ABB PGC5000 Generation 2 Operating Instruction
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ABB PGC5000 Generation 2 Operating Instruction

Process gas chromatograph
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ABB M E ASUR E M E NT & AN ALYT IC S | 8 92J 006 MN AH
PGC5000 Generation 2
(Process Gas Chromatograph)
Operating Instruction
Measurement made easy

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Summary of Contents for ABB PGC5000 Generation 2

  • Page 1 — ABB M E ASUR E M E NT & AN ALYT IC S | 8 92J 006 MN AH PGC5000 Generation 2 (Process Gas Chromatograph) Operating Instruction Measurement made easy...

  • Page 2: Table Of Contents

    — Contents Contents ..........................2 List of figures ........................9 List of tables ........................11 Additional information ......................12 Compliance ......................... 12 Cyber security ........................12 Waste Electrical and Electronic Equipment (WEEE) ..............12 Safety ..........................13 Safety symbol conventions ....................13 Potential safety hazards ......................
  • Page 3 Analyzers with version 4.2.1.14 and later ............33 3.7.5 Master controller as an RUI ................34 Access control list ...................... 34 3.8.1 Log into the PGC5000 Generation 2 analyzer ........... 34 3.8.2 Access levels (optional) ................. 35 3.8.3 Subscriber list ....................35 3.8.4...
  • Page 4 4.2.3 Report subtab ....................38 4.2.4 Overlay subtab .................... 41 Status tab ........................ 42 4.3.1 User-configurable scopes ................44 4.3.2 Configure indicators..................44 4.3.3 Status indicator reset ................... 45 Schedule tab ......................45 4.4.1 Maintenance mode icon................. 45 4.4.2 Power failure recovery icon ................45 4.4.3 Multiple oven and schedule relationship ............
  • Page 5 4.10 Sample handling system .................... 83 5 Hardware and software features ..................83 Function ........................83 Detectors ......................... 84 5.2.1 Flame ionization detector (FID) ..............84 5.2.2 Thermal conductivity detector (TCD) .............. 85 5.2.3 Flame photometric detector (FPD) ..............85 5.2.4 Optional Dielectric Barrier Discharge Ionization Detector (DBDID) ......
  • Page 6 Remote communications overview ................99 5.8.1 MODBUS overview ..................99 5.8.2 PGC5000 MODBUS configuration ..............99 5.8.3 Modbus configuration recommendations ............100 5.8.4 MODBUS slave communication ..............101 5.8.5 Client configurator ..................101 5.8.6 OPC communication ................... 103 Input/output options ....................103 5.9.1 Local input/output option ................
  • Page 7 7.4.13 COMMON floating point array ............... 122 7.4.14 COMMON$ string array ................122 7.4.15 COMPONENT NAME$ function ..............123 7.4.16 COMPONENT TYPE function ................. 123 7.4.17 COMPONENT UNITS function ............... 123 7.4.18 CURRENT STREAM function ................. 123 7.4.19 DEACTIVATE STREAM command ..............124 7.4.20 DIM statement ...................
  • Page 8 7.4.57 SCHEDULE ABORT function................130 7.4.58 SCHEDULE NAME function ................130 7.4.59 SCHEDULE RUN function ................130 7.4.60 SCHEDULE STOP function ................131 7.4.61 SET BASIC ALARM function................131 7.4.62 SLEEP function ................... 131 7.4.63 SQUARE ROOT function ................131 7.4.64 START REPORT statement ................

  • Page 9: List Of Figures

    — List of figures Figure 1-1: Standard PGC5000 with ovens connected by switch ........... 15 Figure 1-2: Oven with integrated controller connections .............. 16 Figure 2-1: Liquid Sample Valve ....................21 Figure 2-2: Inside the Master Controller ..................22 Figure 3-1: Master Controller ....................24 Figure 3-2: Basic Analyzer Screen Layout ..................
  • Page 10 Figure 5-10: Tangent skim ....................... 92 Figure 5-11: RUI ........................98 Figure 5-12: Version Number Comparison ................. 98 Figure 5-13: Version 2.1.02 ABB Client Configurator ..............101 Figure 5-14: MODBUS Configurator Example................102 Figure 5-15: CSV file example ....................103 Figure 5-16: SBC PCB showing local input/output connections ...........

  • Page 11: List Of Tables

    Figure 8-2: Control Panel/Uninstall ..................134 Figure 8-3: Previous Installation ..................... 134 Figure 8-4: Remove Old Software ................... 135 Figure 8-5: GCHelpfiles Folder ....................136 Figure 8-6: XML Dialog Version Converter ................137 Figure 9-1: Oven Compartment ....................138 — List of tables Table 0-1: Related documentation ....................

  • Page 12: Additional Information

    ABB Inc. and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or...

  • Page 13: Safety

    The content of these instructions is neither part of nor provided for changing a previous or existing agreement, promise, or legal relationship. All obligations of ABB result from the respective sales contract, which also contains the full and solely valid warranty clauses. These are neither limited nor extended by the content of these instructions.

  • Page 14: Potential Safety Hazards

    WARNING – Bodily injury. These symbols, and the signal word "WARNING", indicate a potentially dangerous situation. Failure to observe this safety information could result in death or severe injury. The text may state the hazard, how to avoid the hazard, and the result if not followed.

  • Page 15: Introduction

    Remote User Interface (RUI) that has the same operational software on a PC. The term “user interface” in this instruction refers to either the LUI or RUI, whichever applies to the system. The PGC5000 Generation 2 analyzer is compatible with version 4.2.1 and later of the STAR Data Management System.

  • Page 16: Data Package

    The user interface is accessed remotely, as described in Section 3.7. The PGC5000 Generation 2 Master Controller can also act as a stand-alone RUI. In this configuration, the Master controller will not be connected to an oven, and it will not contain SBC CAN Interface Cards or Wago input/output modules.

  • Page 17: Vapor Version

    Class 1 Division 1 location, or an Ex Zone 1 area. Refer to the analyzer nameplate for purge and pressurization specifications. System variations This manual supports the basic PGC5000 Generation 2 analyzer. Section presents additional instruction for the PGC5000TPGC (temperature programmed GC). Section includes information about using the PGC5000A as a CAC replacement.

  • Page 18: Analyzer Location

    NOTICE – Equipment damage. When handling electronic parts and assemblies, it is necessary that proper electrostatic discharge (ESD) precautions be taken (i.e., wear an ESD wrist strap with a grounding cable and use an ESD shielded bag to protect items removed). Analyzer location The analyzer should be located as close to the sample stream as practical.

  • Page 19: Precautions

    ⎯ Ambient operating temperature is 0 to 50 degrees C (32 to 122 degrees F) ⎯ Avoid exposure to corrosive gas ⎯ Not intended for a combustible dust environment ⎯ Not intended for below surface mining applications ⎯ Free from dust and static electricity ⎯...

  • Page 20: Calibration Sample

    ⎯ Carrier gases: varies with the application. The lower the levels of components being measured, the higher the necessary carrier gas purity. ⎯ TCD: for percent level measurements, gases of 99.99% purity; for ppm measurement ranges, 99.995% purity. ⎯ FID: for measurements down to 5 ppm, gases of 99.995% purity; lower ranges require higher levels of purity.

  • Page 21: Sample

    2.4.6 Sample The methods used for transporting the sample from the process stream to the analyzer, or from the calibration sample to the analyzer, are critical to the operation of the analyzer. Refer to the system drawings in the Data Package for specific system connections. 2.4.7 Hydrogen gas DANGER –...

  • Page 22: Set Up The Master Controller

    A grounding (earthing) connection is required. Connect minimum 12 gauge (3.31 mm2) ground wire to the Earthing Connection on the Oven Compartment and on the Master Controller. WARNING – Bodily injury. The Neutral and Ground (earth) connections to the PGC5000 series Master Controller and B class oven must be at earth (0 volts) potential.

  • Page 23: Purge Air Alarm

    The ST connectors have a bayonet mount and a long cylindrical 2.5 mm ceramic or polymer ferrule to hold the fiber. They are spring-loaded and keyed with slots and alignment nubs. Always “stab and twist” to make sure the ST connectors seat properly. IMPORTANT NOTE: If you have signal loss, remove and reconnect to see if this eliminates the problem.

  • Page 24: Touchscreen Layout

    Figure 3-1: Master Controller 3.2.1 Touchscreen layout Figure 3-2 illustrates the basic Master Controller display layout and functionality. Use the touchscreen to navigate. Figure 3-2: Basic Analyzer Screen Layout Legend: Basic Analyzer Screen Layout ID Description ID Description Tabs – Select a tab using the cursor to System Information Bar –...

  • Page 25: Action Icons

    3.2.2 Action icons Action icons represent action commands. Table 3-1 shows the action icons and a brief description of each one. Table 3-1: Action icons Icon Description Icon Description Power Failure Recovery Setup (Schedule USB Flash Drive Operation (Setup Tab) Tab) Maintenance Mode (Schedule Tab) Restore Settings (Setup Tab)

  • Page 26: System Information Bar

    3.2.4 System information bar The System Information Bar (see Figure 3-3), located along the bottom of the screen, gives a variety of information as noted in the following legend table. Figure 3-3: System Information Bar Legend: System Information Bar ID Description Description System Status Indicator - Reflects the overall health Information Area –...

  • Page 27: Keyboard

    Figure 3-4: Master controller keypad Legend: Master controller keypad ID Description ID Description Home – Returns to the default screen Mouse Button – Indicates the mouse selection (Home tab) when needed Help – Jumps to the Quick Help screen. Folder Selection – Moves left to right between screen tabs.

  • Page 28: Oven Led Indicators

    Figure 3-6: Typical ovens 3.3.1 Oven LED indicators Each oven has three LED indicators (see Figure 3-6) which show the current status of the oven. ⎯ If the LEDs are not lit, check power to the unit. ⎯ If the top LED is green and flashing, the system is initializing. ⎯...

  • Page 29: Leak Check Oven

    Turn the power ON at the external circuit breaker or switch. Verify any auxiliary gases in the same manner as the Carrier gas. Check for leaks. If a leak occurs during startup, perform the leak checks described in sections 3.4.1 and 3.4.2.

  • Page 30: Calibrate The Analyzer

    Calibrate the analyzer Use the Setup tab to enter the calibration concentration for all components being calibrated. Follow the steps below to calibrate using either the LUI or RUI. Navigate to the Setup tab (see Figure 3-8). Figure 3-8: Setup Tab, showing calibration concentration Select Components from the Function Selectors list.

  • Page 31: Connect To The Network (Optional)

    STAR Client directly to the primary port of the analyzer and power up the analyzer. When the analyzer boots up, the PGC5000 Generation 2 will appear in the device list of the STAR Client where you can display the configured IP addresses. To launch an RUI, the laptop must be on the same subnet (i.e., 192.168.99.xx) as the analyzer.

  • Page 32: Early Versions Of The Analyzer

    Figure 3-9: Home screen, showing IP address If you call up the RUI by launching the RUI application from a shortcut or Windows folder, you will see “Local” in the box next to the Network Connect button (see Figure 3-10). Figure 3-10: Home screen, showing “Local”...

  • Page 33: Analyzers With Version 4.2.1.14 And Later

    Analyzers with version 4.2.1.14 and later The Identify feature applies only to PGC5000 Generation 2 version 4.2.1.14 or newer. The OVEN LED flashing feature will only work if the GC is equipped with the DTC2 and version 4 software. The Identify feature requires an active connection between the PGC5000 Master Controller and the associated PGC5000 Oven(s) and a list of compatible analyzers with version 4 software.

  • Page 34: Master Controller As An Rui

    LUI and RUI. 3.8.1 Log into the PGC5000 Generation 2 analyzer Access to the analyzer is controlled by creating authorized user names with passwords. To log into the analyzer through the LUI:...

  • Page 35: Access Levels (Optional)

    Figure 3-16: Select a user name Enter your password and press Accept. The information bar at the bottom of the screen displays your access level. The Log In button becomes a Log Out button upon login. To log out, press the Log Out button. 3.8.2 Access levels (optional) Access levels are set with the user interface, STAR Client, or optional VistaNET Name Service...

  • Page 36: Analyzer Shutdown

    Power down and tag out per company established safety procedures. Operation Introduction The PGC5000 Generation 2 analyzer operates from a series of tabs at the top of the screen. All functions of the analyzer are accessed from these tabs and their subtabs located at the bottom of the screen.
  • Page 37 Figure 4-1: Chart subtab Legend: Chart subtab Description Analysis Buttons – Displays the indicator level and analysis progress for all active analyses. The Idle Stream is included for review of chromatograms or reports not currently running. Analysis Graphics – Displays the currently selected analysis (option selected at left) and overlays.

  • Page 38: Status Subtab

    4.2.2 Status subtab The Home>Status subtab displays all triggered active assigned indicators for the selected analysis button, and the date and time the indicator triggered (see Figure 4-3). Figure 4-3: Home>Status screen Legend: Home>Status screen Description Indicator Reset – Reset one or all displayed indicators. Indicator State –...
  • Page 39 Figure 4-4: Home>Report subtab Legend: Home>Report subtab Description Analysis Buttons – Display the indicator level and analysis progress for all active analyses. The Idle Stream is included for review of analyses not currently running. Report Type – Select Raw to display reports in raw data format. Select Previous to display last saved report for the selected stream.
  • Page 40 allow storage of new data, allowing continual data collection. The last five calibration, validation and alarm reports are retained, independent of time stamp. ⎯ The standard report (see Figure 4-5) displays inject time, sample stream, analysis name, report type, detector, component Name / Retention Time / Concentration and validity of the component.

  • Page 41: Overlay Subtab

    Select Raw to view in raw data format. To view a stored report: Ensure the Previous box is cleared and select the Raw box if raw data is preferred. Select the Stream from the first drop-down list. Select the timeframe from the second drop down list. Standard analysis data is saved in hourly folders in Year/Month/Day and Hour format or alarm reports for the select stream.

  • Page 42: Status Tab

    IMPORTANT NOTE: Overlay 1 (top) displays in green; Overlay 2 (bottom) displays in red. To turn off the overlay display, clear the Active box on the Overlay Subtab. The SBC stores analysis data continuously for a maximum of seven days. Report files are overwritten after seven days or when the storage media is filled.
  • Page 43 Figure 4-9: Status Screen Example Legend: Status screen example Item Description Scopes – Use to navigate between All and user-configured scopes. Page Up/Down and Line Up/Down – Press to move vertically through indicators. Depending on location or size of the list, movement arrows may not be shown. (Example: top of list, page up arrows will not be shown.) Indicators–...

  • Page 44: User-Configurable Scopes

    4.3.1 User-configurable scopes The analyzer scopes represent a collection of indicators directly related to the hardware or software within the analyzer system (see Figure 4-10). Each scope allows assignment of configurable indicators to optimize the Condition Monitoring System for each installation. Indicators are assigned reporting levels depending on user need.

  • Page 45: Status Indicator Reset

    Check the Active Box. (Indicators must be marked Active to be monitored and reported.) Check the Hold box to retain the indicator's triggered level until manual reset. 4.3.3 Status indicator reset To reset a single indicator state and date/time, press the Reset button at the far left of the indicator line.
  • Page 46 IMPORTANT NOTE: To ensure that a Clearing Analysis is not defined, select None in the drop- down list (either the Analysis Name or the Stream Name). Which mode the analyzer executes is determined by comparing the actual time the analyzer is ready to the user set times: Time Continue and Time Restart.

  • Page 47: Multiple Oven And Schedule Relationship

    4.4.3 Multiple oven and schedule relationship Each schedule can use the oven hardware in more than one oven, allowing more than one oven association with a single schedule. Each oven operates independently in the system. If an oven goes offline, it impacts only the schedules associated with the assigned oven. Table 4-1 provides an example of a schedule/oven assignment and...
  • Page 48 Figure 4-13: Schedule>Queue Display Legend: Schedule>Queue Display Description Action Icons – Create, edit and control schedules (Action Icons in Table 3-1 lists each icon) Queue Display – Lists live analyses associated with the selected schedule (left-hand column) Schedule List – List of schedules A green entry represents the current running analysis in the selected schedule.

  • Page 49: Step Subtab

    4.4.5 Step subtab Figure 4-14 shows the Step subtab display. It allows the user to add steps to a schedule. Figure 4-14: Schedule>Step display Legend: Schedule>Step display Description Schedule select: Select schedule to show detail. Add Action icon: Press the Add icon to add an analysis. Analysis control area: Add, Delete, Run and Activate.

  • Page 50: Demand Subtab

    Figure 4-15: Schedule>TOD display Legend: Schedule>TOD display Description Schedule select: Select schedule to show detail Add Action icon: Selects and adds streams Analysis control area: Add, Delete, Run and Activate The TOD subtab sets scheduled validations, calibrations, and stream analyses. To add a TOD analysis: Press the Add button at the top of the subtab display and a selection list appears.

  • Page 51: Analysis Tab

    Figure 4-16: Schedule>Demand subtab Legend: Schedule>Demand subtab Description Schedule select: Select schedule to show detail Add Action icon: Select to add analyses Analysis control area: Add, Delete and Run Demand Analyses To create a demand analysis: Press the Add icon at the top of the subtab display. A selection list appears. Select the desired stream from the list and press the Next button to continue.
  • Page 52 Figure 4-17: Analysis>Chart Subtab Legend: Analysis>Chart Subtab Description Action icons: Used for retrieving saved analyses and editing the displayed analysis Function select buttons: User-created analysis objects Chromatogram display: Displays current chromatogram and/or overlay Graphic edit area: Drag and drop objects to edit the selected object's timing. Enable the graphical editor by selecting the Chart subtab (see Figure 4-17).

  • Page 53: Tabular Editor Subtab

    Figure 4-18: Graphic Editor/Tabular Editor Map 4.5.2 Tabular editor subtab The Analysis>Tabular Editor subtab is used to display and edit analytical data (see Figure 4-19). Figure 4-19: Analysis>Tabular Editor subtab Legend: Analysis>Tabular Editor subtab Description Action icons: Create, Add, Delete or Save objects Function select buttons: User-created Analysis objects Editing area: Used to display and edit selected object Refer to section...

  • Page 54: Normalization

    4.5.3 Normalization Normalization is the adjustment of measured component peak areas such that the total volume of measured components is mathematically equal to 100%. It is a technique used for quantitatively assessing a chromatogram to provide a quantitative analysis of the mixture being measured. The quantitative results are obtained by expressing the area of a given peak as a percentage of the sum of the areas of all the peaks.

  • Page 55: New Analysis

    Figure 4-21: Normalized Report 4.5.4 New analysis The analyzer analyzes components by using established methods built from a sequence of TCFs such as valve functions. Examples are: ⎯ Analysis: One or more methods (maximum of one per oven), which produces a measurable, displayable chromatogram ⎯...

  • Page 56: Analysis Error Messages

    14. Fill in the information completely. 15. Select the Add New icon. 16. Select TCF-Method Scope. 17. Select Stream Step. 18. Verify and accept by pressing the Accept button. 19. Fill in the Stream Step information. 20. Save the new analysis to Analysis Config. The Analysis button must be selected when saving. 21.
  • Page 57 Message Issue / Fix Too many script TCFs in The count of the Script TCFs in this Analysis exceeds the maximum limit. [Analysis Name] Invalid min Method TCF A TCF at Method scope was found to have a time offset of less than zero StartTime=%d <...

  • Page 58: Load An Analysis From The Library

    4.5.6 Load an analysis from the library The designed application analyses for the system are stored in the analyzer library and/or the analysis configuration. IMPORTANT NOTE: Only analyses stored in Analysis Config can be added to a schedule. To retrieve an analysis from the library: Select the Analysis>Chart subtab.

  • Page 59: Setup Tab

    must be marked for the Reprocessing Action icon at the right of the Analysis>Overlay subtab to display. Reprocessing is allowed on either overlay. Figure 4-23: Reprocessing Button When the chromatogram data is reprocessed using changed integration parameters, the reprocessed report can be compared to the original report showing any variation in peak results. If the integration change is satisfactory, the changes can be saved to the analysis for later execution.

  • Page 60: File Management

    Figure 4-24: Setup>Config Subtab Example Legend: Setup>Config Subtab Example Description Function Select list: List of all objects in the analyzer Object Configuration Information: Displays all information available for the selected list item including Action Icons (if applicable) and Fields. Editable fields display with a white background.
  • Page 61 Figure 4-25: Recovery and Backup Options If only option names show, then you do not have the correct permissions to use the backup and restore options. NOTICE – Equipment damage or loss of data. Risk of loss of data on USB and the PGC5000.

  • Page 62: System Backup, Restore And Recovery Messages

    Invalid Configuration Host Mismatch Host Name in the configuration does not match the Host Warning! Name on the SBC. Call ABB support. Invalid Configuration Model Manager Task There is an error in one of the configuration files. Call not started ABB support.

  • Page 63: Components

    Message Meaning / Issue / Fix Updating Configuration. Standby for System System is writing configuration files to USB flash drive. Restart USB Recovery Drive Creation Complete Recovery data has been saved to the USB flash drive. USB Recovery Drive No USB Drive Found No USB flash drive found.

  • Page 64: Streams

    • LOW: Low level limit, in seconds, that the peak crest can shift • HIGH: High level limit, in seconds, that the peak crest can shift ⎯ LIMITS: Concentration (Reported Component Values) • LOW-LOW: Sets the low-low indicator concentration limit •...
  • Page 65 Figure 4-29: Master Controller configuration Ovens with Integrated Controllers will show a Master Controller in the Function Select list, even though no physical PGC5000A Master Controller is present. The SBC subtab will be under the Master Controller button. The Power Supply, Purge Control, and Front Panel subtabs will not be shown, as these Master Controller parameters are not needed in the oven with Integrated Controller.
  • Page 66 ⎯ Set the display language. Select the desired language from the drop-down list. The display change is immediate. Multiple languages can be viewed at the same time from the RUI. However, the last language selected for display by either from the LUI or the RUI becomes the default display language when the analyzer is restarted.
  • Page 67 IMPORTANT NOTE: The HOST NAME and STAR Network Port are configured at the ABB factory and should not be changed. Enter the Primary NIC and Secondary NIC addresses. Enter the Subnet Mask addresses. Enter Multicast addresses. Default Multicast addresses are provided.

  • Page 68: Oven Configuration

    Figure 4-32: Clock Set Example To set the date and time: Navigate to Setup>Master Controller>SBC>Clock>Config Subtab. Adjust the date and time as necessary. Save settings by selecting the Save icon at the top of the screen. 4.6.7 Oven configuration IMPORTANT NOTE: Changing the name will affect OPC and Modbus reporting and any method running on the oven.

  • Page 69: Oven Buttons

    ⎯ Oven>DTC 1>Status displays the indicator state of software and hardware, T-Rating issues, and the associated DTC zones. ⎯ Diagnostic information is also displayed. Refer to the PGC5000 Generation 2 Service Instruction for more information. ⎯ Oven>DTC 1>Malfunction Alarm>Config displays the relay type, contact rating, and connection point.
  • Page 70 Figure 4-35: Digital Input Status ⎯ Oven>DTC 1>Pneumatic Actuator>Config displays the actuator part number (see Figure 4-36). All factory configured valve outputs are displayed below the pneumatic actuator button, with the color-coded indicators displaying the state of all regulated and unregulated valves. Regulated valves are those inside the oven, while unregulated valves are external.
  • Page 71 Figure 4-37: Valve Driver Configuration ⎯ Oven>DTC 1>Valve(#)>Config displays the valve information related to the valve driver with the same number. For internal valves (see Figure 4-38), this screen provides the specific information on the valve type and the configuration of the analyzer. The name of the valve, which is used to identify the valve when creating an analysis, can be changed for reference.

  • Page 72: Isothermal Oven

    4.6.9 Isothermal oven Note that the number of temperature zones is application-dependent, and each zone is independently listed as a button. Zone temperature set points are set and verified under the Setup>Config Subtab. The temperature setup is configured from the data sheets at the factory. To configure the Isothermal Oven, enter the NAME, SETPOINT, LOW LIMIT, HIGH LIMIT, ZONE TYPE and then mark ZONE ACTIVE to activate the zone from this screen (see Figure...
  • Page 73 Figure 4-40: EPC Configuration Subtab The Oven>EPC> Status subtab displays the state and date/time of all active indicators in the EPC zone's group of indicators (see Figure 4-41). Diagnostic information is also displayed. Figure 4-41: EPC Status Subtab Zone # Configuration subtab displays the Zone ID, Name, Actual Pressure, Ramp Rate and Setpoint (see Figure 4-42).

  • Page 74: Detector Amplifier

    ⎯ LOW LIMIT: Minimum Alarm Level ⎯ HIGH LIMIT: Maximum Alarm Limit ⎯ ZONE TYPE: Isobaric, Programmable (set at the factory) The Status subtab displays the state and date and time of all active indicators in the EPC group of indicators.

  • Page 75: Subscriber Tab

    Figure 4-45: FPD configuration The Oven> DetAmp> TCD> Configuration subtab displays the Serial, Part, and Channel number (see Figure 4-46). It also displays the Filament Information, Gain factor and Output Voltage. A manual AUTOZERO button is provided. You can also edit the input and output fields for easy reference from this screen.
  • Page 76 Add New: Adds a new subscriber. Name and IP addresses have to be manually entered. NAME Configurable name of the reporting device TYPE The device type of receiver: OPC (ABB’s OPC Server), RD (Report Device) or STR (STAR Server) IP ADDRESS Primary IP network address of the report device SECONDARY IP...

  • Page 77: Subscriber Config Subtab: Str/Opc/Rd

    4.7.1 Subscriber config subtab: str/opc/rd If you select STR, OPC, or RD as the type in the Config subtab, you can create a new subscriber device, add an existing device, identify subscriber events, and support failover (redundancy). The port for each subscriber type defaults to the type of subscription. The port must be opened at the identified IP address or the Network Comm Failure Indicator will be set.
  • Page 78 Figure 4-49: Subscriber Added and Activated example The following table identifies all events which trigger output to the defined subscriber lists. Table 4-6: Subscriber descriptions Event Trigger/Origination Point Associated Indicator Power Recovery: <DateTime> Analyzer completes power up sequence Report Only Power Fail: <DateTime>...

  • Page 79: Subscriber Config Subtab: Mod

    IMPORTANT NOTE: IP addresses cannot be in the same network subnet. If the network is set up to provide data to both a STAR DMS Network and a DCS via Modbus, the STAR DMS should be considered the primary network and the DCS Modbus connection the secondary network.

  • Page 80: Modbus Map Subtab

    Figure 4-51: Subscriber added, MOD type 4.7.3 Modbus map subtab The Modbus Map subtab (located at the bottom of the screen) under the Subscriber tab allows the user to test the Modbus mapping on the PGC5000 as well as change ranges in the Modbus map. Check or test the Instrument level data tags by selecting which Instrument’s tags to view from the drop- down box below the Instrument tab on the top left side of screen (see Figure...

  • Page 81: Subscriber Tab Configuration

    Figure 4-53: Streams tab IMPORTANT NOTE: The SET VALUE box will not display the current contents of the given Modbus address. The SET VALUE will be written to the internal register. If the PGC5000 overwrites the values prior to the Modbus poll request, the value may not be seen by the Modbus Master. Users are also able to change the ranges of any given Stream tag address.

  • Page 82: Program Tab

    configured to report to the OPC Server as an OPC device type when added in the Subscriber tab (see Figure 4-55). Figure 4-55: Subscriber OPC Example Program tab The Program Tab gives the operator a means for programmatic control and calculations in addition to the built-in capabilities.

  • Page 83: 4.10 Sample Handling System

    Select available valves from the valve list. The valve button depresses (becomes lighter) when active. Manual Mode Action Icons are as follows: Icon Meaning Auto Zero: Sets current chart Y axis value to zero. Chart Reset: Resets current chart X axis value to current time. 4.10 Sample handling system The PGC5000 software controls and collects data from a modular, CANopen ANSI/ISA SP76.00.02- 2002 standard SHS.

  • Page 84: Detectors

    Figure 5-1: Typical analytical flow system diagram The volume of sample is determined by the sample loop. When the valve switches, the sample passes into Column 1, to Column 2 and into the detector cell, where it is converted to an electrical signal. Column 1 performs preliminary separation to remove the heavier non-measured components, which are then backflushed to vent.

  • Page 85: Thermal Conductivity Detector (Tcd)

    5.2.2 Thermal conductivity detector (TCD) The Thermal Conductivity Detector (TCD) works on the principle that a heated body loses heat dependent on the composition of the surrounding gas. Filaments sense the rate of heat loss so that any change in filament current results in a bridge output proportional to the change. The TCD contains a reference filament and a measurement filament.
  • Page 86 Power supply 853A038-1 Detector STD amp assembly 851K006-1 The DBDID is used in the ABB analytical process gas chromatograph for parts-per-billion (ppb) and parts-per-million (ppm) measurements of the following: ⎯ Impurities in high purity gases ⎯ Halogenated hydrocarbons ⎯ Impurities in ethylene ⎯...

  • Page 87: Peak Detection

    5.3.2 Min-max method The ABB min-max method of chromatographic peak detection provides a higher level of accuracy than the classic method. The ultimate goal of the PGC is to provide repeatable and accurate determination of component concentrations. Peak detection algorithms are used to scan the chromatogram to determine what part of the signal represents the peaks of interest and their respective concentrations.
  • Page 88 Figure 5-3: Min-max, single peak The min-max method works strictly on finding minimums and maximums. The Identification Window (IW) area defines the maximum point within the window and the time becomes the crest. The shape of the chromatogram inside the IW is not considered. If the chromatogram shows multiple peaks within the IW, the maximum peak is the crest and only one crest can be determined.

  • Page 89: Baseline Correction, Peak Lumping

    Figure 5-5: Min-max, separate peaks 5.3.4 Baseline correction, peak lumping The min-max method completely defines the peak but requires careful placement of the windows to cover all situations. The projection of a peak is used when either the SB or the EB are offset from each other, or when no stable place can be found for one of them.

  • Page 90: Component Detection (Ez Peak)

    The analyzer currently uses min-max peak detection as described in this section. For PGC5000 V3.0.2.1 and later, and for PGC5000 Generation 2, an EZ Peak feature is included in the software. It allows users to define a peak area by entering only two variables: Component Retention Time (RT) and a Threshold measurement.

  • Page 91: Single Peak Integration Range

    stray above this threshold, the user is given the option to multiply this value by a threshold factor. The result gives an envelope above which the second derivative algorithm decides that a peak may be starting. The threshold factor TCF can be adjusted when the sequence TCF is entered. The larger the factor entered at the setup screen, the larger a deviation from baseline is required before a peak is assumed.

  • Page 92: Baseline Drift

    Figure 5-10: Tangent skim In the case of a shoulder where there is no valley, tangential points can still be located until the shoulder decreases to a critical size in which it is impossible to separate it from the larger peak. The smaller peak is also referred to as a dependent peak and the peak on which it is attached, the parent or independent peak.

  • Page 93: Auto Zero

    5.5.1 Auto zero Auto zero supplies an offset which brings the raw baseline signal down to its most sensitive range. An offset voltage setting that is out of range will set an indicator “alarm in status tab” which will trigger an amp board software error alarm as well.

  • Page 94: Do Next If

    5.5.5 Do next if This allows execution of the next TCF in the method only if the stream value equals the stream name entered in the method. This function allows adding a specific TCF to a particular stream, but not to every stream.

  • Page 95: Script Control

    5.5.10 Script control Run a programmed script at a defined time into the analysis, method or sequence. A script must be created prior to adding this TCF. Table 5-12: Script control Parameter Range Units Description User-definable Text Time Offset 0 to 14400 Seconds Script Name Available from configuration...

  • Page 96: Temperature Default

    5.5.15 Temperature default This returns zone temperature to Setup Tab isothermal setpoint. Table 5-17: Temperature default Parameter Range Units Description User-definable Text Time Offset 0 to 14400 Seconds Zone Available from configuration 5.5.16 Unknown peak This searches for an Unknown Peak in the specified area. Table 5-18: Unknown peak Parameter Range...

  • Page 97: Purge Operation

    The purge air enters the analyzer system through a pressure regulator, an orifice, and a gauge used to set purge flow, and then into the electronics housing where purge air flow is maintained until a fault condition exists. When a purge air alarm condition exists, the PGC will set an *** ALARM *** signal display on the screen and cause a purge alarm contact to switch.

  • Page 98: Rui

    DANGER – Serious damage to health / risk to life. The customer must ensure any override jumper is removed when start-up, maintenance or troubleshooting are completed. The PGC5000 Generation 2 analyzer’s RUI provides remote access, across an Ethernet network, to a specified analyzer (see Figure 5-11).

  • Page 99: Remote Communications Overview

    ⎯ The IEEE floating-point format is used to store the value in two consecutive MODBUS registers. IMPORTANT NOTE: The PGC5000 Generation 2 analyzer is a Big-Endian machine. The MODBUS Client operates on a Little-Endian machine, meaning the most-significant and least-significant registers are reversed.

  • Page 100: Modbus Configuration Recommendations

    ⎯ Specify the register format for each tag by appending the keyword followed by the optional scaling limits such as: • Analyzer.Schedule.Process Stream.Propane.Concentration,01,31000,INTEGER • Analyzer.Schedule.Process Stream.Methane.Concentration,01,31001,FLOAT • Analyzer.Schedule.Process Stream.Hexane.Concentration,01,31003,Scaled0- 9999,0.0,100.0 • Analyzer.Schedule.Process Stream.Isobutane.Concentration,01,31004,Scaled0- 4095,0.0,100.0 The following analog tags are always represented as INTEGER values: ⎯...

  • Page 101: Modbus Slave Communication

    Configurator, the correct protocol format option is selected at the top of the Client Configurator. To create the modbus_client.csv file for the Communication Gateway, the MODBUS option is selected. To create the MODBUS.csv file, select the PGC5000 or PGC5000 Generation 2 option. The Client Configurator’s main display is the Configuration Client (see Figure 5-13).
  • Page 102 Figure 5-14: MODBUS Configurator Example Configuration information requires the following name(s): ⎯ Master Controller ⎯ Oven Name(s) ⎯ Schedules ⎯ Streams ⎯ Component Note that ovens with Integrated Controller will show a Master Controller to represent the functions of the Integrated SBC, even though no physical PGC5000A Master Controller is present. Save the csv file on the Configurator system’s local drive or flash unit.

  • Page 103: Opc Communication

    Input/output options The PGC5000 Generation 2 analyzer offers input/output (I/O) options internal and external to the Master Controller. The local input/output is available on the Single Board Computer PCB (see Figure 5-16).

  • Page 104: Local Input/Output Option

    Figure 5-16: SBC PCB showing local input/output connections 5.9.1 Local input/output option The local input option connections are Purge Air and Purge DPS (see Figure 5-16). These alarms are not customer-configurable. The local output option connections are located on the Single Board Computer (SBC) PCB, as shown in Figure 5-16.

  • Page 105: Internal Input/Output Option

    When the button for a specific output module is selected from the Function Select list, the appropriate Module Configuration display appears. Individual channels are listed on the buttons below the output module name. The button names can be edited for reference. Figure 5-18 illustrates the local output display.

  • Page 106: Digital Output

    ⎯ 2 channel relay output, AC 230 V, DC 30 V (red) ⎯ 4 channel digital input, DC 5 V, with high-side switching (yellow) ⎯ 4 channel digital input, 24 V (yellow) The Control Module (grey) is at the left end of the string of Wago modules and the End Module (grey) is at the right end.

  • Page 107: Digital Input

    5.9.5 Digital input Figure 5-22 illustrates the Digital I/O display, with a digital input channel selected. The editable areas are: ⎯ NAME: reference name used for the button name ⎯ STATE: echoes the installed module’s state (red or green indication is dependent on installation specifications) ⎯...

  • Page 108: Analog Input

    Figure 5-23: Local onboard AO 5.9.7 Analog input Figure 5-24 illustrates the analog I/O display, with an analog input channel selected. The editable areas are: ⎯ NAME: reference name, used for the button name ⎯ RANGE LOW: analog input low limit ⎯...

  • Page 109: Troubleshooting

    Troubleshooting This section contains operator troubleshooting for the PGC5000 Generation 2 analyzer Master Controller and attached ovens. For maintenance, service, and in-depth troubleshooting, see the PGC5000 Generation 2 Service Instructions. Common issues Most problems are the result of incorrect system and subsystem installations. To troubleshoot an...

  • Page 110: Status Indicators

    Figure 6-1: Master Rollup indicator Use the following steps to identify and correct issues. If the Master Rollup Indicator is RED, YELLOW or BLUE (triggered), select the Home Tab and note the running analysis button. If an analysis button indicator light is not GREEN, select the Analysis button, then the Status subtab;...
  • Page 111 Check routing tables if applicable. POST Failure Power On Self-Test fails Cycle power. If POST error persists, note error and contact ABB Support. DTC Failure DTC board indicates a Check power to board and CANBus Oven fault;...
  • Page 112 DTC Indicators. T-Rating Conflict DTC T-Rating does not Possible Configuration Error, contact OVEN.DTC1 match As-Built T-Rating ABB for more information. High Temperature Temperature out of range Check setting at Setup DTC Zone (high) Tab>Oven>DTC# Button. Adjust as needed.
  • Page 113 Indicator Issue Resolution Reset Source Detector Fault Rollup of channel Check Diagnostics Display on Status Ovn#.DTM#. diagnostics Subtab. TCD.# Flame Out FID or FPD flame not Check utilities, igniter including fuel, Ovn#.DTM#. detected. burner, connection verify flows, burner FID/FPD# air. Autoignite Limit Retry of Automatic Check utilities, igniter including fuel,...
  • Page 114 Indicator Issue Resolution Reset Source Invalid Analysis Analysis failed validation From Analysis Tab, edit Analysis to Analysis meet requirements. User controlled. DigIn Check TCF Programmable Input See Digital input TCF. Script checks. Prsr Check TCF Pressure Check failed See pressure check TCF. Script Offline Schedule Offline: Oven is...

  • Page 115: Diagnostic Displays

    Indicator Issue Resolution Reset Source Temp Low Low Temperature lower than Information Only. Low Low Limit Temp Low Temperature lower than Information Only. Low Limit Temp High Temperature exceeds Information Only. High Limit Temp High High Temperature exceeds Information Only. High High Limit Vol Flow Low Low Volumetric Flow lower Information Only.
  • Page 116 Check power to board. Check CAN Controller (OC) at startup. connections. Contact ABB. Mismatched Device Oven Board identity does not match Contact ABB. Check config file. config file. Inaccessible Device Oven Board communication not Check CAN connection to Wago viable.

  • Page 117: Scripting

    Oven Electronics Door. Scripting Introduction The PGC5000 Generation 2 analyzer has programmatic control and calculation in addition to the built- in capabilities. The Program Tab provides the means to customize analyzer operation to support most requirements (see Figure 7-1).

  • Page 118: Attachment To Analysis Elements

    Figure 7-1: Scripting Example The scripting language can invoke a script upon the completion of an analysis providing any necessary calculations to support, for example, BTU calculations. The scripting language supports invoking a script during or upon the method or sequence completion. It also supports invoking a script as a Time Coded Function (TCF) and as a schedule entry.

  • Page 119: Create A New Script

    The scripting language also supports invoking a script as a schedule entry and/or on the change of state. A script is either an End-Of-Analysis (EOA) script or an event-driven script (a script that runs during the analysis). The time offset (execution time) of the script determines the script type. If the cycle time of the longest method in an analysis (analyses can have more than one method) is exceeded by the time offset of the script, then it will be a script of End of Analysis type;...

  • Page 120: Add A Line To A Script

    15. Select the Save icon or the Save As icon to save the modified analysis. 7.2.3 Add a line to a script The Insert Line icon adds a new statement to the script. When a line is added to the script, it is inserted above the current selected statement.

  • Page 121: Activate Stream Command

    7.4.2 ACTIVATE STREAM command Description: Sets the state of a Stream to ONLINE. Makes all uses of the Stream in the Schedule ACTIVE. Syntax: ACTIVATE_STREAM( stream$ ) Comments: stream$ is a string variable (or constant) containing the stream name of the stream to be activated.

  • Page 122: Calibration Concentration Function

    7.4.8 CALIBRATION CONCENTRATION function Description: Returns the component’s calibration concentration. Syntax: CALIBRATION_CONCENTRATION ( component$ ) Comments: component$ is a string variable (or constant) containing the component name. Example: 0010 A = CALIBRATION_CONCENTRATION( “Methane” ) Gets the calibration concentration of component named Methane and assigns it to floating point variable A.

  • Page 123: Component Name$ Function

    accesses the same locations in memory. Values can be stored in COMMON$ by a BASIC program and then accessed by another BASIC program. The COMMON$ array passes strings between BASIC programs. This array shall provide for the storage of 128 character strings of length 128. Syntax: COMMON$( I ) Comments:...

  • Page 124: Deactivate Stream Command

    7.4.19 DEACTIVATE STREAM command Description: Sets the state of a Stream to OFFLINE. Makes all uses of the Stream in the Schedule INACTIVE. Syntax: DEACTIVATE_STREAM( stream$ ) Comments: stream$ is a string variable (or constant) containing the stream name of the stream to be deactivated.

  • Page 125: For

    Raises e to the power of floating point variable T and assigns it to floating point variable A. 7.4.25 FOR . . . NEXT statements Description: Does an iteration loop. Syntax: FOR variable = initial x TO y [STEP z] NEXT [variable, variable] Comments: variable is an integer used as a counter.

  • Page 126: Inject Time Function

    Comments: IndicatorGroup$ is a string variable (or constant) containing the name of the indicator group. Example: 0010 FLAMEOUT = 16384 0020 IF INDICATOR( “Oven1.DTM1.FID.1”, FLAMEOUT) THEN 0020 LPRINT( “Flame Out!” ) 0030 ENDIF 7.4.30 INJECT TIME function Description: Returns a string with the sample inject date and time using the same format as TIME$. Syntax: INJECT_TIME$ Example:...

  • Page 127: Natural Logarithm Function

    Contents of A$ will be “BCD” 7.4.36 NATURAL LOGARITHM function Description: Returns natural Logarithm (to the base e) of floating point expression. Syntax: LN( fp ) Comments: fp is a floating point expression. Example: 0010 A = LN( 2.71828 ) The natural logarithm (logarithm to the base e) of 2.71828 is assigned to floating point variable A.

  • Page 128: Peak End Amplitude Function

    7.4.41 PEAK END AMPLITUDE function Description: Returns the amplitude at the end of the peak. Syntax: PEAK_END_AMP( component$ ) Comments: component$ is a string variable (or constant) containing the component name. Example: 0010 FOR I = 1 TO NUMBER_COMPONENTS 0020 LPRINT PEAK_END_AMP( COMPONENT_NAME$( I ) ) 0030 NEXT I Prints the amplitude of each peak’s end.

  • Page 129: Purging Stream Function

    Comments: component$ is a string variable (or constant) containing the component name. Example: 0010 FOR I = 1 TO NUMBER_COMPONENTS 0020 LPRINT PEAK_START_TIME( COMPONENT_NAME$( I ) ) 0030 NEXT I Prints the time at the start of each peak. 7.4.47 PURGING STREAM function Description: Identifies the stream currently purging for the given Schedule.

  • Page 130: Read Analog Input Function

    7.4.52 READ ANALOG INPUT function Description: Returns the value of an Analog Input. Syntax: READ_ANALOG( ovenaddress$ ) Comments: ovenaddress$ is a string variable (or constant) containing the address of the input, e.g. “EXIO1.WAGO1.AI.1” Example: 0010 AN1 = READ_ANALOG ( “EXIO1.WAGO1.ANAIN.1” ) 7.4.53 READ DIGITAL INPUT function Description:...

  • Page 131: Schedule Stop Function

    Example: 0010 SCHEDULE_RUN( “Schedule1” ) 7.4.60 SCHEDULE STOP function Description: Issues a schedule STOP command to the designated schedule. Syntax: SCHEDULE_STOP( schedule$ ) Comments: schedule$ is a string variable (or constant) containing the schedule name. Example: 0010 SCHEDULE_STOP( “Schedule1” ) 7.4.61 SET BASIC ALARM function Description:...

  • Page 132: Time$ Function

    Example: 0010 IF STREAM_STATUS( “CalStream” ) = 0 THEN 0020 LPRINT “CALIBRATION STREAM OFFLINE” 7.4.67 TIME$ function Description: Returns a string containing the date and time in the following format: hh:mm:ss Day DD Mon YYYY (e.g., 17:46:31 Mon 06 Nov 1989) Syntax: TIME$ Example:...

  • Page 133: Y2X Function

    Example: 0020 WRITE_DIGITAL( “InIo.Wago1.DigOut.3”, 0) 7.4.73 Y2X function Description: Returns the value of Y raised to the X power. Syntax: Y2X( fpbase, fpexp ) Comments: fpbase, fpexp are floating point expressions. Example: 0010 LPRINT Y2X( 2, 10 ) Prints the value of 2 raised to the power of 10 ( = 1024 ). 7.4.74 ZONE PRESSURE function Description:...
  • Page 134 To determine if the PC has a previous VistaNET software installation, navigate to the Control Panel/Programs/Uninstall a Program (see Figure 8-2). Figure 8-2: Control Panel/Uninstall If you have a previous installation, you will see Figure 8-3. Figure 8-3: Previous Installation The old version of the VistaNET core software must be uninstalled before you can install the new version.

  • Page 135: Communication Star Gateway Upgrade

    PGC5000 Generation 2. The Communication Gateway will only need upgrading if you intend to receive data from a PGC5000 running version 4 or when connecting a PGC5000 Generation 2 to the system. It is recommended to make an image of the Communication Gateway with the disk imaging software provided in case something goes wrong in the upgrade process.
  • Page 136 Next, perform an installation of the STAR Gateway version 4 software by running the Setup.exe file on the STAR Gateway media provided by ABB Customer Service. Copy the files that were saved before the uninstall to the location where the STAR Core and STAR Gateway products were installed.

  • Page 137: Upgrade Older Pgc5000S

    Gateway server VNSA configuration file, you must remove its entry from the VNSA table. Failure to do so will cause a name conflict when the upgraded PGC5000 / PGC5000 Generation 2 analyzer restarts, and network communication will not work correctly after the system software upgrade.

  • Page 138: Temperature Programmed Oven

    Since the Master Controller for the Temperature Programmed GC is identical to the PGC5000 Generation 2 Master Controller, the information regarding the Master Controller in the relevant sections of the PGC5000 Generation 2 Operating Instructions and Service Instructions is all applicable. 9.1.2...

  • Page 139: Temperature Programmed Oven

    TP oven in order to provide an optimal analytical flow path and eliminate potential cold spots. The detector has a heater block surrounding it; otherwise, it is the same as that used in the standard PGC5000 Generation 2 analyzer. 9.2.3...

  • Page 140: Pgc5000A Used As A Continuous Analyzer Controller (Cac) Replacement

    This chapter is for users that have purchased the PGC5000A controller to be used as a replacement for the ABB CAC. If not familiar with the basic terms and function of a CAC, review the CAC manual provided with the CAC 3220/2220-OPS. Contact ABB Technical Support for these manuals.

  • Page 141: 10.4 Scripting Example To Read I/O

    ⎯ Component at 30 seconds. If multiple components are coming in from the instrument, then space the components in 1 second intervals, making sure all of them are of a type calculated. The scripting is to be run at 1 second past the end of analysis time. 10.4 Scripting example to read I/O Script names will be READ, analog number, then digital number where applied.
  • Page 142 We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

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