ABB PGC5000 Series Service Instructions Manual Download

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PGC5000

PGC5000 Series Service Instructions

5 Diagnostics and troubleshooting

SI/PGC5000-EN, Rev B

If the LEDs are not illuminated, check power to the unit. If the top LED is GREEN and flashing, the system is initializing.

For all other instances use the table below.

LED

Red

Amber

Green

Top

Oven Idle

Future Use

Executing Analysis

Middle

DTC Malfunction

Purge Alarm

T-Rating Mismatch/Violation

Zone Temp Alarm/Violation

Zone Voltage Error

Low Oven Air and/or

Carrier Gas Alarm

DTC Operation Normal

Bottom

FID/FPD Flame Out

Future Use

FID/FPD Flame Ignited

5.2.3 System board battery

The System Board Battery is a small rectangular boxed object (“Snap Hat”) located in the middle of the Single Board Computer

(SBC) in the Master Controller. In the unlikely event the battery fails, it can be replaced.

Failure symptoms: System Clock resets when system is powered off.

Removal procedures: Place fingers or tool on both sides of the battery. Apply equal force to both sides and pull it away from

the SBC.

Installation Procedures: Locate battery connection base on the SBC. Ensure all four connection pins are straight and free of

contaminants. Align pins with base, push in firmly.

5.3 Board level light emitting diodes

Most circuit boards installed in the Master Controller and Ovens are equipped with light emitting diodes (LEDs). The LEDs can

display ongoing activity (communications, activation, etc.) and some are programmed to display diagnostic error codes.

The displayed activity and error codes are used to troubleshoot or confirm the ongoing functions of the analyzer system.

Not all LEDs are assigned blinking response states. They are primarily used for debugging when no user interface is available.

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.

USB

Ports

Network

Activity

Health

Monitor

Fig. 5.3. SBC LEDs

The USB Port Activity light identifies activity on the Universal Serial Busses. One is used to connect to the front panel.

Summary of Contents for PGC5000 Series

Page 1: ...PGC5000 Series Process Gas Chromatographs Service Instructions SI PGC5000 EN Rev B Measurement made easy ...

Page 2: ... a world leader in process automation technology we offer customers application expertise service and support worldwide We are committed to teamwork high quality manufacturing advanced technology and unrivalled service and support The quality accuracy and performance of the Company s products result from over 100 years of experience combined with a continuous program of innovative design and devel...

Page 3: ...rror messages 31 5 8 Restarting the analyzer 32 5 9 Upgrading software 33 5 10 Optional discharge ionization detector 33 5 10 1 Plasma will not light 33 5 10 2 No signal 33 5 10 3 Low signal 34 5 10 4 Noisy 34 5 10 5 High baseline 35 5 10 6 Drifting baseline 35 5 10 7 Spikes 35 5 10 8 Shifting retention times 35 6 Component repair 36 6 1 General 36 6 1 1 Preparation and procedures 36 6 1 2 Electro...

Page 4: ...LSV from the analyzer 66 7 6 4 Installing LSV on the analyzer 66 7 7 CP valve repair 67 7 7 1 Preparation and safety 67 7 7 2 Replacing the slider 67 7 7 3 Replacing the wedges 68 7 7 4 Replacing the o rings 68 7 7 5 Replacing the valve plate 70 7 8 Replacing diaphragm valves 70 7 8 1 Preparation 70 7 8 2 Removing a valve 71 7 8 3 Replacing the diaphragm 4 screw 71 7 8 4 Replacing the diaphragm 1 ...

Page 5: ...r FPD Flame Photometric Detector I O Input Output LCD Liquid Crystal Display LED Light Emitting Diode LSV Liquid Sample Valve LUI Local User Interface operational software interface located on the Master Controller MC Master Controller PC Personal Computer PCB Printed Circuit Board PDO Process Data Object PGC Process Gas Chromatograph PIC Programmable Integrated Circuit POST Power On Self Test PTF...

Page 6: ... not be touched without care Indicates that a risk of electrical shock and or electrocution exists Indicates a potential hazard which could cause serious injury and or death or indicates the presence of a hazard which could result in corruption of software or damage to equipment or property Indicates that referenced items are susceptible to Electrostatic Discharge ESD damage and should not be touc...

Page 7: ...and operation of the analyzer This manual refers to these data sheets and drawings as the Data Package 3 2 Drawings Since analyzer configuration depends on the particular application this manual does not contain generic engineering drawings and diagrams You should utilize the drawings diagrams and replacement parts lists provided on the Data Package supplied with your analyzer to ensure you are us...

Page 8: ... the oven 3 4 2 Vapor version The vapor version has a vapor input to the analysis so it does not require a liquid sample valve The duration of an analysis cycle depends on the applications and consists of the following Carrier gas transports the vaporized sample through the columns The column then separates the components and passes them into the detector The detector measures the sample across th...

Page 9: ...ent air supply Sample system flows and pressures Cylinder gas pressures replace as necessary Verify calibrate and calibrate as necessary Compare resultant chromatograms with those in Data Package Check set analytical flows and pressure as necessary per factory data package Backup controller tables after calibration and or any changes to system operational parameters Check carrier line dryers chang...

Page 10: ... water and detergent Do not use abrasive cleaners on the analyzer Remove dust in the inside of the oven to eliminate electrical conductivity and possible short circuits under high humidity conditions The best way to clean the interior is to dislodge the accumulated dust with dry low velocity air and then remove any remaining dirt with a soft paint brush and vacuum cleaner 4 3 System backup Before ...

Page 11: ...rocess tests fail If the analyzer triggers the POST Failure indicator reboot the Master Controller and watch the Local User Interface LUI display screen for Red text The Red text reveals the board subsystem having the initialization problem 5 1 2 Indicator boxes and hex codes Some functions have associated indicator boxes diagnostic displays and hexadecimal Hex codes displayed on the Setup Tab Sta...

Page 12: ...istance Check heater connections CAN node not found DTC Device did not communicate with Oven Controller or go online Check board LEDs for error Lost CAN heartbeat DTC Device stopped communicating Check board LEDs for error Check CANbus Code download error DTC Failed to send executable code to device Check board LEDs for error Unexpected heater voltage DTC Isothermal oven Internal power test failed...

Page 13: ...en Det Ampl RTC signal missing or irregular Check CAN connections Check power and ground connections Check chassis ground connection to Oven Electronics door 5 2 Power If the Master Controller or Ovens do not power on check for power related problems including external power fusing and breaker boxes for possible issues 5 2 1 Power failure recovery The Master Controller and Ovens power on but the s...

Page 14: ...al force to both sides and pull it away from the SBC Installation Procedures Locate battery connection base on the SBC Ensure all four connection pins are straight and free of contaminants Align pins with base push in firmly 5 3 Board level light emitting diodes Most circuit boards installed in the Master Controller and Ovens are equipped with light emitting diodes LEDs The LEDs can display ongoin...

Page 15: ...SB stick reconnoiter for PGC5000 bin 0x04 finished NAND reconnoiter for PGC5000 bin 0x05 finished loading bin file 0x0E no PGC5000 bin or upgrade bin located 0x0F start to execute bin file System Phase see Figure 5 3 CR24 lower left System Task heartbeat green blinking CR30 upper right Health Monitor heartbeat green blinking CR26 right of CR24 green blinking based upon OC interrupts CR31 lower rig...

Page 16: ...inking then red indicates a loss of the life indicator from the master controller it will turn off if the Master Controller recovers Errors during startup will blink the lower left LED with a code that can be counted between pauses 1 No initialized DPM 2 Unable to create virtual clock 3 Unable to create DPM exception handler 4 Unable to initialize RTC 5 Unable to create tasks 6 CAN comm error not ...

Page 17: ...bootloader operation is executing CR2 Green blinking rapid rate noticeably faster than CR1 indicates method executing and Real Time Clock signal present Amber blinking slow rate No method executing and an RTC signal is present CR3 Green solid AC power present at the DTC analog board Red solid no power detected Example A T rating error will shut down control and disable power resulting in a red LED...

Page 18: ...unctions After the DTC becomes operational unhandled interrupts might occur These are reflected by a staying solid red or blinking CR4 A blinking red CR4 will blink for a count pause and then blink repeat the count again continuously Count the blinks between pauses and determine the cause using the following list Blinks Source 1 unused 2 rfu 3 non maskable 4 illegal operation 5 data logger 6 RTOS ...

Page 19: ...error 000100 no other node on CANBus still trying 000101 CAN and application timer engaged 000110 reload in progress 000111 CAN disabled reload jumping to start over 001000 bootloader initialization 001001 bootloader CAN setup 001010 bootloader start hardware setup 001011 bootloader end hardware setup 001100 bootloader received reset application 100001 bootloader flash erase in progress 110011 boo...

Page 20: ...11 RTOS 010100 emulation 010101 non maskable 010110 illegal operation Other LEDs also indicate various procedures as noted on the previous figure occurring via the board and are noted below CR10 Green Blinking CANBus active CR12 Green Blinking CANBus active CR13 Red blinking Power to zone 2 heater CR14 Red blinking Power being applied to zone 3 heater CR15 Red blinking Power being applied to zone ...

Page 21: ...atus Tab Check the scope sub tabs located at the top of the display for triggered indicators 4 Select the scope displaying the triggered indicator locate the activated indicator s refer to the Status Indicator table later in this section for issue resolution Some Status Scopes have multiple sub scopes to choose from or may require using the Page Down icon to view all indicators If not assigned to ...

Page 22: ...arm MC Purge failure Correct purge issue if installed AOC MC Comm Failure Oven Controller OC Power to board AOC MC Oven 1 4 CANBus Communication CAN connections at oven fails between OC board Fiber connections at oven and oven s or the SBC Oven Controller Board fails to initiatetheOC OCB termination Power down Master Controller and re seat OC Possible bad OC Software Error Software Faults at the O...

Page 23: ... DTC Tz low Tab Oven DTC Button Adjust as needed High Temp Temperatureout of range Check setting at Setup AOC Oven DTC Tz high Tab Oven DTC Button Adjust as needed Out of Control Temperaturedeviates Check analysis temperaturecontrol AOC Oven DTC Tz 10 from setpoint TCF settings Check zone indicators and Diagnostic Displays Ramp Out of Temperaturedeviates Check analysis temperaturecontrol AOC Oven ...

Page 24: ... Replaceas necessary Leak check analyzer and supply lines High Pressure Pressure out ofrange Adjust pressure zone s high limit AOC Ovn EPC PZ high under the Setup Tab ReplaceEPC sensor or solenoid valve as necessary Out of Control Pressure deviates 3 575 Check analysis pressure control TCF AOC Ovn EPC PZ psi from setpoint settings Check Zoneindicators and DiagnosticDisplays Possible leak Leak chec...

Page 25: ...as needed Possible reported leak Possible defectiveEPC pressure sensor Possible plugged inlet filter Validation Measurement out ofrange Information Only Adjust Limits under Wen Component ofdeviation from known the Setup tab as needed Flows revalidated standard incorrectly set DefectiveEPC sensor Missing No peak found matching a Information Edit analysis as needed When Analysis Component component ...

Page 26: ... Only AOC SHS CANbus Address Conflict Two devices with same Check SHS Node ID on device AOC SHS address on SHS CANbus Invalid State Combination of valve Correct Valve conflicts AOC DVM states not allowed Vol Flow Low Low Volumetric Flow lower Information Only AOC ARV than Low Low Limit Vol Flow Low Volumetric Flow lower Information Only AOC ARV than Low Limit Vol Flow High Volumetric Flow exceeds ...

Page 27: ...fferential Pressure Information Only AOC FastLoop exceeds High High Limit 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 5 6 Operation troubleshooting This subsection provides troubleshooting information by category Included in thi...

Page 28: ...mple valve 2 No carrier gas supplied to the analyzer Verify air supply pressure and replace bottle as necessary 3 No air to the sample valve actuator Verify air supply pressure and replace bottle as necessary 4 Baseline offset is extreme Check for contaminated carrier fuel and bottle as necessary 5 Column broken or connection in the column train is disconnected Replace or reconnect column Leak che...

Page 29: ...riable retention times Variable retention times can result in non repeatability Causes 1 Varying Carrier flow rate Verify instrument air is per specification Check oven indicators for more details Monitor oven purge pressure Possible defective air purge regulator 2 Varying oven temperature Verify instrument air is per specification Check oven indicators for more details Monitor oven purge pressure...

Page 30: ...meter is defective b If the voltage is less than 2 5 mv check flows and correct as necessary c Inspect thermocouple for damage and replace as necessary d Inspect jet tip for corrosion and restriction and replace as necessary 5 7 Software A software repair can be as simple as restarting the system or may require performing a System Recovery from files created and saved on a USB flash drive In the u...

Page 31: ... you use a USB drive larger than 32 gb the system will appear to write the data to the drive and give a Creation Complete message but no data will be on the drive RECOVERY Selecting the USB Flash Drive Operation icon creates a recovery drive on the USB flash drive inserted in the Master Controller Single Board Computer This operation takes up to thirty minutes to complete depending on system confi...

Page 32: ...analyzer perform a soft reset to correct mismatch warning Invalid Configuration Model Manager Task not started There is an error in one of the configuration files Call ABB support Restore Point Configuration Capture Complete Restore Point has been written to the USB flash drive Stream Data Files Capture Complete Backup of Stream Data is complete Stream Data Files Delete Complete Stream Files Delet...

Page 33: ...he valves or column connections Next determine the last thing done to the system In general this is the best place to begin the troubleshooting process If these steps identify that the problem is with the detector use the following subsections to identify and correct the problem 5 10 1 Plasma will not light No power If the fuse is good contact ABB customer support for further assistance Air in pla...

Page 34: ...ion times have shifted look for leaks on the valve rod Wrong reaction gas Using nitrogen as the reaction gas will cause low signal Verify that the proper reaction gas is being used Improper restrictor in place Too large of a restrictor results in poor plasma performance leading to low sensitivity Verify that the proper restrictor is in place or replace the restrictor with one of know proper dimens...

Page 35: ...lasma cell leak If the base of the plasma cell is not well sealed it is possible to see a rise in the baseline Initially this may appear as column bleed but the signal will settle down once the oven returns to an isothermal mode Reset the plasma cell in the Swagelok fitting and tighten to make it leak free Contamination or late eluting components Alter the cycle time of injections to determine if ...

Page 36: ...tive tubes bags or boxes Keep electrostatic sensitive parts in their containers until they arrive at static free stations Cover workstations with approved static dissipating material Use a wrist strap connected to the work surface and properly grounded tools and equipment Keep the work area free of nonconductive materials such as ordinary plastic assembly aids and foam packing Always be properly g...

Page 37: ... of the cage 4 Slide cage out 5 To replace reverse order SBC PCB removal and replacement procedure 1 Remove Card Cage as described in the previous paragraph 2 Remove the screws holding the SBC to the Card Cage and retain the screws for re installation 3 Remove the SBC PCB 4 Place the new SBC PCB on the back of the Card Cage 5 Insert the screws that hold the SBC in place 6 Install the Card Cage in ...

Page 38: ...t of connections to the and connections Insert one wire in each terminal when possible If there is a ground wire connect it to one of the connections 6 2 4 Optional wago modules Wago module removal and replacement procedure 1 On the Wago module assemblies to be replaced tag all connecting cables see Figure 6 2 Fig 6 2 Removing a Wago Module 2 Disconnect the cables from the modules to be replaced 3...

Page 39: ...screws holding the PCB assembly 5 Remove the PCB assembly 6 Reverse steps to replace the PCB assembly The power cable ties must be replaced to meet certification requirements 6 3 2 Liquid crystal display assembly Removal and replacement procedure for the LCD Panel see Figure 6 3 1 Remove power from unit and follow plant documentation procedures 2 Label all cables attached to PCB Assembly noting po...

Page 40: ...etector Amplifier Assy EPC Analog PCB Assy Power Supply DTC Digital PCB Fig 6 4 Class B1 Components 6 4 2 Class B oven component locations version 2 Version 2 of 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 5 Before removing any boards ensure power is off and cable routing is noted Some boards my requi...

Page 41: ...compartment door left side of oven In the Class C Oven it is attached to inside of upper electronics compartment door left side of oven Always note routing and marking of cables pin 1 location etc Note jumpers and move to replacement board as necessary 1 Remove cables using proper tools 2 Undo hex head screws and remove board 3 Attach updated or new board to door starting with the center top screw...

Page 42: ... turn off is necessary a Turn off sample supply and burner fuel b Allow analyzer to cool to ambient temperature c Turn off remaining flows at their sources and plug all vents 6 6 2 Removing the epc control assembly This procedure is not required if you are only replacing EPC components 1 Perform the Preparation procedure 2 Remove the four screws holding the top panel on the front of the oven 3 Rem...

Page 43: ...Installing the EPC control assembly 1 Carefully install the Control Assembly and its associated components 2 From the top of the oven install the two screws that hold the EPC Control Assembly in place 3 Reconnect the three fittings to the bottom of the EPC Control Assembly 4 Reconnect the three fittings at the back of the EPC Control Assembly 5 Reinstall the EPC Control Assembly cover inserting an...

Page 44: ...to your left and out of the way see Figure 6 9 AC Power Cable from Backplane PCB J44 Sensor PCB Cable Zone 1 Sensor PCB Cable Zone 2 Sensor PCB Cable Zone 3 Sensor PCB Cable Zone 4 Sensor PCB Cable Zone 5 Large Ribbon Cable from EPC Multibus PCB Heater Cable Valve Cable Zone 5 Valve Cable Zone 4 Valve Cable Zone 3 Valve Cable Zone 2 Valve Cable Zone 1 Fig 6 9 EPC Control PCB Cabling 5 Locate the S...

Page 45: ... Retighten the first screw to 5 in oz 12 Retighten the second screw to 6 in oz 13 Retighten the first screw to 7 in oz 14 Retighten the second screw to 7 in oz 15 Plug the Sensor PCB cable into the corresponding connector on the Control PCB 16 If another Sensor PCB Assembly needs to be replaced repeat the appropriate steps to remove the old Sensor PCB Assembly and install a new one Be careful to o...

Page 46: ...rform the Preparation procedure 2 Remove the four screws holding the top panel on the front of the ovenl 3 Remove the ten screws holding the EPC Control Assembly cover using ABB Tool TL1009 and remove the cover Be careful not to damage the flame proof or explosion proof surfaces of the cover or the body of the Control Assembly 4 Unplug the large ribbon cable from the Control PCB and fold it back t...

Page 47: ...on the new heater 5 Insert the new heater in its cavity in the enclosure making sure it goes all the way down in the cavity 6 Clean any anti seize compound residue from the enclosure 7 Plug the heater connector into the Controller PCB 8 Replace the Sensor PCBs following steps 3 through 8 of Installing a Sensor PCB 9 Ensure that the flame proof or explosion proof surfaces of the cover or the body o...

Page 48: ...plate and retain the ground lug for reinstallation 4 Remove TCD Amplifier Assembly by sliding the mounting plate to the right 5 Install replacement TCD Amplifier Assembly 6 Install ground lug under nut at the right side of the assembly and install and tighten the nut 7 Reinstall all other nuts and tighten 8 Attach cables 9 Test 6 10 Replacing the dtc analog pcb version 1 In the Class B Oven the DT...

Page 49: ...bles 2 Remove eight hex head screws 3 Remove the PCB 4 Install the new PCB 5 Insert and tighten eight hex head screws 6 Reinstall all cables 6 13 Replacing the oven indicator pcb In both the Class B and Class C Ovens the Oven Indicator PCB is attached to the inside of the front electronci compartment door left side of oven Note cable routing and markings locate pin 1 on the cable Removal and repla...

Page 50: ...arkings locate pin 1 on the cable Removal and replacement 1 Loosen and remove all cables 2 Remove the hex head screws holding the PCB 3 Remove the DTC Digital PCB 4 Reverse steps to install the new DTC Digital PCB 6 16 Replacing the dtc auxiliary pcb In both the Class B and Class C Ovens the DTC Auxiliary PCB is attached to thelower section of the inside of the front electronci compartment door le...

Page 51: ...0 Series Service Instructions 6 Component repair SI PGC5000 EN rev B 51 4 Reinstall fuse and blanks in unused plugs 5 Attach new board to mounting bracket using hex head screws 6 Reattach all plugs and tighten 7 Test ...

Page 52: ... the two fittings as necessary if leaks are found 5 Close and secure the Isothermal Oven door 6 Apply air and makeup gases 7 Allow zone temperatures to stabilize 8 Check set carrier flows per data sheet 7 1 3 Capillary column installation Inspect the ends of the column The ends should be round and burr free If either column end is not round or burr free the column end must be trimmed as described ...

Page 53: ...core and gently bend the tubing at the score in the direction opposite the score 4 When the score point opens bend the tubing back towards the score The tubing should make a clean break 5 Inspect the end of the column for roundness and ensure it is burr free If the end is not round and burr free repeat the procedure until it is 6 The column is now ready for installation 7 2 Repairing the flame ion...

Page 54: ... the two red and black wires 2 If applicable remove any cable ties and free the wiring to expose the wire splices 3 Cut and remove the heat shrink and glass tape from the red and black wires to expose the soldered connections 4 Using a 40 watt soldering iron disconnect the wiring splice 5 Using a 3 8 inch open end wrench carefully remove the thermocouple Note its location for reassembly 6 Carefull...

Page 55: ...ass tape over each connection 13 Slide the heat shrink over the taped connection and shrink it with a heat gun 7 2 6 Cleaning the fid jet CENELEC and CSA flame ionization detectors are identified by the presence of three packing adapter nuts 5 8 inch 1 2 inch and 7 16 inch Other models contain only two packing adapter nuts 5 8 inch and 1 2 inch 1 On CENELEC AND CSA models loosen the 7 16 inch pack...

Page 56: ...or on one and a BNC connector on the other end see Figure 7 2 Screw the Microdot connector end of the new cable assembly into the Insertion Tool Microdot Connector BNC Connector Fig 7 2 FID Cable Assembly 5 Pass the Insertion Tool through the grommet holes from the Electronics Housing to the Oven 6 Remove the Insertion Tool from the cable connector 7 Make a slit in each grommet from the outer diam...

Page 57: ...e filaments Replacement filament installation kits are supplied with two cable glands a wire spreader 736 RTV high temperature solder and heat shrink 1 Cut the four filament wires approximately the same length as the wires on the filaments that were removed 2 Insert one pair of filament wires through the threaded end of the gland nut then carefully insert the filament into the detector cell cavity...

Page 58: ... wrap the wire ends 2 Using a 40 watt soldering iron and approved high temperature solder tin each of the harness wire ends 3 Roll the ends of each stripped filament wire between your thumb and index finger to tightly spiral wrap the wire ends 4 Using a 40 watt soldering iron and approved high temperature solder tin each of the filament wire ends 5 Install approved heat shrink over each of the fou...

Page 59: ...ctor assembly by hand 7 4 3 Installing new filaments Filament Replacement Kit 865K001 1 includes a set of four filaments four gland nuts and a wire splice kit 1 Carefully install the new filaments and gland nuts being careful to not damage the filament 2 Install the filaments so they are facing in the direction of flow into the detector housing Not following the torque pattern described in the nex...

Page 60: ...wire using 40 watt soldering iron 21 Refer to Figure 7 4 for wiring color code Fig 7 4 Multiport Filament Layout 22 Route wires as shown in Figure 7 5 and solder to filament leads using a 40 watt soldering iron Fig 7 5 Filament Wiring Location 23 Cover each solder connection with inch of clear shrink sleeving and shrink with a heat gun Pinch the open end of the sleeving together while still hot to...

Page 61: ...ng careful to retain the screws to reinstall the Photomultiplier Assembly 6 Carefully pull the Photomultiplier Assembly straight out of the analyzer 7 Reinstall the Photomultiplier Assembly in reverse order of removing it 7 5 2 Replacing the burner block Refer to Figure 7 6 while performing this procedure Burner Block Fig 7 6 Burner Block 1 Remove power from the analyzer 2 Turn off oven air to the...

Page 62: ... 2 To remove a particular o ring carefully remove the associated connector and then remove the o ring 3 Lubricate the new O Ring with a slight film of silicone grease 4 Insert the new O Ring and reinstall the connector 7 5 4 Replacing the jet Refer to Figure 7 7 when performing this procedure 1 Perform steps 1 through 4 of Replacing the Burner Block 2 Carefully remove the Adapter 3 If the Jet came...

Page 63: ...re Consult MSDS sheets on file at your location for safety requirements Sample valve repair may necessitate the venting of flammable substances into the atmosphere surrounding the analyzer Remove power from all sources of ignition in the immediate area Do not open any purged enclosures that remain powered Ensure proper safety equipment is worn such as rubber gloves and face shield or safety glasse...

Page 64: ...lockwise until the assembly is loose 11 Unscrew the body from the flange and vaporizer chamber 12 Withdraw the piston and the piston rod from the tensioning nut 13 This will free the seals from the stem 14 Replace the seals 15 Inspect the stem for visible imperfections If imperfections are found replace the stem 16 Remove the rear valve seat from the body 17 Remove the 15 Belleville springs from t...

Page 65: ...ston rod into the piston and tighten to 27 to 30 in lb Do not overtighten or bend the rod or stem Do not allow grease to contact the stem 10 Lightly lubricate the body O rings 11 Install the body O rings onto the body and the piston 12 Insert the piston and the piston rod into the sleeve being careful not to cut the O ring Fully insert the piston until it contacts the stops 13 Stack the 15 Bellevi...

Page 66: ...if servicing 28 Slide the cylinder onto the piston and the body 29 Install two cone point set screws into the cylinder and tighten into the groove on the body 30 Reinstall tubing to the LSV being careful to connect each line to the proper connection on the LSV 31 Close the isothermal oven door 7 6 3 Removing the LSV from the analyzer 1 Stop analysis at the end of a cycle 2 Remove power from the an...

Page 67: ... of a cycle 2 Turn off sample and air to the analyzer Verify that the oven is cool ambient temperature before removing carrier gas 3 Turn off power and carrier gas 4 Open the isothermal oven door 5 Locate the valve to be repaired 7 7 2 Replacingtheslider The Slider is part of the Carrier Assembly To ensure you have the correct slider for your application verify the slider part number from the Data...

Page 68: ...bly is locked into the hole in the piston stem 11 Close the front Carrier Assembly latch 7 7 4 Replacingtheo 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 The rework procedure is the same for both valves O Ring Fluorocarbon 1 4 x 1 8 x 1 16 45051 4...

Page 69: ...tall the O ring over the O Ring Tool and into the O ring groove on the piston rod 17 Lubricate O ring part number 45051 4 61 40 psig valve or 45051 4 29 60 psig valve with Molykote 33 and install it in the O ring groove of the piston 18 Remove the old O ring from the Valve Body see Figure 7 15 O RING VALVEBODY Fig 7 15 Installing the O Ring on the Valve Body 19 Wipe the inside of the Valve Body to...

Page 70: ...n not to damage the finish surface of the Valve Plate 3 Dip the screws into RTV Dow Corning 732 or GE 108 to within 1 8 inch from flat surface on bottom of the screw head 4 Position screws through countered bored holes in Valve Body and install into Valve Plate 5 Tighten both screws securing the Valve Plate to the Valve Body Screws should be torqued to 19 in lbs 7 8 Replacing diaphragm valves Two ...

Page 71: ... 4 Set the cap aside in a safe clean place with the polished side up so that it does not get scratched 5 With tweezers or a knife blade under the edge of the diaphragm carefully lift and work the diaphragm off the alignment pin Be careful not to tilt the valve which could let the plungers fall out 6 Set the valve on a clean surface with the base down and the plungers up 7 Put on powder free gloves...

Page 72: ...iaphragm carefully by the edges so that the surface is not contaminated or damaged 9 Slide the diaphragm over the alignment pins with the side marked TOP toward the cap away from the plungers 10 Clean the cap thoroughly with an appropriate solvent and a clean tissue or cotton swab taking care not to damage the surface 11 Blow the cap with clean compressed gas to remove any lint left by the tissue ...

Page 73: ...he electrometer that require scheduled maintenance 7 9 2 Removing the detector 1 Disable the isothermal oven temperature zone 2 Allow the oven to cool to room temperature 3 Turn off power to the oven 4 Turn off the plasma power supply switch located on the top of the supply 5 Wait at 30 seconds for the plasma to discharge 6 Grasp the high voltage shield and remove the plasma high voltage lead from...

Page 74: ... from the detector body 10 Slide the closest nut ferrule and O ring onto the marked end of the plasma cell 11 Gently insert the plasma cell into the body of the detector until it stops 12 Tight the closest nut finger tight only 13 While supporting the plasma cell reconnect the plasma high voltage lead 14 Reconnect the ground lead if necessary 15 Turn on power to the oven 16 Purge the detector for ...

Page 75: ...les Order Number Analyzer Model Number Analyzer Part Number P N and serial number For serial numbered subassemblies such as PCBs include the serial number and the part number including dash number and revision letter for the subassembly in the request If a PCB requires conformal coating prefix the PCB part number with the letters CC Applicable references from the Recommended Spare Parts List of th...

Page 76: ...tion 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...

Page 77: ... Controller PCB 852A002 1 Wago Control Module 866Z001 1 Wago End Module 866Z002 1 Wago 2 channel analog output 4 20 mA 866Z003 1 Wago 4 channel analog output 4 20 mA 866Z004 1 Wago 4 channel analog output 10V 0 10 V 866Z005 1 Wago 2 channel analog input 0 10 V 866Z006 1 Wago 4 channel digital output DC 24 V with low side switching 866Z007 1 Wago 2 channel relay output AC 30 V DC 30 V 866Z008 1 Wag...

Page 78: ...04 _ TCD Amplifier Assembly 851A093 _ FID Amplifier Assembly version 1 851A060 _ FID Amplifier Assembly version 2 851A094 _ FPD Electrometer not shown 804A010 2 DTC Analog PCB Assembly 852A026 1 DTC Digital PCB Assembly 852A021 1 Power Supply 857Z035 2 EPC Control PCB Detector Amplifier Assy EPC Analog PCB Assy Power Supply DTC Digital PCB Fig 8 6 Left Side Components 8 3 2 Left front door compone...

Page 79: ... _ TCD Amplifier Assembly 851A093 _ FID Amplifier Assembly version 1 851A060 _ FID Amplifier Assembly version 2 851A094 _ FPD Electrometer not shown 804A010 2 DTC Analog PCB Assembly 852A027 1 DTC Digital PCB Assembly 852A028 1 Power Supply 857Z035 2 EPC Control PCB Detector Amplifier Assy Power Supply DTC Digital PCB Assy DTC Analog PCB Assy Fig 8 8 Left Side Components 8 4 2 Left front door comp...

Page 80: ...re Sensor Platinum 3617330 1 Makeup Valve 3616890 1 Splitter Valve 3616890 2 Metering Valve 3529409 1 Restrictor Valve 3616446 1 Diaphragm Valve one screw type 8230442 3 Diaphragm Valve four screw type 851Z064 _ Liquid Sample Valve see 8 5 1 Flame Ionization Detector see 8 5 2 Single Port Thermal Conductivity Detector see 8 5 3 Multiport Thermal Conductivity Detector see 8 5 4 Flame Photometric De...

Page 81: ...nch Seal per application 791M001B _ 0 062 inch Stem per application 791A009B _ 0 062 inch Seal per application 791M028B _ Vaporizer per application 805A015 _ Seal Insertion Tool TL 791A006B LSV Fitting Kit SST Swagelok 800K011 1 LSV Fitting Kit Monel Gyrolok 800K011 2 LSV Fitting Kit Monel Swagelok 800K011 3 LSV Fitting Kit Hastelloy C Gyrolok 800K011 4 LSV Fitting Kit Hastelloy C Swagelok 800K011...

Page 82: ...ion dependent see Data Package for correct part Capillary Column Kit NEC 799K001N 1 Packed Column Kit NEC 799K001N 2 Packed Column Kit CENELEC 799K001N 3 Capillary Column Kit CENELEC 799K001N 4 Wire Splice Kit 800K001 1 Microdot Cable Insertion Kit 799K006 1 Fig 812 FID Components 8 5 3 Single port thermal conductivity detector see Figure 8 13 Description Part Number Filament Kit NEC 800K003 1 Fil...

Page 83: ...re 8 14 Description Part Number Filament Kit 865K001 1 Fig 8 14 Multiport TCD 8 5 5 Flame photometric detector Description Part Number Transformer 3617648 1 Capillary Tubing Burner Fuel 5514584 39 Coaxial Cable Assy 3528546 1 Photomultiplier Assy 804A003 1 Solenoid 3 Way for X Purge 3616261 3 Pressure Sensor 3615565 6 Burner Block see 8 5 6 ...

Page 84: ...et O Ring 45051 4 106 O Ring 45051 5 18 Sulfur Addition Wafer Fig 8 15 Burner Block Components 8 5 7 M2CP valve see Figure 8 16 Description Part Number 10 port Slider per application 764M005 _ 6 port Slider per application 764M006 _ 8 port Slider per application 764M007 _ 8 port Backflush to Vent Slider per application 764M008 _ CP Valve Ports Field Service Kit Stainless Steel 753K002N 11 CP Valve...

Page 85: ...se Shield 885Z003 1 Detector Exhaust Tube 885Z004 1 Fig 8 17 DID Replacement Parts 8 6 EPC control assembly see Figure 8 18 The EPC Control Assembly is located inside the top panel of the oven Description Part Number Proportional Valve 3617341 1 O Ring Kit 801K001 1 Control PCB 802A011B 1 Sensor PCB Kit 801K007 2 Heater 81943A042 1 Metric Hex Key Wrenches TL161 1 EPC Service Tool Kit 801K005 1 Pro...

Page 86: ...PGC5000 PGC5000 Series Service Instructions 8 Replacement parts SI PGC5000 EN Rev B 86 8 7 Class c oven The Class C Ovens have the same components as the Class B Ovens although the quantities may differ ...

Page 87: ...PGC5000 PGC5000 Series Service Instructions Notes SI PGC5000 EN Rev B 87 NOTES ...

Page 88: ...ation in this document We reserve all rights in this document and in the subject matter and illustrations contained therein Any reproduction disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB Copyright 2013 ABB All rights reserved 3KXF211101R1001 Sales Service Software ABB Inc Process Automation Analytical Measurements ...

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