ABB PGC2000 - Electronic Pressure Control Troubleshooting

To Next Page

To Previous Page

6-28 2000-OSM, F1

ELECTRONIC PRESSURE CONTROL TROUBLESHOOTING

The Pressure Control Assembly (see Figure 6-15) requires special tools and equipment for repair. If

you suspect a problem with this assembly please contact your ABB service representative.

Figure 6-15. EPC PRESSURE CONTROL ASSEMBLY

Main Page

Table of Contents4
Glossary23
Equipment Description29
Pgc2000 with Flame Photometric Detector30
Air Purge Systems30
System Variations31
Specifications31
Physical31
Safety Area Classification31
Power32
Instrument Air32
Analytical Detectors32
Isothermal Analytical Oven32
Gas Control (Analog)33
Gas Control (Digital)34
Installation and Start-Up35
Safety Considerations35
Preparing for Installation35
Installation Tools and Equipment35
Plumbing Installation36
Gas Requirements36
Calibration Sample36
Purge Air Alarm37
Liquid Sample Valve37
Equipment Mounting38
Connections38
Tubing38
Analyzer Air39
Carrier Gas39
Sample39
Hydrogen Gas39
Vent39
Electrical40
Initial Setup of Equipment41
Equipment and Supplies Required41
Precautions41
Sample System Checkout42
GCC Pre-Checks42
Analyzer Pre-Checks42
Leak Check43
Matching Column Flows44
Manual Operation of Valves44
Checking Total Column Flow45
Checking Analytical Flow Adjust46
Checking Backflush Flow47
Checking Selector Flow Adjust48
Checking Selector Vent48
Equipment Startup49
Initial Power on49
Chroma Board Screen52
Verify GCC Operation53
Background Screen54
Calibration Run55
Request Analysis Screen56
Checking Streams57
Chroma I/O PCB Setup57
Chroma I/O Board Setup58
Remote Number Identification with SW159
Analytical Operation60
Verify Zero Baseline on Chromatogram60
Manual Control Mode Screen61
Time Cycle Check62
Verify Reports62
Benchmark Run63
TCD Zero Adjust (Filament TCD Only)65
Stopping the Analyzer65
CONNECTING the ANALYZER to Vistanet66
Initial Setup66
VN Menu Screen (Startup Highlighted)67
Setting Access Levels68
Subscriber List69
VN Menu Screen (Tables Highlighted)70
Completing the Vistanet Connection71
Controller Status Screen72
Controls and Indicators73
Gas Chromatograph Controller (GCC)73
Regulator and Gauge Panels74
Oven Compartment74
Preparing for Operation74
Display Screen75
Checking Calibration75
Request Analysis Screen76
Checking Streams77
Analytical Operation77
Starting Analytical Operation77
Stopping Analytical Operation78
Alarms78
Chromatograms79
Displaying a Chromatogram79
Recording a Chromatogram79
Shut down Procedures80
Command Tree81
Technical Description82
Functional Description82
Detectors83
Introduction83
Flame Ionization Detector (FID)84
Thermal Conductivity Detector (TCD)85
Flame Photometric Detector (FPD)86
Intercolumn Detector86
Sequential Dual Detectors86
Simultaneous Dual Detectors87
Background Screen, Simultaneous Dual Detectors88
Second Chroma Board Screen89
Control Parameters Screen90
Manual Control Mode Screen91
Circuit Boards92
Power Supply PCB92
Chroma I/O PCB92
Single Board Computer (SBC) PCB92
DC Solenoid Driver PCB92
Front Panel PCB92
FID Amplifier PCB92
TCD Amplifier PCB93
FPD Amplifier and Interface Pcbs93
DTC Backplane PCB93
AC Conditioning PCB93
DTC Zone PCB93
EPC Multibus PCB93
EPC Control PCB93
EPC Sensor PCB93
LO COMM PCB (Option)93
Communications PCB (Option)94
Vistanet Interconnect PCB (Option)94
Ethernet PCB (Option)94
Analog Output PCB (Option)94
Digital Input/Output PCB (Option)94
Method Tables94
Calibrating the Method94
Preparing a Method Table96
Method Table #?? Screen97
Method Table #01 Screen98
Editing a Method Table99
Printing a Method Table100
Peak Detection101
Forced Gating102
Slope Detection: Introduction102
Slope Detection: Basic Functions102
Slope Detection: Supplemental Functions103
Example of Tangent Skim104
Examples of Peak End105
Example of Reverse Projection106
Other Time-Coded Functions107
Auto Zero107
Stream Step108
Valve on and Valve off108
Tic Mark108
Skip Next TCF on Alarm108
Skip Next TCF if Stream109
Do Next TCF if Stream109
Pressure Check109
Pressure Control109
Temperature Check109
Temperature Control109
Other Tables and Reports109
Viewing or Editing Tables109
Printing Tables110
Printing Reports110
Random Stream Stepping Table110
Random Streams Screen111
Time Table112
Stream Table113
Raw Data Report114
Regular Report114
Short Report115
Standard Calibration Report115
Air Purging115
Y and Z Purge115
Purge Operation116
Purge Override Option117
Purge Override Contacts118
E2Prom118
Save Tables to E2PROM118
Restore Tables from E2PROM119
Digital Temperature Controller120
Physical Description120
Operator Settings120
Manual Temperature Control Mode121
Zone Names and Limits Table122
Pressure and Temperature Control Screen123
Configuring SWITCH124
Temperature Control Table125
Method Table #01 Screen126
Temperature Check Table127
Controller Type128
Temperature Configuration Table129
Temp Config Table Screen130
Programming Notes131
Alarms132
Electronic Pressure Control Option132
Physical Description132
Operator Settings132
Manual Pressure Control Mode132
Pressure and Temperature Control Screen133
Pressure Configuration Table134
Pressure Configuration Table Screen135
Configuring SWITCH136
Pressure Control Table137
Method Table #01 Screen138
Pressure Check Table139
Alarms140
Raw Chromatogram Storage and Reprocessing140
Accessing Raw Chromatogram Storage141
Checking Available Memory141
Erasing (Releasing) Chromatogram Data142
Saving Chromatograms143
Displaying Saved Data144
Reprocessing Saved Chromatograms146
Remote Gc Operation Option147
LO COMM PCB Setup147
Address Identification with SW1148
Remote Operation149
Remote Controller Screen150
Analog Output Option151
Digital I/O Option152
Vistanet OPTION153
VN Menu Screen154
Cursor to the Board Address Line and Enter the Communication Board's Address155
Cursor to the Domain 1 Line and Enter Your Gcc's Domain 1 Identification155
10. Cursor to the Domain 2 Line and Enter Your Gcc's Domain 2 Identification155
11. Cursor to the VNSA Address Line and Enter the Complete Address of the VNSA Serving Your GCC155
Cursor to the Router Address Line and Enter the Complete Address of the Router Serving Your GCC155
Vistanet Essential Addresses Screen155
Solenoid Valves156
Maintenance157
Preventive Maintenance157
Gas Cylinder Replacement157
Cleaning158
Diagnostic Tests158
ROM Checksum158
Commands Screen159
Chroma Board160
Digital Output160
Diagnostic Tests Screen (Tools Selected)161
Trend Output162
Hardware Setup163
Software Verification164
Preliminary Steps164
Chroma Board 1 Input Table165
Chroma Board 1 Output Table165
Digital Board 1 Input Table166
Digital Board 1 Output Table167
Digital Board 2168
Chroma Board 2168
Trend and Detector169
BASIC COMMON! Size169
Final Steps169
Section 6. Troubleshooting171
Troubleshooting Guidelines171
Baseline Problems171
Baseline or Signal Offset (TCD)171
Cyclic Short Term Drift172
Continuous Upward or Downward Drift172
Baseline Continuous Noise173
Baseline or Signal Offset (FID)173
Baseline Signal Random Noise (FID)174
Signal Offset (FPD)175
Signal Random Baseline Noise (FPD)175
Analysis Problems176
No Peaks176
Double Sampling177
Additional Peaks of Unknown Origin (Mystery Peaks)178
Variable Sample Size178
Variable Retention Times179
Individual Peak Missing on Report179
Peak Inversion180
Chromatogram Oversized or off Scale180
Reduced Detector Sensitivity181
Peak Discrimination182
Temperature Control Hardware Problems182
Temperature Probe Open182
Temperature Probe Shorted182
Isothermal Oven Heater Thermocouple Faulty183
Temperature Control Micro #2183
Loss of Air184
Triac Failure184
T-Rating Disagreement185
Exclusion Jumper Disagreement186
Oven Temperature Is Greater than T-Rating186
Reasonableness186
AC Zero Crossing Loss187
Over Temp Trial Test Fail187
Controller Housing Internal Temperature Greater than 80 Degrees C188
Set Point Unacceptable189
Reconfiguration Failure189
Out of Control189
Open or Shorted Heater190
Blown Fuse, AC Conditioning Board190
Low Oven Temperature191
High Oven Temperature191
Programmed Oven Temperature Not Cooling or Slow to Cool191
Output Problems192
Printer Not Generating Report192
Trend Output Not Functioning Correctly192
Digital PCB Malfunction192
No Recorder Output192
No Analyzer Keypad Response193
LOCOM PCB Symptoms and Possible Causes193
Flame out LED on194
Flame will Not Ignite (FID)194
Flame will Not Ignite (FPD)194
Low Carrier Pressure Hardware Alarm195
Low Sample Flow Hardware Alarm195
Loss of Purge Air195
Stream Not Selected196
Analyzer will Not Power up (X-Purge)196
Electronic Pressure Control Troubleshooting198
Controller Problems199
Input Power199
Power Distribution200
Poor Display Contrast201
Alarms201
Alarms Screen202
Sensors Active203
Sensors Held203
Component High203
Component Low204
Clock Error204
TCF Error204
Post Analysis Error205
Communications Error206
Pressure Board206
Temperature Board207
Raw Chromatogram Storage209
Alarm Mask209
Control Parameters Screen211
Alarm Common Output Connections212
Alarm Common Output Checks212
Control Parameters Screen213
Common DO Mask Main Screen214
Section 7. Test Procedures215
Tp 1: Carrier, Makeup and Utility Gas Supplies215
Tp 2: Carrier and Makeup Gas Flow Adjustments215
Tp 3: Sample Valve Leaking/Column Flooding215
Tp 4: Carrier or Makeup Gas Regulator216
Tp 5: Tc Detector Balance217
Tp 6: Filament Tcd Test217
Tp 7: Column Train Problems218
Tp 8: Baseline Cyclic Temperature Controller (Tcd)219
Tp 9: Baseline Cyclic Carrier Regulator219
Tp 10: Baseline Cyclic Flow Controller219
Tp 11: Common Usage of Gases220
Tp 12: Utility Gas Contamination Procedure220
Tp 13: Burner Air Catalytic Cleanup Unit220
Tp 14: Coaxial Cable220
Tp 15: Fid Reduced Sensitivity221
Tp 16: Fid will Not Light222
Tp 17: Verification Flame Is Ignited222
Tp 18: Sample Valve Actuation Air223
Tp 19: Double Sampling224
Tp 20: Variable Sample Size224
Tp 21: Open Temperature Sensor225
Tp 22: Shorted Temperature Sensor226
Tp 23: Loss of Oven Air226
DTC Backplane PCB227
Tp 24: Isothermal Oven Overtemp Sensor Open228
Tp 25: Zone Input Sensor Open228
Tp 26: Open or Shorted Heater229
Tp 27: Open Fuse to Ac Conditioning Board230
Tp 28: Fid Polarizing Voltage Test230
Tp 29: "Flame Out" Led Remains on after Fid Flame Ignition231
FID Amplifier Showing C6 Location232
Tp 30: Checking Temperature Table Values233
Manual Control Mode Screen234
Zone Names and Limits Table Screen235
Manual Temperature Control Mode Screen236
Commands Screen237
Tp 31: Plugged Jet or Breather238
Tp 32: Peak Discrimination239
Tp 33: Checking Method Table Configuration240
Commands Screen241
Tp 34: Vent Back Pressure244
Tp 35: Printer Test245
Tp 36: Residual Sample245
Tp 37: Trend Output245
Tp 38: Digital I/O Pcb247
Tp 39: Low Carrier Pressure247
Tp 40: Low Sample Flow Hardware Alarm248
Tp 41: Programmed Temperature Oven Cool down248
Tp 42: Stream Switching250
Tp 43: Fpd Gain Setting251
Tp 44: Fpd Flame will Not Light252
Tp 45: "Flame Out" Led Remains on after Fpd Flame Ignition253
Section 8. Repair255
Replacing Heaters255
Isothermal Temperature Oven Heater255
Sample Valve Heater256
Sample Valve Repair257
Disassembly on the Analyzer259
Reassembly on the Analyzer260
Stacking the Belleville Springs261
Removing the LSV from the Analyzer262
Disassembly on the Workbench263
Reassembly on the Workbench264
Stacking the Belleville Springs265
Installing the LSV on the Analyzer266
Replacing the LSV Vaporizer Assembly266
Column Installation or Replacement267
Column Removal267
Packed Column Installation267
Capillary Column Installation268
Cutting Capillary Columns268
Fid Repair269
FID Cell Access270
Replacing the Breather270
Replacing the Thermocouple Assembly271
Accessing the Polarizer and Ignitor Elements272
Replacing the Polarizer272
Replacing the Ignitor Assembly273
Closing the Detector273
Cleaning the FID Jet274
Cleaning the Collector275
Replacing the FID Cable Assembly276
Filament Tcd Repair277
T/C Detector Access277
Removing the Filaments277
Installing the Filaments278
Filament Checkout279
Connecting the Filaments279
Leak Test280
Potting the Filaments (CENELEC and CSA Only)280
Thermistor Tcd Repair281
T/C Detector Access281
Removing the Thermistors282
Installing the Thermistors282
Thermistor Checkout282
Connecting the Thermistors283
Leak Test284
Fpd Repair284
Replacing the Photomultiplier Assembly285
Replacing the Burner Block286
Replacing the Burner Block O-Rings287
Replacing the Jet287
Methanizer/Air Cleanup Repair288
Removing the Methanizer/Air Cleanup Assembly289
Removing the Catalytic Tubes290
Installing the Catalytic Tubes290
Packing the Housing291
Installing the Methanizer/Air Cleanup Assembly291
Air Cleanup Testing292
Air Cleanup Final Preparation292
Repairing the Carrier Gas Panel (Analog)293
Removing the Carrier Gas Panel293
Front Right Side of Oven294
Replacing a Regulator295
Replacing a Gauge295
Installing the Carrier Gas Panel295
Repairing the Epc Control Assembly296
Preparation296
Removing the EPC Control Assembly297
Installing the EPC Control Assembly298
Removing a Sensor PCB298
EPC Control Assembly Components299
Installing a New Sensor PCB300
Removing a Proportional Valve301
Installing a New Proportional Valve302
Removing the Control PCB302
Installing a New Control PCB303
Removing the Heater303
Installing a New Heater304
Calibrating the Electronic Pressure Controller304
Location of Zone Fittings305
Pressure and Temperature Control Screen306
Repairing Purge Air Panel Components307
Removing the Purge Air Panel307
Replacing a Regulator307
Replacing a Gauge308
Installing the Purge Air Panel308
Setting Jumpers308
Backplane PCB309
DTC Backplane PCB310
DTC Zone PCB311
VAC Conditioning PCB312
Front Panel PCB312
FID Amplifier PCB313
Filament TCD Amplifier PCB313
Thermistor TCD Amplifier Interface PCB314
EPC Multibus PCB315
EPC Control PCB315
Chroma I/O PCB (Old Type)316
Chroma I/O PCB (New Type)316
Valco Diaphragm Valve Repair317
Removing the Valve317
Repairing the Valve317
Exploded View of Valco Diaphragm Valve318
Reinstalling the Valve319
Vistanet DEBUG MONITOR319
Purpose319
Making the Connections319
Startup320
Information Display320
Menu Items321
Typical Show Registers Screen322
Statistical Display323
Dual Air Cleanup Repair326
Removing the Dual Air Cleanup Assembly326
Removing the Air Cleanup Tubes327
Installing the Air Cleanup Tubes328
Packing the Housing328
Installing the Dual Air Cleanup Assembly328
Air Cleanup Testing329
Air Cleanup Final Preparation330
Repairing the Cp Valve330
Preparation and Safety330
Replacing the Slider331
Replacing the Wedges332
Replacing the O-Rings333
Installing the O-Rings on the Piston Rod and Piston334
Section 9. Replacement Parts336
Ordering Information336
Equipment Identification336
Hardware Configuration Identification336
Software Configuration Identification337
How to Order337
Gc Controller338
GCC Chassis339
Components on Right Side Door339
Purge Air Panel340
Electronic Pressure Control Panel340
Carrier Gas Panel341
Isothermal Oven Components342
Liquid Sample Valve342
Flame Ionization Detector342
Liquid Sample Valve343
Filament Type Thermal Conductivity Detector344
Flame Ionization Detector344
Thermistor Type Thermal Conductivity Detector345
Type 781 Methanizer/Air Clean up System346
Type 805 Methanizer/Air Clean up System346
Dual Air Cleanup System347
Valco Diaphragm Valve347
Flame Photometric Detector (Fpd)348
Transformer and Photomultiplier Components348
Burner Block Components349
Temperature Programmed Oven349
Flame Ionization Detector with Heater Block349
Filament Type TC Detector with Heater Block350
Introduction351
Using the Editor351
Vista BASIC Line Format352
Character Set352
Constants352
Variables353
Arrays353
Expressions and Operators354
Alphabetic Listing355
ABSOLUTE VALUE Function355
ACTIVATED by Function355
ACTIVATE STREAM Command355
ADD TCF Command355
ALARM Function356
ASC Function356
ASSIGN STREAM Command356
BPRINT Statement356
CHAIN Statement356
CHR$ Function357
CLEAR Command357
CLOCK ERROR ALARM Function357
COMMON Floating Point Array357
COMMON String Array357
COMMUNICATION ERROR ALARM Function358
COMPONENT NAME Function358
COMPONENT TYPE Function358
CURRENT METHOD Function358
CURRENT STREAM Function358
CYCLE TIME Function359
DEACTIVATE STREAM Command359
DELETE ALL GATE TCFS Command359
DELETE ALL TCFS of a TYPE Command359
DIM Statement360
END Statement360
EXPONENT Function360
FLAME out ALARM Function360
FLOATING POINT Conversion Routine360
For361
GET ACTUAL RETENTION TIME Function361
GET ASTM Function361
GET BENCHMARK CONCENTRATION Function361
GET BLEND Function361
GET CALIBRATION CONCENTRATION Function362
GET COMPONENT CONCENTRATION Function362
GET CORRELATION FACTOR TABLE Command362
GET EXPECTED RETENTION TIME Function362
GET MAXIMUM PEAK PARAMETER Function363
GET MULTIPLIER EXPONENT Function363
GET OUTSTANDING REQUESTS Function363
GET PEAK TYPE PARAMETER Function363
GET PERCENT off for a TEMPERATURE Command363
GET PERCENT off for a TIME Command363
GET PERCENT off TABLE Command364
GET PRESSURE of a ZONE Command364
GET RESPONSE FACTOR Function364
GET STREAM ASSIGNMENT Function364
GET TEMPERATURE for a PERCENT off Command364
GET TEMPERATURE for a TIME Command365
GET TEMPERATURE of a ZONE Command365
GET TEMPERATURE TABLE Command365
GET TIME for a PERCENT off Command365
GET TIME for a TEMPERATURE Command365
GET TIME VS. BOILING POINT TABLE Command366
GOTO Statement366
GO to SUBROUTINE Statement366
HARDWARE ALARM Function366
HIGH CONCENTRATION ALARM Function366
IDLE ALARM Function367
IF Statement367
INJECT TIME Function367
INJECT UCT Function367
INSTR Function367
INTEGER TYPE Conversion Routine367
LENGTH of CORRELATION FACTOR TABLE Function368
LENGTH of PERCENT off TABLE Function368
LENGTH of STRING Function368
LENGTH of TEMPERATURE TABLE Function368
LENGTH of TIME VS. BOILING POINT TABLE Function368
LET Statement369
LOGARITHM BASE TEN Function369
LOW CONCENTRATION ALARM Function369
LPRINT Statement369
MAXIMUM SIM DIS PEAK HEIGHT Command371
NATURAL LOGARITHM Function371
NUMBER of COMPONENTS Function371
NUMBER of PEAKS Function371
OFFLINE ALARM Function371
OPERATOR MESSAGE ALARM Function371
PEAK AREA Function372
PEAK COMPONENT NUMBER Function372
PEAK CREST AMPLITUDE Function372
PEAK CREST TIME Function372
PEAK END AMPLITUDE Function372
PEAK END TIME Function373
PEAK HEIGHT Function373
PEAK RAW AREA Function373
PEAK START AMPLITUDE Function373
PEAK START TIME Function373
POST ANALYSIS ERROR ALARM Function373
POWER FAIL ALARM Function374
PREVIOUS INJECT TIME Function374
PREVIOUS INJECT UCT Function374
PREVIOUS METHOD Function374
PREVIOUS STREAM Function374
PURGING STREAM Command374
PURGING STREAM Function374
PUT ACTUAL RETENTION TIME Command375
PUT ASTM Command375
PUT BENCHMARK CONCENTRATION Command375
PUT BLEND Command375
PUT CALIBRATION CONCENTRATION Command375
PUT COMPONENT CONCENTRATION Command376
PUT COMPONENT NAME Command376
PUT CORRELATION FACTOR TABLE Command376
PUT EXPECTED RETENTION TIME Command376
PUT MULTIPLIER EXPONENT Command377
PUT PERCENT off TABLE Command377
PUT PRESSURE of a ZONE Command377
PUT REPORT TYPE Command377
PUT RESPONSE FACTOR Command378
PUT TEMPERATURE of a ZONE Command378
PUT TEMPERATURE TABLE Command378
PUT TIME VS. BOILING POINT TABLE Command378
READ ANALOG INPUT Function378
READ DIGITAL INPUT Function379
REMARKS Command380
REPORT TYPE Function380
REQUEST ANALYSIS Command380
REQUEST BENCHMARK Command380
REQUEST CALIBRATION Command380
RESET TIME LIMIT Command381
SENSOR ALARM Function381
SET BASIC ALARM Function381
SET BASIC COMPONENT ALARM Function381
SPACE Function381
SQUARE ROOT Function381
START ANALYSIS Command382
STOP ANALYSIS Command382
STREAM NAME Function382
STREAM STATUS Function382
SUBSTRING Function382
TCF ERROR ALARM Function382
TEMPERATURE UNITS Function382
TIME Function383
TIME UCT Function383
TIME VS. BOILING POINT TABLE Function383
TOTAL PEAK RAW AREA Function383
TOTAL SIM DIS AREA Command383
UCT to TIME Conversion Routine384
VALUE Function384
VALVE Command384
WRITE DIGITAL OUTPUT Command384
WRITE TREND OUTPUT Command384
Y2X Function385
ZERO OUTSTANDING REQUESTS Command385
Vista BASIC Support for Vistanet Communications385
Subject Listing387
General Statements387
Math Routines387
String and Conversion Routines387
GCC Commands and Functions388
SIM DIS (Only) Commands389
Simultaneous Dual Detector Commands390
Vistanet Commands391
Error Messages391
Compilation Error Messages391
Run-Time Error Messages392
Real-Time Vista Basic393
Real Time Operation393
Screens394
Real Time BASIC Status Screen395
Real-Time Vista BASIC Commands396
Section 11. Drawings and Diagrams398

ABB PGC2000 - Electronic Pressure Control Troubleshooting

Table of Contents

Related product manuals