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A B B M E A S U R E M E N T & A N A LY T I C S | S E R v I C E I N S T R U C T I o N
PGC5000 Generation 2
Process gas chromatograph
Measurement made easy
Further information
Additional documentation on the PGC5000
Generation 2 process gas chromatograph is
available for download at www.abb.com/analytical.
Alternatively simply scan this code.
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Table of Contents
Troubleshooting
Related Manuals for ABB PGC5000 Generation 2
Summary of Contents for ABB PGC5000 Generation 2
- Page 1 A B B M E A S U R E M E N T & A N A LY T I C S | S E R v I C E I N S T R U C T I o N PGC5000 Generation 2 Process gas chromatograph Measurement made easy Further information Additional documentation on the PGC5000 Generation 2 process gas chromatograph is available for download at www.abb.com/analytical. Alternatively simply scan this code.
- Page 2 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 information.
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Page 3: Table Of Contents
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Contents Glossary .............. 5 Restarting the analyzer ........28 Upgrading software ........... 28 Safety and symbols ..........6 5.10 Optional discharge ionization detector ....28 5.10.1 Plasma will not light ....... 29 Introduction ............ - Page 4 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 7.1.3 Capillary column installation ....48 7.9.2 Removing the detector......69 7.1.4 Cutting capillary columns ....... 49 7.9.3 Installing the detector ......69 Repairing the flame ionization detector ....49 7.9.4 Replacing the Exhaust tube ....
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Page 5: Glossary
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 1 Glossary Access Control List Absence of Condition BIOS Basic Input/Output System Controller Area Network Central Processing Unit Discharge Ionization Detector Digital Signal Processor Digital Temperature Controller Electronic Pressure Controller Electrostatic Discharge Flame Ionization Detector Flame Photometric Detector Input/Output... -
Page 6: Safety And Symbols
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 2 Safety and symbols The following symbols are used in this manual to alert the user to possible hazards and to provide additional information. Indicates that the referred item can be Indicates that referenced items are hot and should not be touched without susceptible to Electrostatic Discharge... -
Page 7: Introduction
LUI or RUI, whichever applies to the particular system. The PGC5000 Generation 2 analyzer is compatible with version 4.2.1, and greater, of the STAR Data Management System. Each analyzer has a temperature code (T-Rating) listed on the nameplate. This T-Rating indicates the temperature classification of the area in which the analyzer has been designed to operate. -
Page 8: Drawings
Section 5.7. 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. It will be connected to the analyzer network via Ethernet and can connect to any PGC5000 Generation 2 device that is supported. -
Page 9: Vapor Version
Ex Zone 1 area. Refer to the analyzer nameplate for purge and pressurization specifications. 3.8 System variations This manual supports the basic PGC5000 Generation 2 analyzer. An appendix to the main manual presents additional instruction for special applications such as PGC5000TPGC (temperature programmed GC), PGC5007 (fuel sulfur GC), and PGC5009 (fast GC). -
Page 10: Maintenance
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 4 Maintenance 4.1 Equipment and supplies required Factory Data Sheets from the Data Package Flow measuring device 4.2 Preventive maintenance The oven design is specifically designed to eliminate the need for extensive and complex maintenance. Where preventive maintenance procedures require particular time frames or intervals, maintain an inspection log and inspection data. -
Page 11: Cleaning
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D When you use a single cylinder to supply a gas, check the cylinder regularly and replace it when the pressure falls below 100 psig, using another cylinder containing the specified gas. 4.2.2 Cleaning Prior to cleaning the analyzer, turn off the power to the unit. -
Page 12: Diagnostics And Troubleshooting
Tab>Status subtab (see Figure 5.1, which shows the DTC1 screen). The indicator boxes, when filled (black), indicate the named action. The hex codes represent error codes. When submitting an issue to ABB support, always include a screen capture, or record and include the filled indicator boxes and hex codes shown on the display. Include with your report all screens that apply (i.e., Oven, EPC DTC, and zones). -
Page 13: Power Failure Recovery
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 5.2.1 Power failure recovery The Master Controller and Ovens power on, but the schedule does not start immediately. The schedule will not start until the Oven has met the minimal temperature requirements established in the Setup Tab. For more information refer to the Operating Instructions, OI/PGC5000/GEN2, which provides more information on restarts after power failure in the Power Failure setup paragraph of the Schedule Tab section. -
Page 14: Single Board Computer
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 5.3.1 Single board computer The SBC PCB has eight LEDs, numbered CR1 through CR8 left to right (see Figure 5.3). These LEDs are connected to GPIO pins on the MPC8309 processor and are turned on and off with firmware. CR1 to CR8 SBC CAN Interface Cards Fig. - Page 15 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D If the Digital Signal Processor (DSP) system fails during power-up, the LED bank indicates what was being attempted. CR7 and CR8 are off. CR1 (MSB) through CR6 form a binary code as follows: 000001 CAN initialization error 000010...
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Page 16: Detector Canbus Node Identification
5.3.4 Detector CANbus node identification The Detector CANbus node identification is set at the factory by jumpers per ABB Bulletin 851J003. This bulletin is supplied with all replacement detector amplifiers. The bulletin covers all jumper settings required for any detector amplifier. To ensure correct jumper settings are applied to the new detector amplifier, take a picture of the original detector amplifier and reference this picture when applying jumpers to the new board. -
Page 17: Identifying Issues
POST failure Power On Self-Test fails Cycle power. If POST error persists, MC or Oven with Displays RED text on MC note error and contact ABB Support. Integrated Controller or RUI screen Network Comm Communication to an Subscriber comm path incomplete,... - Page 18 Defective temperature sensor. System power Oven.DTC#.Tz.# exceeded oven T-Rating Check temperature probe as MUST be cycled described in Over Temp Resolution in this section. Contact ABB for more information. Low Temp Temperature out of range Check setting at Setup Oven.DTC#.Tz.# (low) Tab>Oven>DTC# Button.
- Page 19 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D INDICATOR ISSUE RESOLUTION (CHECK & CORRECT) RESET SOURCE Out of Control Temperature deviates > Check analysis temperature control Oven.DTC#.Tz.# ±10 deg from setpoint TCF settings. Check zone indicators and Diagnostic Displays. Ramp Out of Temperature deviates >...
- Page 20 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D INDICATOR ISSUE RESOLUTION (CHECK & CORRECT) RESET SOURCE Out of Control Pressure deviates >±3.575 Check analysis pressure control TCF Oven.EPC.PZ.# prsi from setpoint settings. Check Zone indicators and Diagnostic Displays. Possible leak Leak check analyzer.
- Page 21 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D INDICATOR ISSUE RESOLUTION (CHECK & CORRECT) RESET SOURCE Unknown Peak detected in the Check flows. Verify correct operation When Analysis Component analysis and not defined in of all analytical valves. Verify sample Reported the method flow to oven.
- Page 22 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D INDICATOR ISSUE RESOLUTION (CHECK & CORRECT) RESET SOURCE Vol Flow High High Volumetric Flow exceeds Information Only. High High Limit Pressure Low Low Pressure lower than Low Information Only. Low Limit Pressure Low Pressure lower than Low Information Ony.
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Page 23: Operation Troubleshooting
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D “#” is used in place of numbers to eliminate repeats in multiple card and oven systems. "Information Only" signifies the set indicator is activated in response to the setup criteria. It does not necessarily identify a fault. -
Page 24: Double Sampling
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Sample valve failure. Manual verify that valves are operating. Manually verify that solenoid valves are operating. Service valves or replace solenoid as applicable. Replace DTC Master Digital. Failed Detector Amplifier PCB. 5.6.4 Double sampling The chromatogram peaks appear to have double apexes. -
Page 25: Reduced Peak Size
Possible defective air purge regulator Leak in column train. Leak check analyzer. Contact the ABB factory for assistance in testing the functionality of the EPC Proportional Valves as well as Pressure Sensors in the EPC block. 5.6.10 Reduced peak size The chromatogram or peaks have reduced in size from that of a previous analysis. -
Page 26: System Backup And Recovery
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D It is important that you perform the system restore in the order described in this document. 5.7.1 System backup, restore and recovery From the Setup tab the PGC5000 has several recovery options available (see Figure 5.6). The options allow restore point creation and/or chromatogram data file copy or deletion Factory Restore Access... -
Page 27: System Backup Error Messages
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Creating the recovery drive takes several minutes. Wait for the “Operation Completed” message before ejecting and removing the USB thumb drive. Remove and store the Recovery drive in a safe place. You must use a USB drive having 32 gb or less. -
Page 28: Restarting The Analyzer
It is not necessary to cycle oven power unless the Oven contains the Integrated Controller. 5.9 Upgrading software Software upgrades may be available through the ABB Support on a need basis. Please follow the guidelines described in the Section 8, paragraph 8.1.1 of these instructions. -
Page 29: Plasma Will Not Light
5.10.2 No signal No power to plasma power supply: If the fuse is good, contact ABB customer support for further assistance. Verify power to plasma: Observe the plasma tube with the lights off. There should be a pink or almost white glow in the plasma tube. -
Page 30: Noisy
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 5.10.4 Noisy Bad electrical connections: Check the signal cable connection and the bias voltage cable connection. Check the signal cable shield for fit. This fitting should be snug for best performance. Verify the connection between ground and ground. Leak: Especially true when operating in the helium ionization detection (HID) mode. -
Page 31: Shifting Retention Times
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Defective bias voltage: If the bias voltage is not stable, it is possible to get signal spikes. Verify the bias voltage and stability using a VOM connected between the bias voltage rod and the oven chassis ground. 5.10.8 Shifting retention times If compounds elute early, the wrong restrictor may be in place. -
Page 32: Component Repair
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 6 Component repair 6.1 General 6.1.1 Preparation and procedures The following instructions assume that all equipment has been properly installed and checked, that the analyzer has been application engineered, and that temperature controllers, alarm switches and other adjustments have been properly set. Ensure no hazardous or flammable gases are present in the immediate area of the analyzer, as they may create the potential for fire, explosion, and damage to property and injury to personnel. -
Page 33: Master Controller Cabinet
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 6.2 Master controller cabinet The Master Controller houses the following components, located as shown in Figure 6.1. • Single Board Computer (SBC) and Mounting Bracket • Power Supply Optional input/output modules •... -
Page 34: Sbc Can Interface Cards
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Using a flat blade screwdriver, release the Power Supply from the DIN rail and discard it. Install the new Power Supply onto the DIN rail on the back of the Mounting Bracket. Connect the wires to the new Power Supply, using the tags to ensure proper reconnection. -
Page 35: Master Controller Cabinet Door
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 6.3 Master controller cabinet door The back of the Master Controller front door assembly comes complete with the Front Panel PCB, Liquid Crystal Display, Touch Panel Controller, and associated cables (see Figure 6.3). LCD Assembly Front Panel PCB Board Part Number... -
Page 36: Oven Component Locations
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 6.4 Oven component locations 6.4.1 Class B oven components The Class B Oven incorporates PCBs mounted on the inside of the front and side doors and on walls of the electronics compartment (see Figure 6.4). -
Page 37: Replacing The Epc Control Pcb
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D In the Oven with Integrated Controller, the SBC resides on the lower door at the top location. The second Detector Amplifier is on the top door (see Figure 6.6). Detector Amplifier SBC PCB Detector Amplifier DTC Analog PCB... -
Page 38: Preparation
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 6.6.1 Preparation Before performing EPC repair, you must turn off power to the analyzer as described in the following steps. Be sure that the EPC Control Assembly has cooled to ambient temperature (approximately one hour) before proceeding. -
Page 39: Installing The Epc Control Assy
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D On the wall inside the left side of the oven, remove the lock nut on the pipe nipple which retains the EPC Panel cables (see Figure 6.7). Lock Nut Fig. 6.7. EPC Cable Lock Nut 10. -
Page 40: Installing A New Sensor Pcb
Slightly tighten the two screws evenly, removing any play in the assembly (but applying no torque) and ensuring it is mounted straight up and down. Tighten one screw, using torque limiting screwdriver ABB Tool 801Z003-1, set at 1 in.-oz. Tighten the second screw to 2 in.-oz. -
Page 41: Removing A Proportional Valve
18. Ensure that the flame-proof or explosion-proof surfaces of the cover or the body of the Control Assembly are not damaged. 19. Reinstall the EPC Control Assembly cover and insert the ten screws and tighten them to 16 in.-lb, using ABB Tool TL1000/TL1002. -
Page 42: Installing A New Control Pcb
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Using 2.5 mm hex socket wrench ABB Tool TL1007, remove three screws and washers (two from the triacs and one from the PCB mounting bracket at the right side of the PCB). -
Page 43: Fid Amplifier Assembly
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 10. Reinstall the EPC Control Assembly cover and then insert the ten screws and tighten them to 16 in.-lb, using ABB Tool TL1000/TL1002. 11. Reinstall the top panel and tighten the four screws. -
Page 44: Fpd Gain Adjustment, New Electrometer
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Select the Setup tab (see Figure 6.11). Auto Zero Offset Button Fig. 6.11. Setup Tab, Showing FPD features In the Function Select list, select the desired oven. Select the desired Det Amp. Select FPD. - Page 45 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Select the Setup tab (see Figure 6.13). Auto Zero Offset Button Fig. 6.13. Setup Tab, Showing FPD features In the Function Select list, select the desired oven. Select the desired Det Amp. Select FPD.
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Page 46: Tcd Amplifier Assembly
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 6.9 Thermal conductivity detector amplifier assembly In the Class B Oven, the TCD Amplifier Assembly is attached to inside of electronics compartment door (left side of oven) on the center section of the door. In the Class C Oven, it is attached to inside of the lower electronics compartment door (left side of oven), on the upper section of the door. -
Page 47: Replacing Dtc Auxiliary Pcb
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Remove the DTC Digital PCB. Reverse steps to install the new DTC Digital PCB. 6.12 Replacing the dtc auxiliary pcb In both the Class B and Class C Ovens, the DTC Auxiliary PCB is attached to the lower section of the inside of the front electronci compartment door (left side of oven). -
Page 48: Subassembly Repair
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 7 Subassembly repair 7.1 Column repair 7.1.1 Column removal If analyzer is running and a column is to be replaced, stop the analysis. Reduce Isothermal Oven temperature by reducing oven heater air pressure to zero psig. Wait for columns to cool to room temperature Power down analyzer. -
Page 49: Cutting Capillary Columns
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 11. Set carrier pressure and purge column for at least 30 minutes and leak check. NOTE: SNOOP™ IS NOT recommended for leak checking capillary columns. 12. Perform the PGC5000 series startup procedure as described in Operating Instructions OI/PGC5000/GEN2. 13. -
Page 50: Fid Cell Access
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 7.2.1 FID cell access If power is applied to the analyzer, turn it off. Turn off oven air to the Isothermal Oven and allow all temperature zones to cool. Turn off carrier and other utility gases, as applicable. Open the isothermal oven door. -
Page 51: Replacing The Igniter Assembly
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Spread or expand the end of approved heat shrink to allow easy installation over the solder connection. 10. Install heat shrink over each wire and slide it as far as possible from the connection. This will prevent premature shrinking when the connection is soldered. -
Page 52: Replacing The Fid Cable Assembly
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 7.2.7 Replacing the fid cable assembly This procedure requires a special tool, Insertion Tool ABB P/N TL799M013-1, to assist in passing the cable through the insulation between the Electronic Housing and the Oven. -
Page 53: Removing The Filaments
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D It is the customer’s responsibility to ensure that the area is safe and hazard free, and will remain so the entire time the analyzer is open. This responsibility includes ensuring adequate ventilation in analyzer shelter and obtaining proper work permits, etc. -
Page 54: Leak Test
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D If all resistance measurements are correct, go to "Connecting the Filaments." If any resistance is too low, go to step 8. If the resistance measurement is approximately 20 ohms, filament being tested is contacting the internal wall of the detector cell cavity. -
Page 55: Repairing The Multiport Tcd
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 7.4 Repairing the multiport thermal conductivity detector This repair should only be attempted by people who are properly trained and possess the expertise for this repair. 7.4.1 Accessing the detector Turn off power to the analyzer. Turn off instrument air. - Page 56 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D ABB recommends using an alcohol such as Methanol to check for leaks as it dries quickly and leaves no residue. 15. Power down the oven. 16. Turn off carrier and utility gases.
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Page 57: Repairing The Flame Photometric Detector
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 7.5 Repairing the flame photometric detector 7.5.1 Replacing the photomultiplier assembly It is the customer’s responsibility to ensure that the area is safe and hazard free, and will remain so the entire time the analyzer is open. -
Page 58: Replacing The Burner Block O-Rings
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 7.5.3 Replacing the burner block o-rings Refer to Figure 7.7 when performing this procedure. O-Ring 45051-4-106 O-Ring 45051-4-102 O-Ring 45051-5-18 Adapter Fig. 7.7. Burner Block Cross Section (showing O-rings) Perform steps 1 through 4 of “Replacing the Burner Block.” To remove a particular O-ring, carefully remove the associated connector and then remove the O-ring. -
Page 59: Lsv Disassembly On The Analyzer
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D It is also important to use two wrenches when tightening the sample line connections. One wrench must be used to back up the force applied to tighten the fitting. Direct wrench force (not using a back-up wrench) will damage the seals and possibly bend the stem. -
Page 60: Lsv Reassembly On The Analyzer
If you remove an O-ring, you must always replace it with a new O-ring. Do not re-use O-rings. In all steps the lubricant used is High Vacuum Grease, ABB part number 006904-1. Clean the seals with acetone and air dry them. - Page 61 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 13. Stack the 15 Belleville springs onto the 1/4-inch thin wall plastic tubing, as shown in Figure 7.10. Fig. 7.10. Stacking the Belleville Springs 14. Using the tubing only as a guide, slide the Belleville springs over the stem into the bore of the body. 15.
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Page 62: Removing Lsv From The Analyzer
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 31. Close the isothermal oven door. 7.6.3 Removing the LSV from the analyzer Stop analysis at the end of a cycle. Remove power from the analyzer. Allow all temperature zones to cool, maintaining flow while the columns are cooling. Turn off carrier, sample, and air to the analyzer. -
Page 63: Preparation And Safety
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 7.7.1 Preparation and safety Ensure that there are no hazardous or flammable gases present in the immediate area of the analyzer. The purged electrical sections of the analyzer will be declassified when purge is removed, and a danger exists for fire, explosion, damage to property and injury or death to plant personnel during the nonpurged time. -
Page 64: Replacing The O-Rings
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 7.7.4 Replacing the o-rings If you remove an O-ring, you must always replace it with a new O-ring. Do not re-use O-rings. Since the O-rings are inside the valve, you will have to remove the Valve Body from the analyzer. The O-rings come in a kit, with different kits for 40-psig and 60-psig CP valves (see Figure 7.13). - Page 65 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 15. Position O-Ring Tool part number 3122-1 over the piston rod (see Figure 7.14). LOCKWASHER PISTON PISTON O-RING PISTON ROD SCREW O-RING PISTON ROD INSTALLATION TOOL Fig. 7.14. Installing the O-Rings on the Piston Rod and Piston 16.
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Page 66: Replacing The Valve Plate
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Check the operation of the valve. 7.7.5 Replacing the valve plate To replace the Valve Plate (see Figure 7.16): VALVE PLATE SCREWS VALVE BODY Fig. 7.16. Installing the Valve Plate on the Valve Body Clean the inside counter-bored holes of the Valve Body to remove contamination and old sealant. -
Page 67: Removing A Valve
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Service or replacement of the O-rings, plungers, or springs must be performed at the factory. Do not disassemble the valve unless system malfunction is definitely isolated to the valve. Perform all other system checks first. -
Page 68: Replacing The Diaphragm (1 Screw)
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 7.8.4 Replacing the diaphragm (one screw type) Remove the hex head cap screw from the center of the valve cap (see Figure 7.18). Screw Port 1 Fig. 7.18. One-Screw Cap, Showing Port 1 Orientation Lift the cap from the two alignment pins. -
Page 69: Optional Discharge Ionization Detector
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 7.9 Optional discharge ionization detector Replacing the reactor tube while it is in the oven is not advised. Due to the small pieces and awkward angles involved in the procedure, it is highly recommended the Discharge Ionization Detector (DID) be removed before attempting replacement. The detector is located in the oven as shown in Figure 7.19. -
Page 70: Replacing The Exhaust Tube
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Secure the shield with the Phillips head screw retained earlier. Remove, inspect, and replace if necessary, the PTFE ferrule in the reaction gas assembly before continuing. The plasma cell is marked with a dot on the end of the cell that installs in the detector body. Install the unmarked end of the plasma cell into the reaction gas assembly. -
Page 71: Replacement Parts
8.1.1 Equipment identification Include the following information, found in the Data Package and on the analyzer nameplate, in any communication concerning replacement parts or components: • ABB Sales Order Number. Analyzer Model Number. • Analyzer Part Number (P/N) and serial number. -
Page 72: Oven Configuration Identification
Fig. 8.3. Software Configuration Identification 8.1.5 How to order Please contact your local ABB sales or service representative for specific instructions on ordering parts. Always include the information listed in Equipment Identification and Configuration Identification in your request. The remainder of this section lists the replaceable parts and components by their location in the equipment. Part numbers and drawing numbers listed here are for identification purposes only. -
Page 73: Master Controller
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 8.2 Master controller 8.2.1 Master controller chassis (see Figure 8.4) Description Part Number Power Supply 857Z035-1 SBC Controller PCB 852A059-1 SBC Carrier PCB 852A060-1 SBC CAN Interface Card 852A061-1 SD Card 857Z047-1 Electronic Pressure Switch Assembly 851A105-1... -
Page 74: Back Of Door
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 8.2.2 Back of door (see Figure 8.5) Description Part Number Front Panel PCB 852A009-1 LCD Display 857Z002-1 LCD Display 857Z039-1 Touch Panel Controller 857Z030-2 LCD Assembly Front Panel PCB Board Part Number Touch Panel Controller Fig. -
Page 75: Left Front Door Components
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 8.3.3 Left front door components (see Figure 8.7) Description Part Number DTC Auxiliary PCB 852A029-1 DTC Auxiliary PCB Fig. 8.7. Left Front Door... -
Page 76: Class B Main Interior Components
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 8.3.4 Class B main interior (see Figure 8.8) Description Part number Oven Heater Kit, 115 V 1000 W 856Z003-1 Oven Heater Kit, 230 V 1000 W 856Z003-2 Oven Heater Kit, 115 V 500 W 856Z003-3 Oven Heater Kit, 230 V 500 W 856Z003-4... -
Page 77: Liquid Sample Valve
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 8.3.5 Liquid sample valve (see Figure 8.9) Description Part Number O-Ring Seal Kit 791K003N-1 0.125 inch Stem (per application) 791A008B-_ 0.125 inch Seal (per application) 791M001B-_ 0.062 inch Stem (per application) 791A009B-_ 0.062 inch Seal (per application) 791M028B-_... -
Page 78: Single-Port Tcd
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 8.3.7 Single-port thermal conductivity detector (see Figure 8.11) Description Part Number Filament Kit NEC 800K003-1 Filament Kit CENELEC/CSA 800K003-2 Reference Measure Filament Filament Fig. 8.11. Single-Port TCD Components 8.3.8 Multiport Thermal Conductivity Detector (see Figure 8.12) Description Part Number Filament Kit... -
Page 79: Burner Block Components
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 8.3.10 Burner block components (see Figure 8.13) Description Part Number Burner Block Assy 804A005-1 Burner Block Assy with Temp Sensor 804A005-3 Heater Cartridge, 70W 3617444-1 Thermocouple Assy 3617462-1 Electrode Nut 804A004-1 3617432-1 O-Ring 15/16-in OD, Fluorocarbon 45051-4-106... -
Page 80: Optional Did Replacement Parts
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 8.3.12 Optional DID replacement parts (see Figure 8.15) Part Number Description Quantity 852A038-1 Power Supply DBDID 885A005-1 Detector Cell Assembly DBDID 851K006-1 FID/DBDID Amplifier Kit (Order 851K006-1 Amp Kit to build the standard 851A094-11412 per included 851J003 bulletin.) Fig. -
Page 81: Class C Oven
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Proportional Valve Sensor PCB Heater Control PCB Fig. 8.16. EPC Control Assembly 8.5 Class C oven The Class C Ovens have the same components as the Class B Ovens, although the quantities may differ. 8.6 Extended input/output option The Extended Input/Output Option parts are the same for all versions (internal, external EIO, and external AIO). -
Page 82: Temperature Programmed Oven
General troubleshooting procedures are detailed in the Service Instructions. The recommended procedure for troubleshooting beyond the scope of that manual is to return the analyzer to ABB for service, repair or replacement. The analyzer is designed with self-diagnostics to identify malfunctions and probable causes. When the analyzer identifies a malfunction, the Single Board Computer (SBC) takes steps to prevent or minimize damage (i.e., closes the inlet valves and opens... -
Page 83: Replacing Fid Components
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D Caution should be used when working with the soldering iron. The soldering iron, melted solder and heated wiring can cause severe burns. Safety glasses and protective gloves should be used to protect against hot molten solder and hot surfaces. -
Page 84: Removing Tcd Insulation And Heater
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 9.3.1 Removing the TCD insulation and heater block It is the customer’s responsibility to ensure that the area is safe and hazard-free, and will remain so the entire time the analyzer is open. This responsibility includes ensuring adequate ventilation in analyzer shelter and obtaining proper work permits, etc. -
Page 85: Temperature Programmed Oven
PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D 9.4.2 Temperature programmed oven (see Figure 9.3). Description Part Number Flame Ionization Detector (FID) with Heater Block 888A005-1 Single Port Thermal Conductivity Detector (TCD) with Heater Block 888A006-1 Detector with Heater Block Fig. - Page 86 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D NOTES...
- Page 87 PGC5000 ǀ PROCESS GAS CHROMATOGRAPH ǀ SI/PGC5000/GEN2-EN Rev D NOTES...
- Page 88 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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