Skip Next TCF on Alarm....................................................................................................................4-27
Skip Next TCF If Stream =.................................................................................................................4-28
Do Next TCF If Stream =...................................................................................................................4-28
Pressure Check.................................................................................................................................4-28
Pressure Control................................................................................................................................4-28
Temperature Check...........................................................................................................................4-28
Temperature Control .........................................................................................................................4-28
OTHER TABLES AND REPORTS...........................................................................................................4-28
Viewing or Editing Tables .................................................................................................................4-28
Printing Tables...................................................................................................................................4-29
Printing Reports.................................................................................................................................4-29
Random Stream Stepping Table.......................................................................................................4-29
Time Table.........................................................................................................................................4-31
Stream Table.....................................................................................................................................4-32
Raw Data Report...............................................................................................................................4-33

2000-OSM, F1 v
TABLE OF CONTENTS (continued)
Title Page
Regular Report ..................................................................................................................................4-33
Short Report ......................................................................................................................................4-34
Standard Calibration Report..............................................................................................................4-34
AIR PURGING .........................................................................................................................................4-34
Y and Z Purge....................................................................................................................................4-34
X Purge Operation.............................................................................................................................4-35
X Purge Override Option...................................................................................................................4-36
X Purge Override Contacts................................................................................................................4-37
E2PROM..................................................................................................................................................4-37
Save Tables to E2PROM ..................................................................................................................4-37
Restore Tables from E2PROM..........................................................................................................4-38
DIGITAL TEMPERATURE CONTROLLER.............................................................................................4-39
Physical Description ..........................................................................................................................4-39
Operator Settings...............................................................................................................................4-39
Manual Temperature Control Mode...................................................................................................4-40
5 Zone Names and Limits Table........................................................................................................4-41
Configuring SWITCH.........................................................................................................................4-43
Temperature Control Table ...............................................................................................................4-44
Temperature Check Table.................................................................................................................4-46
Controller Type..................................................................................................................................4-47
Temperature Configuration Table......................................................................................................4-48
Programming Notes...........................................................................................................................4-50
Alarms................................................................................................................................................4-51
ELECTRONIC PRESSURE CONTROL OPTION....................................................................................4-51
Physical Description ..........................................................................................................................4-51
Operator Settings...............................................................................................................................4-51
Manual Pressure Control Mode.........................................................................................................4-51
Pressure Configuration Table............................................................................................................4-53
Configuring SWITCH ........................................................................................................................4-55
Pressure Control Table......................................................................................................................4-56
Pressure Check Table.......................................................................................................................4-58
Alarms................................................................................................................................................4-59
RAW CHROMATOGRAM STORAGE AND REPROCESSING ..............................................................4-59
Accessing Raw Chromatogram Storage ...........................................................................................4-60
Checking Available Memory..............................................................................................................4-60
Erasing (Releasing) Chromatogram Data .........................................................................................4-61
Saving Chromatograms.....................................................................................................................4-62
Displaying
Saved Data......................................................................................................................4-63
Reprocessing Saved Chromatograms ..............................................................................................4-65
REMOTE GC OPERATION OPTION......................................................................................................4-66
LO COMM PCB Setup.......................................................................................................................4-66
Remote Operation .............................................................................................................................4-68
ANALOG OUTPUT OPTION....................................................................................................................4-70
DIGITAL I/O OPTION...............................................................................................................................4-71
VistaNET OPTION...................................................................................................................................4-72
SOLENOID VALVES................................................................................................................................4-75
SECTION 5. MAINTENANCE
PREVENTIVE MAINTENANCE.................................................................................................................5-1
Gas Cylinder Replacement..................................................................................................................5-1

vi 2000-OSM, F1
TABLE OF CONTENTS (continued)
Title Page
Cleaning...............................................................................................................................................5-2
DIAGNOSTIC TESTS................................................................................................................................5-2
ROM Checksum.........................................................................................................................................5-2
Chroma Board .....................................................................................................................................5-4
Digital Output.......................................................................................................................................5-4
Trend Output........................................................................................................................................5-6
Hardware Setup...................................................................................................................................5-7
SOFTWARE VERIFICATION.....................................................................................................................5-8
Preliminary Steps.................................................................................................................................5-8
Chroma Board 1 Input Table...............................................................................................................5-9
Chroma Board 1 Output Table ............................................................................................................5-9
Digital Board 1 Input Table................................................................................................................5-10
Digital Board 1 Output Table.............................................................................................................5-11
Digital Board 2...................................................................................................................................5-12
Chroma Board 2 ................................................................................................................................5-12
Trend and Detector............................................................................................................................5-13
BASIC COMMON! Size.....................................................................................................................5-13
Final Steps.........................................................................................................................................5-13
SECTION 6. TROUBLESHOOTING
TROUBLESHOOTING GUIDELINES........................................................................................................6-1
BASELINE PROBLEMS.............................................................................................................................6-1
Baseline or Signal Offset (TCD)..........................................................................................................6-1
Cyclic Short Term Drift ........................................................................................................................6-2
Continuous Upward or Downward Drift...............................................................................................6-2
Baseline Continuous Noise .................................................................................................................6-3
Baseline or Signal Offset (FID)............................................................................................................6-3
Baseline Signal Random Noise (FID)..................................................................................................6-4
Signal Offset (FPD)..............................................................................................................................6-5
Signal Random Baseline Noise (FPD) ................................................................................................6-5
ANALYSIS PROBLEMS.............................................................................................................................6-6
No Peaks.............................................................................................................................................6-6
Double Sampling .................................................................................................................................6-7
Additional Peaks of Unknown Origin (Mystery Peaks)........................................................................6-8
Variable Sample Size ..........................................................................................................................6-8
Variable Retention Times....................................................................................................................6-9
Individual Peak Missing on Report......................................................................................................6-9
Peak Inversion...................................................................................................................................6-10
Chromatogram Oversized or Off Scale .............................................................................................6-10
Reduced Detector Sensitivity ............................................................................................................6-11
Peak Discrimination...........................................................................................................................6-12
TEMPERATURE CONTROL HARDWARE PROBLEMS........................................................................6-12
Temperature Probe Open..................................................................................................................6-12
Temperature Probe Shorted..............................................................................................................6-12
Isothermal Oven Heater Thermocouple Faulty .................................................................................6-13
Temperature Control Micro #2...........................................................................................................6-13
Loss of Air..........................................................................................................................................6-14
Triac Failure.......................................................................................................................................6-14
T-Rating Disagreement .....................................................................................................................6-15
Exclusion Jumper Disagreement.......................................................................................................6-16

2000-OSM, F1 vii
TABLE OF CONTENTS (continued)
Title Page
Oven Temperature is Greater Than T-Rating ...................................................................................6-16
Reasonableness................................................................................................................................6-16
AC Zero Crossing Loss .....................................................................................................................6-17
Over Temp Trial Test Fail..................................................................................................................6-18
Controller Housing Internal Temperature Greater Than 80 Degrees C............................................6-18
Set Point Unacceptable.....................................................................................................................6-19
Reconfiguration Failure .....................................................................................................................6-19
Out of Control ....................................................................................................................................6-19
Open or Shorted Heater....................................................................................................................6-20
Blown Fuse, AC Conditioning Board.................................................................................................6-20
Low Oven Temperature.....................................................................................................................6-21
High Oven Temperature....................................................................................................................6-21
Programmed Oven Temperature Not Cooling or Slow to Cool.........................................................6-21
OUTPUT PROBLEMS .............................................................................................................................6-22
Printer Not Generating Report...........................................................................................................6-22
Trend Output Not Functioning Correctly............................................................................................6-22
Digital PCB Malfunction.....................................................................................................................6-22
No Recorder Output ..........................................................................................................................6-22
No Analyzer Keypad Response.........................................................................................................6-23
LOCOM PCB Symptoms and Possible Causes................................................................................6-24
Flame Out LED On............................................................................................................................6-24
Flame Will Not Ignite (FID)................................................................................................................6-24
Flame Will Not Ignite (FPD)...............................................................................................................6-24
Low Carrier Pressure Hardware Alarm .............................................................................................6-25
Low Sample Flow Hardware Alarm...................................................................................................6-25
Loss of Purge Air...............................................................................................................................6-25
Stream Not Selected .........................................................................................................................6-26
Analyzer Will Not Power Up (X-Purge)..............................................................................................6-26
ELECTRONIC PRESSURE CONTROL TROUBLESHOOTING.............................................................6-28
CONTROLLER PROBLEMS....................................................................................................................6-29
Input Power........................................................................................................................................6-29
Power Distribution..............................................................................................................................6-30
Poor Display Contrast........................................................................................................................6-31
ALARMS...................................................................................................................................................6-31
Sensors Active...................................................................................................................................6-33
Sensors Held.....................................................................................................................................6-33
Component High................................................................................................................................6-33
Component Low.................................................................................................................................6-34
Clock Error.........................................................................................................................................6-34
TCF Error...........................................................................................................................................6-34
Post Analysis Error............................................................................................................................6-35
Communications Error.......................................................................................................................6-36
Pressure Board..................................................................................................................................6-36
Temperature Board ...........................................................................................................................6-37
Raw Chromatogram Storage.............................................................................................................6-39
Alarm Mask........................................................................................................................................6-39
Alarm Common Output Connections.................................................................................................6-42
Alarm Common Output Checks.........................................................................................................6-42

viii 2000-OSM, F1
TABLE OF CONTENTS (continued)
Title Page
SECTION 7. TEST PROCEDURES
TP 1: CARRIER, MAKEUP, AND UTILITY GAS SUPPLIES....................................................................7-1
TP 2: CARRIER AND MAKEUP GAS FLOW ADJUSTMENTS................................................................7-1
TP 3: SAMPLE VALVE LEAKING/COLUMN FLOODING........................................................................7-1
TP 4: CARRIER OR MAKEUP GAS REGULATOR .................................................................................7-2
TP 5: TC DETECTOR BALANCE.............................................................................................................7-3
TP 6: FILAMENT TCD TEST....................................................................................................................7-3
TP 7: COLUMN TRAIN PROBLEMS.......................................................................................................7-4
TP 8: BASELINE CYCLIC TEMPERATURE CONTROLLER (TCD)........................................................7-5
TP 9: BASELINE CYCLIC CARRIER REGULATOR................................................................................7-5
TP 10: BASELINE CYCLIC FLOW CONTROLLER .................................................................................7-5
TP 11: COMMON USAGE OF GASES.....................................................................................................7-6
TP 12: UTILITY GAS CONTAMINATION PROCEDURE.........................................................................7-6
TP 13: BURNER AIR CATALYTIC CLEANUP UNIT................................................................................7-6
TP 14: COAXIAL CABLE..........................................................................................................................7-6
TP 15: FID REDUCED SENSITIVITY.......................................................................................................7-7
TP 16: FID WILL NOT LIGHT...................................................................................................................7-8
TP 17: VERIFICATION FLAME IS IGNITED............................................................................................7-8
TP 18: SAMPLE VALVE ACTUATION AIR ..............................................................................................7-9
TP 19: DOUBLE SAMPLING..................................................................................................................7-10
TP 20: VARIABLE SAMPLE SIZE ..........................................................................................................7-10
TP 21: OPEN TEMPERATURE SENSOR..............................................................................................7-11
TP 22: SHORTED TEMPERATURE SENSOR ......................................................................................7-12
TP 23: LOSS OF OVEN AIR...................................................................................................................7-12
TP 24: ISOTHERMAL OVEN OVERTEMP SENSOR OPEN.................................................................7-14
TP 25: ZONE INPUT SENSOR OPEN ...................................................................................................7-14
TP 26: OPEN OR SHORTED HEATER...................................................................................................7-15
TP 27: OPEN FUSE TO AC CONDITIONING BOARD..........................................................................7-16
TP 28: FID POLARIZING VOLTAGE TEST............................................................................................7-16
TP 29: “FLAME OUT” LED REMAINS ON AFTER FID FLAME IGNITION............................................7-17
TP 30: CHECKING TEMPERATURE TABLE VALUES .........................................................................7-19
TP 31: PLUGGED JET OR BREATHER ................................................................................................7-24
TP 32: PEAK DISCRIMINATION............................................................................................................7-25
TP 33: CHECKING METHOD TABLE CONFIGURATION.....................................................................7-26
TP 34: VENT BACK PRESSURE...........................................................................................................7-30
TP 35: PRINTER TEST...........................................................................................................................7-31
TP 36: RESIDUAL SAMPLE...................................................................................................................7-31
TP 37: TREND OUTPUT ........................................................................................................................7-31
TP 38: DIGITAL I/O PCB ........................................................................................................................7-33
TP 39: LOW CARRIER PRESSURE......................................................................................................7-33
TP 40: LOW SAMPLE FLOW HARDWARE ALARM..............................................................................7-34
TP 41: PROGRAMMED TEMPERATURE OVEN COOL DOWN...........................................................7-34
TP 42: STREAM SWITCHING................................................................................................................7-36
TP 43: FPD GAIN SETTING....................................................................................................................7-37
TP 44: FPD FLAME WILL NOT LIGHT....................................................................................................7-38
TP 45: "FLAME OUT" LED REMAINS ON AFTER FPD FLAME IGNITION...........................................7-39