OPERATION AND SERVICE MANUAL Process Gas Chromatograph PGC OSM F2: October 2008

Transcription

1 OPERATION AND SERVICE MANUAL Process Gas Chromatograph PGC OSM F2: October 2008

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

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

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

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

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

7 TABLE OF CONTENTS (continued) Title Page Regular Report Short Report Standard Calibration Report AIR PURGING Y and Z Purge X Purge Operation X Purge Override Option X Purge Override Contacts E2PROM Save Tables to E2PROM Restore Tables from E2PROM DIGITAL TEMPERATURE CONTROLLER Physical Description Operator Settings Manual Temperature Control Mode Zone Names and Limits Table Configuring SWITCH Temperature Control Table Temperature Check Table Controller Type Temperature Configuration Table Programming Notes Alarms ELECTRONIC PRESSURE CONTROL OPTION Physical Description Operator Settings Manual Pressure Control Mode Pressure Configuration Table Configuring SWITCH Pressure Control Table Pressure Check Table Alarms RAW CHROMATOGRAM STORAGE AND REPROCESSING Accessing Raw Chromatogram Storage Checking Available Memory Erasing (Releasing) Chromatogram Data Saving Chromatograms Displaying Saved Data Reprocessing Saved Chromatograms REMOTE GC OPERATION OPTION LO COMM PCB Setup Remote Operation ANALOG OUTPUT OPTION DIGITAL I/O OPTION VistaNET OPTION SOLENOID VALVES SECTION 5. MAINTENANCE PREVENTIVE MAINTENANCE Gas Cylinder Replacement OSM, F1 v

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

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

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

11 TABLE OF CONTENTS (continued) Title Page SECTION 8. REPAIR REPLACING HEATERS Isothermal Temperature Oven Heater Sample Valve Heater SAMPLE VALVE REPAIR Disassembly on the Analyzer Reassembly on the Analyzer Removing the LSV from the Analyzer Disassembly on the Workbench Reassembly on the Workbench Installing the LSV on the Analyzer Replacing the LSV Vaporizer Assembly COLUMN INSTALLATION OR REPLACEMENT Column Removal Packed Column Installation Capillary Column Installation Cutting Capillary Columns FID REPAIR FID Cell Access Replacing the Breather Replacing the Thermocouple Assembly Accessing the Polarizer and Ignitor Elements Replacing the Polarizer Replacing the Ignitor Assembly Closing the Detector Cleaning the FID Jet Cleaning the Collector Replacing the FID Cable Assembly FILAMENT TCD REPAIR T/C Detector Access Removing the Filaments Installing the Filaments Filament Checkout Connecting the Filaments Leak Test Potting the Filaments (CENELEC and CSA only) THERMISTOR TCD REPAIR T/C Detector Access Removing the Thermistors Installing the Thermistors Thermistor Checkout Connecting the Thermistors Leak Test FPD REPAIR Replacing the Photomultiplier Assembly Replacing the Burner Block Replacing the Burner Block O-Rings Replacing the Jet METHANIZER/AIR CLEANUP REPAIR Removing the Methanizer/Air Cleanup Assembly OSM, F1 ix

12 TABLE OF CONTENTS (continued) Title Page Removing the Catalytic Tubes Installing the Catalytic Tubes Packing the Housing Installing the Methanizer/Air Cleanup Assembly Air Cleanup Testing Air Cleanup Final Preparation REPAIRING THE CARRIER GAS PANEL (ANALOG) Removing the Carrier Gas Panel Replacing a Regulator Replacing a Gauge Installing the Carrier Gas Panel REPAIRING THE EPC CONTROL ASSEMBLY Preparation Removing the EPC Control Assembly Installing the EPC Control Assembly Removing a Sensor PCB Installing a New Sensor PCB Removing a Proportional Valve Installing a New Proportional Valve Removing the Control PCB Installing a New Control PCB Removing the Heater Installing a New Heater CALIBRATING THE ELECTRONIC PRESSURE CONTROLLER REPAIRING PURGE AIR PANEL COMPONENTS Removing the Purge Air Panel Replacing a Regulator Replacing a Gauge Installing the Purge Air Panel SETTING JUMPERS Backplane PCB DTC Backplane PCB DTC Zone PCB VAC Conditioning PCB Front Panel PCB FID Amplifier PCB Filament TCD Amplifier PCB Thermistor TCD Amplifier Interface PCB EPC Multibus PCB EPC Control PCB Chroma I/O PCB (old type) Chroma I/O PCB (new type) VALCO DIAPHRAGM VALVE REPAIR Removing the Valve Repairing the Valve Reinstalling the Valve VistaNET DEBUG MONITOR Purpose Making the Connections Startup x 2000-OSM, F2

13 TABLE OF CONTENTS (continued) Title Page Information Display Menu Items Statistical Display DUAL AIR CLEANUP REPAIR Removing the Dual Air Cleanup Assembly Removing the Air Cleanup Tubes Installing the Air Cleanup Tubes Packing the Housing Installing the Dual Air Cleanup Assembly Air Cleanup Testing Air Cleanup Final Preparation REPAIRING THE CP VALVE Preparation and Safety Replacing the Slider Replacing the Wedges Replacing the O-Rings SECTION 9. REPLACEMENT PARTS ORDERING INFORMATION Equipment Identification Hardware Configuration Identification Software Configuration Identification How to Order GC CONTROLLER Back of Front Panel Card Cage GCC Chassis Components on Right Side Door PURGE AIR PANEL ELECTRONIC PRESSURE CONTROL PANEL CARRIER GAS PANEL ISOTHERMAL OVEN COMPONENTS Liquid Sample Valve Flame Ionization Detector Filament Type Thermal Conductivity Detector Thermistor Type Thermal Conductivity Detector M2CP Valve Type 781 Methanizer/Air Clean Up System Type 805 Methanizer/Air Clean Up System Dual Air Cleanup System Valco Diaphragm Valve FLAME PHOTOMETRIC DETECTOR (FPD) Transformer and Photomultiplier Components Burner Block Components TEMPERATURE PROGRAMMED OVEN Flame Ionization Detector with Heater Block Filament Type TC Detector with Heater Block OSM, F2 xi

14 TABLE OF CONTENTS (continued) Title Page SECTION 10. VISTA BASIC INTRODUCTION Using the Editor Vista BASIC Line Format Character Set Constants Variables Arrays Expressions and Operators ALPHABETIC LISTING ABSOLUTE VALUE Function ACTIVATED BY Function ACTIVATE STREAM Command ADD TCF Command ALARM Function ASC Function ASSIGN STREAM Command BPRINT Statement CHAIN Statement CHR$ Function CLEAR Command CLOCK ERROR ALARM Function COMMON Floating Point Array COMMON String Array COMMUNICATION ERROR ALARM Function COMPONENT NAME Function COMPONENT TYPE Function COPY ARRAY Command CURRENT METHOD Function CURRENT STREAM Function CYCLE TIME Function DEACTIVATE STREAM Command DELETE ALL GATE TCFS Command DELETE ALL TCFS OF A TYPE Command DIM Statement END Statement EXPONENT Function FLAME OUT ALARM Function FLOATING POINT Conversion Routine FOR...NEXT Statements GET ACTUAL RETENTION TIME Function GET ASTM Function GET BENCHMARK CONCENTRATION Function GET BLEND Function GET CALIBRATION CONCENTRATION Function GET COMPONENT CONCENTRATION Function GET CORRELATION FACTOR TABLE Command GET EXPECTED RETENTION TIME Function GET MAXIMUM PEAK PARAMETER Function GET MULTIPLIER EXPONENT Function xii 2000-OSM, F1

15 TABLE OF CONTENTS (continued) Title Page GET OUTSTANDING REQUESTS Function GET PEAK TYPE PARAMETER Function GET PERCENT OFF FOR A TEMPERATURE Command GET PERCENT OFF FOR A TIME Command GET PERCENT OFF TABLE Command GET PRESSURE OF A ZONE Command GET RESPONSE FACTOR Function GET STREAM ASSIGNMENT Function GET TEMPERATURE FOR A PERCENT OFF Command GET TEMPERATURE FOR A TIME Command GET TEMPERATURE OF A ZONE Command GET TEMPERATURE TABLE Command GET TIME FOR A PERCENT OFF Command GET TIME FOR A TEMPERATURE Command GET TIME VS. BOILING POINT TABLE Command GOTO Statement GO TO SUBROUTINE Statement HARDWARE ALARM Function HIGH CONCENTRATION ALARM Function IDLE ALARM Function IF Statement INJECT TIME Function INJECT UCT Function INSTR Function INTEGER TYPE Conversion Routine LENGTH OF CORRELATION FACTOR TABLE Function LENGTH OF PERCENT OFF TABLE Function LENGTH OF STRING Function LENGTH OF TEMPERATURE TABLE Function LENGTH OF TIME VS. BOILING POINT TABLE Function LET Statement LOGARITHM BASE TEN Function LOW CONCENTRATION ALARM Function LPRINT Statement MAXIMUM SIM DIS PEAK HEIGHT Command NATURAL LOGARITHM Function NUMBER OF COMPONENTS Function NUMBER OF PEAKS Function OFFLINE ALARM Function OPERATOR MESSAGE ALARM Function PEAK AREA Function PEAK COMPONENT NUMBER Function PEAK CREST AMPLITUDE Function PEAK CREST TIME Function PEAK END AMPLITUDE Function PEAK END TIME Function PEAK HEIGHT Function PEAK RAW AREA Function PEAK START AMPLITUDE Function PEAK START TIME Function POST ANALYSIS ERROR ALARM Function OSM, F1 xiii

16 TABLE OF CONTENTS (continued) Title Page POWER FAIL ALARM Function PREVIOUS INJECT TIME Function PREVIOUS INJECT UCT Function PREVIOUS METHOD Function PREVIOUS STREAM Function PURGING STREAM Command PURGING STREAM Function PUT ACTUAL RETENTION TIME Command PUT ASTM Command PUT BENCHMARK CONCENTRATION Command PUT BLEND Command PUT CALIBRATION CONCENTRATION Command PUT COMPONENT CONCENTRATION Command PUT COMPONENT NAME Command PUT CORRELATION FACTOR TABLE Command PUT EXPECTED RETENTION TIME Command PUT MULTIPLIER EXPONENT Command PUT PERCENT OFF TABLE Command PUT PRESSURE OF A ZONE Command PUT REPORT TYPE Command PUT RESPONSE FACTOR Command PUT TEMPERATURE OF A ZONE Command PUT TEMPERATURE TABLE Command PUT TIME VS. BOILING POINT TABLE Command READ ANALOG INPUT Function READ DIGITAL INPUT Function REMARKS Command REPORT TYPE Function REQUEST ANALYSIS Command REQUEST BENCHMARK Command REQUEST CALIBRATION Command RESET TIME LIMIT Command SENSOR ALARM Function SET BASIC ALARM Function SET BASIC COMPONENT ALARM Function SPACE Function SQUARE ROOT Function START ANALYSIS Command STOP ANALYSIS Command STREAM NAME Function STREAM STATUS Function SUBSTRING Function TCF ERROR ALARM Function TEMPERATURE UNITS Function TIME Function TIME UCT Function TIME VS. BOILING POINT TABLE Function TOTAL PEAK RAW AREA Function TOTAL SIM DIS AREA Command UCT TO TIME Conversion Routine VALUE Function xiv 2000-OSM, F1

17 TABLE OF CONTENTS (continued) Title Page VALVE Command WRITE DIGITAL OUTPUT Command WRITE TREND OUTPUT Command Y2X Function ZERO OUTSTANDING REQUESTS Command Vista BASIC Support for VistaNET Communications SUBJECT LISTING General Statements Math Routines String and Conversion Routines GCC Commands and Functions SIM DIS (Only) Commands Simultaneous Dual Detector Commands VistaNET Commands ERROR MESSAGES Compilation Error Messages Run-Time Error Messages REAL-TIME VISTA BASIC Introduction Real Time Operation Screens Real-Time Vista BASIC Commands SECTION 11. DRAWINGS AND DIAGRAMS 2000-OSM, F1 xv

18 ILLUSTRATIONS Figure Title Page 1-1 Typical Process Gas Chromatograph PGC PGC with Flame Photometric Detector LSV Connection Methods, Early Analyzers LSV Connection Methods, New Analyzers Side View of Analyzer, Showing Manifold Vent Location Analyzer Adjustments Manual Control Mode Screen Checking Total Column Flow Matching Flow Through Analytical Flow Adjust Valve Checking Backflush Flow Matching Flow Through Selector Flow Adjust Valve Chroma Board Screen Manual Temperature Control Mode Screen Background Screen Request Analysis Screen Chroma I/O Board Setup Remote Number Identification with SW Manual Control Mode Screen Printer Report Type Screen TCD Amplifier PCB VN Menu Screen (Startup Highlighted) VistaNET Essential Addresses Screen VistaNET Access Level Screen VN Menu Screen (Tables Highlighted) Subscriber List Screen Controller Status Screen GCC Card Cage Controls and Indicators Electronics Housing Controls and Indicators Regulator and Gauge Panels Background Screen with Elements Identified Request Analysis Screen Alarms Screen Chromatogram Attenuation Ranges Command Tree Typical Analytical Flow System Diagram Chroma Board Screen Flame Ionization Detector Thermal Conductivity Detectors Flame Photometric Detector Background Screen, Simultaneous Dual Detectors First Chroma Board Screen Second Chroma Board Screen Control Parameters Screen Stream Assignment Screen Manual Control Mode Screen Chromatogram of Analysis Data for Method Table xvi 2000-OSM, F1

19 ILLUSTRATIONS (continued) Figure Title Page 4-14 Method Table #?? Screen Cal Define & Cycle Time Screen Method Table #01 Screen Component Definition Screen Print Tables Screen Printed Method Table Example of Basic Slope Detection Functions Example of Peak Lumping Example of Tangent Skim Examples of Peak End Example of Forward Projection Example of Reverse Projection Example of Suspend End Example of End=Crest Random Streams Screen Random Stream Stepping Table Time Table Screen Stream Assignment Screen Raw Data Report Regular Report Short Report Without Alarm Standard Calibration Report X Purge With Cover Removed Table Storage Screen Manual Temperature Control Mode Screen Pressure and Temperature Control Screen Zone Names and Limits Table Screen Method Table #01 Screen Temperature Control Screen Temperature Check Screen Controller Type Screen Temp Config Table Screen Pressure and Temperature Control Screen Manual Pressure Control Mode Screen Pressure Configuration Table Screen Method Table #01 Screen Pressure Control Screen Pressure Check Screen Commands Screen Memory Used Screen Automatically Save Analyses Screen Reprocess Screen Location of LO COMM PCB Location of LO COMM PCB Switches Address Identification with SW Remote Front Panel Mode Screen Remote Controller Screen Trend Table Screen Digital Table Screen VN Menu Screen VistaNET Essential Addresses Screen OSM, F1 xvii

20 ILLUSTRATIONS (continued) Figure Title Page 4-65 Solenoid Valves Recommended Preventive Maintenance Schedule Commands Screen Diagnostic Tests Screen (Tests Selected) Diagnostic Tests Screen (Tools Selected) Manual Control of Digital Outputs Screen Manual Control of Trend Outputs Screen Serial Configuration Screen Chroma Board Digital Input Screen # Chroma Board Digital Output Screen # Digital Board Digital Input Screen Digital Board Digital Output Screen Trend and Detector Configuration Screen Example of Baseline Offset Cyclic Short Term Drift Continuous Upward Drift Baseline Noise Baseline Offset Baseline Random Noise Baseline Random Noise No Peaks Double Sampling Mystery Peaks Variable Sample Size Variable Retention Time Peak Inversion Chromatogram Off Scale EPC Pressure Control Assembly Backplane PCB Power Connections Input Power Distribution Location of Contrast Adjustment Alarms Screen Control Parameters Screen Alarm Mask Main Screen Backplane PCB Digital Alarm Connections Control Parameters Screen Common DO Mask Main Screen DTC Backplane PCB FID Amplifier Showing C6 Location Background Screen Manual Control Mode Screen Pressure and Temperature Control Screen Zone Names and Limits Table Screen Manual Temperature Control Mode Screen Commands Screen Method Table Screen Temperature Control Screen xviii 2000-OSM, F1

21 ILLUSTRATIONS (continued) Figure Title Page 7-11 Background Screen Commands Screen Method Table Screen FPD Zone Board Analyzer Oven Compartment LSV Connection Methods, Early Analyzers LSV Connection Methods, New Analyzers Liquid Sample Valve Component Location Stacking the Belleville Springs Liquid Sample Valve Component Location Stacking the Belleville Springs Flame Ionization Detector FID Cable Assembly Filament TC Detector Thermistor TC Detector FPD Photomultiplier Assembly End View Burner Block Burner Block, Showing O-Rings Burner Block, Showing Jet Methanizer/Air Cleanup Assembly Carrier Gas Panel from Right Side Front Right Side of Oven Control Housing Access Area, Right Side of Analyzer EPC Panel Cable Lock Nut EPC Control Assembly Components EPC Control PCB Cabling Location of Zone Fittings Pressure and Temperature Control Screen Manual Pressure Control Mode Screen Purge Air Panel Fasteners Backplane PCB Jumper Locations DTC Backplane PCB Switch and Jumper Locations DTC Zone Board Jumper Location VAC Conditioning Board Jumper Locations Front Panel PCB Adjustment and Jumper Locations FID Amplifier PCB Jumper Locations Filament TCD Amplifier PCB Jumper Locations Thermistor Amplifier Interface PCB Jumper Locations EPC Multibus PCB Jumper Location EPC Control PCB Jumper Location Old Chroma I/O PCB Jumpers New Chroma I/O PCB Jumpers Valco 10-Port Diaphragm Valve Cap Orientation Exploded View of Valco Diaphragm Valve Communications Board Debug Connection Main Menu Typical Dump Memory Screen Typical Show Registers Screen Typical Dump History Screen OSM, F2 xix

22 ILLUSTRATIONS (continued) Figure Title Page 8-47 Dual Air Cleanup Assembly Typical M2CP Valve O-Ring Kits Installing the O-Rings on the Piston Rod and Piston Installing the O-Ring on the Valve Body Typical Nameplate Background Screen Back of Front Panel Card Cage Components Chassis Components Right Side Door of GCC Purge Air Panel Electronic Pressure Control Panel Carrier Gas Panel Isothermal Oven Components Liquid Sample Valve FID Components Filament Type TCD Components Thermistor Type TCD Components M2CP Valve Components Type 781 Methanizer/Air Cleanup System Type 805 Methanizer/Air Cleanup System Dual Air Cleanup System Valco Diaphragm Valve PGC2000 Showing FPD Components Burner Block Components Temperature Programmed Oven FID with Heater Block Filament Type TCD with Heater Block Chroma I/O Board, Showing UG1 and UH Background Screen Report, Basic I/O and Options Screen Real Time BASIC Status Screen BASIC COMMON! Area Edit Screen xx 2000-OSM, F2

23 GLOSSARY A/D converter analyzer ASCII Auto Zero baseline benchmark calibration run CE Mark CENELEC Chroma I/O components concentration CPU cursor keys DCS Data Package default values detector background noise device that converts an analog signal to a digital value process gas chromatograph American Standard Code for Information Interchange; standardized computer coding for printed characters procedure bringing the detector signal as close to electrical zero as possible; brings the signal into the most sensitive area of the A/D reference point from which peak height or peak area is measured on a chromatogram; detector signal level at which no components are detected sample known to be a definite concentration; used to compare an analyzer's present performance to its past performance analysis that involves injecting a standard sample consisting of specific components whose concentrations and elution sequences are known certification process and marking which denote that analyzer complies with applicable new approach directives within the European Union Comite Europeen de Normalisation Electrotechnique; the European electronics organization that determines standards and testing to ensure safe operation of electrical instrumentation in hazardous areas Chromatographic Input/Output PCB; provides the interface between the analog domain of the gas chromatographic analyzer and the digital domain of the controller peaks, parameters or ratios that are being measured or calculated from a chromatographic analysis the amount of a specific substance within a sample Central Processing Unit; controls the analyzer and collects and manipulates the data front panel control keys marked with directional arrows Distributed Control System application-specific engineering information (such as component tables, function tables, chromatograms, and temperature, pressure and flow settings) shipped with each analyzer assigned parameters the controller will assume unless the operator redefines the values random electronic signals picked up by a sensing device in the absence of valid measurable input (see noise ) 2000-OSM, F1 G-1

24 GLOSSARY (continued) Digital I/O DIP switch drift EIA elution time EMC EMI Engineering Data Package EPC EPROM E2PROM FID field forced gating Gate On/Off GC GCC Help key highway address HL Digital Input/Output PCB; enables the use of additional stream valves and/or alarm sensors PCB switch that is used to set values through hardware instead of software the variances from the baseline or the norm; generally associated with uncontrolled or unwanted changes in pressure or temperature Electronic Instrument Association the amount of time from the start of analysis that it takes for a peak to be fully detected electromagnetic compatibility electromagnetic interference see Data Package Electronic Pressure Control Erasable, Programmable, Read Only Memory; program software that can be erased and reprogrammed a limited number of times Electrically Erasable Programmable Read Only Memory; used for the safe storage of tables (sometimes written E 2 PROM or EEPROM) Flame Ionization Detector highlighted area on display screen where data entry and modification are allowed; data entry is ended (terminated) by filling the field with characters or by pressing ENTER or any soft key or cursor key technique of chromatographic data collection in which the controller collects the detector signal during a specified period of time the time-coded function command which turns on and off the collection of data from the detector Gas Chromatograph Gas Chromatographic Controller front panel control key used to access information pertaining to the current screen display content numbers from one to 32 that uniquely identify remote GCCs High Limits, entered into a component table; when a component's measured and calculated value exceeds the HL value, an alarm is generated G OSM, F1

25 GLOSSARY (continued) host link integer I/O LCD LED LL LO COMM LSV method table microprocessor noise numeric field Panic key PCB peak area serial communications link which allows the transmitting of analysis results to the host computer whole numbers that do not contain decimal points Input/Output Liquid Crystal Display Light Emitting Diode Low Limits, entered into a component table; when a component's measured and calculated value falls below the LL value, an alarm is generated Local Communication Module PCB; optional PCB in the GCC that makes the analyzer communications network possible (sometimes written LOCOM) Liquid Sample Valve; used to inject small amounts of liquid into the sample column operator-entered data specifying the name, retention time, key designation, response factor, low and high limits, and calibration concentrations of the various elements of an analysis; also specifies when, how, and under what conditions the method of data collection is to proceed the semiconductor circuit containing the central processing unit functions any unwanted signal superimposed upon a useful signal which tends to obscure the desired information field that accepts number entries nickname for F1 key directly under the screen (soft key); pressing this key will return the display to the Background screen without changing any current values in memory; may need press it several times consecutively, depending on where the current screen relative to the Background screen Printed Circuit Board method of measurement in which total peak area beneath the peak envelope is used to calculate the concentration peak discrimination the non-linear unequal dilution of hydrocarbons in the column train peak height PID method of measurement in which peak maximum is used to calculate peak concentration proportional-integral-derivative; refers to a control method in which the controller output is proportional to the error, its time history, and the rate at which it is changing OSM, F1 G-3

26 GLOSSARY (continued) Post Analysis routine Postan PROM PSFC psia psig RAM ROM redundant highways response factor retention time RFI RS-232 SBC selection field slope detect S.O. Soft Keys stream purging stream step TCF text field the portion of the controller program that calculates the value for the components from the collected data, after completion of the analysis abbreviation for the post analysis routine Programmable Read Only Memory Process Supercritical Fluid Analyzer pounds per square inch absolute pounds per square inch gauge Random Access Memory; contains current operating conditions Read Only Memory; contains the executable program the means by which a remote GCC can be connected to one or two central devices by two separate, but equivalent, data highways numeric value determined by calibration; used in calculating concentration the time, from the start of analysis, that a peak maximum elutes from the column Radio Frequency Interference voltage based electrical communications protocol, short range; common term for EIA RS-232 serial data interchange format Single Board Computer PCB horizontal screen display; Right and Left cursor keys move through options printed on screen; make selection by leaving field with Up or Down cursor key a technique of chromatographic data collection in which the controller automatically ascertains the presence of a peak and collects data accordingly Sales Order (Customer Order) four front panel control keys directly under the screen the procedure allowing the next stream sample to be analyzed to flow continuously through the sample loop of the injection valve in preparation for the next sample injection and analysis cycle TCF command that permits the next stream sample to purge the sample loop during the remainder of the present cycle Time-Coded Function; keystroke command sequence; entry in method table that defines what action is to be performed (e.g. Valve ON) at what time in the analysis field that accepts data entered with all non-terminating keys G OSM, F1

27 GLOSSARY (continued) trend output VN VNSA watchdog timer analog signal related to concentration of specified component VistaNET; analytical network that links analyzers, DCS, and support people using the data VistaNET Name Service Administrator; PC software that serves as the address book for the VistaNET hardware circuit alarm that indicates when the software fails to cycle through its entire task structure within a set period of time 2000-OSM, F1 G-5

28 CAUTION All analyzers bearing the CE Mark imprint on their nameplates have electromagnetic compatibility (EMC) shielding that meets the requirements for CE Marking. When working with one of these analyzers, you must handle it carefully to avoid damaging the shielding. If any shielding becomes damaged or is removed from the analyzer, new shielding must be installed to maintain the CE Marking conformity. ABB Lewisburg has designed Total Envelope Protection into its analyzers. The basic enclosure itself, when it is properly grounded or earthed, becomes the first barrier of protection from emissions that could radiate from the unit. In addition, the enclosure also provides a high level of immunity from electromagnetic interference (EMI) which could affect the performance of the analyzer. In order for the analyzers produced by ABB Lewisburg to maintain their EMC integrity, the installation methods employed are of equal importance. The grounded enclosure produces a Faraday Shield around the electronic components, detection systems, and other sensitive components which could generate EMI or be affected by EMI. An extension of this Faraday shield must be carried throughout the installation scheme. NOTE Special conditions of Certificate of Conformity LCIE 02 ATEX 6025 X apply to the electrical equipment for its safe use. Special conditions for electrical and purge and pressurization are included on the nameplate of the analyzer. In addition, a multilingual safety manual listing these special conditions is included with the shipment of each analyzer. Special conditions for manufactured Ex components, which are described in the individual subsections of Section 8 ( REPAIR ) of this manual, apply to the following certified components: Manufactured Ex Components Detector/Chromatographic Column Electronic Pressure Control Model 801 Flame Ionization Detector Model 794 or 799 Flame Photometric Detector Type 804 Heater Block Model 791 Heating Device Model 800 Methanizer/Air Clean-up Type 805 Overpressure and Purging Control Device Thermal Conductivity Detector Model 002A Thermal Conductivity Detector model 795/798 G OSM, F1

29 0 0 EQUIPMENT DESCRIPTION SECTION 1. INTRODUCTION The Process Gas Chromatograph PGC2000 separates and measures the individual components of gas or liquid samples. It automatically samples and analyzes process streams, using the analyzer's Gas Chromatograph Controller (GCC) to control analytical functions. The analyzer (see Figure 1-1) may be mounted on a wall, a rack, or a floor stand. It includes an insulated, air-heated Oven Compartment, a Gas Chromatograph Controller, a purge air panel, and a pressure control panel. X-Purge Gas Chromatograph Controller (GCC) Purge Air Panel Pressure Control Panel Oven Compartment Nameplate Figure 1-1. TYPICAL PROCESS GAS CHROMATOGRAPH PGC2000 The Oven Compartment houses an isothermal oven which contains the analytical columns, the detectors, and the sample valves. The Gas Chromatograph Controller (GCC) contains the card cage with PCBs, the Temperature Controller, and one or more of the following detector amplifiers: flame ionization (FID), thermal conductivity (TCD), and flame photometric (FPD). The front panel has a liquid crystal display (LCD), keyboard, and controller board. The FPD assembly itself is located in a special cabinet mounted on the left side of the analyzer. Below the GCC are the Purge Air Panel and the Pressure Control Panel. The Purge Air Panel contains the heater air and purge air gauges and regulators. The Pressure Control Panel contains the Electronic Pressure Controller (EPC) or a group of mechanical regulators and gauges. When the EPC is installed the Pressure Control Panel has a blank front panel OSM, F1 1-1

30 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. T- Ratings and area classifications for analyzer locations are determined and supplied by the customer. A package titled Important Papers comes with the analyzer. Included in this package are data sheets and installation drawings needed to support installation and setup of the analyzer. This manual refers to these data sheets and drawings as the Data Package. PGC2000 WITH FLAME PHOTOMETRIC DETECTOR When the analyzer has a flame photometric detector (FPD), a panel attached to the left side of the analyzer contains the detector, the detector amplifier, and the high-voltage transformer that provides the spark to ignite the FPD (see Figure 1-2). X-Purge Transformer FPD Electrometer Assembly 0 0 Detector Figure 1-2. PGC WITH FLAME PHOTOMETRIC DETECTOR AIR PURGE SYSTEMS If the analyzer will be in a Class I hazardous location, an air purging system must be installed to reduce the risk of explosion. Class I locations are those in which flammable gases or vapors are or may be present in the air in quantities sufficient to produce explosive or ignitable mixtures. The GCC purge is part of the basic design of the analyzer and must remain functional under all operational circumstances OSM, F1

31 SYSTEM VARIATIONS This manual supports the PGC2000 basic analyzer. An appendix to the main manual presents additional instructions for special applications such as PGC2002 (simulated distillation), PGC2003 (PNA), PGC2005 (temperature programmed GC), PGC2007 (fuel sulfur), PGC2008 (olefins), and PGC2030 (Sparging Sample Conditioning System). SPECIFICATIONS Physical Environmental (Enclosure): Ambient Temperature Range: Humidity: Dimensions: Weight: Mounting: Wall: Floor: EMI/RFI Consideration: Electrical Entries: Pneumatic Entries: Sample Entries: Gas: Liquid: Vents: Protected from weather: IP 52, (NEMA Type 12) Equivalent 32 to 122 F (0 to +50 C); application dependent maximum of 95% relative humidity, non-condensing 19.5 in. W x 13.4 in. D x 46.3 in. H (495 mm W x 340 mm D x 1176 mm H) 160 lb (73 kg) (minimum, configuration dependent) 1.3 in. (32 mm) from wall with brackets Optional wheeled dolly Conforms to Class A Industrial Environment Top Right Side Bottom Right Side Bottom and/or Right Side Safety Area Classification NEC: ATEX: CSA/NRTL: Z or Y-Purge Wait Time: X-Purge Timeout: Class I, Div 1 Group B, C, D with type Y-Purge T4, T3 or T2 Conforms to ATEX Directive 94/9/EC and EMC Directive 89/336/EED as amended by 92/31/EEC & 93/68/EEC Zone 1: CE 0081; II 2G, EEx pde [ib] ib [ia] IIB+H2 T4, T3 or T2 Zone 2: CE; II 3G EEx np [ib] ib IIB+H2 T4, T3 or T2 (T-code and protection method are dependent upon application) Class I, Div 1 Group B, C, D with type X-Purge T4, T3 or T2 Class I, Div 2 Group B, C, D with type Z-Purge T4, T3 or T2 4.5 minutes Hz, Hz 2000-OSM, F1 1-3

32 Power WARNING The Neutral and Ground (Earth) connections to the PGC2000 must be at earth (0 Volts) potential. Failure to maintain earth (0 volts) potential at these connection points constitutes a serious safety hazard. Voltage and Frequency: 100 VAC (+15, -6 VAC), 50/60 Hz ± 10% 120 VAC ± 10%, 50/60 Hz ± 10% 230 VAC ± 10%, 50/60 Hz ± 10% Power Consumption: 1,200 VA Startup, 900 VA Steady-State Operation (Typical, varies with installed options) Instrument Air Supply Connection: Supply Pressure: Quality: 3/8 inch tube, minimum 60 psig (414 kpa, 4.14 bar) minimum 100 psig (689 kpa, 6.89 bar) maximum Instrument grade: Clean, Oil Free and -34 C, (-30 F) dewpoint Flow Rates, all purge types: Start-up Purge: ft 3 /min ( L/min) at 60 F (20 C) Steady State Purge : ft 3 /min ( L/min) at 60 F (20 C) Analytical Detectors Standard Detectors: Configuration: Third-party detectors: Thermal Conductivity, Flame Ionization, Flame Photometric, Inter-column Thermal Conductivity Up to two simultaneous detectors, each with capability for sequential inter-column TC detector (one FPD per analyzer) Consult Factory for availability Isothermal Analytical Oven Oven Liner: Internal Dimensions: Number of Valves: Columns: Heat: Stainless Steel 15.3 in. W x 20.4 in. H x 9.0 in. D (390 mm W x 520 mm H x 230 mm D) Standard provisions for five gas samples or column switching valves in oven; standard provisions for two external liquid sample valves (consult factory for special requirements) 1/16, 1/8, 3/16 inch, Packed Stainless or Fused Silica Capillary Forced Air OSM, F1

33 Temperature Control Method: Ambient Oven Temperature: Setpoint Resolution: Temperature Stability: Steady Ambient: Ambient Range: Closed loop PID + 30 to 180 C (Settings and display in C only) 1 C ±0.1 C ±1.0 C Gas Control (Analog) Control Method: Filtration: Inlet Pressure: Minimum: Maximum: Mechanical regulators 2 microns at inlet, provided Setpoint + 20 psig (138 kpa, 1.38 bar) 150 psig (1034 kpa, bar) NOTE Supply pressure must be less than or equal to 50 psig (345 kpa, 3450 mbar) higher than the maximum output required (e.g., supply to a 100 psig (689 kpa, 6.89 bar) regulator should not exceed 150 psig (1034 kpa, bar). It is the customer's responsibility to set relief devices used to protect the analyzer and prevent hazardous releases should be set at a maximum of 200 psig (1380 kpa, bar). Range: 2-15 psig 5-30 psig psig Gauges: 0-15 psig 0-30 psig psig (0-102 kpa) (0-200 kpa) (0-700 kpa) ( bar) ( bar) bar) Temp Coefficient: Regulation: Accuracy: Repeatability: Allowable Gasses: Quality: Flow Adjustment: Tube Fittings: 0.3 psi/77 F (2.1 kpa/25 C) 0.01 psi (0.7 kpa) outlet / 1.0 psi (6.9 kpa) inlet N/A N/A H 2, He, N 2, Air, Ar GC Grade Oven mounted needle valves or flow controllers with external adjustment 316 SS Gyrolok (standard) 316 SS Swagelok (optional) 1/16, 1/8, 1/4 inch connections 2000-OSM, F1 1-5

34 Gas Control (Digital) Control Method: Closed loop PID; temperature stabilized Number of Zones: 1 to 5 Filtration: Inlet Pressure: Minimum: Maximum: 2 microns at inlet, provided Setpoint + 10 psig (69 kpa, 0.7 bar) 100 psig (689 kpa, 6.89 bar) NOTE It is the customer's responsibility to set relief devices used to protect the analyzer and prevent hazardous releases at a maximum of 200 psig (1380 kpa, bar). Range: Gauges: Temp Coefficient: Regulation: 0 to 100 psig (0 to 689 kpa, 0 to 6.89 bar), bubble tight, nonventing Electronic readout: 0.01 psig (0.07 kpa, 0.7 mbar) resolution Setpoint resolution: 0.01 psig (0.07 kpa, 0.7 mbar) None See below Accuracy: 0 to 50 psig: 1.7% 50 to 100 psig: 2.7% Repeatability: Allowable Gasses: Quality: Flow Adjustment: Tube Fittings: ±0.1 psig (±0.7 kpa, ±7 mbar) H 2, He, N 2, Air, Ar GC Grade Oven mounted needle valves or flow controllers with external adjustment 316 SS Gyrolok (standard) 316 SS Swagelok (optional) 1/16, 1/8, 1/4 inch connections OSM, F1

35 SAFETY CONSIDERATIONS SECTION 2. INSTALLATION AND START-UP Before starting to install the analyzer, read the safety information below. WARNING Before beginning installation, repair, or maintenance on the analyzer, contact the local Safety Department to ensure that all safety guidelines, regulations and procedures are followed. This includes obtaining the proper work permits. The user is responsible for being familiar with and complying with all safety and health guidelines, regulations and procedures at analyzer location. Consult Material Safety Data Sheets for safety requirements. When working on the analyzer there is the possibility of exposure to hydrogen, nitrogen, and other compressed gases. All appropriate precautions and extreme care should be taken when working with all compressed gases. Become familiar with the application specifications before working on the analyzer. Wear protective clothing and equipment such as rubber gloves, and goggles or safety glasses with side shields. CAUTION Before opening analyzer enclosure doors, be sure the area is safe from hazardous gases and will remain so the entire time analyzer is open. When handling electronic parts and assemblies, it is necessary that proper electrostatic discharge (ESD) precautions are taken (i.e., wear an ESD wrist strap with a grounding cable and use an ESD shielded bag to protect items removed). PREPARING FOR INSTALLATION Locate the analyzer as close as practical to the stream to be sampled. Analyzer location and area classification are the customer's responsibility. When determining where to install the analyzer, include the following location criteria: EMC certification, where required area classification, as specified by the customer protection from rain, direct sunlight, temperature extremes avoiding exposure to corrosive gas free from dust and static electricity space of at least 450 mm (18 in.) to the right of the analyzer for various customer connections and for servicing. Installation Tools and Equipment The following tools and equipment are required to install and check out the system. Tools: #2 Phillips screwdriver #1 Phillips screwdriver with short handle 2000-OSM, F1 2-1

36 3/16-inch flat blade screwdriver 1/8-inch flat blade screwdriver 9/64-inch ball driver 7/16-inch open end wrenches (2) 1/2-inch open end wrenches (2) 9/16-inch open end wrenches (2) 5/8-inch open end wrenches (2) 6-inch adjustable wrench 12-inch adjustable wrench 3/8-inch drive socket set with ratchet handle and leverage bar 5/16-inch (8 mm) hex key wrench (supplied with Analyzer) 5/64-inch (2 mm) hex key wrench (supplied with Analyzer) Equipment: Leak testing solution (e.g., Snoop ) Flow Meter Stop Watch (if not using a digital flow meter) Chart Recorder Flashlight Plumbing Installation All plumbing connections enter at the right side of the cabinet. Be careful to avoid damaging fittings and to ensure tight connections. Refer to the Data Package for specific plumbing information. For brass and stainless steel pipe fittings, wrap the threads with Teflon tape or a suitable thread sealant. Make all connections and then tighten them appropriately. Leak check each connection as described in the "Leak Check" paragraph. Gas Requirements The following information represents general requirements. Due to differences in applications, refer to the Data Package supplied with your analyzer for application-specific requirements. Instrument Air: instrument grade air. Burner Air: ISA Hydrocarbon Free Grade with hydrocarbon content less than 1 ppm and dew point less than -40 C. 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, % purity. FID: for measurements down to 5 ppm, gases of % purity; lower ranges require higher levels of purity (refer to the Data Package for specifics). FPD: varies with the application; refer to the Data Package for specifics. Calibration Sample A primary factor in determining the accuracy of the analyzer's calibration is the quality and precision of the calibration sample. Regardless of the sample composition or number of complete analysis components, generally only measured components are in the calibration sample OSM, F1

37 Purge Air Alarm The analyzer contains circuits that detect the loss of purge air to the analyzer and generate alarm signals to the operator. The customer has the responsibility to connect the purge alarm to a visual or audible annunciator located in a constantly monitored area, as required by NFPA 496 (1993). Liquid Sample Valve The Liquid Sample Valve (LSV) utilizes two different connection methods for the sample lines. Earlier analyzers had these sample lines connected directly to the LSV, as shown in Figure 2-1. Putting a loop in the tubing or using flexible hose reduces any sideways force at the connection. Forcing the tubing into a position can exert a sideways force at the connection, causing valve leakage. INCORRECT CORRECT Figure 2-1. LSV CONNECTION METHODS, EARLY ANALYZERS 2000-OSM, F1 2-3

38 New analyzers have the sample lines connected to a mounting plate attached to the LSV's mounting flange, as shown in Figure 2-2. Customer Connections Figure 2-2. LSV CONNECTION METHODS, NEW ANALYZERS You must take extreme care to avoid having the sample lines exert force on the sample connections of the Liquid Sample Valve. For example, if stiff 1/4-inch tubing or heat-traced lines are bent into position and attached to the valve, the force will cause premature failure of the valve stem and seals, resulting in leakage. A loop of 1/8-inch tubing or a flex hose is recommended between the valve and the sample line (this may be insulated if necessary). Figure 2-1 illustrates the incorrect and correct connection methods. It is important to use two wrenches when tightening the sample line connections to the sample chamber, and when tightening the carrier fittings on the vaporizer. One wrench must be used to back up the force applied to tighten the fitting (direct wrench force will bend the stem or the vaporizer). NOTE To ensure the integrity of the components within the Liquid Sample Valve (LSV), use the tools in LSV Tool Kit 791K009-1 when assembling or disassembling the LSV. EQUIPMENT MOUNTING WARNING Depending on the configuration of the analyzer, it can weigh from 175 to 300 pounds. You should have one or more persons help you lift it and move it. Unpack the analyzer near the installation site and move it with a transportation machine. Handle the analyzer carefully so that it does not fall. For floor-mounted units, secure the Analyzer with anchor bolts. Secure wall-mounted units appropriately. Refer to the Outline and Mounting Dimensions drawing in the Data Package for specific mounting information. CONNECTIONS Tubing Refer to the applicable drawings in your Data Package for specific tubing and connection information while you perform the following steps OSM, F1

39 1. Do not remove the tube caps, provided at the analyzer tubing ports to prevent deterioration of the columns, until immediately before making each connection. 2. Use an anticorrosion material for the lines and fittings. 3. To ensure using proper size tubing and pipe, refer to the Outline and Mounting Dimensions Diagram contained in the Data Package. 4. Use lines and fittings free of interior contamination from grease, oil or other substances. Before connecting these lines, completely air-purge their interiors. 5. Carefully connect the lines so that there are no leaks from the connections. Leak check each connection as described in the "Leak Check" paragraph. Analyzer Air The air supply is connected to the fitting marked Air In. Carrier Gas The carrier gas is connected to the fitting marked Carrier In. 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 sample system connections. Hydrogen Gas Vent WARNING Hydrogen is highly explosive. Follow applicable safety precautions and use extreme care in making connections. It is the customer s responsibility to ensure that the hydrogen supply to the analyzer does not exceed 100 psig (689 kpa, 6.89 bar) and that the customer s pressure relieving devices are set to relieve at 200 psig (1380 kpa, 13.8 bar). Failure to control the hydrogen pressure within these specifications may cause loss of property and loss of life. The analyzer uses hydrogen gas as a burner fuel with flame cell detectors (FID and FPD) and sometimes uses it as a carrier gas. Verify that the hydrogen gas meets the criteria stated in the "Gas Requirements" paragraph. Refer to the Data Package for specific connection information. Typical analyzer vents are: Cell Vents, Backflush Vent, Sample Vent, and Housing Vent. All vents must be at atmospheric pressure unless otherwise specified in the Data Package. The vent lines should slope down from the analyzer so that condensation will not collect in the analyzer or cause backpressure in the external tubing. Refer to the Data Package for specific connection information. It is the customer s responsibility to set relief devices used to protect the analyzer and prevent hazardous releases at a maximum pressure of 200 psig (1380 kpa, 13.8 bar) OSM, F1 2-5

40 The manifold vent must be plumbed from the analyzer to a safe area at 0 psia or atmospheric vent. To do this, connect appropriate tubing to the manifold vent (see Figure 2-3) and run this tubing to a hazard-free area. MANIFOLD VENT Figure 2-3. SIDE VIEW OF ANALYZER, SHOWING MANIFOLD VENT LOCATION No analyzer vent should be connected to any type of collection header without engineering-level review to address possible problems or safety issues that can result from such a connection. Proper installation of this analyzer also requires engineering-level consideration of possible ingress of toxic or hazardous materials into the analyzer or shelter via some types of sample system stream select valves. While these valves are not a part of the analyzer, a failure in an air-operated manifold style stream select valve can allow sample to flow into the air lines connected to the stream select solenoids that are within the analyzer, thus contaminating the solenoid vent and causing damage to the solenoid valve and analyzer. Electrical The analyzer must be installed according to all applicable codes. If it will be in a hazardous area, the wiring method must conform to the applicable explosion proof requirements. Install signal wiring and power wiring in separate conduit pipes or cable trays to reduce noise and crosstalk. If a grounding (earthing) connection is required, connect the appropriate size grounding wire to the Earthing Connection on the right side of the oven compartment. The following wiring is required, though the amount of wiring varies with the installation. Power wiring for heater, power circuits, electronics, and grounding circuit (circuit breaker protection must be provided by the customer). The Neutral and Ground (Earth) connections must be at earth (0 volts) potential. Failure to maintain earth (0 volts) potential at these connection points constitutes a serious safety hazard. Signal wiring between the GCC and the VistaNET OSM, F1

41 Contact output Error alarms, timing signal, status signal, and annunciator Contact input Operation start/stop, mode-selection request, etc. Analog output (4 to 20 ma) Analog hold output, chromatogram recorder output Analog input (-10 to +10 volts) Detector output (10 volts) Refer to the applicable drawings in your Data Package for specific interconnection wiring information. INITIAL SETUP OF EQUIPMENT 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. CAUTION 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. Equipment and Supplies Required 1. Analyzer Data Sheets from the Data Package 2. Flow measuring device Precautions 1. Refer to the Data Package for correct values and settings before adjusting pressure, flow, temperature, etc. 2. Review all data on alarms and corrective action before operating the analyzer. 3. Connect the analyzer purge alarm to a visual or audible annunciator located in a constantly monitored area, as per NFPA 496 (1993). This is the customer's responsibility. 4. Observe and take note of all caution tags attached to the analyzer; make all adjustments using the specific data sheets for this analyzer. 5. Ensure all air, gas and sample supply lines coming into the analyzer are properly connected and turned OFF at the external flow shutoff valves (these shutoff valves are normally associated with analyzer installation and are not a part of the analyzer itself). 6. Ensure the power supply line is properly connected and turned OFF at the circuit breaker outside the analyzer (this circuit breaker is associated with analyzer installation and is not part of the analyzer itself) OSM, F1 2-7

42 Sample System Checkout Verify that the sample system has been leak and flow checked and is known to be operating correctly. GCC Pre-Checks CAUTION Before opening any analyzer doors, ensure the area is safe and hazard-free and will remain so the entire time the analyzer is open. 1. Verify that the circuit breaker which supplies power to the analyzer is turned OFF. 2. Release the GCC front panel by turning the panel latches fully counterclockwise with a 5/16-inch (or 8 mm) hex key wrench. 3. Open the GCC front panel. 4. Verify all PCB s are secure and latched in place. 5. Close GCC front panel and hold front panel shut while you tighten the panel latches. Analyzer Pre-Checks The purge air and heater air pressures are set during factory checkout and calibration tests. These settings should not be changed during installation setup and operation. They can be verified at the gauges on the Purge Air Panel. Analytical pressures are also set during factory checkout and calibration tests but these settings may have to be adjusted for the installation environment. Once you have verified proper operation of the analyzer, adjust the analytical pressures as necessary. Perform initial startup by following the steps listed below. 1. Visually inspect the analyzer for inoperative or damaged gauges, loose or damaged connections, and overall condition. 2. If you have not completed the GCC pre-checks (previous paragraph), perform those steps now. 3. Turn on the instrument air at its source. 4. Refer to the Data Package to ensure that air supply at the specified pressure is provided to the INSTRUMENT AIR inlet OSM, F1

43 5. Refer to Figure 2-4 (when EPC is installed, the Pressure Control Panel will be blank). The purge air and heater air pressures should be as specified on the label below the corresponding regulator. Purge Air Panel Pressure Control Panel 6. Turn on carrier gas at its source. Figure 2-4. ANALYZER ADJUSTMENTS 7. Refer to the Data Package to ensure that the specified carrier gas is provided at the specified pressure to each CARRIER inlet. 8. At the external circuit breaker or switch turn the power ON. 9. For EPC-equipped analyzers, refer to the Manual Pressure Control Mode screen. Verify that carrier and gas pressures are the same as those specified in the Data Package. If necessary, adjust each set point (SP) until it is the same as the Data Package value. 10. If the analyzer has mechanical regulators, verify from the Pressure Control Panel gauge that carrier and pressures are the same as that specified in the Data Package. If necessary, adjust each regulator until its gauge value is the same as the Data Package value. 11. Verify any other gases in the same manner as Carrier # If a leak occurs during start-up, perform the leak check described in "Leak Check." 13. Allow sufficient time for oven warm-up. The oven should stabilize at the temperature indicated in the Data Package. If adjustments are required, adjust the Digital Temperature Controller as described in "DIGITAL TEMPERATURE CONTROLLER" in Section Proceed to "MATCHING COLUMN FLOWS." Leak Check If a leak occurs during initial turn-on, perform a simple leak check on the analyzer section as follows: 1. Plug all carrier gas vents and pressurize to 30 psig. Shut off the carrier supply. 2. Note pressure drop-off on the carrier supply and column pressure gauges. A visual decline is excessive. 3. Starting at the inlet to the detector and working back to the carrier gas supply, plug the exit of each valve or column to locate the leak. 4. Use Snoop or other suitable leak detection solution to check for leaks OSM, F1 2-9

44 MATCHING COLUMN FLOWS When you are matching column flows, refer to the Data Package for flow rates and valve configurations. Although methods of matching column flows vary with valve configurations, the following procedures apply to most configurations. Verify flows using a flow meter connected to the point being checked (e.g., cell vent). Manual Operation of Valves Operate the valves manually as follows: 1. On the Background screen press the F2 (Manual Control) soft key. 2. On the Manual Control Mode screen (see Figure 2-5), the first line ( Valves: ) indicates which valves are ON. The cursor will be on the second line ( Enter Valve: 0 ), which enables you to turn valves on and off. 3. To turn Valve One ON, verify that the number 1 does not appear on the first line, then press the 1 key on the keyboard. The number 1 appears momentarily on the second line and then appears on the first line. 4. To turn Valve One OFF, verify that the number 1 appears on the first line ( Valves: ). Move the cursor to the second line and press the number 1 key. The number 1 disappears from the first line of the screen. 5. Turn Valve Two and other valves on and off manually in the same manner. ****** Manual Control Mode ****** Valves: Time:00000 Enter Valve: [0] Cycle Time:00000 RECORDER: Method Tbl: 000 Offset : 0 % Stream: 01 Attn : 5 Purging: 01 Off Chroma Bar Trend Peaks: 00 PURGE SELECT: 0 State: Idle Start Crest End Peak Time Time Time Area Type Last: Val-Bas Bas-Val Exit Detector Manually Press. & to and Zero Temp. Background Graphics Baseline Control F1 F2 F3 F4 Figure 2-5. MANUAL CONTROL MODE SCREEN OSM, F1

45 Checking Total Column Flow To check column flow using a 10-port sample valve and an 8-port selector valve, perform the following steps (other valve configurations use similar procedures): 1. Turn all valves off as described in the previous paragraph. 2. See Figure 2-6. To check total column flow, set Valves One and Two to ON. 3. Connect the flow-measuring device to the CELL VENT of the detector cell and measure the flow rate. The total column flow should be as specified in the Data Package. s If necessary, adjust the COLUMN PRESSURE regulator to obtain the specified flow rate. CARRIER IN COLUMN PRESSURE ADJ PI AIR OUT AIR IN AIR OUT AIR IN VALVE ON VALVE ON SAMPLE VENT SELECTOR 1 6 FLOW ADJ SAMPLE IN COLUMN SELECTOR VENT ANALYTICAL FLOW ADJ COLUMN 3 COLUMN 1 SAMPLE LOOP BACKFLUSH VENT DETECTOR CELL VENT Figure 2-6. CHECKING TOTAL COLUMN FLOW 2000-OSM, F1 2-11

46 Checking Analytical Flow Adjust 1. Set Valve One to OFF; Valve Two remains ON (see Figure 2-7). CARRIER IN COLUMN PRESSURE ADJ PI AIR IN AIR OUT AIR OUT AIR IN VALVE "OFF" VALVE "ON" SAMPLE VENT SELECTOR 1 6 FLOW ADJ SAMPLE IN COLUMN SELECTOR VENT ANALYTICAL FLOW ADJ BACKFLUSH VENT COLUMN 3 COLUMN 1 SAMPLE LOOP DETECTOR CELL VENT Figure 2-7. MATCHING FLOW THROUGH ANALYTICAL FLOW ADJUST VALVE 2. To compensate for the pressure drop through Column 1, adjust the ANALYTICAL FLOW ADJUST needle valve (accessed from the right side of the Oven Compartment) until the flow rate at the cell vent of the detector cell is the same as the total column flow. 3. If the analyzer has several valves, first set the lowest-numbered valve ON and check the flow rate. Then set the other valves on one at a time, checking the flow rate and adjusting the corresponding restrictor (if necessary) after each valve is turned on OSM, F1

47 Checking Backflush Flow 1. Connect the flow-measuring device to the Backflush Vent and verify that Valves One and Two are OFF (see Figure 2-8). 2. Adjust the Backflush Vent restrictor to the flow rate stated in the Data Package. CARRIER IN COLUMN PRESSURE ADJ PI AIR IN AIR OUT AIR IN AIR OUT VALVE OFF VALVE OFF SAMPLE VENT 1 6 SELECTOR FLOW ADJ SAMPLE IN COLUMN SELECTOR VENT ANALYTICAL FLOW ADJ COLUMN 3 COLUMN 1 SAMPLE LOOP BACKFLUSH VENT DETECTOR CELL VENT Figure 2-8. CHECKING BACKFLUSH FLOW 2000-OSM, F1 2-13

48 Checking Selector Flow Adjust 1. See Figure 2-9. Set Valve One to ON and Valve Two to OFF. CARRIER IN COLUMN PRESSURE ADJ PI AIR OUT AIR IN AIR IN AIR OUT VALVE "ON" VALVE "OFF" SAMPLE VENT SELECTOR 1 6 FLOW ADJ SAMPLE IN 3 8 COLUMN SELECTOR VENT ANALYTICAL FLOW ADJ COLUMN 3 COLUMN 1 SAMPLE LOOP BACKFLUSH VENT DETECTOR CELL VENT Figure 2-9. MATCHING FLOW THROUGH SELECTOR FLOW ADJUST VALVE 2. To compensate for the pressure drop through Columns 1 and 2, adjust the SELECTOR FLOW ADJUST needle valve until the flow rate at the cell vent is the same as the total column flow. Checking Selector Vent 1. See Figure 2-9. Connect the flow-measuring device to the Selector Vent and verify that Valve One is ON and Valve Two is OFF. 2. To compensate for the pressure drop through Column 3, adjust the Selector Vent restrictor until the flow rate at the Selector Vent is the same as the total column flow OSM, F1

49 EQUIPMENT STARTUP CAUTION Before opening any analyzer doors, ensure the area is safe and hazard-free and will remain so the entire time the analyzer is open. 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. CAUTION When you stop an analysis, select "At End of Analysis" unless an emergency occurs. Selecting "Now" stops an analysis immediately, which could inadvertently damage the analyzer if it stops while an analysis is in progress. Stopping during an analysis could trap sample in a column or permit temperature or pressure ramps to continue without adequate control. Initial Power On For Y and Z purged analyzers, note the purge label on the analyzer and allow sufficient air purge time before switching on the power source at the circuit breaker. Once the purge requirements are met, turn power to the equipment ON at the supply breaker. The following components receive power: oven heater system, optional heated devices (Liquid Sample Valve vaporizer, Air Cleanup/Methanizer), detector power supply, and GC Controller (display illuminates). CAUTION Verify that the X Purge is not in override (see "X Purge Override Option" in Section 4). For X Purged and CENELEC certified analyzers, you can turn the power supply ON at the circuit breaker immediately after the air supply is turned ON. X Purge automatically controls the purge time and applies power to the analyzer only after the purge cycle is completed. Refer to the Data Package for specific purge cycle time. (There is an X Purge Override operation that may be used during startup, if necessary. See "AIR PURGING" in Section 4 for detailed information.) 1. Turn ON carrier gas to purge the columns. Do this before the oven is heated to prevent the columns from being damaged. 2. For FID and FPD only: if the Flameout LED on the GCC front panel is not illuminated, turn off Burner Fuel at the Pressure Control Panel. The isothermal oven must be at operating temperature before igniting the flame, to prevent damage to the detector. 3. Allow adequate time for the oven to heat to proper operating temperature before continuing. Condensation damage may occur to the Methanizer/Air Clean-up unit if the oven is not at operating temperature before Burner Air flow starts. NOTE The oven will begin to cycle and control temperature in about one hour. However, total equilibrium may take 8 to 12 hours depending on the analyzer configuration and ambient conditions. Baselines will continue to drift until the system stabilizes. 4. Check the oven temperature on the Temperature Control screen (see "Temperature Control Table" in Section 4) OSM, F1 2-15

50 CAUTION It is the customer s responsibility to ensure that the hydrogen supply to the analyzer does not exceed 100 psig (689 kpa, 6.89 bar) and that the customer s pressure relieving devices are set to relieve at 200 psig (1380 kpa, 13.8 bar). Failure to control the hydrogen pressure within these specifications may cause loss of property and loss of life. 5. Turn ON Burner Fuel and Burner Air at the flow shut off valves and observe the Actual values shown on the Manual Pressure Control Mode screen. Ensure pressures are set according to the Data Package and adjust set points (SP) as necessary. If the analyzer has mechanical regulators, observe the gauges on the Pressure Control Panel and adjust the regulators as necessary. 6. After the temperature stabilizes, recheck all purge air pressures at the gauges on the Purge Air Panel. Adjust corresponding regulators, if needed, according to the Data Package. 7. Check column pressure by examining the Actual values for Carrier #1 and Carrier #2 shown on the Manual Pressure Control Mode screen. Verify these values with the Data Package specification and adjust the Carrier #1 and Carrier #2 set points as necessary. 8. If the analyzer has mechanical regulators, check column pressure by examining the Carrier #1 and Carrier #2 gauges on the Pressure Control Panel and verify these values with Data Package specifications. Adjust the Carrier #1 and Carrier #2 regulators as necessary. 9. Turn ON Calibration Gas supply (may be called Standard Sample). The gauges and regulators used to monitor the calibration gas are normally part of the Sample Conditioning System. If necessary, adjust the appropriate controls on the Sample Conditioning System to provide the analyzer with correct sample pressure and flow, according to the Data Package. 10. On the Background screen press the F2 (Manual Control) soft key. 11. On the Manual Control Mode screen press the F2 (Detector and Graphics) soft key. 12. For an analyzer with a TCD: a. On the Chroma Board screen press the F3 (Manually Zero Baseline) soft key. b. Add the values of the Hardware Zero reading and Software Zero reading. c. Open the GCC front panel and locate the TCD Amplifier Board on the left side wall of the GCC. d. Adjust the TCD Zero Adjust on the TCD Amplifier Board until the Detector Reading on the Chroma Board screen is equal to the sum of the Hardware and Software Zero readings. e. On the Chroma Board screen, press the F3 (Manually Zero Baseline) soft key. The Detector Reading should now be 2.00 ± 0.05 mv and the Hardware Zero should be 10% or less. f. Close and fasten the GCC front panel OSM, F1

51 CAUTION Do not ignite FPD/FID flame if the isothermal oven temperature is below operational level. Low oven temperature will result in condensation damage to the flame cell. Check oven temperature on the Temperature Control screen (see "Temperature Control Table" in Section 4). 13. For an analyzer with an FID: a. On the Chroma Board screen, observe the Flame line. If "Lit" is underlined the flame should be on and the Flameout LED on the front panel should be off. b. If the Flame is not lit and the Ignitor is Off, press the F4 (Manual Ignitor On) soft key to light the cell flame. The ignitor coil remains powered for the specified Timeout period. Once the flame lights the Flame Out LED will go off. The cell flame burns as long as there is sufficient burner air and hydrogen fuel in the cell. 14. For an analyzer with an FPD: a. On the Chroma Board screen, observe the Flame line. If "Lit" is underlined the flame should be on and the Flameout LED on the front panel should be off. NOTE With an FPD, if "Lit" in underlined on the Chroma Board screen and the Flameout LED on the front panel is ON, verify the Flameout Alarm is set to normally open (NO). See "SOFTWARE VERIFICATION" in Section 5 for instructions on checking the status of the Flameout Alarm OSM, F1 2-17

52 b. On the Chroma Board screen, verify that the FPD Temp Zone is the same as that specified in the Data Package (see Figure 2-10). c. On the Chroma Board screen, observe the "Ignitor" line. "Manual" should be underlined. d. Press the F1 (Exit) soft key. e. On the Manual Control Mode Screen, press the F4 (Press. & Temp. Control) soft key. f. On the Pres and Temp Control screen, cursor to TEMP CONTROL and press the F2 (Manual Temp Control) soft key. ***** Chroma Board ***** Detector: FPD Flame: Lit Ignitor: Off H2: None Hardware Zero: 5.10mV ( 4.7%) Software Zero: mV Detector Reading: 1.98mV Ignitor: Manual Auto Auto Timeout Timeout: 0 seconds FPD Temp Zone: 0 Manually Manual Exit Graphics Zero Ignitor Baseline On F1 F2 F3 F4 Figure CHROMA BOARD SCREEN OSM, F1

53 g. On the Manual Temperature Control Mode screen (see Figure 2-11), verify that the actual temperature for the FPD is at least 120 degrees. **** Manual Temperature Control Mode **** Zone Config Actual SP Rate ISO-OVEN ISO PROG. OVEN PROG/C FPD ISO LSV ISO Valve # : [0] Time : 0125 Zone # : 2 State : Pk Back Set Point: Ramp Rate: T-Rating Ver VALVES : T2 290C Accept Zero Span Escape Control All All Point Zones Zones F1 F2 F3 F4 Figure MANUAL TEMPERATURE CONTROL MODE SCREEN h. When the temperature is at least 120 degrees, press the F1 (Escape) soft key two times to return to the Manual Control Mode screen. i. On the Manual Control Mode screen, press the F2 (Detector and Graphics) soft key. j. On the Chroma Board screen, verify the flame is off and the Ignitor is Off. k. Press the F4 (Manual Ignitor On) soft key to light the cell flame. The ignitor coil remains powered for the specified Timeout period. Once the flame lights the Flame Out LED will go off. The cell flame burns as long as there is sufficient burner air and hydrogen fuel in the cell. 14. With Dual Detectors, perform steps 12 and 13 for each detector, as appropriate. 15. Again verify settings with the Data Package and adjust as needed. Check oven temperature on the Temperature Control screen (see "Temperature Control Table" in Section 4). Verify GCC Operation Restore all tables from E2PROM as follows: 2000-OSM, F1 2-19

54 1. Verify that the Background screen is displayed (see Figure 2-12). If it is not displayed, press the F1 soft key several times until the Background screen appears. ********** B A C K G R O U N D ********** ABB Analytical GCC Remote V029-1R (Std GCC) (C) 2001 **ALARM** **ALARM** 20-JUN-2002 THU 08:16:01 **ALARM** Analysis Time :00114 Peaks Found:00 Cycle Time :00000 State:Idle Current Stream :01 Key Component: Purging Stream :01 none Method :01 entered Exit Manual Cur Report, to Control Basic I/O & Alarms Commands Options F1 F2 F3 F4 Figure BACKGROUND SCREEN 2. Press the F1 (Exit to Commands) soft key. 3. On the Commands screen cursor down to STORAGE & CONFIG. 4. Press the F2 (Save or Restore Tables) soft key. 5. On the Table Storage screen cursor down to RESTORE TABLES FROM E2PROM. 6. Press the F2 (Restore Tables) soft key. 7. When Are You Sure? Y/N appears on the screen, press the Y key. 8. Press the F1 soft key as necessary to return to the Background screen. This restores to main memory the tables that were most recently saved to E 2 PROM. If ABB Lewisburg provided Applications Engineering, verify all method tables by comparing them to those in the Data Package. This is done most easily by printing the tables (if a printer is connected to the analyzer). To print the method tables: 1. Display the Background screen. 2. Press the F1 (Exit to Commands) soft key. 3. On the Commands screen cursor down to PRINTER OSM, F1

55 4. Press the F2 (Test Printer) soft key. A string of characters should print. If characters print go to step 5. If a string of characters does not print go to step Verify that the cursor is on PRINTER. 6. Press the F3 (Print Tables) soft key. 7. Select a table to print. Repeat until you have printed all tables. 8. Verify that the printed tables are the same as those in the Data Package. If so, go to "Calibration Run." 9. If a string of characters did not print when you selected Test Printer, cursor to TESTING/SET UP. 10. Press the F3 (Hardware Set Up) soft key. 11. On the Hardware Set Up screen, verify that the baud rate, parity, data bits, and stop bits values match those set at the printer. Refer to the printer manual if necessary. 12. Press the F2 (Exit & Update) soft key and return to the Commands screen. 13. Perform steps 3 through 8. Calibration Run If you have a calibration run specified for your analyzer, request a calibration and compare the results with those in the Data Package. To do this perform the following steps (which will enable you to perform a single calibration run): 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On Commands screen cursor to TABLE EDIT and press the F2 (Methods) soft key. 3. The Method Table #?? screen will appear. Use the number keys on the GCC front panel to enter the number of the method to be calibrated. When the desired number appears on the screen, press the F2 (Edit The Table) soft key. 4. The Cal Define & Cycle Time screen will appear. Note the calibration stream number that appears on the Primary Cal Stream line. 5. Press the F1 (Continue) soft key. 6. When the next Method Table screen appears, press the F1 (Exit) soft key, then press the F1 (Escape) soft key. 7. When the Commands screen appears, cursor to ANALYSIS CONTROL and then press the F2 (Request Analysis) soft key OSM, F1 2-21

56 8. On the Request Analysis screen (see Figure 2-13), select the method number for a calibration run. ****** Request Analysis ****** Analysis Requests: For a benchmark or calibration enter the method#, otherwise enter the stream#:[1 ] None Stream Bench Cal PENDING: Accept Clear Escape The All Request Requests F1 F2 F3 F4 Figure REQUEST ANALYSIS SCREEN 9. Place the cursor on Cal and then press the F2 (Accept The Request) soft key. 10. Press the F1 (Escape) soft key to return to the Commands screen. 11. If the analyzer is running, go to step 14. If the analyzer is stopped, go to step On the Commands screen, press the F4 (Start/Stop Analysis) soft key. 13. On the Start/Stop Analysis screen, press the F2 (Start Analyzer) soft key. The controller will perform the calibration as soon as it completes all other requests. 14. Press the F1 soft key as necessary to return to the Background screen. 15. Watch the screen to determine when the calibration stream (noted in step 4) has purged and starts the calibration. 16. Press the F3 (Current Report, Basic I/O, and Options) soft key. 17. On the Report, Basic I/O and Options screen, cursor to CURRENT REPORT, if necessary, and press the F2 (View Current Report) soft key. The desired report will display at the end of the calibration. 18. When the report is complete, press the F1 soft key as necessary to return to the Background screen. The analyzer will continue to run until the operator stops it. 19. To stop the analyzer, press the F1 (Exit to Commands) soft key OSM, F1

57 20. On the Commands screen cursor to ANALYSIS CONTROL, if necessary, and press the F4 (Start/Stop Analysis) soft key. 21. On the Start/Stop Analysis screen, cursor to At End of Analysis? and then press the F2 (Stop Analyzer) soft key. 22. Press the F1 soft key as necessary to return to the Background screen. Checking Streams To verify the operation of each stream, perform a single analysis on each one before going into full operation. 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen cursor to ANALYSIS CONTROL, if necessary, and then press the F2 (Request Analysis) soft key. 3. On the Request Analysis screen (see Figure 2-11), select the stream to be analyzed. 4. Place the cursor on Stream and then press the F2 (Accept The Request) soft key. 5. Press the F1 (Escape) soft key to return to the Commands screen. 6. On the Commands screen, press the F4 (Start/Stop Analysis) soft key. 7. On the Start/Stop Analysis screen, press the F2 (Start Analyzer) soft key. The controller will start the analysis on this stream as soon as all other requests have been completed. 8. Press the F1 soft key as necessary to return to the Background screen. 9. Watch the screen to determine when the desired stream has purged and starts the analysis. 10. Press the F3 (Current Report, Basic I/O, and Options) soft key. 11. On the Report, Basic I/O and Options screen, cursor to CURRENT REPORT, if necessary, and press the F2 (View Current Report) soft key. The desired report will display at the end of the analysis. 12. When the report is complete, press the F1 soft key as necessary to return to the Background screen. 13. To repeat the process for the remaining streams or to rerun this stream, repeat steps 1 through When checkout is complete, press the F1 soft key to return to the Background screen. Chroma I/O PCB Setup The Chroma I/O PCB, located in slot 2 of the GCC Card Cage, requires setting of switches for network operation and local control options. Eight-position DIP Switch SW1 controls these features. Refer to the Data Package to see if a network identification ( Remote Number ) is assigned to the analyzer. When you determine the Remote Number for this analyzer, set or verify this identification using positions 1 through 5 of SW1, as follows OSM, F1 2-23

58 NOTE Each time one of these address switches is changed, you must initialize the switch selections. To do this, open the GCC Front Panel, press and release the RESET switch on the Single Board Computer PCB, and then close the Front Panel. Additionally, you must restore the tables from E 2 PROM (see "Verify GCC Operation"). 1. Turn power to the analyzer OFF. 2. Open the GCC front panel. CAUTION Always wear a fully-connected anti-static wrist strap when removing or installing PC boards. 3. Remove the Chroma I/O PCB from the Card Cage. 4. Locate Switch SW1 on the Chroma I/O PCB (see Figure 2-14). ON OFF SW1 Figure CHROMA I/O BOARD SETUP OSM, F1

59 5. Set the switch positions to the desired remote number, using Figure 2-15 as a guide. Switch No Switch No # #17 # #18 # #19 # #20 # #21 # #22 # #23 # #24 # #25 # #26 # #27 # #28 # #29 # #30 # #31 # #32 Remote No. Figure REMOTE NUMBER IDENTIFICATION WITH SW1 6. Insert the Chroma I/O PCB into slot 2 of the Card Cage and make sure the PCB is securely in place. 7. Close and lock the GCC front panel. 8. Turn power to the analyzer ON at the circuit breaker. The local control options are manual control, view only, and screen saver, using SW1 positions 6, 7, and 8 (SW1 positions 6 and 7 interact). Setting SW1-7 to OFF locks the screen in a view only mode; you cannot edit any tables or functions. Setting SW1-7 to ON disables the view only function. SW1-6 provides manual control but does not let you update tables. Setting SW1-6 to OFF enables manual control, but only when SW1-7 is in the ON position. When SW1-7 is set of OFF this overrides the setting of SW OSM, F1 2-25

60 The screen saver option lets you blank the display screen when it is not being used. SW1-8 OFF activates the screen saver, while SW1-8 ON disables this feature. If the GCC has user nameable inputs option, you may insert names for up to five sensor inputs (digital inputs on the Chroma I/O Board). To enter these names, perform the following steps: 1. On the Background screen, press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor down to NAMES and press the F2 (Name Sensors & Basic) soft key. 3. On the Sensor And Basic Alarm Names screen, enter the desired names (up to ten alphanumeric characters each) and then press the F2 (Exit and Update) soft key to save the names. Analytical Operation Once you have verified the calibration data and each stream s data, you are ready to place the analyzer into full operation. Display the Background screen and then perform the following steps: 1. Press the F1 (Exit to Commands) soft key. 2. On the Commands screen cursor to ANALYSIS CONTROL, if necessary, and then press the F4 (Start/Stop Analysis) soft key. 3. On the Start/Stop Analysis screen press the F2 (Start Analyzer) soft key. The analyzer will run according to an already designated method table (usually #1). The analyzer will continue to operate until you command it to stop (see "Stopping the Analyzer"). Verify Zero Baseline on Chromatogram You can verify a chromatogram s zero baseline in one of the following ways: Record the chromatogram, to compare it with the Data Package Display the chromatogram Display the percent offset used to achieve zero Recording a Chromatogram 1. On the Background screen press the F2 (Manual Control) soft key OSM, F1

61 2. On the Manual Control Mode screen (see Figure 2-16), cursor down to CHROMA, then left to OFF. ****** Manual Control Mode ****** Valves: Time:00000 Enter Valve: [0] Cycle Time:00000 RECORDER: Method Tbl: 000 Offset : 0 % Stream: 01 Attn : 5 Purging: 01 Off Chroma Bar Trend Peaks: 00 PURGE SELECT: :0 State: Idle Start Crest End Peak Time Time Time Area Type Last: Val-Bas Bas-Val Exit Detector Manually Press. & To and Zero Temp. Background Graphics Baseline Control F1 F2 F3 F4 Figure MANUAL CONTROL MODE SCREEN 3. Press the ENTER key. The recorder turns off. 4. Cursor to CHROMA and then press the ENTER key. The recorder turns on and will record the chromatogram. 5. When the chromatogram is complete, press the F1 soft key as necessary to return to the Background screen. Displaying a Chromatogram 1. On the Background screen press the F2 (Manual Control) soft key. 2. On the Manual Control Mode screen press the F2 (Detector and Graphics) soft key. 3. On the Chroma Board screen press the F2 (Graphics) soft key. 4. On the Graphics Mode screen press the F2 (Display the Graphics) soft key. A chromatogram will scroll up the screen as it happens. A baseline at mid-screen is good. 5. When you have completed the chromatogram display, press the F1 soft key as necessary to return to the Background screen. Displaying the Percent Offset 1. On the Background screen press the F2 (Manual Control) soft key. 2. On the Manual Control Mode screen press the F3 (Manually Zero Baseline) soft key OSM, F1 2-27

62 3. A message line appears above the soft key, similar to the following: Zero Offset Used 004%. A value less than 10% is good. 4. When you have completed the zero offset check, press the F1 soft key as necessary to return to the Background screen. Time Cycle Check Perform a complete program cycle to verify that each stream and method is operating according to the Data Package. Verify Reports Compare all reports in the Data Package to the corresponding reports in the analyzer by printing the analyzer reports. Putting a Header on Printed Reports 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor down to NAMES and then press the F3 (Name Headers) soft key. 3. On the Name Headers screen, enter a header (up to two lines) and then press the F2 (Exit and Update) soft key to save the headers. 4. Press the F1 soft key as necessary to return to the Background screen. Printing the Reports 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen cursor down to REPORTS OSM, F1

63 3. Press F2 (Printer Report Type) soft key to display Printer Report Type screen (see Figure 2-17). Highlighted or underlined items on this screen indicate current selections. 4. Cursor right or left to the report type you want to print: Raw Data, Regular, or Short (see "OTHER TABLES AND REPORTS" in Section 4 for detailed examples of report types). 5. Cursor down to Print and then cursor right to Always to activate the printer. 6. Cursor down to Alarm Report and select No (or Yes to print an alarm report). 7. Cursor down to Frequency if you are changing how often you print this report. Frequency in this screen means whether you will print the report each time it occurs ( 1 ), only every other time it occurs ( 2 ), only every third report that occurs ( 3 ), etc. ****** Printer Report Type ****** GC Analysis Report: Type: [Raw Data] Regular Short Print: Never Always On Alarm Alarm Reports: No Yes Frequency: 1 Inhibit Cal/Bench Report: No Yes Escape Exit and Update F1 F2 F3 F4 Figure PRINTER REPORT TYPE SCREEN 8. When you have made and verified your selections, press the F2 (Exit and Update) soft key to print the report. 9. Repeat steps 2 through 8 for each report you want to print. 10. When you have printed all required reports, return to the Printer Report Type screen and set the Print selection to Never so that the printer does not keep printing reports. 11. Press the F2 (Exit and Update) soft key to save your setting. 12. Press the F1 soft key as necessary to return to the Background screen. Benchmark Run Benchmarks are periodic tests used to ensure the analyzer is functioning properly. If you perform a benchmark of each applicable method at the end of start-up, this will provide a reference for later benchmarks. In order to do benchmarks, the benchmark concentrations must be entered into the 2000-OSM, F1 2-29

64 Component Definition screen and the benchmark stream must be defined (see "Preparing a Method Table" in Section 4). To run a benchmark test: 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen cursor to TABLE EDIT and then press the F2 (Methods) soft key. 3. The Method Table #?? screen will appear. Use the number keys on the GCC front panel to enter the number of the method to benchmark. When the desired number appears on the screen, press the F2 (Edit The Table) soft key. 4. The Cal Define & Cycle Time screen will appear. Note the benchmark stream number that appears on the Benchmark Stream line. 5. Press the F1 (Continue) soft key. 6. When the next Method Table screen appears, press the F1 (Exit) soft key, then press the F1 (Escape) soft key. 7. When the Commands screen appears, cursor to ANALYSIS CONTROL and then press the F2 (Request Analysis) soft key. 8. On the Request Analysis screen select the method number to be benchmarked. 9. Place the cursor on Bench and then press the F2 (Accept The Request) soft key. 10. Press the F1 (Escape) soft key to return to the Commands screen. 11. If the analyzer is running, go to step 14. If the analyzer is stopped, go to step On the Commands screen press the F4 (Start/Stop Analysis) soft key. 13. On the Start/Stop Analysis screen press the F2 (Start Analyzer) soft key. The controller will perform the benchmark as soon as all other requests have been completed. 14. Press the F1 soft key as necessary to return to the Background screen. 15. Watch the screen to determine when the benchmark stream (noted in step 4) has purged and starts the benchmark. 16. Press the F3 (Current Report, Basic I/O, and Options) soft key. 17. On the Report, Basic I/O and Options screen, cursor to CURRENT REPORT, if necessary, and press the F2 (View Current Report) soft key. The desired report will display at the end of the benchmark run. 18. When the report is complete, press the F1 soft key as necessary to return to the Background screen. The analyzer will continue to run as directed by the Stream Assignment Table unless it is stopped by the operator. 19. To stop the analyzer press the F1 (Exit to Commands) soft key. 20. On the Commands screen, cursor to ANALYSIS CONTROL, if necessary, and press the F4 (Start/Stop Analysis) soft key OSM, F1

65 21. On the Start/Stop Analysis screen, cursor to At End of Analysis? and then press the F2 (Stop Analyzer) soft key. 22. Press the F1 soft key as necessary to return to the Background screen. TCD Zero Adjust (Filament TCD Only) To adjust the Thermal Conductivity Detector (TCD) zero, perform the following steps: 1. On the Background screen press the F2 (Manual Control) soft key. 2. On the Manual Control Mode screen press the F2 (Detector and Graphics) soft key. 3. On the Chroma Board screen press the F3 (Manually Zero Baseline) soft key. The Detector Reading should change to a value of 2.00 mv ± 0.05 mv. 4. Note the readings (on the Chroma Board screen) for Hardware Zero, Software Zero, and Detector Reading values. 5. Open the Controller front door. 6. Locate the TCD Amplifier PCB on the left side wall of the GCC and remove the plug covering the Zero Adjust Potentiometer (see Figure 2-16). 7. Adjust the Zero Adjust potentiometer until the Detector Reading is equal to the sum of the Hardware Zero and Software zero values noted in step Press the F3 (Manually Zero Baseline) soft key and recheck the readings. The detector is adequately zeroed when the Hardware Zero percentage is less than 10%. Zero Adjust Potentiometer Figure TCD AMPLIFIER PCB Stopping the Analyzer To stop the analyzer perform the following steps: 1. On the Background screen press the F1 (Exit to Commands) soft key OSM, F1 2-31

66 2. On the Commands screen cursor to ANALYSIS CONTROL, if necessary, and then press the F4 (Start/Stop Analysis) soft key. 3. On the Start/Stop Analysis screen, verify that the highlighted area is on "At End of Analysis?" and press the F2 (Stop Analyzer) soft key. The analyzer will stop at the end of the analysis. 4. Press the F1 soft key as necessary to return to the Background screen. CONNECTING THE ANALYZER TO VISTANET If the analyzer is connected to ABB's VistaNET, you must connect the GCC to the VistaNET PC as described in the VistaNET 2.0 Installation Guide (2300-IG). After the connections have been completed and verified you must set up the GCC to work on this network. This setup consists of several sets of front panel display entries. Initial Setup These steps set up the analyzer to work with VistaNET. The paragraphs that follow explain specific additional information required for full VistaNET operation. NOTE Before changing VistaNET screens, verify all data with your Network Administrator to ensure proper VistaNET connection and operation. 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor to TESTING/SETUP and then press the F4 (Status Display) soft key. 3. On the Controller Status screen, press the F2 (Clear Highway Stats) soft key to reset all data to zero so you will know when VistaNET data is sent and received. 4. On the Commands screen, cursor to VISTANET and then press the F2 (VistaNET Tables and Commands) soft key OSM, F1

67 5. On the VN Menu screen (see Figure 2-19), cursor to STARTUP and then press the F2 (Essential Addresses) soft key. ************ VN Menu ********** TABLES STARTUP TESTING Essential Access Refresh Escape Addresses Level VNSA Tables F1 F2 F3 F4 Figure VN MENU SCREEN (STARTUP HIGHLIGHTED) 6. On the VistaNET Essential Addresses screen (see Figure 2-20), enter the GCC's identification on the Name line. This identifies the device type and location. 7. Cursor down to the Tag line and enter the GCC's tag number. This usually identifies the tap in the process that connects to the analyzer. 8. Cursor to the Board Address line and enter the Communication Board's address. 9. Cursor to the Domain 1 line and enter your GCC's Domain 1 identification. 10. Cursor to the Domain 2 line and enter your GCC's Domain 2 identification. 11. Cursor to the VNSA Address line and enter the complete address of the VNSA serving your GCC. 12. Cursor to the Router Address line and enter the complete address of the Router serving your GCC OSM, F1 2-33

68 13. When you have completed and verified your entries, press the F2 (Exit and Update) soft key to save your entries. ******* VistaNET Essential Addresses ******* Name: [GCC10 ] Tag: GCC10 Board Address: 0.10 Domain 1: 0.1 Domain 2: 0.2 VNSA Address: Router Address: Escape Exit and Update F1 F2 F3 F4 Figure VistaNET ESSENTIAL ADDRESSES SCREEN Setting Access Levels Next you must enter the appropriate access level. There are three levels of remote access (i.e., via VistaNET) granted by the analyzer: 1. Net Locked: no remote modification of the analyzer's tables is permitted. It requires a SUPERVISOR VNSA access level to modify any of the analyzer's tables from the front panel (see the applicable VistaNET Installation Guide for more information). 2. Restricted: remote modification of tables is limited to users that have SUPERVISOR or NORMAL access level. 3. Unrestricted: remote modifications can be performed by any user. You set the remote access level for an analyzer from the front panel as follows: OSM, F1

69 1. At the VN MENU screen, cursor to STARTUP and press the F3 (Access Level) soft key (see Figure 2-21). 2. Select level desired from scroll list and select Exit and Update. ***** VistaNET Access Level ***** Access Level: Unrestricted Escape Exit and Update F1 F2 F3 F4 Figure VistaNET ACCESS LEVEL SCREEN Subscriber List Since you want the analyzer to automatically send analysis results and analyzer events to the VistaREPORTER, the HIU, and VistaSTORAGE, you must enter their addresses and associated time-outs in the Subscriber List. The time-out determines how long the analytical device will wait for an appropriate response from the server before trying an alternate domain or different server altogether. Unlike the Essential Addresses and Access Level, the Subscriber List can be edited remotely. This installation procedure will only cover editing the Subscriber List from the device s front panel. To edit the Subscriber List: 2000-OSM, F1 2-35

70 1. At the VN MENU screen cursor to TABLES (see Figure 2-22). **** VN Menu ***** TABLES STARTUP TESTING Subscriber SQC Escape List Config Table F1 F2 F3 F4 Figure VN MENU SCREEN (TABLES HIGHLIGHTED) OSM, F1

71 2. Press the F2 (Subscriber List) soft key to access the VistaNET Subscriber List (see Figure 2-23). ***** VistaNET Subscriber List ***** Command: Previous Next Add Delete Type: HIU Primary Address: Secondary Address: Time Out: 7000 ms This Entry: 1 Total Entries: 3 Exit Accept Expand Escape & Update Command Address F1 F2 F3 F4 Figure SUBSCRIBER LIST SCREEN 3. Cursor to Type field and select server type: HIU, RD (VistaREPORTER), or SD (VistaSTORAGE). 4. Cursor to Primary Address field and enter the full address of the server that the analytical results or analyzer events will be sent to first. 5. Cursor to Secondary Address field and enter the full address of the server that is contacted only when no proper response has been received from the Primary Address within the time limit set in the Time Out field. 6. Cursor to the Time Out field and enter the time period before the analytical device will switch to the Secondary Address for services. The time-out period must be entered in milliseconds. Note: If the HIU time-out period is inadequate for HIU communications with the DCS, the HIU will automatically modify the analytical device s Subscriber List. 7. Cursor to the Command field, then cursor to Add. 8. Press the F3 (Accept Command) soft key. 9. Repeat steps 2 through 7 for each Subscriber List entry. 10. When you have completed all entries, press the F2 (Exit & Update) soft key. Completing the VistaNET Connection When all entries have been completed and verified, you should perform the following steps to ensure VistaNET is operating properly OSM, F1 2-37

72 1. On the VN Menu screen with Startup highlighted, press the F4 (Refresh VNSA Tables) soft key and then press the Escape soft key to return to the Commands screen. 2. On the Commands screen, cursor to TESTING/SETUP and then press the F4 (Status Display) soft key. 3. On the Controller Status screen (see Figure 2-24), note that "Blocks Acked" and "Blocks Received" both have numbers, indicating that your command to Refresh VNSA Tables was sent and acknowledged. You are now connected to VistaNET. ***** Controller Status ***** CPU: 41% Memory: 089% / Bytes Channel: One Two Domain: # Blocks Acked # Blocks Not Acked # Blocks Received # Purges/Queued # Time Outs # Blocks Dropped # Blocks Avail/Used Escape Clear Highway Stats F1 F2 F3 F4 Figure CONTROLLER STATUS SCREEN OSM, F1

73 SHIF T SECTION 3. OPERATION CONTROLS AND INDICATORS Gas Chromatograph Controller (GCC) The GCC s internal controls and indicators are as shown in Figure 3-1. Chroma I/O PCB Single Board Computer (SBC) PCB Reset Switch (resets SBC PCB) Halt Time Out Run Highway 2 Transmit Highway 2 Receive Highway 1 Transmit Highway 1 Receive Figure 3-1. GCC CARD CAGE CONTROLS AND INDICATORS The GCC s external controls and indicators are as shown in Figure 3-2. Video Display (presents screens & displays) Hardware Fault LED (indicates hardware fault) Software Fault LED (indicates software fault) Flame Out LED (indicates FID/FPD Flame out) Soft Keys (access screens) Cursor Keys (move in a screen) A B C D E F G K L M N O P Q SPA U VWX. Y Z CE 1 : 2 ; 3 4, 5 * 6 / < 7 H I J R S T BKS + P - > ( ) Front Panel Latch (holds front door closed) Alpha/Vista BASIC Keys (enter alphabetic commands) Numeric Keys (enter numeric information) Recorder Jacks (connect chart recorder) ENTER Key (makes screen Selection) HELP Key (gets help from internal computer) Side Panel Latch (holds side door closed) Front Panel Latch (holds front door closed) Figure 3-2. ELECTRONICS HOUSING CONTROLS AND INDICATORS 2000-OSM, F1 3-1

74 Regulator and Gauge Panels The Purge Air Panel contains the pressure regulators and gauges for controlling the purge air and heater air (see Figure 3-3). Purge Air Panel Pressure Control Panel Figure 3-3. REGULATOR AND GAUGE PANELS If the analyzer has mechanical regulators and gauges, the Pressure Control Panel will have the analytical regulators and gauges. (The application determines which specific regulators and gauges are installed.) If the analyzer has EPC, the Pressure Control Panel has a blank front panel. Oven Compartment On the right side of the oven compartment are located the column flow adjustments for setting flows. These needle valves, located in the oven for thermal stability, allow flows to be set using a screwdriver through the oven wall without disturbing the thermal integrity of the analysis zone. PREPARING FOR OPERATION When the analyzer is first installed or when it is being turned on for the first time after maintenance or repair, you should verify that all installation and startup checks have been completed (see Section 2 of this manual) OSM, F1

75 Display Screen This analyzer operates from a series of menus and screens, using the display on the GCC. The Background screen is the default screen, from which you can select the other screens. Since all screens are divided into the same basic elements, you should understand this screen structure before operating the analyzer (see Figure 3-4). ********** B A C K G R O U N D ********** Screen Title ABB Analytical GCC Remote V029-1R (Std GCC) (C) 2001 **ALARM** **ALARM** 20-JUN-2002 THU 08:16:01 **ALARM** Data Display Analysis Time :00114 Peaks Found : 00 Current Stream :01 Purging Stream :01 Key Component: none entered Message Line Exit Manual Cur Report, to Control Basic I/O & Alarms Soft Key Commands Options Labels F1 F2 F3 F4 Soft Keys Figure 3-4. BACKGROUND SCREEN WITH ELEMENTS IDENTIFIED When the Background screen is not displayed, you can return to the Background screen by repeatedly pressing the F1 soft key until the Background screen appears. Before you start into full analytical operation, perform a calibration (if appropriate) and a single analysis on each stream. These precautions enable you to verify the analyzer and the process. CAUTION When you stop analytical operation, select At End of Analysis unless an emergency occurs. Selecting Now stops an analysis immediately, which can inadvertently damage the analyzer if it stops while an analysis is in progress. Stopping during an analysis can trap sample in a column or permit temperature or pressure ramps to continue without adequate control. Checking Calibration If you have a calibration run specified for your analyzer, request a calibration run and compare the results with those in the Data Package. To do this perform a single calibration run: 2000-OSM, F1 3-3

76 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen cursor to ANALYSIS CONTROL, if necessary, and then press the F2 (Request Analysis) soft key. 3. On the Request Analysis screen (see Figure 3-5) select the method number to be calibrated. ****** Request Analysis ****** Analysis Requests: For a benchmark or calibration enter the method#, otherwise enter the stream#: [1 ] None Stream Bench Cal PENDING: Accept Clear Escape The All Request Requests F1 F2 F3 F4 Figure 3-5. REQUEST ANALYSIS SCREEN 4. Place the cursor on Cal and press the F2 (Accept The Request) soft key. 5. Press the F1 (Escape) soft key to return to the Commands screen. 6. On the Commands screen press the F4 (Start/Stop Analysis) soft key. 7. On the Start/Stop Analysis screen press the F2 (Start Analyzer) soft key. The controller will run the calibration when all other requests have been completed. 8. When the calibration run is complete, verify that the Commands screen is displayed and then press the F4 (Start/Stop Analysis) soft key. 9. On the Start/Stop Analysis screen, cursor to At End of Analysis? and then press the F2 (Stop Analyzer) soft key. 10. Press the F1 soft key as necessary to return to the Background screen. 11. On the Background screen press the F3 (Cur Report, Basic I/O & Options) soft key. The screen will display the current report. The analyzer will run the calibration when it clears other requests and the report will appear on the screen as it happens. 12. When you have completed the calibration test, press the F1 soft key to return to the Background screen OSM, F1

77 Checking Streams To verify the operation of each stream, perform a single analysis on each one, as follows: 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen cursor to ANALYSIS CONTROL, if necessary, and then press the F3 (Streams) soft key. 3. On the Stream Assignment screen, determine which streams are active. Then press the F1 (Exit) soft key to return to the Commands screen. 4. On the Commands screen press the F2 (Request Analysis) soft key. 5. On the Request Analysis screen (see Figure 3-5), select the stream number to be analyzed. 6. Place the cursor on Stream and then press the F2 (Accept The Request) soft key. 7. Press the F1 (Escape) soft key to return to the Commands screen. 8. On the Commands screen, press the F4 (Start/Stop Analysis) soft key. 9. On the Start/Stop Analysis screen press the F2 (Start Analyzer) soft key. The controller will start the analysis on this stream when all other requests have been completed. 10. Press the F1 soft key as necessary to return to the Background screen. 11. Watch the screen to determine when the selected stream has purged and is starting its analysis. 12. Press the F3 (Cur Report, Basic I/O, & Options) soft key. 13. On the Report, Basic I/O and Options screen, cursor to CURRENT REPORT, if necessary, and press the F2 (View Current Report) soft key. The desired report will display at the end of the analysis. 14. When the report is complete, press the F1 soft key as necessary to return to the Background screen. 15. To repeat the process for remaining streams or to rerun this stream, repeat steps 1 through When checkout is complete press the F1 soft key to return to the Background screen. ANALYTICAL OPERATION Once you have verified the calibration data and each stream s data, you are ready to place the analyzer into full analytical operation. Starting Analytical Operation 1. Display the Background screen. 2. Press the F1 (Exit to Commands) soft key. 3. On the Commands screen cursor to ANALYSIS CONTROL, if necessary, and press the F4 (Start/Stop Analysis) soft key OSM, F1 3-5

78 4. On the Start/Stop Analysis screen press the F2 (Start Analyzer) soft key. The analyzer will run the stream for which it is purging, according to the method designated in the Stream Assignment screen. The analyzer will continue in analytical operation until you command it to stop. Stopping Analytical Operation 1. Display the Background screen. 2. Press the F1 (Exit to Commands) soft key. 3. On the Commands screen cursor to ANALYSIS CONTROL, if necessary, and press the F4 (Start/Stop Analysis) soft key. 4. On the Start/Stop Analysis screen cursor to At End of Analysis? and press the F2 (Stop Analyzer) soft key. 5. Press the F1 soft key as necessary to return to the Background screen. ALARMS The analyzer has different types and levels of alarms to help you resolve analyzer problems. When an alarm signal appears on the Background Screen, press the F4 (Alarms) soft key to display the ALARMS screen with the alarm message (see Figure 3-6). When you finish with the alarm messages, press the F1 (Exit) soft key to return to the Background screen without deleting the alarms, or press the F2 (Clear Alarms and Exit) soft key to clear the alarms and return to the Background screen. ****** ALARMS ****** ****** ALARM ****** Post Analysis Error: *Valve Manually Switched Exit Clear Alarms and Exit F1 F2 F3 F4 Figure 3-6. ALARMS SCREEN OSM, F1

79 Alarm messages are of two primary types: main alarms and subordinate alarms. Main alarms identify a major alarm category. These alarms appear on the alarm screen at the left margin (e.g., Post Analysis Error: in Figure 3-6). If a main alarm has subordinate alarms, the main alarm title will include a colon (:). Subordinate alarms appear below the main alarms, indented and preceded by an asterisk (*) to show their subordinate status (e.g., *Valve Manually Switched in Figure 3-6). For more information on these alarms refer to "ALARMS" in Section 6, which describes each alarm in detail. CHROMATOGRAMS Chromatograms can be displayed on the screen or recorded on a strip chart recorder while the analysis is in progress. This can be useful when you suspect an analysis problem. Displaying a Chromatogram 1. On the Background screen press the F2 (Manual Control) soft key. 2. On the Manual Control Mode screen press the F2 (Detector and Graphics) soft key. 3. On the Chroma Board screen, press the F2 (Graphics) soft key. 4. On the Graphics Mode screen, set % of Screen Offset to 0 and press the F2 (Display The Graphics) soft key. The chromatogram will scroll up the screen as it happens. 5. If the chromatogram is too large for the screen or too small to read, press the right or left cursor arrow key to change attenuation. The attenuation value appears at the bottom of the Graphics screen, after the letter R, with higher numbers representing more attenuation. 6. To change the speed at which the chromatogram scrolls, press the up (faster) or down (slower) cursor arrow key. Speed appears at the bottom of the Graphics screen after the letter S, with higher numbers representing faster speed. 7. On the Manual Control Mode screen, cursor down to the attenuation line (Attn:) and change the attenuation value as necessary to obtain the desired chromatogram size. The attenuation ranges from 0 to 12 (lower numbers provide more sensitivity). 8. After you have selected an attenuation value, press the F2 (Detector and Graphics) soft key and then repeat steps 3 through Press any soft key to turn off the chromatogram display. Recording a Chromatogram 1. Connect the recorder to the red and black front panel jacks or to J104 terminals 2 (+) and 1 (-) on the left side of the GCC. For a mv recorder, install a 1000-ohm, 1/4 watt, 1% resistor across these terminals. 2. On the Background screen press the F2 (Manual Control) soft key. 3. On the Manual Control Mode screen, cursor down to Chroma, then left to Off. 4. Press the ENTER key to turn the recorder off. 5. Cursor to Chroma and press ENTER. The recorder will turn on and record the chromatogram OSM, F1 3-7

80 6. If the chromatogram is too large for the recorder or too small to read, press the F1 soft key as necessary to return to the Manual Control Mode screen. 7. On the Manual Control Mode screen, cursor down to the attenuation line (Attn:) and change the attenuation value as necessary to obtain the desired chromatogram size. Figure 3-7 correlates attenuation values with recorder ranges. These ranges exclude any operator-entered ZERO OFFSET. (If you have entered a 5% ZERO OFFSET, the recorder range for Attenuation 1 would become to mv.) 8. When you finish plotting chromatograms, go to the Manual Control Mode screen. 9. Cursor to Chroma, then to Off, and then press ENTER. The recorder will stop. Attenuation Recorder Range SHUT DOWN PROCEDURES mv mv mv mv mv mv mv mv V V V V Figure 3-7. CHROMATOGRAM ATTENUATION RANGES If it is necessary to turn off power to the analyzer for maintenance, perform the following steps: 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen cursor to ANALYSIS CONTROL, if necessary, and press the F4 (Start/Stop Analysis) soft key. 3. On the Start/Stop Analysis screen, cursor to At End of Analysis? and press the F2 (Stop Analyzer) soft key. The analyzer will stop at the end of the analysis. 4. If a temporary turn-off is necessary, place the external circuit breaker to OFF. 5. If an extended turn-off is necessary: a. Turn off sample and burner fuel. b. Allow analyzer to cool to ambient temperature. c. Turn off remaining flows at their sources and plug all vents. 6. To return the analyzer to operational status, perform the normal turn-on and calibration procedures OSM, F1

81 COMMAND TREE The menu system (command tree) branches out from general to specific topics, eventually leading you to a screen that allows you to view or edit the desired parameters. The soft key selections move you down the command tree one level at a time. Figure 3-8 shows the command tree. BACKGROUND REQUEST ANALYSIS ANALYSIS CONTROL STREAMS PRINTER REPORT TYPE START/STOP ANALYSIS REPORTS VIEW REPORT TABLE EDIT ANALOG DIGITAL HOST METHODS OTHER TABLES TREND TABLE TIME TABLE DIGITAL TABLE TEST PRINTER RANDOM STREAM TABLE PRINTER PRINT TABLES VISTA BASIC PROGRAM PRINT SIM DIS TABLES EXIT TO COMMANDS STORAGE & CONFIG. NAMES MISC. UPDATE DIGITAL CONFIG. SAVE OR RESTORE TABLES CONTROL PARAMETERS TIME AND DATE NAME SENSORS & BASIC NAME HEADERS NAME STREAMS DIAGNOSTIC TESTS CHROMA BOARD 1 DIGITAL BOARD 1 DIGITAL BOARD 2 CHROMA BOARD 2 OTHER TESTING/SETUP HARDWARE SETUP STATUS DISPLAY DISPLAY SAVED DATA MEMORY USED CHROMATOGRAM STORAGE VISTANET VISTANET TABLES AND COMMANDS REPROCESS SAVED DATA DEFINE SAVE AND RELEASE GRAPHICS REPORT TO PRINTER LOG IN/OUT MANUAL CONTROL DETECTOR & GRAPHICS MANUALLY ZERO BASELINE PRESS. & TEMP CONTROL TEMP CONTROL PRES CONTROL MANUAL TEMPERATURE CONTROL VIEW ALARMS MANUAL PRESSURE CONTROL PRESSURE CONFIG CURRENT REPORT, BASIC I/O & OPTIONS CURRENT REPORT BASIC INPUT AND OUTPUT START/STOP AND EDIT BASIC OPTIONS TEMP CONFIG VIEW ALARMS ZONE CONFI NAMES AND LIMITS CONTROLLER TYPE ALARMS CLEAR ALARMS & WARNINGS Figure 3-8. COMMAND TREE 2000-OSM, F1 3-9

82 FUNCTIONAL DESCRIPTION SECTION 4. TECHNICAL DESCRIPTION Figure 4-1 shows a typical analytical flow system, using the flame ionization detector for illustration. Connections at the right side of the analyzer cabinet provide all gas and air inputs. Sliding plate valves, liquid sample valves, or a combination of both, provide control and measurement of the sample. Each analytical valve is air-actuated by an electrical solenoid valve, which in turn is controlled by the Solenoid Driver PCB. An operational cycle for the valves consists of three modes: sample purge, sample inject, and backflush. In the sample purge mode, sample flows through the sample loop to vent. In the sample inject mode, the sample valve switches, capturing a plug of sample which the carrier then sweeps through the column train to the detector. In the backflush mode, the carrier backflushes Column 1 to vent. SUPPLY AIR PURGE AIR ADJ SV SAMPLE VENT SV CARRIER IN COLUMN PRESSURE ADJ ANALYTICAL FLOW ADJ 1 6 SELECTOR FLOW ADJ COLUMN 2 SELECTOR VENT COLUMN 1 SAMPLE LOOP COLUMN 3 DETECTOR CELL VENT SAMPLE IN OVEN BACKFLUSH VENT Figure 4-1. TYPICAL ANALYTICAL FLOW SYSTEM DIAGRAM The sample valve captures a sample in the sample loop. When the valve switches, the carrier gas sweeps a sample plug through the sample/backflush valve, through 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. Column 2 separates the components to be measured, which elute sequentially. The electronic output signal from the detector represents the component inputs proportionally. The selector valve determines which components will be measured. The sample output from Column 2 goes through Column 3 to the detector for measurement. When the valve switches, the sample not being measured is flushed through the Selector Vent OSM, F1

83 The carrier gas has three purposes: to purge the columns and cell prior to introducing a sample, to sweep the sample into the detector cell, and to backflush the backflush column. An externally mounted pressure regulator and gauge regulate the input flow. The sample system, together with the GCC, controls the calibration sample input. The sample system flow and pressure control depend on the sample system configuration. DETECTORS Introduction Standard detectors are the Flame Ionization Detector (FID), the Thermal Conductivity Detector (TCD), and the Flame Photometric Detector (FPD). These detectors may be used separately, in combination, or as dual detectors. FID and TCD cell subassemblies are located in the upper half of the oven chamber; the FPD is mounted in a panel on the left side of the analyzer. The Manual Control Mode screen provides access to detector information and adjustment, as follows: 1. On the Background screen press the F2 (Manual Control) soft key. 2. On the Manual Control Mode screen press the F2 (Detector and Graphics) soft key. 3. The Chroma Board screen (see Figure 4-2) shows detector status and adjustments. 4. For FID and FPD equipped analyzers, operate the ignitor manually by pressing the F4 (Manual Ignitor On) soft key. 5. For TCD equipped analyzers, set the baseline by adjusting TCD Zero Adjust on the TCD Amplifier Board (inside the GCC) while watching the Detector Reading on the screen. Turn the adjustment screw until you reach the minimum value for the Detector Reading. 6. When you finish the detector adjustments and have verified them, press the F1 soft key as necessary to return to the Background screen. If an analyzer with an FPD has the FLAME OUT LED illuminated on the front panel, it can be ignited either automatically or manually. When the Chroma Board screen has Auto or Auto Timeout highlighted, the ignitor operates as follows: 1. If the temperature zone associated with the FPD is greater than 110 deg C (or the temperature zone number is set to 0 ), the ignitor is turned on for three seconds. 2. The analyzer waits 15 seconds, then checks the state of the flame. If the flame is lit the ignition sequence is complete. 3. If the flame is not lit, the analyzer repeats steps 1 and 2 (up to six times) OSM, F1 4-2

84 4. If, after six attempts to light the flame, it still is not lit, the ignition sequence terminates and the hydrogen is shut off. ***** Chroma Board ***** Detector: FID Flame: Lit Ignitor: Off H2: None Hardware Zero: 5.10mV ( 4.7%) Software Zero: mV Detector Reading: 1.98mV Ignitor: Manual Auto Auto Timeout Timeout: 0 seconds FPD Temp Zone: 0 Manually Manual Exit Graphics Zero Ignitor Baseline On F1 F2 F3 F4 Figure 4-2. CHROMA BOARD SCREEN 5. From the Chroma Board screen you can press the F4 (Manual Ignitor On) soft key to request ignition. This automatically turns on the hydrogen supply. If an analyzer with an FID has the Flameout LED illuminated on the front panel, it can be ignited either automatically or manually. When the Chroma Board screen has Auto highlighted, the ignitor will continuously try to ignite the flame. When Auto Timeout is highlighted, the ignitor will attempt to ignite the flame for the time specified by Timeout on the Chroma Board screen. Flame Ionization Detector (FID) The FID cell (see Figure 4-3) reduces the physical sample to an electrical signal which an interpretation device such as a recorder can condition and plot. Breather Adapter Microdot Connector Thermocouple Ignitor Polarizer Jet Figure 4-3. FLAME IONIZATION DETECTOR OSM, F1

85 The cell consists of a polarized jet, a collector, and a chamber in which hydrogen fuel and sample are burned in air. A current, whose magnitude is proportional to the concentration of the sample, flows between the jet and the collector. This current goes to the FID Amplifier Assembly. The FID Amplifier Assembly provides ignition control for the FID cell and amplification of the detector cell output signal prior to routing the signal to the control section for signal processing. It consists of a power supply, ignitor assembly, electrometer amplifier, and associated circuitry. The power supply provides the necessary dc voltages for the FID Amplifier Assembly and FID. The ignitor assembly provides control for the ignitor in the detector cell. In the event of a flame-out, the thermocouple senses the flame-out, illuminates the Flame-Out LED, and sends a message to the ignitor assembly, which re-ignites the flame. The electrometer amplifier takes the FID cell s output, amplifies it, and sends it to the control section for signal processing. Thermal Conductivity Detector (TCD) Two types of thermal conductivity detector are used in this analyzer, a filament TCD and a thermistor TCD (see Figure 4-4). The filament 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. When the reference carrier gas flows across both filaments, the two filaments have the same filament temperature and the bridge has a zero output. During a measurement cycle a sample flows through the measurement filament, changing thermal conductivity and the filament temperature, thereby causing a corresponding change in electrical resistance. The bridge senses this change in current and increases or decreases current flow through the bridge to compensate for the temperature change. The change in current flow sensed by the bridge is proportional to the component concentration in the sample being measured. Cable Reference Filament Measure Filament Reference Vent Measure Thermistor Reference Thermistor Sample In Sample Vent Measurement Vent Reference Vent Reference In Filament TCD Measurement In Thermistor TCD Reference In Figure 4-4. THERMAL CONDUCTIVITY DETECTORS The thermistor TCD works on the principle that thermistor resistance varies inversely with temperature change. The TCD contains a reference thermistor and a measurement thermistor, connected to a comparator circuit. When the reference carrier gas flows across both thermistors, the two thermistors have the same resistance and the comparator circuit generates a zero output. During a measurement cycle a sample flows across the measurement thermistor, thereby creating a resistance difference between the two thermistors. This resistance difference sensed by the comparator circuit creates an output signal representing component concentration in the sample being measured OSM, F1 4-4

86 Flame Photometric Detector (FPD) Flame photometric detection works on the principle that when sulfur is burned in a hydrogen-rich atmosphere, luminescence (light) characteristic to sulfur is produced. The FPD cell (see Figure 4-5) consists of a teflon burner chamber equipped with a spark ignition system, and a photomultiplier tube which is thermoelectrically temperature controlled. A narrow bandpass filter optically connects the burner chamber and the photomultiplier tube. An exponential amplifier conditions and amplifies the photomultiplier tube output to provide a linear output over a wide dynamic range. Sulfur addition permits accurate measurement of low-level sulfur compounds. Photomultiplier Tube Burner Block Figure 4-5. FLAME PHOTOMETRIC DETECTOR When a sulfur compound passes through the hydrogen-rich flame, strong luminescence occurs between 320 and 460 nm. The narrow band-pass filter allows a sulfur spectra-centered transmission at 394 nm ± 5 nm to achieve a specific ratio of sulfur to non-sulfur compounds between 10,000 and 30,000:1. A photomultiplier tube views the filtered light and outputs a voltage proportional to the intensity of the filtered luminescence. For maximum sensitivity, the detector is optimized with respect to temperature, gas flow rates, and bias voltage on the photomultiplier tube. Because the amount of sulfur in the sample is very small, a sulfur addition module provides a standard level of sulfur. This keeps the sulfur readings above the noise level within the analyzer. When the analyzer processes a sulfur compound, the sulfur in the sample adds to the standard sulfur, providing a level more easily measured by the photomultiplier tube. Intercolumn Detector The intercolumn detector measures the total sample elution profile before complete component separation takes place in the analytical column, or as a part of a heart cut, or backflush valve switch. It is generally used as a setup aid during installation or after rework. While the exact location of the intercolumn detector is application dependent, it can be connected between the sample valve and the column, between the column and the analytical detector, or between the sample valve and the backflush valve. Sequential Dual Detectors Sequential dual detectors allow one analyzer to provide the detection output of two detectors to meet speed or sensitivity requirements. Because these detectors function sequentially using any two detectors, one Chroma I/O Board controls both detectors and their signal output in series. Valve switching in the method tables determines which detector's data will be processed by the Chroma I/O Board at any given time. Sample flow through the detectors is application-specific; the details are shown in the Data Package OSM, F1

87 Simultaneous Dual Detectors Simultaneous dual detectors function in parallel using any two detectors. To accomplish this simultaneous processing requires one Chroma I/O Board in the analyzer for each detector. Chroma I/O Board #1 is in GCC Card Cage slot 2 and Chroma I/O Board #2 is in slot 1. Stream assignments and method tables determine which detector processes each stream and method. Since sample flow through the detectors is application-specific, refer to the Data Package for this information. NOTE The same Method Table cannot be used for both Chroma I/O Boards. Each Chroma I/O Board must have its own calibration stream. Normalized analyses do not normalize across detectors. There are two modes of running simultaneous dual detectors. In the Master/Master mode each Chroma I/O Board controls a separate sample system, which allows totally independent analyses to be run simultaneously. In the Master/Slave mode there is only one sampling system. The methods assigned to the Master Chroma I/O (Chroma Bd #1) perform the stream stepping and control the analysis time. The slave (Chroma Bd #2) starts its cycle simultaneously with the master, but the slave s cycle time is shorter than that of the master. When the slave completes its analysis it waits until the beginning of the next master cycle to start another run. All stream and valve outputs originate in Chroma I/O Board #1 (the total number of streams and valves for any particular GCC configuration remains the same). Alarm inputs generic to the GCC (e.g., purge air) connect to both Chroma I/O Boards. Detector specific alarm inputs connect to the appropriate Chroma I/O Board. Each Chroma I/O Board can have up to five user-defined sensors. However, you can assign a total of only five sensor names, so the sensors for the two boards share sensor names (i.e., Sensor #1 for Chroma I/O Board #2 may differ from Sensor #1 for Chroma I/O Board #1, but they have the same sensor name). When the Simultaneous Dual Detector option is installed, many screens and functions change to support this option. The Background screen shows data for both Chroma I/O Boards all the time (see 2000-OSM, F1 4-6

88 Figure 4-6). While the Background screen provides information on both detectors, other screens will show the data from only one of the two detectors at a time. ********** B A C K G R O U N D ********** ABB Analytical GCC Remote V031-1R (Sim Dual Det) (C) JUN-2002 WED 15:52:34 Chroma 1 Chroma 2 Analysis Time: 0863/ /1076 Stream/Method: 20/01 19/02 Purging : #Peaks/State : 10/Baseline 03/Baseline Key Component: HEXANE + E-MERCAPT Exit Manual Cur Report, to Control Basic I/O & Alarms Commands Options F1 F2 F3 F4 Figure 4-6. BACKGROUND SCREEN, SIMULTANEOUS DUAL DETECTORS To select or change which detector s data is viewed, press the F2 (Manual Control) soft key on the Background screen. On the Manual Control Mode screen, press the F2 (Detector and Graphics) soft key. When the Chroma Board screen appears (see Figure 4-7), the top line identifies the board whose data is shown. ********** Chroma Board #? ********** Chroma Board #: [ 1 ] Select Select Escape Chroma Bd Chroma Bd and View and Exit F1 F2 F3 F4 Figure 4-7. FIRST CHROMA BOARD SCREEN OSM, F1

89 To view the data from the second Chroma I/O Board, enter "2" in the highlighted box on the screen and then press the F2 (Select Chroma Bd and View) soft key. The Chroma Board #2 screen will appear (see Figure 4-8) and all screens showing Chroma I/O Board data will now show the data from Chroma Board #2. ********** Chroma Board #2 ********** Detector: FID Flame: Lit Ignitor: Off H2: None Hardware Zero: 5.10mV ( 4.7%) Software Zero: mV Detector Reading: 1.98mV Ignitor: Manual Auto Auto Timeout Timeout: 0 seconds FPD Temp Zone: 0 Manually Manual Exit Graphics Zero Ignitor Baseline On F1 F2 F3 F4 Figure 4-8. SECOND CHROMA BOARD SCREEN Pressing the F3 (Select Chroma Bd and Exit) soft key will also change the selected board, but it will not display the Chroma I/O Board #2 screen. The Control Parameters screen contains the entries for selecting whether Chroma I/O Board #2 is run as a master or a slave. To view the Control Parameters screen, press the F1 (Commands) soft key on the Background Screen. On the Commands screen, cursor to MISC. and press the F2 (Control 2000-OSM, F1 4-8

90 Parameters) soft key. On the Control Parameters screen (see Figure 4-9), cursor down the selections until "Detector 1 Mode" and "Detector 2 Mode" appear. Select the desired mode for Detector 2 and then press the F2 (Exit and Update) soft key to save this setting. ********** Control Parameters ********** Update Trends on Alarm: No Yes Auto Update of RF: No Yes Max RF Variation: Unknown Peak RF: Unknown Peak Units: % ppm Slope Detect Tics: Never Last First Detector 1 Mode: Master Detector 2 Mode: Master Slave Analyzer Name: More Below Exit Alarm Common Escape and Mask Digital Update Out. Mask F1 F2 F3 F4 Figure 4-9. CONTROL PARAMETERS SCREEN The Stream Assignment screen adds two columns to its standard screen (see Figure 4-10), one to identify the detector used for each stream and method (Det), the other to identify the link between master and slave (Link). ****** Stream Assignment ****** Stream Status Method Basic Det Link 01 Active Active Active Active Inactive Inactive Inactive Inactive Exit F1 F2 F3 F4 Figure STREAM ASSIGNMENT SCREEN OSM, F1

91 Since there is no dummy stream in Master/Master mode, all Link column entries are "00". In Master/Slave mode, the Link column in the Stream Assignment screen shows which stream the slave is using. Because only the Master detector controls the actual streams used, this slave stream is a "dummy" stream. In Figure 4-10, stream 01 has "01" in the Det column (Master) and "02" in the Link column. Stream 02 (which is the Link for stream 01) has "02" in the Det column (Slave) and "00" in the Link column (no link). Each Chroma I/O Board can send analog output to a recorder, using the terminal board connections on the right side of the GCC. Chroma I/O Board #2 will always provide data associated with its respective detector. Chroma I/O Board #1 can provide data associated with either detector, depending on selections made on the Manual Control Mode screen. In addition, Chroma Board #1's selected data is available at the front panel Recorder jacks. The Manual Control Mode screen (see Figure 4-11) controls the recorder output locations for Chroma I/O Board #1. The RECORDER field selects which detector's output Chroma I/O Board #1 will send to the recorder outputs. The Mode field selects the type of output to be sent to the recorder (chromatogram, bar graph, etc.). Press the left and right cursor keys to scroll the selections. *** Manual Control Mode - Chroma Bd #1 *** VALVES: Time: 200 Enter Valve: 0 Cycle Time: 240 RECORDER: Chroma BD: 1 Method Tbl: 002 Offset: 5% Stream: 08 Atten: 007 Purging: 09 Mode: Chroma Peaks: 00 PURGE SELECT: 0 State: Start Crest End Peak Time Time Time Area Type Last: Exit Detector Manually Pres & To And Zero Temp Bkgnd Graphics Baseline Control F1 F2 F3 F4 Figure MANUAL CONTROL MODE SCREEN Other screens and menus have minor changes to help identify which detector is being used at any given time. Changes you may encounter are: Entries in the Random Streams screen must be streams running Master analyses. If a stream is assigned to the Slave detector, the entry will be skipped. The Alarm screen is really two screens with Simultaneous Dual Detectors. When you press the Alarms soft key, the first screen identifies alarms associated with Chroma I/O Board 1. Pressing the Exit soft key accesses the second alarm screen, identifying alarms associated with Chroma I/O Board OSM, F1 4-10

92 Vista Basic commands identify the detector by placing the Chroma I/O Board number after the alarm name (e.g., CUR_STRM (1) or INTEGER = RAI (1,0), where the first digit identifies the Chroma I/O Board). Before starting an analysis, the GCC prompts for the Chroma I/O Board to use during the analysis. The selected Chroma I/O Board must be in Master mode or the analysis will not start. If the second Chroma I/O Board is running as Slave and it is linked to the Master board, an analysis will start on it as well. If both boards are in Master mode, the analyses can be synchronized by pressing the F4 (Start on Both Masters) soft key. This scheme works only if the cycle times are the same length for the methods used. CIRCUIT BOARDS Power Supply PCB The Power Supply PCB, on the left side wall of the GCC Card Cage, converts the system input power to provide voltages for the other boards and functions in the analyzer. Its outputs include +5 Vdc for digital circuits, +15 Vdc and -15 Vdc for analog circuits, and 18 Vac for current modules on the Analog Output PCB. The Power Supply PCB also has alarm LEDs to assist in isolating power problems. Chroma I/O PCB The Chroma I/O PCB, in GCC Card Cage slot 2, uses the control information from the SBC to switch valve and recorder output functions. During an analysis, the Chroma I/O Board processes detector amplifier output to provide digital and analog outputs for post analysis verification. When a second Chroma I/O PCB is used it is in GCC Card Cage slot 1. Single Board Computer (SBC) PCB The Single Board Computer PCB, in GCC Card Cage slot 3, provides all analyzer system control functions. On the SBC reside E 2 PROM storage, computer memory, and the address and data control circuits which coordinate internal and external data activities. DC Solenoid Driver PCB The DC Solenoid Driver PCB, at the bottom left of the GCC Card Cage, has ten solenoid control circuits. It generates a +110 volt signal for energizing the solenoids controlling the analyzer and sample system valves. When the controlling signal (common) from the control section is applied to any of the inputs, a transistor completes the circuit to the appropriate solenoid. If a second DC Solenoid Driver PCB is used, it is at the bottom right of the GCC Card Cage. Front Panel PCB The Front Panel PCB, on the inside of the GCC front panel, provides the interface for the display, the intrinsically safe recorder jacks, and the keypad. This assembly is also the platform for the optional LO COMM PCB. FID Amplifier PCB The FID Amplifier PCB, on the left side wall of the GCC, amplifies the flame ionization detector output signal and applies it to the Chroma I/O Board for processing. This assembly also accomplishes FID flame sensing and ignition. This PCB's gain configuration is set at the factory OSM, F1

93 TCD Amplifier PCB The TCD Amplifier PCB, on the left side wall of the GCC, amplifies the thermal conductivity detector output signal and provides it to the Chroma I/O Board for processing. FPD Amplifier and Interface PCBs The FPD Amplifier PCB linearizes and amplifies the flame photometric detector output signal and applies it to the Chroma I/O Board for processing. This assembly also contains circuitry for control of thermoelectric coolers for the photomultiplier tube and for FPD flame sensing and ignition, conditioned through the FPD Interface Assembly. It is located inside the FPD panel at the left of the analyzer. DTC Backplane PCB The DTC Backplane PCB, located on the GCC right-hand door, has two micro controller chips, one to run the DTC Backplane PCB and the other to check continuously for over-temperature conditions in the temperature controlled zones. If the temperature in any zone exceeds the T-Rating limit, the DTC Backplane PCB shuts off power to the temperature zones and aborts the analysis. AC Conditioning PCB The AC Conditioning PCBs, piggybacked on the DTC Backplane PCB, provide AC heater voltage to the zone boards, power compensation and zero crossing signals to the DTC Backplane PCB, and the coolant control output to the Coolant Control Solenoid. DTC Zone PCB The DTC Zone PCBs, piggybacked on the DTC Backplane PCB, provide individual zone temperature sensing and power application to heaters for each zone of the digital temperature controller. EPC Multibus PCB The Electronic Pressure Control Multibus PCB, located in Card Cage slot 4, continuously checks the pressure controlled zones. If any zone loses pressure control, the Electronic Pressure Control Multibus PCB sends an alarm to the Single Board Computer PCB, which aborts the analysis. EPC Control PCB The EPC Control PCB, mounted in the EPC Module, provides the overall control for the electronic pressure controller. EPC Sensor PCB The EPC Sensor PCBs, mounted on the pressure transducers in the EPC Module, provide the individual zone pressure data to the EPC Module PCB. LO COMM PCB (Option) The Local Communications Module (LO COMM) PCB, piggybacked on the Front Panel PCB, provides remote access for the analyzer, so that this analyzer can operate with other Vista GCC front panels. See 'REMOTE GC OPERATION OPTION" for a detailed explanation of remote GC operation OSM, F1 4-12

94 Communications PCB (Option) The Communications PCB, in any open slot in the GCC Card Cage, provides a two-channel interface between the GCC and the VistaNET. This PCB is not used when the analyzer has the optional Ethernet PCB. See "VISTANET OPTION" for a detailed explanation of the VistaNET option. VistaNET Interconnect PCB (Option) The VistaNET Interconnect PCB, located on the side of the GCC Card Cage, provides low-speed interface between the GCC and the VistaNET. It is used in low-speed systems in conjunction with the Communications PCB. Ethernet PCB (Option) The Ethernet PCB, in any open slot in the GCC Card Cage, provides two-way communication with the plant network and the VistaNET software application by way of Ethernet. The Ethernet PCB connects to an Analytical Ethernet switch using standard Ethernet cabling. Analog Output PCB (Option) The Analog Output (Trend) PCB has two configurations: a voltage board providing up to 48 outputs and a current board providing up to 16 outputs. Trend PCBs are in GCC Card Cage slots 6 and 7. See "ANALOG OUTPUT OPTION" for a detailed explanation of the Analog Output option. Digital Input/Output PCB (Option) The Digital Input/Output PCB has two configurations: up to 48 outputs or up to 16 inputs and 32 outputs. Digital I/O PCBs are in GCC Card Cage slots 5 and 6. See "DIGITAL I/O OPTION" for a detailed explanation of the Digital Input/Output option. METHOD TABLES A method table is the program used to control an analyzer during an analysis. It contains all the instructions and data required to identify each component of the sample and produce a meaningful analysis report. The analyzer can have a maximum of eight method tables, each supporting up to 62 components. In order for the analysis to be accurate, the analyzer must be calibrated first. Calibrating the Method Calibration provides a response factor which converts the individual component s peak area or peak height into an actual component concentration value. This response factor is generated by one of three calibration methods performed prior to obtaining any valid analysis results. These calibration methods are: External Standard, in which the controller calibrates the analyzer against an external calibration standard of precisely known component concentration External Standard calibration requires you to provide the calibration concentration (CC) for each component to be analyzed. Each component must be contained in one of the two calibration streams so that the detector response may be determined for each component independent of all other components. The system performs an analysis of the calibration stream, obtaining corrected values for the peak area (A) and peak height (H) of each component contained in that stream. The controller then calculates the response factor (RF) for each component as follows: OSM, F1

95 RF = CC/A, for peak area analysis of a given component or RF = CC/H, for peak height analysis of a given component Normalized, in which the controller calibrates the analyzer against the external standard, then calculates the sum of all peak areas and determines the percent contribution of each component peak Normalized calibration requires you to provide the component concentration value of each component to be analyzed in a calibration stream. The system performs an analysis of the stream, obtaining corrected peak area counts for each component and for the total stream. A response factor is generated as: RFi = (Atot/Ai)CCi, where Ai is for individual component, Atot for total Indirect External Standard, in which the controller uses a previously developed or literaturederived set of response factors to calculate the relationship between the key component and each of the other components. This mode is used when the components cannot be individually calibrated. Calibrating the key component of the standard sample updates only the K-factor, while the other components are updated through the relationship of the various components. Indirect External Standard calibration requires you to provide the concentration of a specific component in a calibration stream, plus the relative response factor (RRF), for each component to be measured. The system performs an analysis of the calibration stream, obtaining a corrected peak area value for the calibration component (Ac). A K-factor is then calculated for the stream, as follows: K = (CCc/Ac)(1/RRFc), where subscript c is for the calibration component Component concentration values are then obtained based on corrected peak area values following an analysis: CCi = (Ai)(K)(RRFi), where subscript i is for the individual component As part of the calibration you can also select primary and secondary calibration streams, benchmark stream, multiplier exponent, and K-factor: primary calibration stream has a default setting in the analyzer of stream 10. This does not need to be set or changed (but it can be changed if desired). secondary calibration stream is necessary when all standard components are not compatible in the same container. NOTE You can only assign a secondary calibration stream to a method table if the GCC uses the External Standard calculation technique. Normalized and Indirect External Standard calculation require a single calibration stream. multiplier exponent is an exponential value which allows the analyzer to present the response factor as an easily identified number (e.g., if response factor is , analyzer might show response factor = 5 and multiplier exponent = 6). K-factor is used with the indirect external standard to provide a means of relating the calibration standards of all components when only one component can be measured. Once the relationship 2000-OSM, F1 4-14

96 between the various components is established (at installation), only the K-factor is changed during calibration. Preparing a Method Table This subsection explains how to prepare a method table by constructing a sample method table. Figure 4-12 shows a chromatogram of the analysis to be controlled. This analysis is 90 seconds long and has three components to measure: A, B, and C. These components elute at the following times (after the start of the analysis): component A, 30 seconds; component B, 50 seconds; and component C, 70 seconds. A C B 0 90 TIME (in seconds) Figure CHROMATOGRAM OF ANALYSIS In order to construct a method table for this analysis, you need to know when to turn valves on and off, how the components are defined, and how to measure the components. For this analysis we shall use slope detection, which is described in detail in "PEAK DETECTION." Figure 4-13 illustrates the data needed to construct a method table for this analysis. TIME-RELATED DATA OTHER DATA Time Function Value Method Table No.: 1 Analysis Cycle Time: 90 sec 0001 Valve On One Calibration type: external std 0005 Valve Off One Analysis Normalization: no 0006 Stream Step N/A Primary Cal Stream: Auto Zero N/A Secondary Cal Stream: not used 0012 Slope Detect On Now Benchmark Stream: not used 0020 Valve On Two Multiplier Exponent: Valve Off Two K Factor: Component One Component Units: PPM 0040 Valve On Three Key Component: # Valve Off Three Retention Time Deviation: ±5 sec 0050 Component Two Response Factor: Valve On Two required Calibration Concentration: Valve Off Two for each Benchmark Concentration: Component Three component High Concentration Alarm: Slope Detect Off Now Low Concentration Alarm: 0 Calculate By: area In Primary Cal Stream: yes Figure DATA FOR METHOD TABLE To construct this method table perform the following steps: 1. On the Background screen, press the F1 (Exit to Commands) soft key OSM, F1

97 2. On the Commands screen, cursor down to TABLE EDIT and then press the F2 (Methods) soft key. 3. The Method Table #?? screen will appear (see Figure 4-14). Use the number keys on the GCC front panel to enter the number 1 for this method (the method number given in Figure 4-13 data). When the correct number shows on the screen, press the F2 (Edit the Table) soft key. ***** Method Table #?? ***** Enter the table number: [1] Escape Edit The Table F1 F2 F3 F4 Figure METHOD TABLE #?? SCREEN 4. The Cal Define & Cycle Time screen will appear (see Figure 4-15). Set the analysis cycle time for 90 seconds using the number keys. ****** Cal Define & Cycle Time ****** Analysis Cycle Time: [300] Sec Calibration Type Ext Std Normalized Indirect Std Analysis Normalization No Yes Primary Cal Stream: 10 Secondary Cal Stream: 0 Benchmark Stream: 0 Multiplier Exponent: 0 K Factor: Continue F1 F2 F3 F4 Figure CAL DEFINE & CYCLE TIME SCREEN 2000-OSM, F1 4-16

98 5. Cursor to the Calibration Type line. The current choice is underlined. To change the choice, cursor right or left to the desired type (in this case Ext Std) and then cursor to the next line. Moving the cursor up or down sets the new choice. 6. Cursor to each line in turn and choose the appropriate term or value: Analysis Normalization: No Primary Cal Stream: 10 Secondary Cal Stream: 0 Benchmark Stream: 0 Multiplier Exponent and K Factor are updated by calibration; it is not necessary to set them. 7. Review each line to ensure you have entered the correct data and then press the F1 (Continue) soft key. 8. The Method Table #01 screen will appear (see Figure 4-16), allowing you to enter the timerelated data from Figure ***** Method Table #01 ***** Time Function Value [0001] Valve On One 0005 Valve Off One 0006 Stream Step N/A 0007 Auto Zero N/A 0012 Slope Detect On Now 0020 Valve On Two 0021 Valve Off Two 0030 Component One More Below Exit Insert Delete Cal Define Line Line & Cycle Time F1 F2 F3 F4 Figure METHOD TABLE #01 SCREEN 9. Press the F2 (Insert Line) soft key and then enter 1 using the number keys. 10. Cursor to the Function column. The number you entered now changes to In the Function column, use the up and down arrow keys to scroll the function names until Valve On appears, and then cursor to the right. 11. In the Value column, cursor up or down until One appears. 12. Press the F2 (Insert Line) soft key and repeat the insertion procedure for each line in the Method Table down through Valve Two Off. 13. After you complete the Valve Two Off line, press the F2 (Insert Line) soft key OSM, F1

99 14. Enter 30 for Component #1 s time and then cursor right to select Component. Since this is the first component entered into the table, Undefined will appear in the Value column. 15. Cursor right to the Value column. The Component Definition screen will appear (see Figure 4-17), which will allow you to define this component. Cursor to each line in turn and enter the appropriate data. ****** Component Definition ****** Name: [ ONE ] Units: PPM % Calculated Key Component: No Yes Retention Time Dev: ± secs Response Factor: Calibration Concentration: Benchmark Concentration: High Concentration Alarm: Low Concentration Alarm: More Below Continue F1 F2 F3 F4 Figure COMPONENT DEFINITION SCREEN 16. Review each line to ensure you have entered the correct data and then press the F1 (Continue) soft key. 17. When the Method Table #01 screen appears, enter the data for the remaining items in the Method Table. Remember to name Component Two B and Component Three C. 18. When you have completed all lines in the Method Table, review the table to ensure all data are correct and then press the F1 (Exit) soft key. 19. On the Method Table #01 screen, press the F2 (Exit and Update) soft key to save this Method Table. Editing a Method Table The procedure for editing a method table is the same as that for preparing a new table. Follow the applicable steps in "Preparing a Method Table" to access the particular screen to be changed and then insert the new information in place of the information already existing. If the data to be revised exists in the time-related portion of the method table, perform the following steps to edit the table: 1. Access the method table as described in "Preparing a Method Table," steps 1 to In step 3 insert the desired method number and then proceed to step OSM, F1 4-18

100 3. In steps 4 through 7, review the Cal Define & Cycle Time screen and make changes as necessary. 4. When the Method Table #01 (or other number you have chosen) appears, locate the specific line you want to change. 5. If necessary, cursor to the Time column, and then cursor down to the line you want to edit. 6. If you want to change the time, use the number keys to insert the new time. If this changes the place of this line in the table, it will automatically move to the correct place when you leave the Time column. 7. If you want to change the function, cursor right to the Function column and scroll up or down to display the new function. 8. If you want to change the value, cursor right to the Value column and make the necessary changes. 9. When you have completed the changes, press the F1 (Exit) soft key. 10. On the Method Table #01, press the F2 (Exit and Update) soft key to save your changes to the method table. Printing a Method Table 1. On the Background screen, press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor down to PRINTER and then press the F2 (Print Tables) soft key. 3. On the Print Tables screen (see Figure 4-18), cursor to METHOD TABLE and then press the F2 (Select Table) soft key. ****** Print Tables ****** [METHOD TABLE] TREND TABLE TIME TABLE DIGITAL TABLE RANDOM TABLE VISTA BASIC PROGRAM STREAM TABLE PRESS. & TEMP. DIGITAL INS & OUTS Escape Print Selected Table F1 F2 F3 F4 Figure PRINT TABLES SCREEN OSM, F1

101 4. On the second Print Tables screen, enter the Method Table number and then press the F2 (Print Selected Table) soft key. The Method Table and Component Table will print (see Figure 4-19). METHOD TABLE #01 8:25:29 Fri 30 Sep 1994 Cycle Time = TIME FUNCTION VALUE 0001 Noise Calc On 0003 Noise Calc Off 0004 Auto Zero N/A 0005 Stream Step N/A 0010 Temp Check One 0015 Slope Detect On Now 0016 Pres Check One 0017 Valve On One 0019 Valve Off One 0028 Component One 0037 Valve On Two 0039 Valve Off Two 0048 Component Two 0049 Pres Control One 0057 Valve On One 0059 Valve Off One 0062 Temp Control Two 0068 Component Three 0077 Valve On Two 0079 Valve Off Two 0088 Component Four 0097 Valve On One 0099 Valve Off One 0108 Component Five 0138 Slope Detect Off Now 0139 Component Six 0139 Component Seven 0139 Component Eight 0139 Component Nine METHOD TABLE #01 8:25:57 Fri 30 Sep 1994 NAME RRT W KEY LL HL RF CC METHANE Y % ETHANE N % ETHYLENE N % H N % CO N % Z N Clc REAL HEAT N Clc SORT OF B N Clc IDEAL HEAT N Clc Figure PRINTED METHOD TABLE 5. When all the data have printed, press the F1 soft key as necessary to return to the Background screen. PEAK DETECTION The analyzer measures peaks in two different ways: forced gating and slope detection. Both methods can exist in the same analysis, but they cannot both measure peaks at the same time. If the 2000-OSM, F1 4-20

102 method has forced gating and slope detection on at the same time, the controller uses the one turned on first, ignoring the second one and sending an alarm to tell you that both peak detection methods were on. Forced Gating When a component's elution time is known, forced gating can measure the peak. You specify the gating time on and off, which lets you measure only that amount of peak area you desire. In the method table, forced gating has four commands associated with it. Base Base Valley Valley Base tells the controller it is at the base and to start measuring. The controller continues to measure until it reads Base or Valley regardless of whether there are no peaks, one peak, or multiple peaks. The other functions work similarly. Slope Detection: Introduction Slope detection determines a peak s starting and ending points using the analyzer s computer. With slope detection active, the controller constantly checks the chromatographic signal for changes which would indicate the start of a peak, a peak s maximum, and the end of a peak. Slope detection utilizes several other functions: noise calculation, peak lumping, tangent skim, baseline definitions, peak width, and suspend end. In order to explain how these functions interact, the chromatogram in Figure 4-20 shows the basic functions, and the following paragraphs describe the functions. NOISE CALC ON NOISE CALC OFF SLOPE DETECT ON NOW PEAK WIDTH SLOPE DETECT OFF NOW T0 TIME T-END Figure EXAMPLE OF BASIC SLOPE DETECTION FUNCTIONS Slope Detection: Basic Functions The basic slope detection functions used in a method table are Noise Calculation, Peak Width, and Slope Detect. Slope Detect On and Slope Detect Off must always appear in the method table when you want to use slope detection. If noise calculation and peak width are not specified, the controller will use its stored default values. Noise calculation determines the noise level in the analysis during a period of inactivity. Shortly after the start of the analysis, Noise Calc is turned on for at least two seconds, and then turned off. This noise level measured by Noise Calc is used to decide when the slope of the chromatogram indicates a peak change and not just random fluctuation due to noise. Peak width is used to calculate the minimum slope of the start of a peak. A lower number causes the system to respond more quickly to the start of a peak but is less sensitive to long term change. A OSM, F1

103 higher number causes the system to respond less quickly but is more sensitive. For that reason the default is set at 8, a median value that provides both good response and sensitivity for most applications. Peak width only has meaning when slope detect is running. Slope Detect On tells the method that slope detection will be used for this analysis. It should appear in the method well before the first peak is expected to start. Slope Detect Off tells the method that you are finished using slope detection. Slope detection has six commands associated with it use: On Now Off Now Base Valley Min Neg Peak On Now starts slope detection at the next peak. Off Now stops slope detection immediately. Base" turns off slope detection at the next baseline condition. Valley turns off slope detection at the next valley. Min turns off slope detection at the next minimum, whether it is a baseline or a valley. Neg Peak looks for a negative going slope to trigger the slope detection algorithm. The negative peak search only works for one peak. You must enter another Neg Peak to continue the search for a second negative peak. Slope Detection: Supplemental Functions In addition to the basic functions, there are six supplemental slope detection functions which may or may not be used: peak lumping, tangent skim, baseline definitions, suspend end, end=crest plus, and area rejection. When and how the method uses them depends on the specific application. Peak lumping allows you to sum consecutive peaks into a single lumped peak for calculation. It allows you to focus on the total area of several consecutive components rather than the individual peak areas. To use peak lumping, turn Peak Lump On prior to the end of the first peak in the series of peaks to be lumped together (see Figure 4-21). Turn Peak Lump Off after the end of the last peak in the series. The lumped peak file will include all peaks which end while the lumped peaks function is active (peaks 2, 3, 4, and 5 in Figure 4-21) TIME PEAK LUMP ON PEAK LUMP OFF Figure EXAMPLE OF PEAK LUMPING Tangent skim lets you analyze a smaller peak riding on the tail of a large peak. Tangent skim directs the slope detection algorithm to look for this by identifying a tangent termination point for the next 2000-OSM, F1 4-22

104 peak which begins on a valley point (see Figure 4-22). Since the tangent skim termination search operates only during a single peak, it is activated by setting Tangent Skim at the proper time in the method table (no On/Off is required). To use tangent skim, choose a time in the method table that occurs at a point before the peak in question and set Tangent Skim. The search begins at the first valley point (point B in Figure 4-22) after the request point (point A) and ends at the peak termination point. The controller determines it has found a tangent termination point when the slope of the chromatogram being measured at point C equals the slope of the line BC. The tangent point identifies this second peak as being a small peak on the tail of a larger peak, rather than a separate peak. 1 B 2 C A D TIME TANGENT SKIM Figure EXAMPLE OF TANGENT SKIM Baseline definitions override the normal slope detection definition of the peak topology. This permits you to define how the baseline is drawn for a peak or series of peaks. In the method table, the baseline function has five commands associated with it: Pk End =Vly Pk End =Base Proj Forward Proj Reverse Proj Term If a specific application is such that the slope detect algorithm has difficulty determining whether a particular point at the end of a peak is a valley or a baseline, it can provide erratic data. The algorithm sometimes calls the point a valley and sometimes it calls it a baseline, thus providing OSM, F1

105 different peak areas in adjacent analyses (see Figure 4-23). By selecting Pk End =Vly you can force the routine to call it a valley each time it occurs, thus removing the indecision and stabilizing the calculations. Pk End =Base is used the same way as Pk End =Vly. Selecting Pk End =Vly or Pk End=Base forces the slope detect algorithm to call the point a valley or a baseline every time, whichever provides the more accurate data. The difference between the two is shown in Figure 4-23, where the area within triangle ABC is not measured in Pk End=Base. It is important to measure these peaks the same way every time, for consistency. PEAK END AREA MEASURED PEAK END AREA MEASURED TIME PK END =VLY B A C TIME PK END =BASE Figure EXAMPLES OF PEAK END The remaining baseline commands allow you to project a horizontal baseline between two defined points on the chromatogram. This projected baseline may be set forward (to measure from the baseline before the peak) or reverse (to measure from the baseline after the peak). The command to start a projection must be entered at a time before the slope detect function senses the start of a peak, and the ending command must be entered at a time before the slope detect routine senses an end of peak. Proj Forward is a forward projection flag inserted before the start of a desired peak. This sets the baseline as the start of the peak (see HBF in Figure 4-24). Proj Term is a flag to end the projection, thereby identifying the peak or group of peaks to be measured. It is set after Proj Forward and before the end of the peak (see HBT in Figure 4-24). Line AB in Figure 4-24 represents the baseline. C D A B TIME HBF HBT Figure EXAMPLE OF FORWARD PROJECTION 2000-OSM, F1 4-24

106 Proj Reverse is a reverse projection flag that identifies the end of a desired peak or group of peaks. It is set in the baseline after the end of the peak (see HBR in Figure 4-25). With reverse projection, Proj Term is set before the start of the peak and before Proj Reverse (see HBT in Figure 4-25). The system then measures the peak that occurs between HBT and HBR. Line JK in Figure 4-25 represents the baseline. H I K J TIME HBR HBT Figure EXAMPLE OF REVERSE PROJECTION Suspend End permits the operator to suspend automatic baseline determination. It is generally used when the component peak is badly tailing. Suspend End permits you to choose the end-ofpeak determination (see Figure 4-26). BASELINE FOUND BUT IGNORED B A C D E F TIME SUSPEND END ON SUSPEND END OFF SUSPEND END WAS IMPLEMENTED BECAUSE THE OPERATOR DECIDED THAT AF WAS THE BEST CORRECTED BASELINE. Figure EXAMPLE OF SUSPEND END OSM, F1

107 Another method for handling badly tailing peaks is End=Crest+ (see Figure 4-27). This code forces the end of the peak to be the crest time plus the time specified in the code, providing a reproducible end to the peak even if the crest of the peak is moving. To use this command, insert End = Crest+ into the method together with a specified time after the crest. The method allows times from 1 to 380 for the length of time after the crest. CREST END SPECIFIED BY END=CREST+ TIME END=CREST+ Figure EXAMPLE OF END=CREST+ Area rejection is used to separate smaller, unwanted, peaks from larger peaks. If several small peaks are close to peaks of interest, area rejection allows you to define a minimum area a peak has to reach to be retained. Slope detection still measures all the peaks, but at the end of the analysis all peaks below the rejection area are disregarded. To use area rejection, insert Reject Area into the method, together with the threshold area value which tells the controller what minimum peak area is to be retained for analysis. The method allows you to specify areas from 1.0 to 9,000,000 for the rejection area (corrected peak area in the Raw Data Report). OTHER TIME-CODED FUNCTIONS This section discusses the time-coded functions that are not part of peak detection. A method table will contain one or more of these functions when the particular application requires it. The following sections describe each function. Auto Zero Auto zero supplies an offset which brings the raw baseline signal down to its most sensitive range. It also supplies a software offset to bring the signal to 2.0 mv. The auto zero offset is ±100 mv with a resolution of 1.7 mv. Using all of the offset voltage generates an alarm. The auto zero function occurs immediately when requested, except that it is ignored during any of the following situations (which cause alarms): When a noise calculation routine is in progress If a forced gate routine is in progress If a slope detect routine is currently processing a peak 2000-OSM, F1 4-26

108 Stream Step NOTE If any of the above conditions exist, an error will occur. Stream Step begins the automatic sample purge of the sample stream being analyzed. It must occur after completion of the sample inject for this stream. This is particularly important when the current stream being analyzed requires multiple sample injections. The analyzer samples the active streams in sequential order. However, you can change the order by setting a random stream-stepping order (using the Random Stream Step table accessed from the Commands screen). You may request calibration, benchmark, or analysis of a specific stream at any time. The GCC stacks and executes multiple stream analysis requests on a last in - first out basis following the next stream step. The controller will step to any manually requested stream regardless of its active/inactive status. Only after all requested stream analyses are completed does the controller step to the next active stream in the routine sequence. When the screen displays the desired method table, you can change the timing of the stream step or add a stream step if the method table does not contain one. NOTE Each method table must contain a stream step in order for the equipment to operate properly. If a method table does not have a stream step, the controller will continue to process the last-identified stream, repeating it until the purge stream is manually changed or a stream step is inserted into the method table. Valve On and Valve Off Valve On and Valve Off control the operation of a selected valve. Each method table should contain the valve on and off sequences required for the selected stream. The time of the first Valve On in a method table is used in all reports as the sample inject time. Occasionally you may have to add a valve on-off sequence, delete a sequence, or change the timing of a sequence. To turn on a valve: access the method table, set the desired time to turn on the valve, and then select Valve On and the valve number. To turn off a valve: access the method table, set the desired time to turn off the valve, and then select Valve Off and the valve number. Tic Mark This allows you to generate positive or negative event markers for the reconstructed chromatogram. Tic marks identify a particular point in time on the chromatogram that you select. A tic mark can go upward from the analysis line (positive) or downward (negative). Skip Next TCF On Alarm This allows you to skip the next time-coded function if any sensor alarm is active. This allows you to bypass sample injection if the chromatographic sensors indicate that the analyzer is not operating according to preset parameters, such as temperature OSM, F1

109 Skip Next TCF If Stream = This allows you to skip the next time-coded function when this stream value equals the stream number entered in the method table. This function allows you to skip a TCF on a particular stream, usually because that TCF does not apply to that stream. Do Next TCF If Stream = This allows you to execute the next TCF in the method only if the stream value equals the stream number entered in the method table. This function allows you to add a specific TCF to a particular stream, but not to every stream. Pressure Check Pressure check, part of the optional Electronic Pressure Controller, lets you check for pressure zone variances. A pressure value outside the zone limit causes an alarm. This feature is described in detail in "ELECTRONIC PRESSURE CONTROL OPTION." Pressure Control Pressure control, a feature of the optional Electronic Pressure Controller, lets you review or modify the pressure zone set point and ramp rate. This feature is described in detail in "ELECTRONIC PRESSURE CONTROL OPTION." Temperature Check Temperature Check lets you check for temperature zone variances. A temperature value outside the zone limit causes an alarm and, depending on the condition, aborts the analysis. This feature is described in detail in "DIGITAL TEMPERATURE CONTROLLER." Temperature Control This lets you review or modify the temperature zone set point and ramp rate. This feature is described in detail in "DIGITAL TEMPERATURE CONTROLLER." OTHER TABLES AND REPORTS This section discusses tables and reports that are not covered elsewhere. Viewing or Editing Tables Unless otherwise stated, perform the following steps to view or edit a table: 1. On the Background screen, press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor down to TABLE EDIT and press the F3 (Other Tables) soft key. 3. On the Edit Other Tables screen, cursor down to the desired table and then press the F2 Edit the Table) soft key. 4. View or edit the table, then press the F1 (Exit) soft key. 5. On the next screen, press the F2 (Exit and Update) soft key to save the new data, or press the F1 (Escape) soft key to retain the original data OSM, F1 4-28

110 6. Press the F1 soft key as necessary to return to the Background screen. Printing Tables 1. On the Background screen, press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor down to PRINTER and then press the F2 (Print Tables) soft key. 3. On the Print Tables screen, cursor to the desired table and then press the F2 (Print Selected Table) soft key. The table will print. Printing Reports 1. On the Background screen, press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor down to REPORTS and then press the F2 (Printer Report Type) soft key. 3. On the Printer Report Type screen, cursor to the Type line and select the type of report print by highlighting it. 4. Cursor to the Print line and select No if you do not want to print a report, Yes if you want to print each time the report is created, Alarm if you want to print only when an alarm condition occurs, Change if you want to print only when an alarm condition changes, or Freq if you want to set how often to print a report. 5. Cursor to the Alarm Reports line and select No or Yes. Selecting No or Yes in step 4 overrides any alarm selection. 6. Cursor to the Frequency line and select how often you want to print a report. In this usage, 1 means the report will print every time the report occurs; 2 means it will print every other time; 3 means it will print every third report. Selecting No or Yes in step 4 overrides any frequency value. 7. Cursor to the Inhibit Cal/Bench Report line and select No or Yes. This selection determines whether calibration and benchmark reports print in addition to analysis reports (Yes), or just the analysis reports (No) will print. 8. When you have completed all entries, review the screen to verify all data. Then press the F2 (Exit and Update) soft key to save the changes, or press the F1 (Escape) soft key to retain the original values. The printer will print the report as you have specified it. 9. Press the F1 soft key as necessary to return to the Background screen. Random Stream Stepping Table The Random Stream Stepping Table establishes the sequence in which the various streams are to be analyzed, up to a maximum of 50 entries. The table lists the streams in numerical order unless the OSM, F1

111 operator orders a different sequence. Figure 4-28 shows the Random Streams screen and Figure 4-29 shows the printed table. ****** Random Streams ****** Stream More Below Insert Delete Exit Line Line F1 F2 F3 F4 Figure RANDOM STREAMS SCREEN RANDOM TABLE 8:27:50 Fri 30 Sep 1994 Stream Figure RANDOM STREAM STEPPING TABLE 2000-OSM, F1 4-30

112 Time Table This table contains the schedules for automatic calibrations, benchmarks and stream analyses (see Figure 4-30). The Time Table lists information by the day of the month and time of day (using a 24- hour clock). If you enter 00 as the day, hour, or minute, the specified event will occur every day, hour, or minute. ****** Time Table ****** Day Hour Minute Function Value Cal Method Cal Method Bench Method Bench Method Anal Stream Anal Stream Valve On Valve Off 01 More Below Insert Delete Exit Line Line F1 F2 F3 F4 To prepare or edit a Time Table: Figure TIME TABLE SCREEN 1. On the Background screen, press the F1 (Exit To Commands) soft key. 2. On the Commands screen, cursor to TABLE EDIT and then press the F3 (Other Tables) soft key. 3. On the Edit Other Tables screen, cursor to TIME TABLE and then press the F2 (Edit the Table) soft key. 4. On the Time Table screen, cursor to the desired line and edit the table as described in steps 6 through 10, as necessary. 5. If there are no entries in the Time Table, press the F2 (Insert Line) soft key. 6. Use the up and down cursor arrow keys to set the desired day. 7. Cursor right one column and set the desired hour with the up and down cursor arrow keys. 8. Cursor right one column and set the desired minute with the up and down cursor arrow keys. 9. Cursor right one column and select a function using the up and down cursor arrow keys. The available selections are: Cal Method Valve On Report Freq Bench Method Valve Off Vista Basic Anal Stream OSM, F1

113 10. Cursor right one column and select the value for the desired function (method number, valve number, Vista Basic program, etc.). Use the keyboard number keys to enter the number and then press ENTER. 11. Add more lines by inserting lines and repeating steps 6 through 10 as needed. 12. When you have completed the Time Table, press the F1 (Exit) soft key. 13. On the next screen press the F2 (Exit And Update) soft key to save the Time Table changes, or press the F1 (Escape) soft key to retain the original values. 14. Press the F1 soft key as necessary to return to the Background screen. Stream Table The Stream Table identifies the status of each stream. This identifies the active streams and the method number and Vista BASIC program assigned to each stream. It also allows you to edit the table. You access the Stream Table for printing the same way as other tables, but you access it for viewing or editing differently from other tables. To view and edit a Stream Table: 1. On the Background screen, press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor, if necessary, to ANALYSIS CONTROL and then press the F3 (Streams) soft key. 3. On the Stream Assignment screen (see Figure 4-31) review the stream data and edit as necessary. This table lists the active streams and the method number and Vista BASIC program number assigned to each stream. When 00 is in the Vista BASIC column, no Vista BASIC program is associated with that stream. ****** Stream Assignment ****** Stream Status Method Basic 01 Active Inactive Inactive Inactive Inactive Inactive Inactive Inactive More Below Exit F1 F2 F3 F4 Figure STREAM ASSIGNMENT SCREEN 2000-OSM, F1 4-32

114 4. When you finish editing the stream data, press the F1 (Exit) soft key. 5. On the next screen, press the F2 (Exit and Update) soft key to save the new stream data, or press the F1 (Escape) soft key to retain the original data. 6. Press the F1 soft key as necessary to return to the Background screen. Raw Data Report This report (see Figure 4-32) provides analytical information on each component in a particular method. The data includes retention time, concentration, uncorrected and corrected peak heights and areas, slope sensitivity, peak width, start and end times, and start and end amplitudes. This level of information is often useful to have when troubleshooting the equipment. 8:09:18 Fri 30 Sep 1988 Stream 01 *** ALARM *** High Concentration * For Comp. #09: IDEAL HEAT Raw Data Report For a Regular Analysis Method Table 01 Name Retention Conc Flags Uncorrected Corrected Slope Pk Start Start End End Time tart End Pk Hgt.Pk.Area Pk.Hgt Pk.Area Sens. Wd Time Amp Time Time METHANE % ETHANE % ETHYLENE % H % CO % Regular Report Figure RAW DATA REPORT This report (see Figure 4-33) summarizes the analytical information on each component in a given method, providing only retention time and concentration data. 8:09:18 Fri 30 Sep 1988 Streams 01 TEST PROGRAM FOR 2020 SOFTWARE *** ALARM *** High Concentration * For Comp. #09: IDEAL HEAT Regular Analysis Report Method Table 01 Name RT Conc METHANE % ETHANE % ETHYLENE % H % CO % Z Clc REAL HEAT Clc SQRT OF B Clc IDEAL HEAT Clc Figure REGULAR REPORT OSM, F1

115 Short Report This report (see Figure 4-34) gives basic information on the analysis, which you can use to check analyzer operation periodically. It is a one-line report which provides the stream number, injection time, and concentration for each component by number. The Short Report comes in two forms: without alarm, which has only the analytical data (shown in Figure 4-34) with alarm, which identifies any active alarm (has two-line alarm message above the report) ST INJT Figure SHORT REPORT WITHOUT ALARM Standard Calibration Report This report (see Figure 4-35) automatically prints after each calibration run. Depending on how you set the parameters, the calibration will update the response factors automatically, leave them as previously set, or update only when the deviation does not exceed the level you originally specified. AIR PURGING 8:09:18 Fri 30 Sep 1988 Stream 10 Calibration Report Method Table 01 Multiplier Exponent 04 External Standard Mode Name RT New RF Old RF % Deviation Update METHANE YES ETHANE YES ETHYLENE YES H YES CO YES Figure STANDARD CALIBRATION REPORT When an area classification indicates combustible gases or particles are present in the air, and you have an analyzer containing a possible source of ignition located in this environment, the analyzer may have an air purging system to reduce the degree of risk. The type of air purge used depends on the classification of the analyzer and its environment; the analyzer is labeled accordingly. This safety purge is part of the basic design of the analyzer and must remain operational. Y Purge reduces the internal classification of the analyzer from Division 1 or Zone 1 to Division 2 or Zone 2. Z Purge reduces the internal classification of the analyzer from Division 2 or Zone 2 to Nonhazardous/General Purpose. X Purge reduces the internal classification of the analyzer from Division 1 or Zone 1 to Nonhazardous/General Purpose. Y and Z Purge The analyzer has a standard air purge system which will reduce the internal classification by one level. For a Division 1 internal classification, this purge system, labeled Y Purge, reduces the classification to Division 2. For a Division 2 internal classification, this purge system, labeled Z Purge, 2000-OSM, F1 4-34

116 will reduce the classification to Nonhazardous/General Purpose. Since the Y and Z Purge systems are identical except for nomenclature, the following explanation applies to both. 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 GCC will set an *** ALARM *** signal display on the screen and cause a purge alarm contact to switch. A Y or Z Purge alarm alerts you to the condition, but it does not turn off the analyzer. NOTE It is the customer s responsibility to connect the purge alarm contact to a visual or audible annunciator located in a constantly monitored area, as referenced in NFPA 496 (2003) and IEC :2001. Purge time depends on the application. Refer to the analyzer label or Data Package for specific analyzer purge time. X Purge Operation While X Purge (see Figure 4-36 for features and Figure 1-1 for location) is an optional feature, some installations specifying certification require it. X Purge reduces risk by two levels and turns off the analyzer when an alarm occurs. TB L2 (NEUT) CUSTOMER POWER CONNECTIONS L1 (HIGH) GND OVERRIDE PUSH BUTTON Figure X PURGE WITH COVER REMOVED When you turn the power ON, X Purge begins monitoring the electronics housing (GCC and Purge Air Panel) air purge pressure. When the air purge pressure reaches the specified level, the X Purge starts a timed cycle. If the air purge pressure remains at the specified level during the timed cycle, X Purge will supply power to the equipment when it completes the timed cycle. If the air purge pressure drops before the X Purge completes the timed cycle, X Purge resets the timer and starts over. It continues to reset the timer until the analyzer achieves and maintains the correct pressure for a complete timed cycle. The X Purge will not supply power to the analyzer until it successfully completes the timed cycle OSM, F1

117 The X Purge cycle time depends totally on the application, but it may vary with analyzer configuration and condition. Refer to the analyzer label or Data Package for specific purge specifications. Once X Purge applies power to the analyzer, power continues to the analyzer as long as the electronics housing maintains air purge pressure. X Purge removes power from the analyzer when the electronics housing air purge pressure drops below specifications. It locks out power to the analyzer and causes a purge alarm contact to switch. The analyzer has connections available to the customer for connecting the purge alarm to a visual or audible annunciator located in a constantly monitored area. In order to re-start the analyzer after an X Purge alarm, you must first correct the cause of the drop in pressure. Then turn the power OFF at the circuit breaker for at least ten seconds and turn the power back ON. This starts a new X Purge timed cycle, which it must complete before it will supply power to the analyzer. If you do not correct the cause and cannot achieve and maintain pressure, the X Purge will not complete the cycle and will not supply power to the analyzer. When X Purge removes and locks out power to the analyzer after a drop in electronics housing purge air pressure (or before pressure has initially attained the specified level), you can use Override to provide power to the analyzer for troubleshooting or maintenance purposes. Override does not cancel the X Purge power lockout but temporarily overrides it. X Purge Override Option WARNING Before you enable X Purge Override to override its control of power to the analyzer, ensure the area where the analyzer is located is safe and hazard free, and remains so for the entire time the X Purge housing cover is removed. CAUTION Override must not be left on during regular operation of the analyzer. Use the X Purge Override Option only for start up, troubleshooting, and maintenance. Do not leave it on during regular operation of the analyzer. Override requires a well-lighted area to function. A light sensor inside the X Purge housing allows you to enable Override after you remove the X Purge housing cover. When you replace the cover, the light sensor cancels Override. The following steps describe how to use the override function. 1. Ensure the area is safe and well-lit. 2. Remove the X Purge housing cover and press the Override button (see Figure 4-36) to apply power to the analyzer. NOTE All versions of the X Purge have a set screw in the lid that must be removed before the housing cover can be removed. 3. Perform the necessary maintenance and troubleshooting. 4. When you have completed the maintenance and troubleshooting, replace the X Purge housing cover (and the set screw). 5. To cancel Override safely and properly and to reset X Purge, turn the supply power OFF at the circuit breaker outside the analyzer (for at least ten seconds) and then turn power ON again OSM, F1 4-36

118 6. With X Purge reset, the air purge timed cycle begins in the electronics housing. When you use Override during start-up, it overrides the X Purge control of power to the analyzer, but the air purge timed cycle continues. Once the electronics housing has pressurized and X Purge completes its timed purge cycle, the analyzer will have power from the X Purge. If you replace the housing cover without turning the power off at the circuit breaker, the analyzer will still have power because of X Purge. If the electronics housing pressure drops during Override use and if the timed cycle is complete, the X Purge will lock out its power to the analyzer. Since Override bypasses the X Purge, the analyzer will still have power. If you cancel Override by replacing the housing cover without turning off the power at the circuit breaker, the X Purge power lock out will cause the analyzer to be without power. To restart X Purge, you must correct the cause of the drop in pressure, then turn power OFF (for at least ten seconds), and then ON again. The X Purge must complete its timed cycle before the analyzer will receive power. X Purge Override Contacts The X Purge housing has terminals for connecting an override jumper (see Figure 4-36). The customer is solely responsible for connecting and maintaining this jumper, which is only to be used during start-up, maintenance and troubleshooting. The customer must ensure the override jumper is removed when start-up, maintenance and troubleshooting are completed. E2PROM The Electrical Erasable Programmable Read Only Memory (E2PROM) can store the following tables and functions. Method Tables Stream Table Digital Table Trend Tables Time Table Random Stream Table Report Format Report Headers User Sensor Names Vista Basic Tables Control Parameters Temp Check Table Temp Control Table Press. Check Table Press. Control Table VistaNET Tables Name Headers Name Streams Chromatogram Storage Parameters This feature preserves vital tables and functions if you have power failure. Changing any of these tables or functions the GCC enters the change into RAM. To preserve the tables and functions, you must save them to nonvolatile memory (E2PROM). NOTE The SAVE TABLES TO E2PROM and RESTORE TABLES FROM E2PROM commands alter significant portions of memory. Be sure to read this entire subsection before executing either command. Save Tables to E2PROM This command saves tables and functions to nonvolatile memory to ensure an analyzer failure will not erase them OSM, F1

119 CAUTION Saving tables and functions from RAM to E2PROM erases tables or functions already residing in E2PROM. Since these tables and functions in RAM will replace the tables already in E2PROM, be certain they are correct before you perform this sequence. To save tables to E2PROM: 1. On the Background screen, press the F1 (Exit To Commands) soft key. 2. On the Commands screen, cursor down to STORAGE & CONFIG. and then press the F2 (Save or Restore Tables) soft key. 3. On the Table Storage screen (see Figure 4-37), cursor to SAVE TABLES TO E2PROM and press the F2 (Save Tables) soft key. The tables save to E2PROM. ****** Table Storage ****** [ ] RESTORE TABLES FROM E2PROM SAVE TABLES TO E2PROM Escape F1 F2 F3 F4 Figure TABLE STORAGE SCREEN 4. When Are You Sure? Y or N appears on the screen, press the Y key on the GCC front panel to confirm you want to save the tables. 5. Press the F1 soft key as necessary to return to the Background screen. CAUTION If you activate the Reset switch on the SBC PCB, you must perform RESTORE TABLES FROM E2PROM to load the latest tables and functions into RAM. Restore Tables from E2PROM This command restores tables and functions from nonvolatile memory to RAM. It is used when you have lost RAM for any reason OSM, F1 4-38

120 CAUTION Restoring tables and functions from E2PROM will erase any tables or functions already residing in RAM. Since these tables and functions in E2PROM will replace the tables already in RAM, be certain they are correct before you perform this sequence. NOTE If tables and functions in E2PROM are corrupted, you will not be able to restore them. To replace the E2PROM contents, re-enter the data from the Data Sheets or your records and then save it to E2PROM as described in "Save Tables to E2PROM." To restore tables from E2PROM: 1. On the Background screen, press the F1 (Exit To Commands) soft key. 2. On the Commands screen, cursor down to STORAGE & CONFIG. and then press the F2 (Save or Restore Tables) soft key. 3. On the Table Storage screen (see Figure 4-37), cursor down to RESTORE TABLES FROM E2PROM and then press the F2 (Restore Tables) soft key. 4. When Are Your Sure? Y or N appears on the screen, press the Y key on the GCC front panel to confirm restoring the tables. When the GCC restores the tables to RAM, they supersede any tables and functions already in RAM. 5. Press the F1 soft key as necessary to return to the Background screen. DIGITAL TEMPERATURE CONTROLLER Physical Description The Digital Temperature Controller's temperature zones represent areas in the analyzer having heated components: the Isothermal Oven, the Temperature Programmable Oven, the LSV, the Methanizer, and the TCD and/or FID cells. The Digital Temperature Controller is comprised of a DTC Backplane PCB, up to two AC Conditioning PCBs, and up to five Temperature Zone PCBs. NOTE The Digital Temperature Controller is set up at the factory and should not require adjustment on site. Your application may require different setting from those described in this manual; see the Data Package to ensure you use the correct settings. Operator Settings You can set the controller type and the zone functions for the Digital Temperature Controller, as well as program specific functions in the Method Table. Use the following screens to make these changes: Manual Temperature Control Mode Valve On/Off Set Point, by zone Ramp Rate, by zone OSM, F1

121 Temperature Configuration Table Temperature Control Table Temperature Check Table Zone Controller Type Zone Config Table Low/High Alarm Limits Zone Name Zone relationship Set Point, by entry number in method Ramp Rate, by entry number in method Zone relationship Alarm Temperature value, by entry number in method Action (Display or Abort), by entry number in method Controller type Zone Configuration Sensor Type Heat/Air relationship Manual Temperature Control Mode This screen allows operator control of the Digital Temperature Controller. The Manual Temperature Control Mode screen allows you to change these fields: Valve #, Zone #, Set Point, and Ramp Rate. Always check the original application-specific temperature limits listed in the analyzer's Data Package to validate any changes. To access this screen perform the following steps: 1. On the Background screen, press the F2 (Manual Control) soft key. 2. On the Manual Control Mode screen, press the F4 (Press. & Temp. Control) soft key. 3. On the Pres and Temp Control screen, cursor to TEMP CONTROL and press the F2 (Manual Temp Control) soft key OSM, F1 4-40

122 4. On the Manual Temperature Control Mode screen (see Figure 4-38), select the desired field using the Up and Down cursor keys. Enter two digits for valve numbers (e.g. 04), as some installations have more than nine valves. **** Manual Temperature Control Mode **** Zone Config Actual SP Rate ISO-OVEN ISO 79.9C 80.0C 0.0 PROG. OVEN PROG/C 220.1C 220.0C 30.0 T/C CELL SWITCH 199.8C 200.0C 10.0 LSV ISO 199.9C 200.0C 10.0 Valve # : [0] Time : 0125 Zone # : 2 State : Pk Back Set Point: Ramp Rate: T-Rating Ver VALVES : T2 290C Accept Zero Span Escape Control All All Point Zones Zones F1 F2 F3 F4 Figure MANUAL TEMPERATURE CONTROL MODE SCREEN 5. After you enter changes in the Set Point or Ramp Rate fields, press the F2 (Accept Control Point) soft key to save the new data. Data changes made on the screen go to the DTC Backplane PCB, which compares the new settings with the application-specific temperature limits. If the new settings fall within the limits, it accepts them and applies them to the analysis. If entries in the Set Point or Ramp Rate fields fall outside the set limits, the * TEMP BD ALARM * flashes on the screen s message line. Temperature Zone specific alarms also cause the zone name to flash. To identify the type of alarm, press Escape to return to the Pres & Temp Control Screen, then press the F4 (Alarms) soft key to display the Alarm Screen. After you note the type of alarm triggered and consult the Data Package for the set limits, clear the alarm, return to the Manual Temperature Control Screen, and change the entries to values within the set limits. If the DTC Backplane PCB accepts the new settings, there will be no * TEMP BD ALARM * display on the screen after you press the F2 (Accept Control Point) soft key. Zero All Zones and Span All Zones settings are made in the factory and are not intended to be changed. 5 Zone Names and Limits Table This screen allows you to enter low and high alarm limits and change the temperature zone names. Always check the original application-specific temperature limits listed in the analyzer's Data Package to validate any changes. To access the 5 Zone Names and Limits Table perform the following steps: 1. On the Background screen, press the F2 (Manual Control) soft key. 2. On Manual Control Mode screen, press the F4 (Press. & Temp. Control) soft key OSM, F1

123 3. On the Pres and Temp Control screen (see Figure 4-39), cursor to TEMP CONFIGURATION and press the F3 (Names and Limits) soft key. **** Pres and Temp Control **** TEMP CONTROL PRES CONTROL TEMP CONFIGURATION Names Escape Zone and Controller Config Limits Type F1 F2 F3 F4 Figure PRESSURE AND TEMPERATURE CONTROL SCREEN 4. On the 5 Zone Names and Limits Table screen (see Figure 4-40), select the desired field using the cursor keys. **** 5 Zone Names & Limits **** Zone Low High Num Name Limit(C) Limit(C) 1 ISO-OVEN PROG. OVEN T/C CELL LSV TEMP ZONE Exit F1 F2 F3 F4 Figure ZONE NAMES AND LIMITS TABLE SCREEN 2000-OSM, F1 4-42

124 5. In the Names field you can change the zone name by typing a new name, up to a maximum of ten characters long. When you have completed the name, cursor to another field. 6. In the low and high alarm limits field, type the desired alarm value and then cursor to another field. 7. After you have completed and verified the changes, press the F1 (Exit) soft key. 8. On the next screen, press the F2 (Exit And Update) soft key to save the changes, or press the F1 (Escape) soft key to retain the original values. Pressing F2 saves the values in the Name, Low Limit, and High Limit fields. 9. Press the F1 soft key as necessary to return to the Background screen. Configuring SWITCH SWITCH displayed in the Config column indicates an Isothermal Zone with a temperature Set Point configured at the factory and not intended to be changed. If it becomes necessary to change the Set Point, perform the following sequence of steps. CAUTION Before opening any analyzer doors, ensure the area is safe and hazard-free, and will remain so the entire time the analyzer is open. If the analyzer has X Purge, operate the override function as described in "X Purge Override Option." 1. Open the GCC control panel. 2. On the Background screen, press the F2 (Manual Control) soft key. 3. On Manual Control Mode screen, press the F4 (Pres & Temp Control) soft key. 4. On the Pres & Temp Control screen, cursor to TEMP CONTROL and then press the F2 (Manual Temp Control) soft key. 5. On the Manual Temperature Control Mode screen, cursor to the Zone # field and enter the desired zone number (1-5). 6. Cursor to the Set Point field and enter the setpoint temperature (the required operating temperature for this zone). 7. Press the F2 (Accept Control Point) soft key. The GCC displays Hold Switch on Temp Board to Accept New Set Point. 8. Hold down the switch on the DTC Backplane PCB. The GCC displays the message Are You Sure? 9. Continue holding the switch down and press Y on the keyboard to confirm the change. The GCC sends the new setting to the DTC Backplane PCB where it is checked against the established limits (this only takes a few seconds). 10. If it accepts the new temperature, the temperature appears on the screen in the Set Point field. Release the switch and close the front panel. 11. If the GCC does not accept the Set Point, Temp Zone name flashes and * TEMP BD ALARM * flashes on the message line. If this happens, release the switch and check the temperature with the T-Rating on the Manual Temperature Control Mode screen OSM, F1

125 12. Enter a set point temperature within T-Rating limits by repeating steps 5 through If you do not hold the switch long enough, * TEMP BD ALARM * will also display and the new setting will not be accepted. Check the temperature with the T-Rating on the Manual Temperature Control Mode screen and the temperature setting specified in the Data Package and repeat steps 5 through To cancel the alarm press the F1 (Escape) soft key to return to the Pres & Temp Control screen. 15. Verify that TEMP CONTROL is selected and press the F4 (Alarms) soft key to display the alarm explanation on the Alarm Screen. 16. After noting the alarm explanation, press the F2 (Clear Alarms & Exit) soft key. If the GCC cannot clear the alarm due to other activity, press the F1 (Exit) soft key and clear the alarm as soon as possible. 17. Return to the Manual Temperature Control Mode screen and repeat steps 5 through 10 to set a temperature for a SWITCH Configured Isothermal Zone. Temperature Control Table This screen allows you to select zone names and change set points and ramp rates, all related to the time they occur in the analysis method. To access this screen perform the following steps: 1. On the Background screen, press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor to TABLE EDIT and press the F2 (Methods) soft key. 3. On the Methods Table #?? screen, enter the number of the Method Table to be changed and press the F2 (Edit the Table) soft key. 4. On the Cal Define & Cycle Time screen, press the F1 (Continue) soft key. 5. On the Method Table screen (see Figure 4-41), cursor to the appropriate line in the Time field, or press the Insert Line soft key to insert a new line (just below the cursor) and enter the time into the cycle when the function is to be performed OSM, F1 4-44

126 6. Cursor to the Function field and scroll to Temp Contrl. In Figure 4-41, with Temp Contrl in the Function field the Value column lists Two as the function to be performed from the Temperature Control Table. ***** Method Table #01 ***** Time Function Value [0001] Temp. Contrl Two 0010 Temp. Check One 0120 Noise Calc On 0125 Noise Calc Off 0128 Auto Zero N/A 0130 Skp, Nxt,Str= Nine 0132 Valve On One 0155 Valve Off One More Below Insert Delete Cal Define Exit Line Line & Cycle Time F1 F2 F3 F4 Figure METHOD TABLE #01 SCREEN 7. Move the cursor to the Value column and the Temperature Control Table appears, with the cursor on Entry line 02 (see Figure 4-42). Note the Entry line number when you enter the table so you can exit the table from the same line, if desired. ***** Temperature Control ***** Set Point Ramp Rate Entry Zone C C/MIN 01 Temp Zone [02] Temp Zone Temp Zone Temp Zone Temp Zone Temp Zone Temp Zone Temp Zone More Below Exit F1 F2 F3 F4 Figure TEMPERATURE CONTROL SCREEN OSM, F1

127 8. On the Temperature Control screen, move the cursor as necessary to select the Zone Name from among the names in the list, and to change Set Point and Ramp Rate values of the desired entries. CAUTION When you exit the Temperature Control screen, the value in the Entry line highlighted when you exit becomes the Value entry in the Method Table. Unless you want to change the Value entry, exit on the same Entry line number that you entered the Temperature Control screen. 9. Verify the changed values and place the cursor on the desired Entry number. Then press the F1 (Exit) soft key. Temperature Check Table This screen allows you to select zone names and change alarm temperature values and alarm methods, all related to the time they occur in the analysis method. To access this screen perform the following steps: 1. On the Background screen, press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor to TABLE EDIT and press the F2 (Methods) soft key. 3. On the Methods Table #?? screen, enter the number of the Method Table to be changed and press the F2 (Edit the Table) soft key. 4. On the Cal Define & Cycle Time screen, press the F1 (Continue) soft key. 5. On the Method Table screen (see Figure 4-41), cursor to the appropriate line in the Time field, or press the Insert Line soft key to insert a new line (just below the cursor) and enter the time into the cycle when the function is to be performed. 6. Cursor to the Function field and scroll to Temp Check. In Figure 4-41, with Temp Check in the Function field the Value column lists One as the function to be performed from the Temperature Check Table OSM, F1 4-46

128 7. Move the cursor to the Value column and the Temperature Check Table appears, with the cursor on Entry line 01 (see Figure 4-43). Note the Entry line number when you enter the table so you can exit the table from the same, if desired. ***** Temperature Check ***** Temperature Entry Zone C Action [01] Temp Zone1 < Abort 02 Temp Zone1 < Display 03 Temp Zone1 < Abort 04 Temp Zone1 < Display 05 Temp Zone1 < Display 06 Temp Zone1 < Display 07 Temp Zone1 < Display 08 Temp Zone1 < Display More Below Exit F1 F2 F3 F4 Figure TEMPERATURE CHECK SCREEN 8. On the Temperature Check screen, move the cursor as necessary to select the Zone Name and to change less than (<), more than (>), alarm value, and the alarm mode of the desired entries. CAUTION When you exit the Temperature Check screen, the value in the Entry line highlighted when you exit becomes the Value entry in the Method Table. Unless you want to change the Value entry, exit on the same Entry line number that you entered the Temperature Check screen. 9. Verify the changed values and place the cursor on the desired Entry number. Then press the F1 (Exit) soft key. Controller Type There are several types of temperature controllers, such as Sulfur, Sparger, PINA, PNA, and Regular. This screen is set at the factory and should not have to be changed. If you want to verify the setting, perform the following steps. 1. On the Background screen, press the F2 (Manual Control) soft key. 2. On the Manual Control Mode screen, press the F4 (Press. & Temp. Control) soft key. 3. On the Pres and Temp Control screen (see Figure 4-39), cursor to TEMP CONFIGURATION and press the F4 (Controller Type) soft key OSM, F1

129 4. On the Controller Type screen (see Figure 4-44), verify that the controller type is the same as specified in the Data Package. ***** Controller Type ***** Controller Type: Regular Escape Exit and Update F1 F2 F3 F4 Figure CONTROLLER TYPE SCREEN 5. If you want to change the controller type, use the cursor arrow keys to select the desired type and then press the F2 (Exit and Update) soft key to save the changes, or press the F1 (Escape) soft key to retain the original controller type. 6. If you made changes, "Hold Switch on Temp Board" will appear on the screen. 7. Open the GCC Front Panel and hold down the switch on the DTC Backplane PCB. 8. The CRT will display the message, "Are You Sure? Y or N." Continue holding the switch down and press "Y" on the GCC keyboard to accept the change. 9. If the change is accepted, an acknowledging message appears on the screen. Release the switch and close the front panel. 10. Press the F1 soft key as necessary to return to the Background screen. Temperature Configuration Table This screen allows you to select temperature zone names and sensor types. It also allows you to select the heat/air relationship in zones 3 and 4. To access the Temperature Configuration Table perform the following steps: 1. On the Background screen, press the F2 (Manual Control) soft key. 2. On the Manual Control Mode screen, press the F4 (Press. & Temp. Control) soft key. 3. On the Pres and Temp Control screen (see Figure 4-39), cursor to TEMP CONFIGURATION and press the F2 (Zone Config) soft key OSM, F1 4-48

130 4. On the Temp Config Table screen (see Figure 4-45), select the desired field using the cursor keys. **** Temp Config Table **** Remove Heat On Num Config Sensor Air Loss 1 ISO Probe Yes 2 ISO Probe Yes 3 INACT Probe No 4 INACT Probe No 5 ISO TC Yes Exit F1 F2 F3 F4 Figure TEMP CONFIG TABLE SCREEN 5. In the Config field, you can change the temperature configuration by scrolling through the list of titles and selecting the appropriate one for this zone, then cursor to another field. The five Temperature Zone configuration choices are: INACT SWITCH ISO PROG PROG/C Inactive Isothermal Controlled by toggle switch on Temp. Control PCB Isothermal Regular Programmable Programmable with Vortex Cooler NOTE SWITCH, displayed in the Config column, indicates an isothermal zone that is not intended to be changed. If a change in the zone configuration becomes necessary, the pushbutton switch on the DTC Backplane PCB confirms the change. Refer to "Configuring SWITCH," steps 8 and In the Sensor field, you can toggle between Probe and TC. Refer to the Data Package to ensure you select the appropriate sensor type. 7. In the Remove Heat On Air Loss field you can toggle between Yes and No. Refer to the Data Package to ensure you make the appropriate selections. 8. After you have completed and verified the changes, press the F1 (Exit) soft key. 9. On the next screen, press the F2 (Exit And Update) soft key to save the changes, or press the F1 (Escape) soft key to retain the original values OSM, F1

131 10. Hold Switch on Temp Board will appear on the screen. CAUTION Before opening any analyzer doors, ensure the area is safe and hazard-free, and will remain so the entire time the analyzer is open. If the analyzer has X Purge, operate the override function as described in "X Purge Override Option." 11. Open GCC Front Panel and hold down the switch on the DTC Backplane PCB. 12. The screen will display the message, Are You Sure? Y or N. Continue holding the switch down and press Y on the GCC keyboard to accept the change. 13. If the GCC accepts the change, an acknowledging message appears. Release the switch and close the front panel. 14. On the Pres and Temp Control screen, cursor to TEMP CONFIGURATION and press the F2 (Zone Config) soft key. 15. Verify that changes have been accepted and then press the F1 soft key as necessary to return to the Background screen. If the GCC accepts the new configuration settings, they appear on the screen in the appropriate fields. If it does not accept them, the field settings do not change and a *TEMP BD ALARM* signal appears. If you do not hold the switch long enough, a *TEMP BD ALARM* signal appear and the new settings will not be accepted. Check the established limits for the settings in the Data Package and try again. Programming Notes There are two types of programmable zones, standard programmable zone (PROG) and programmable zone with the vortex cooler (PROG/C). You can program both types of programmable zones from the Manual Temperature Control Mode screen. The maximum value of Ramp Rate for any PROG or PROG/C zone is 50 C/minute, in increments of one-tenth of a degree. Setting a Ramp Rate of 0.0 C/minute causes the temperature controller to maintain the present temperature. A Ramp Rate of 50 C/minute sends the temperature zone as rapidly as possible to the intended setpoint. This happens without consideration of true rate or out of control conditions. Programming for the PROG and PROG/C zones differs only in the cool down ramp rate. In zones programmed as PROG/C, a coolant solenoid rapidly cools down the zones. This solenoid activates when it receives a Ramp Rate of 0.1 C/minute. Once the solenoid recognizes the 0.1 C setting, it forces vortex cooled air into the programmed zone to cool it down. The rate of cool down depends solely on the zone temperature and the volume of the cool air. Once the zone reaches the lower set point, power is applied to the heater for this zone to maintain the new set point while the cool air is still flowing. The coolant solenoid stops the air flow when a ramp rate other than 0.1 C/minute is received. Both Set Points and Ramp Rates may originate from a Method Table being run automatically by the GCC, or the Workstation, or may be entered manually on the Manual Temperature Control Mode screen. The last programming information entered runs the analysis, whether entered on the Manual Temperature Control Mode screen or in the Method Table OSM, F1 4-50

132 Alarms NOTE On power loss, Set Points and Ramp Rates for all programmable zones (PROG and PROG/C) are lost. You must re-enter the Values manually or execute the method stored in the Method Table. Digital Temperature Controller alarms are described in "Temperature Board" alarms in Section 6. When a temperature alarm occurs, it appears as *** ALARM *** flashing on the Background screen and * TEMP BD ALARM * flashing on the Manual Temperature Control Mode screen. To identify the specific alarm, press the F4 (Alarm) soft key on the Background screen. ELECTRONIC PRESSURE CONTROL OPTION The optional Electronic Pressure Control (EPC) replaces the mechanical regulators and gauges in the Pressure Control Panel. The EPC provides up to five individually controlled pressure zones. Physical Description The EPC is comprised of an Electronic Pressure Control Multibus PCB and an EPC Module which contains up to five pressure zones. NOTE The EPC is set up at the factory and should not require adjustment on site. Operator Settings You can set the zone functions for the EPC and also program specific functions in the method tables. The functions you can set or program appear on the following screens: Screen Manual Pressure Control Mode Pressure Configuration Table Pressure Control Table Pressure Check Table Function Valve On/Off Set Point, by zone Ramp Rate, by zone Range Zone Name Zone relationship Set Point, by entry number in method Ramp Rate, by entry number in method Zone relationship Alarm Pressure value, by entry number in method Action, by entry number in method Manual Pressure Control Mode This screen allows operator control of the Electronic Pressure Controller. The Manual Pressure Control Mode screen allows you to change these fields: Enter Valve, Zone #, Set Point, and Ramp Rate. Always check the original application-specific pressure limits listed in the Data Package provided with the analyzer to ensure any changes are valid. To access this screen perform the following steps: OSM, F1

133 1. On the Background screen press F2 (Manual Control). 2. On the Manual Control Mode screen press F4 (Press. & Temp. Control). 3. On the Pres and Temp Control screen (see Figure 4-46), cursor to PRES CONTROL and press F2 (Manual Pressure Control). **** Pres and Temp Control **** TEMP CONTROL PRES CONTROL TEMP CONFIGURATION Manual Pressure View Escape Pressure Config Alarms Control F1 F2 F3 F4 FIGURE PRESSURE AND TEMPERATURE CONTROL SCREEN 2000-OSM, F1 4-52

134 4. On the Manual Pressure Control Mode screen (see Figure 4-47), select the desired field to change using the cursor arrow keys. Enter two digits for valve numbers (e.g., 04), as some installations have more than nine valves. **** Manual Pressure Control Mode **** Zone Config Actual SP Rate CARRIER #1 ISO PURGEAIR ISO N2DIL ISO Valve # : [0] Time : 0125 Zone # : 1 State : Idle Set Point: Ramp Rate: Ver A VALVES : Accept Calibrate Escape Control Zone Point F1 F2 F3 F4 Figure MANUAL PRESSURE CONTROL MODE SCREEN 5. After you enter and verify your changes, press F2 (Accept Control Point) to save the new data. The Electronic Pressure Control Multibus PCB compares the data changes made on the screen with the application-specific pressure limits. If the new settings are within the limits, they will be accepted and applied to the analysis. If the Set Point (SP) or Ramp Rate (Rate) values are not within the set limits, the * PRES BD ALARM * flashes on the screen s message line. Pressure Zone specific alarms also cause the zone name to flash. To identify the type of alarm, press Escape to return to the Pres & Temp Control Screen, then press F4 (Alarms) to display the Alarm Screen. After noting the type of alarm triggered and consulting the Applications Package for the set limits, clear the alarm, return to the Manual Pressure Control Screen, and change the entries to values within the set limits. If the new settings are accepted, there will be no * PRES BD ALARM * display on the screen after F2 (Accept Control Point) is pressed. Calibrate Zone settings are made in the factory and are not intended to be changed. Pressure Configuration Table This screen allows you to enter a pressure range, change the configuration choices, and change the pressure zone names. Always check the original application-specific pressure limits listed in the analyzer's Data Package to ensure any changes are valid. To access the Pressure Configuration Table perform the following steps: 1. On the Background screen press F2 (Manual Control). 2. On the Manual Control Mode screen press F4 (Press. & Temp. Control) OSM, F1

135 3. On the Pres and Temp Control screen, cursor to PRES CONTROL and press F3 (Pressure Config). 4. On the Pressure Config Table screen (see Figure 4-48), select the desired field using the cursor keys. **** Pressure Config Table **** Zone Num Name Config Range 1 COLUMN ISO 30 2 ANALYSIS ISO 30 3 SELECTOR ISO 50 4 ANALYSIS ISO 50 5 COLUMN PROG 100 Exit F1 F2 F3 F4 Figure PRESSURE CONFIGURATION TABLE SCREEN 5. In the Name field you can change the zone name by typing a new name, up to a maximum of ten characters long. When you have completed the name, cursor to another field. 6. In the Config field, you can change the pressure configuration by scrollling through the list of titles and selecting the appropriate one for this zone, then cursor to another field. 7. In the Range field, type the range value and then cursor to another field. 8. After you complete and verify the changes, press F1 (Exit). 9. On the next screen press F2 (Accept Control Point) to save the changes, or press F1 (Escape) to retain the original values. 10. Hold Switch on Pres Board will appear on the screen. CAUTION Before opening any analyzer doors, ensure the area is safe and hazard-free, and will remain so the entire time the analyzer is open. If the analyzer has X Purge, operate the override function as described in "X Purge Override Option." 11. Open the GCC Front Panel and hold down the switch on the Electronic Pressure Control PCB. 12. The screen will display the message, Are You Sure? Y or N. Continue holding the switch down and press Y on the GCC keyboard to accept the change OSM, F1 4-54

136 13. If the GCC accepts the change, an acknowledging message appears. Release the switch and close the front panel. 14. On the Pres and Temp Control screen, cursor to PRES CONTROL and press F3 (Pressure Config). 15. Verify that changes have been accepted and then press F1 as necessary to return to the Background screen. If the GCC accepts the new configuration settings, it displays them on the screen in the appropriate fields. If it does not accept them, the field settings do not change and a *PRES BD ALARM* signal is displayed. If you do not hold down the switch long enough, a *PRES BD ALARM* signal will display and the new settings will not be accepted. Check the established limits for the settings in the Data Package and try again. Configuring SWITCH SWITCH displayed in the Config column on the Manual Pressure Control Mode screen or the Pressure Config Table screen indicates a zone with a pressure Set Point that is not intended to be changed. If it becomes necessary to change the Set Point, perform the following steps. CAUTION Before opening any analyzer doors, ensure the area is safe and hazard-free, and will remain so the entire time the analyzer is open. If the analyzer has X Purge, operate the override function as described in "X Purge Override Option." 1. Open the GCC front panel. 2. On the Background screen press F2 (Manual Control). 3. On the Manual Control Mode screen press F4 (Pres & Temp Control). 4. On the Pres & Temp Control screen, cursor to PRES CONTROL and then press F2 (Manual Pressure Control). 5. On the Manual Pressure Control Mode screen, cursor to the Zone # field and enter the desired zone number (1-5). 6. Cursor to the Set Point field and enter the setpoint pressure (the required operating pressure for the component in this zone). 7. Press F2 (Accept Control Point). The GCC displays Hold Switch on Pres Bd to Accept SP. 8. Hold down the switch on the Electronic Pressure Control PCB. The GCC displays the message Are You Sure? 9. Continue holding the switch down and press Y on the keyboard to execute the change. The GCC sends the new setting to the Electronic Pressure Control Multibus PCB where it is checked against the established limits (this only takes a few seconds). 10. If the new pressure is accepted, it is displayed on the screen in the Set Point field. Release the switch and close the front panel OSM, F1

137 11. If the Set Point is not accepted, the Pres Zone name flashes and * PRES BD ALARM * flashes on the message line. If this happens, release the switch and check the pressure with the pressure limits prescribed for this zone. 12. Enter a set point pressure within these limits by repeating steps 5 through If the switch is not held long enough * PRES BD ALARM * will also be displayed and the new setting will not be accepted. Check the pressure with the pressure setting specified in the Data Package and repeat steps 5 through To cancel the alarm press F1 (Escape) to return to Pres & Temp Control screen. 15. Verify that PRES CONTROL is selected and press F4 (View Alarms) to display the alarm explanation on the Alarm Screen. 16. After noting the alarm explanation, press F2 (Clear Alarms & Exit). If the GCC cannot clear the alarm due to other activity, press F1 (Exit) and clear the alarm as soon as possible. 17. Return to the Manual Pressure Control Mode screen and repeat steps 5 through 10 to set a pressure for a SWITCH Configured Zone. Pressure Control Table This screen allows you to select zone names and change set points and ramp rates, all related to the time they occur in the analysis method. To access this screen: 1. On the Background screen press F1 (Exit to Commands). 2. On the Commands screen, cursor to TABLE EDIT and press F2 (Methods). 3. On the Methods Table #?? screen, enter the number of the Method Table you want to change and press F2 (Edit the Table). 4. On the Cal Define & Cycle Time screen, press F1 (Continue). 5. On the Method Table screen (see Figure 4-49), cursor to the appropriate line in the Time field, or press the Insert Line soft key to insert a new line (just below the cursor) and enter the time into the cycle when the function is to be performed OSM, F1 4-56

138 6. Cursor to the Function field and scroll to Pres Contrl. In Figure 4-49, with Pres Contrl displayed, the Value column lists Two as the function to be performed. ***** Method Table #01 ***** Time Function Value [0001] Pres Contrl Two 0010 Pres Check One 0120 Noise Calc On 0125 Noise Calc Off 0128 Auto Zero N/A 0130 Skp, Nxt,Str= Nine 0132 Valve On One 0155 Valve Off One More Below Insert Delete Cal Define Exit Line Line & Cycle Time F1 F2 F3 F4 Figure METHOD TABLE #01 SCREEN 7. Move the cursor to the Value column and the Pressure Control Table appears, with the cursor on Entry line 02 (see Figure 4-50). Note the Entry line number when you enter the table so you can exit the table from the same line, if desired. ***** Pressure Control ***** Entry Zone Set Point Ramp Rate 01 Pres Zone [02] Pres Zone Pres Zone Pres Zone Pres Zone Pres Zone Pres Zone Pres Zone More Below Exit F1 F2 F3 F4 Figure PRESSURE CONTROL SCREEN OSM, F1

139 8. On the Pressure Control screen, move the cursor as necessary to select the Zone Name from among the names in the list, and to change Set Point and Ramp Rate values of the desired entries. CAUTION When you exit the Pressure Control screen, the Entry line highlighted when you exit becomes the Value entry in the Method Table. Unless you want to change the Value entry, be sure to exit on the same Entry line number on which you entered the Pressure Control screen. 9. Verify the changed values and place the cursor on the desired Entry number. Then press F1 (Exit). Pressure Check Table This screen allows you to select zone names and change alarm pressure values and alarm methods, all related to the time they occur in the method. The Pressure Check Table is reached from the Method Table as follows: 1. On the Background screen press F1 (Exit to Commands). 2. On the Commands screen cursor to TABLE EDIT and press F2 (Methods). 3. On the Methods Table #?? screen, enter the number of the Method Table you want to change and press F2 (Edit the Table). 4. On the Cal Define & Cycle Time screen, press F1 (Continue). 5. On the Method Table #01 screen (see Figure 4-49), cursor to the appropriate line in the Time field, or press the Insert Line soft key to insert a new line (just below the cursor) and enter the time into the cycle when the function is to be performed. 6. Cursor to the Function field and scroll to Pres Check. In Figure 4-49, with Pres Check in the Function field the Value column lists One as the function to be performed from the Pressure Check Table OSM, F1 4-58

140 7. Move the cursor to the Value column and the Pressure Check Table appears, with the cursor on Entry line 01 (see Figure 4-51). Note the Entry line number when you enter the table so you can exit the table from the same, if desired. ***** Pressure Check ***** Pressure Entry Zone psi Action [01] Pres Zone1 < Abort 02 Pres Zone1 < Display 03 Pres Zone1 < Abort 04 Pres Zone1 < Display 05 Pres Zone1 < Display 06 Pres Zone1 < Display 07 Pres Zone1 < Display 08 Pres Zone1 < Display More Below Exit F1 F2 F3 F4 Figure PRESSURE CHECK SCREEN 8. On the Pressure Check screen, cursor to select the Zone Name and to change less than (<), more than (>), alarm value, and alarm mode of the desired entries. CAUTION When you exit the Pressure Check screen, the Entry line highlighted at exit becomes the Value entry in the Method Table. Unless you want to change the Value entry, be sure to exit on the same Entry line number on which you entered the screen. 9. Verify the changed values and place the cursor on the desired Entry number. Then press F1 (Exit). Alarms Electronic Pressure Control alarms are described in "Pressure Board" alarms in Section 6. When a pressure alarm occurs, it displays as *** ALARM *** flashing on the Background screen and * PRES BD ALARM * flashing on the Manual Pressure Control Mode screen. To identify the specific alarm, press the F4 (Alarms) soft key on the Background screen. RAW CHROMATOGRAM STORAGE AND REPROCESSING This is a standard feature on GCCs which have the VistaNET option, but it is optional on all other units. Raw chromatogram storage gives GCCs the ability to remember an analysis under a user specified condition (i.e., an alarm), after which the analysis can be checked for problems. Checking involves looking at the chromatogram, feeding data back through the controller (as if it were coming from the detector), and generating reports OSM, F1

141 The raw chromatogram storage and reprocessing option allows only one chromatogram of each type to be saved (last, calibration, benchmark, typical or alarm), regardless of the length of the cycle. When the chromatogram is saved, the Raw Data Report is saved also (but method tables are not saved). Raw chromatograms are saved in GCC memory but they are not saved on E 2 PROM. You can save and release raw chromatograms manually or automatically. You can view the saved chromatogram on the screen and send the report to the printer. The GCC does this by feeding the chromatogram back through the controller, allowing the controller to reprocess it off-line, then displaying it on the screen and sending the report to the printer. Accessing Raw Chromatogram Storage Select the Raw Chromatogram Storage and Reprocessing option from the Commands screen, as shown in Figure ****** COMMANDS ****** ANALYSIS CONTROL REPORTS TABLE EDIT PRINTER STORAGE & CONFIG. NAMES MISC. TESTING/SETUP [CHROMATOGRAM STORAGE] Go To Display Reprocess Define Background Saved Saved Save And Data Data Release F1 F2 F3 F4 Figure COMMANDS SCREEN To use this feature, ensure the GCC has sufficient memory to save chromatograms, save the desired chromatograms, then display, save and reprocess chromatograms. Checking Available Memory Before you select any chromatograms to save, first verify the status of available memory for this purpose as follows: 1. On the Commands screen, cursor to CHROMATOGRAM STORAGE and then press the F2 (Display Saved Data) soft key OSM, F1 4-60

142 2. On the Display Saved Data screen, cursor to MEMORY USED/LEFT and press the F2 (Execute the Command) soft key. The Raw Chromatogram Memory Used/Left screen will appear (see Figure 4-53). **** Raw Chromatogram Memory Used/Left **** Total Used = bytes Total Left = bytes Start End Bytes Type/Lock Num Stream Time Time Used Current U Last Alarm Calibrate Bench Escape F1 F2 F3 F4 Figure MEMORY USED SCREEN This screen shows the total memory used and left, and the amount used by each saved chromatogram. The available GCC memory resides in two separate pools that cannot be shared: memory available for saving raw chromatograms (304KB), and memory available for building operational tables and saving the Raw Data Reports with the chromatograms (192KB). The GCC saves the current analysis. At cycle end, the GCC determines if its program specifies the analysis just saved as a type to be automatically saved. If it does not specify it for automatic saving, the GCC erases the current analysis data from memory. Chromatogram storage uses from 2 to 4 KB of memory for each minute of analysis cycle. When estimating the memory needed, calculate 4 KB/cycle minute (e.g., 20 KB for a 5 minute cycle, 80 KB for a 20 minute cycle). Alarms and warning signals indicate when either memory pool runs low. The GCC displays the message NOT ENOUGH MEMORY, NOT SAVED if the 304KB pool empties or runs low. If the GCC does not have enough memory, you must erase (release) some saved data. This screen identifies analyses saved and memory used under Type/Lock. You can erase all saved analyses or one saved analysis at a time (see next subsection). Erasing (Releasing) Chromatogram Data When the GCC does not have sufficient memory to save new chromatogram data, you must erase (release from memory) existing chromatograms. First you must identify which chromatograms to erase. Then perform the following steps to erase these chromatograms: 1. Press the F1 soft key as necessary to return to the Commands screen. 2. Cursor to CHROMATOGRAM STORAGE and press the F2 (Define Save And Release) soft key OSM, F1

143 3. On the Define Save/Release screen, cursor to MANUAL RELEASE and then press the F2 (Execute The Command) soft key. 4. On the Manually Release Analysis screen, select the type of data to release and press the F2 (Manually Release Analysis) soft key. If you want to release more than one analysis, you must select the type of data separately for each analysis released. Alternatively, you can release all analyses at once by pressing the F3 (Release All Analyses) soft key. 5. After you have released (erased) all desired data, press the F1 (Escape) soft key to return to the Display Saved Data menu screen. Saving Chromatograms You must save chromatograms before you can display or reprocess them. You can save chromatograms either manually or automatically. Saving a Chromatogram Manually 1. On the Commands screen cursor to CHROMATOGRAM STORAGE and press the F2 (Define Save And Release) soft key. 2. On the Define Save/Release screen, cursor to MANUAL SAVE and then press the F2 (Execute The Command) soft key. 3. On the Manual Save Analysis screen, select which type of chromatogram you want to save. 4. Next select how you want this chromatogram saved (as a calibration analysis, benchmark, etc.) 5. Verify your selections and press the F2 (Manually Save Analysis) soft key. 6. When you have completed saving analyses, press the F1 soft key as necessary to return to the Commands screen. Saving Chromatograms Automatically 1. On the Commands screen cursor to CHROMATOGRAM STORAGE and press the F2 (Define Save And Release) soft key. 2. On the Define Save/Release screen, cursor to AUTO SAVE/RELEASE and then press the F2 (Execute The Command) soft key. 3. On the Automatically Save Analyses screen (see Figure 4-54), select which types of chromatograms you want to save. If you do not want any data saved automatically, select No for each entry OSM, F1 4-62

144 4. Note the number under Alarm Mask. This represents the alarm configuration set on the Define Alarm Mask screen. If you want to verify or change the alarm mask, press the F4 (Expand Alarm Mask) soft key. ****** Automatically Save Analyses ****** Save This Type Alarm Cal Bench Last Alarm Mask 01 Yes Yes Yes Yes Exit Expand Alarm Mask F1 F2 F3 F4 Figure AUTOMATICALLY SAVE ANALYSES SCREEN 5. On the Define Alarm Mask screen, select No or Yes, as applicable, for each alarm category. The No/Yes designations (the choices are underlined) specify which alarms the GCC should watch for when gathering data to be saved as the alarm analysis. Each arrangement of alarm choices on this screen is represented by a different set of numbers in the Alarm Mask field on the Automatically Save Analyses Screen. 6. Verify your selections and press the F1 (Continue) soft key. This returns you to the Automatically Save Analyses screen. 7. On the Automatically Save Analyses screen, verify your selections and then press the F1 (Exit) soft key. 8. On the second Automatically Save Analyses screen, press the F2 (Exit And Update) soft key to save your changes, or press the F1 (Escape) soft key to retain the original values. 9. When you have completed saving analyses, press the F1 soft key as necessary to return to the Commands screen. Displaying Saved Data Once you have saved a chromatogram, you can display the chromatogram and print its raw data report. Displaying a Chromatogram 1. On the Display Saved Data screen, cursor to GRAPHICS and press the F2 (Execute The Command) soft key OSM, F1

145 2. On the Graphics Setup screen, select the type of chromatogram to save: Calibration (Cal), Benchmark (Bench), most recent (Last), Alarm, or typical (Typ). 3. Next select the amount of screen offset, which determines where on the screen the chromatogram will display. Start with 0 and adjust if necessary. 4. Then select the amount of screen attenuation, to ensure the entire chromatogram will appear on the screen. 5. Determine whether the chromatogram needs to be compressed to fit by selecting No or Yes. 6. Set the chromatogram s start time ("0" to start at the beginning of the analysis). 7. Set the end time according to how much of the analysis you want to see. 8. Verify the selections and then press the F2 (Execute The Command) soft key. The chromatogram will start to scroll on the display screen. 9. Press the F1 (Escape) soft key to return to the Display Saved Data screen. Printing a Raw Data Report 1. On the Display Saved Data screen, cursor to REPORT TO PRINTER. 2. On the Send Report To Printer screen, select the type of data to be printed. 3. Next select whether you want calibration and benchmark data printed as raw data. 4. Verify the selections and press the F2 (Send Report To Printer) soft key. The Command is being updated will appear on the message line and the raw data report will be printed. The report will not appear on the display screen. 5. Press the F1 (Escape) soft key to return to the Display Saved Data screen OSM, F1 4-64

146 Reprocessing Saved Chromatograms The Reprocess Saved Data Screen (soft key F3 on the Command Screen) allows you to select type of raw data to reprocess, how to process it. Reprocessing takes saved data and sends it back through peak detection in an off-line mode, then produces a report available to VistaNET (but not displayed on the screen). Because reprocessing uses some of the same program functions as the analysis, the GCC cannot run a real analysis and reprocess a saved analysis at the same time. To reprocess a chromatogram, perform the following steps: 1. Stop the analysis. 2. On the Commands screen cursor to CHROMATOGRAM STORAGE and then press the F3 (Reprocess Saved Data) soft key. 3. On the Reprocess Saved Raw Chromatogram screen (see Figure 4-55), select the type of chromatogram to be reprocessed. *** Reprocess Saved Raw Chromatogram *** Type: [Cal] Bench Last Alarm Typ Process As: Cal Bench Last Method Table: 1 Update Alarms, Trends and Digitals: No Yes Escape Execute The Command F1 F2 F3 F4 Figure REPROCESS SCREEN 4. Select how to process this data (calibration, benchmark, or last analysis). 5. Then select the method number to use in the reprocessing. 6. Select whether you want the resulting raw data report sent to VistaNET and whether you want alarms, trends, and digitals to be updated. 7. After you complete the entries, verify the selections and press the F2 (Execute The Command) soft key. The reprocessed chromatogram appears on the display. 8. When the chromatogram is complete, if you have no further data to reprocess press the F1 soft key as necessary to return to the Background screen. If you want to reprocess another chromatogram, repeat steps 2 through If desired, start the analysis OSM, F1

147 REMOTE GC OPERATION OPTION The analyzer can operate with other ABB GCC front panels. To implement this option requires the following changes to the analyzer: an optional PCB and several changes in wiring connections and switch settings. This section of the manual explains how to prepare the analyzer for remote operation and how to operate it in this configuration. LO COMM PCB Setup The optional Local Communications Module (LO COMM) PCB provides the remote access for the analyzer. The analyzer has this board, mounted on the Front Panel PCB located inside the GCC (see Figure 4-56), only when remote operation is specified. The LO COMM PCB connections terminate at TB4 in the GCC cabinet. FRONT PANEL PCB LO COMM PCB LO COMM CABLE DISPLAY PANEL Figure LOCATION OF LO COMM PCB Each LO COMM PCB has a unique address to ensure positive communication. Switch SW1, an eight-position dip switch on the LO COMM PCB (see Figure 4-57), sets this address. LO COMM CABLE SW1 OFF ON 8 SW2 Figure LOCATION OF LO COMM PCB SWITCHES 2000-OSM, F1 4-66

148 The first five switch positions on SW1 (labeled 0 through 4 on the PCB), determine the analyzer's address. Switch positions 6, 7 and 8 are always ON ("1"). Figure 4-58 shows how to identify the address from the switch positions. Switch No Switch No # #17 # #18 # #19 # #20 # #21 # #22 # #23 # #24 # #25 # #26 # #27 # #28 # #29 # #30 # #31 # #32 Address Figure ADDRESS IDENTIFICATION WITH SW1 NOTE Be sure to save the tables to E 2 PROM before cycling the analyzer power. Each time you use one of these address switches, you must turn the unit OFF and back ON again to initialize the switch selections. Switch SW2 on the LO COMM PCB provides two other user-selected switch settings. The PCB labels these No Analyzer and Lock Out Remote. The OFF position is to the left of SW2 as it is shown in Figure NOTE Be sure to save the tables to E 2 PROM before cycling the analyzer power. Each time you use either of these switches, you must turn the unit OFF and back ON again to initialize the switch selection OSM, F1

149 When you set the No Analyzer switch ON, the front panel will communicate only with other GC s; the front panel will not communicate with an attached analyzer. When the Lock Out Remote switch is ON, another front panel on the network cannot access this front panel, but this front panel can access other network front panels. Remote Operation To understand remote mode operation, visualize the LO COMM PCB as directing analyzer data traffic along three different routes. When the operator at this display/keyboard communicates only with this analyzer, data runs back and forth between the display/keyboard and the analyzer. This represents the standard, or standalone, mode of operating the analyzer. When the operator at this display/keyboard communicates with a remote GCC, data runs back and forth between this display/keyboard and the remote GCC. When the operator at a remote display/keyboard communicates with this analyzer, data runs back and forth between the remote GCC and this analyzer. Since the remote mode functions simply by establishing communication routes, operating an analyzer from a remote location is virtually identical to local operation once you establish the communication link. The only differences are a remote front panel status message and the method by which recorder outputs are handled. To establish remote communication, perform the following steps: 1. From any screen menu, press and release the following keys in sequence: Upper, Enter, R. 2. The Remote Front Panel Mode menu appears on the screen (see Figure 4-59). This mode starts automatically if you turn power ON with No Analyzer switch ON. ****** REMOTE FRONT PANEL MODE ****** Enter a Controller Address between 1 and 256: [ ] If the entry is correct, then press EXECUTE to contact the controller. If the entry is incorrect, then press CLEAR ENTRY and re-enter the address. CLEAR EXIT ENTRY EXECUTE F1 F2 F3 F4 Figure REMOTE FRONT PANEL MODE SCREEN 2000-OSM, F1 4-68

150 3. Enter the number of the remote analyzer you want to access. Verify you have entered the number correctly and then press the F3 (EXECUTE) soft key. 4. If you entered the remote number incorrectly, press the F2 (CLEAR ENTRY) soft key, re-enter the number, and then press the F3 (EXECUTE) soft key. NOTE If the remote GCC is in use, Requested Controller is busy. Press EXECUTE to retry will appear on the screen. Wait thirty seconds and try again to access the remote GCC. 5. After a short time the Background screen will appear, with the remote number shown at the top left of the screen in reverse video. 6. At the remote analyzer, a message appears on the screen indicating that analyzer is being remotely controlled (see Figure 4-60). A Remote Front Panel is accessing this controller. OVERRIDE REMOTE OPERATOR F1 F2 F3 F4 Figure REMOTE CONTROLLER SCREEN 7. The only active keys on the remote GCC s front panel are the soft keys. All other keys are locked out until the accessing operator logs off the GCC or the operator at the remote analyzer presses the OVERRIDE REMOTE OPERATOR soft key. 8. Use the screen and front panel keys as necessary to obtain the information desired. All commands and displayed data will reflect what is happening at the remote analyzer. 9. When you complete the remote activity, press Upper, ENTER, R, to return to the Remote Front Panel Mode screen. 10. On the Remote Front Panel Mode screen, press the F1 (EXIT) soft key to exit remote mode and return to normal operation of the analyzer. Wait for the screen to resynchronize before attempting any operations OSM, F1

151 ANALOG OUTPUT OPTION This option provides analog outputs to a printer, computer, or other external device. Up to two optional PCBs, installed in the GCC Card Cage, provide different combinations of current and voltage outputs. These combinations are: one current board, with up to 16 output channels two current boards, with up to 32 output channels one voltage board, with up to 48 output channels two voltage boards, with up to 96 output channels one voltage board (with up to 16 output channels) and one current board (with up to 16 output channels) With the current board, the output signal ramps from 4 to 20 ma in proportion to the signal level. If the output is below the specified low range, the output signal will indicate the lowest possible signal. If the output is above the specified high range, the output signal will indicate the highest possible signal. With the voltage board, the output signal ramps from 0 to 5 vdc in proportion to the signal level. If the output is below the specified low range, the output signal will indicate the lowest possible signal. If the output is above the specified high range, the output signal will indicate the highest possible signal. The Trend Table screen controls the Analog Output option. This screen lists each available channel, the associated stream, the component being measured, and the low and high range values for that component (see Figure 4-61). If you select stream 00 for a particular channel, then the specified component will apply on that channel for all streams. At the end of each analysis, each analog output sends the latest current or voltage value to the external device connected to the Analog Output. When this value is between the low and high range limits, the analog output represents a proportion of the difference between low and high. If the analog output is outside the limits, the board will supply its lowest or highest possible value. To access the Trend Table screen: 1. Press the F1 soft key as necessary to display the Background screen. 2. On the Background screen, press the F1 (Exit to Commands) soft key. 3. On the Commands screen, cursor down to TABLE EDIT and then press the F3 (Other Tables) soft key. 4. On the Edit Other Tables screen, cursor to TREND TABLE, if necessary, and then press the F2 (Edit The Table) soft key. 5. When the first Trend Table screen appears, cursor across and down the table to highlight a value you want to change. Then insert the new value OSM, F1 4-70

152 6. When you have completed the changes to this Trend Table screen, review them to ensure all items are correct and then press the F1 (Exit) soft key. ****** Trend Table ****** Range Range Chan Stream Comp Low High More Below Insert Delete Exit Line Line F1 F2 F3 F4 Figure TREND TABLE SCREEN 7. On the second Trend Table screen, press the F2 (Exit and Update) soft key to save the changes or press the F1 (Escape) soft key to retain the original values. 8. Press the F1 soft key as necessary to return to the Background screen. DIGITAL I/O OPTION The Digital Input/Output option provides up to 48 output channels, or up to 32 output channels and 16 input channels. Since the system can support two Digital I/O PCB s, the maximum capability is 96 output channels, or 64 output channels and 32 input channels. The digital output channels provide component high and low alarm warnings, independent of any other alarms in the analyzer. No alarms or other indications occur when component concentrations are within their specified ranges, but if a component goes outside the specified range it changes the state of the appropriate digital contact. The Digital outputs are contact closures (rated at 30 vdc and 50 ma maximum), available to connect to audio or visual alarms to alert the operator or technician. The digital input channels can be read in Vista BASIC, permitting external digital information, such as alarms, to be used in the analyzer. The Digital Table screen controls the concentration alarm digital outputs. This screen lists each available channel, the associated stream, the component being measured, and the low and high OSM, F1

153 range values for that component (see Figure 4-62). If you select stream 00 for a particular channel, the specified component will apply on that channel for all streams. ****** Digital Table ****** Range Range Chan Stream Comp Low High More Below Insert Delete Exit Line Line F1 F2 F3 F4 Figure DIGITAL TABLE SCREEN To access the Digital Table screen: 1. Press the F1 soft key as necessary to display the Background screen. 2. On the Background screen press the F1 (Exit to Commands) soft key. 3. On the Commands screen, cursor down to TABLE EDIT and then press the F3 (Other Tables) soft key. 4. On the Edit Other Tables screen, cursor to DIGITAL TABLE and then press the F2 (Edit Table) soft key. 5. When the first Digital Table screen appears, cursor across and down the table to highlight a value you want to change. Then insert the new value. 6. When you have completed the changes to this Digital Table screen, review them to ensure all items are correct and then press the F1 (Exit) soft key. 7. On the second Digital Table screen, press the F2 (Exit and Update) soft key to save the changes or press the F1 (Escape) soft key to retain the original values. 8. Press the F1 soft key as necessary to return to the Background screen. VISTANET OPTION If the analyzer is connected to VistaNET, you must set up the analyzer to work on this network. Once the network connection is set up and running, it runs automatically. To set up the network connection perform the following steps: 2000-OSM, F1 4-72

154 NOTE Before making changes to VistaNET screens, verify all data with your Network Administrator to ensure proper connection and operation with VistaNET. 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor to TESTING/SETUP and then press the F4 (Status Display) soft key. 3. On the Controller Status screen, press the F2 (Clear Highway Stats) soft key. This will reset all data to zero so you will know when VistaNET data is sent and received. 4. On the Commands screen, cursor to VISTANET and then press the F2 (VistaNET Tables and Commands) soft key. 5. On the VN Menu screen (see Figure 4-63), cursor to STARTUP and then press the F2 (Essential Addresses) soft key. ************ VN Menu ********** TABLES STARTUP TESTING Essential Access Refresh Escape Addresses Level VNSA Tables F1 F2 F3 F4 Figure VN MENU SCREEN OSM, F1

155 6. On the VistaNET Essential Addresses screen (see Figure 4-64), enter the GCC's identification number on the Name line. ******* VistaNET Essential Addresses ******* Name: [GCC10 ] Tag: GCC10 Board Address: 0.10 Domain 1: 0.1 Domain 2: 0.2 VNSA Address: Router Address: Escape Exit and Update F1 F2 F3 F4 Figure VistaNET ESSENTIAL ADDRESSES SCREEN 7. Cursor down to the Tag line and enter the GCC's tag number. 8. Cursor to the Board Address line and enter the Communication Board's address. 9. Cursor to the Domain 1 line and enter your GCC's Domain 1 identification. 10. Cursor to the Domain 2 line and enter your GCC's Domain 2 identification. 11. Cursor to the VNSA Address line and enter the complete address of the VNSA serving your GCC. 12. Cursor to the Router Address line and enter the complete address of the Router serving your GCC. 13. When you have completed and verified your entries, press the F2 (Exit and Update) soft key to save your entries. 14. On the VN Menu screen, press the F4 (Refresh VNSA Tables) soft key and then press the Escape soft key to return to the Commands screen. 15. On the Commands screen, cursor to TESTING/SETUP and then press the F4 (Status Display) soft key. 16. On the Controller Status screen, note that "Blocks Sent" and "Blocks Received" both have numbers, indicating that your command to Refresh VNSA Tables was sent and acknowledged. You are now connected to VistaNET. 17. Press the F1 soft key as necessary to return to the Background screen OSM, F1 4-74

156 SOLENOID VALVES The PGC2000 uses two different types of solenoid valves in the Purge Air Panel, a vented type and a non-vented type (see Figure 4-65). Since these solenoids are not interchangeable, you must ensure that a replacement solenoid is the same type as the solenoid being replaced. Vented Solenoid Vents Non-vented Solenoid Figure SOLENOID VALVES The non-vented solenoid valve was introduced at sales order number HF (the sales order number is listed on the analyzer nameplate). PGC2000 analyzers shipped prior to this sales order number have the vented solenoid OSM, F1

157 PREVENTIVE MAINTENANCE SECTION 5. MAINTENANCE The analyzer design eliminates the need for extensive and complex maintenance. Where preventive maintenance procedures require specific time frames or intervals, you should maintain an inspection log and inspection data. Figure 5-1 lists inspection routines, with recommended time intervals for each routine. In addition, you should verify analyzer calibration periodically to ensure operating efficiency. To aid in preventive maintenance, keep system chromatograms for reference and compare them to current data to ensure early detection of a problem, whether in the analyzer or in the analysis itself. It is the customer s responsibility to ensure that all maintenance personnel assigned to work on analyzers are trained and experienced in instrumentation maintenance and hazardous area maintenance. INTERVAL ROUTINE Daily 1. Perform a visual inspection of the analyzer and check for: a. Damaged or inoperative gauges or meters b. Loose control knobs c. Loose hardware d. Low pressure or flow indicators e. Equipment grounding connections f. Unsecured or loose cables 2. Check physical condition of analyzer for corrosion, rust, etc. Take corrective action as necessary. 3. Using the Data Package supplied with the analyzer, verify all flow and pressure settings are as specified. Adjust as necessary. Monitor gas usage to help detect leaks in utility gas delivery systems. 4. Check to ensure cylinder gas pressures are above 100 psig. Replace cylinders as necessary. 5. Check sampling system as applicable (i.e., pressures and flows). Monthly Monthly (Weekly for first month to ensure stability as required) Check air supply filters. Check carrier line dryers; change as necessary to prevent pressure drop. Calibrate and compare resultant chromatograms with those in Data Package. Figure 5-1. RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE Gas Cylinder Replacement When you use two cylinders to supply a gas, connect the cylinders in an automatic switchover configuration to ensure continuous flow to the analyzer when you replace an exhausted cylinder. In this configuration, the second cylinder switches in automatically when the first cylinder is exhausted 2000-OSM, F1 5-1

158 (100 psig or less). When your check indicates an exhausted cylinder, replace the cylinder with another containing the specified gas. When you use a single cylinder to supply a gas, you should check this cylinder regularly and replace it when the pressure falls below 100 psig, using another cylinder containing the specified gas. Cleaning Clean the analyzer as often as environmental conditions require. Accumulation of dirt in certain analyzer subassemblies can cause overheating and component failure, because dirt on components acts as insulating material preventing efficient heat dissipation. CAUTION Prior to cleaning the analyzer, turn off the power to the unit. Avoid using chemical agents which might damage the component parts of the analyzer. Remove loose dirt accumulated on the outside of the analyzer with a soft cloth or a small paint brush. Remove any remaining dirt with a soft cloth dampened in a mild solution of water and detergent. Do not use abrasive cleaners on the analyzer. Remove dust in the inside of the analyzer, 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. DIAGNOSTIC TESTS The analyzer contains a number of built-in diagnostic tests and tools, identified as follows: ROM Checksum Chroma Board Digital Output Trend Output Hardware Setup ROM Checksum The ROM Checksum test checks all four ROMs for problems and posts the results on the screen. To run this test, perform the following steps: 1. On the Background screen press the F1 (Exit to Commands) soft key OSM, F1

159 2. On the Commands screen (see Figure 5-2), cursor down to TESTING/SETUP and then press the F2 (Diagnostic Tests) soft key. ***** COMMANDS ***** ANALYSIS CONTROL REPORTS TABLE EDIT PRINTER STORAGE & CONFIG. NAMES MISC. [TESTING/SETUP] CHROMATOGRAM STORAGE VISTANET Diagnostic Diagnostic Exit Tests Tools F1 F2 F3 F4 Figure 5-2. COMMANDS SCREEN 3. On the Diagnostic Tests screen (see Figure 5-3), cursor to DIAGNOSTIC TESTS and press the F2 (ROM Checksum Test) soft key. ***** Diagnostic Tests ***** [DIAGNOSTIC TESTS] DIAGNOSTIC TOOLS ROM Chroma Exit Checksum Board Test Test F1 F2 F3 F4 Figure 5-3. DIAGNOSTIC TESTS SCREEN (TESTS SELECTED) 2000-OSM, F1 5-3

160 4. When the test is complete, this message will appear on the screen: ROM Check PASSED. Any key to continue. Press any soft key to return to the Diagnostic Tests screen. If the ROM check fails, contact your service representative. 5. After you complete diagnostic testing, press F1 as necessary to return to the Background screen. If you are performing another diagnostic test, start that procedure from the Diagnostic Tests screen. Chroma Board The Chroma Board test requests the Chroma I/O Board to test itself and display the results. NOTE The following test can only be run when the analyzer is stopped. 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor down to TESTING/SETUP and then press the F2 (Diagnostic Tests) soft key. 3. On the Diagnostic Tests screen, verify that DIAGNOSTIC TESTS is highlighted and press the F3 (Chroma Board Test) soft key. 4. When the test is complete, this message will appear on the screen: Chroma Board Check PASSED. Any key to continue. Press any soft key to return to the Diagnostic Tests screen. If the Chroma Board check fails, contact your service representative. 5. After you complete diagnostic testing, press F1 as necessary to return to the Background screen. If you are performing another diagnostic test, start that procedure from the Diagnostic Tests screen. Digital Output The Digital Output test allows changing states of individual or all digitals by board and displays the status of inputs in real time. To run this test, perform the following steps: CAUTION You must stop the analysis before accessing the Digital Output test, to ensure the digital output settings are not accidentally changed. 1. Determine which digital outputs you want to test and prepare to verify the test results. 2. On the Background screen press the F1 (Exit to Commands) soft key. 3. On the Commands screen, cursor down to TESTING/SETUP and then press the F2 (Diagnostic Tests) soft key OSM, F1

161 4. On the Diagnostic Tests screen (see Figure 5-4), cursor to DIAGNOSTIC TOOLS and press the F2 (Digital Output Test) soft key. ***** Diagnostic Tests ***** DIAGNOSTIC TESTS [DIAGNOSTIC TOOLS] Digital Trend Exit Output Output Test Test F1 F2 F3 F4 Figure 5-4. DIAGNOSTIC TESTS SCREEN (TOOLS SELECTED) 5. On the Manual Control of Digital Outputs screen (see Figure 5-5), select which board you want to test. *** Manual Control of Digital Outputs ** Board: Chroma Dig1 Dig2 Pin Number: [ 0] Pin: Chroma Dig1 No board present Dig2 No board present Pin: Chroma Dig1 No board present Dig2 No board present Exit Deactivate All On Board F1 F2 F3 F4 Figure 5-5. MANUAL CONTROL OF DIGITAL OUTPUTS SCREEN 2000-OSM, F1 5-5

162 6. Cursor down to the line marked Pin Number and enter the desired Chroma I/O Board pin number. On the corresponding line below the pin number, the digital value will change from 0 to 1 or from 1 to When the digital value changes, check the output circuit to verify that it changed as directed. 8. Repeat steps 6 and 7 for each digital pin you want to check. If any circuit does not work properly, contact your service representative. 9. When you have completed checking digital channels, press the F1 (Exit) soft key to return to the Diagnostic Tests screen. The Chroma I/O and Digital Board settings will automatically reset to the values that were in effect when you accessed the Manual Control of Digital Outputs screen. 10. After you complete diagnostic testing, press F1 as necessary to return to the Background screen. If you are performing another diagnostic test, start that procedure from the Diagnostic Tests screen. Trend Output The Trend Output test allows changing values of individual trend (analog) outputs. To run this test, perform the following steps: 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen cursor to ANALYSIS CONTROL, if necessary, and then press the F4 (Start/Stop Analysis) soft key. 3. On the Start/Stop Analysis screen, verify that the highlighted area is on "End of Analysis?" and press the F2 (Stop Analyzer) soft key. The analyzer will stop at the end of the analysis. 4. Press the F1 soft key as necessary to return to the Background screen. 5. Select a trend (analog) output channel to test and connect a meter or recorder to that output. 6. On the Background screen press the F1 (Exit to Commands) soft key. 7. On the Commands screen, cursor down to TESTING/SETUP and then press the F2 (Diagnostic Tests) soft key. 8. On the Diagnostic Tests screen, cursor to DIAGNOSTIC TOOLS and press the F3 (Trend Output Test) soft key OSM, F1

163 9. On the Manual Control of Trend Outputs screen (see Figure 5-6), select the trend channel you want to check. 10. Cursor down and enter the desired trend value. This value is a percentage of the total trend range. Check your output to verify the trend value changed. If it did not change, try a different value. If no valid entries will cause a change at the trend output, contact your service representative. 11. When you have completed checking trend channels, press the F1 (Exit) soft key to return to the Diagnostic Tests screen. The Trend Board settings will automatically reset to the values that were in effect when you accessed the Manual Control of Trend Outputs screen. 12. Press the F1 soft key as necessary to return to the Background screen. *** Manual Control of Trend Outputs *** Trend Channel: [ 1 ] Value: Exit F1 F2 F3 F4 Figure 5-6. MANUAL CONTROL OF TREND OUTPUTS SCREEN Hardware Setup 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor down to TESTING/SETUP and press the F3 (Hardware Setup) soft key OSM, F1 5-7

164 3. On the Serial Configuration screen (see Figure 5-7), verify that the setup data is the same as that specified in the Data Package. *** Serial Configuration *** Printer Setup Baud Rate: Parity: None Even Odd Data Bits: 7 8 Stop Bits: 1 2 Exit Test Escape and Printer Update F1 F2 F3 F4 Figure 5-7. SERIAL CONFIGURATION SCREEN 4. If you want to make changes, use the cursor arrow keys to select the desired data line and enter your changes. 5. When you have completed your changes, verify the data on the screen. To test these changes press the F3 (Test Printer) soft key. If the results are not satisfactory, make additional changes and test again. 6. When the results are complete and verified, press the F2 (Exit and Update) soft key to save the changes, or press the F1 (Escape) soft key to retain the original values. 7. Press the F1 key as necessary to return to the Background screen. SOFTWARE VERIFICATION This section describes software checks that are not part of normal operation, but which may be used to troubleshoot the analyzer. The primary task is to verify the digital configuration by performing the following steps. Preliminary Steps 1. If you have not already done so, verify all reports as described in "Verify Reports" in Section After all reports have been verified, press the F1 soft key as necessary until the Background screen appears. 3. On the Background screen press the F1 (Exit To Commands) soft key OSM, F1

165 4. On the Commands screen, cursor to STORAGE & CONFIG and then press the F4 (Update Digital Config) soft key. 5. On the first Digital Configuration screen, enter RESETDIGIO as the password and then press the F2 (Accept Entered Password) soft key. 6. On the second Digital Configuration screen, cursor to the board whose configuration you want to verify and then follow the steps in the paragraph pertaining to that board. The final steps for saving configuration changes are described in "Final Steps." Chroma Board 1 Input Table 1. After you cursor to Chroma Board 1 on the second Digital Configuration screen, press the F2 (Edit The Input Table) soft key. 2. On the first Chroma Board 1 Digital Input screen, cursor to VistaII and press the F1 (Continue) soft key. 3. On the second Chroma Board 1 Digital Input screen (see Figure 5-8), verify each pin and function. ***** Chroma Board 1 Digital Input ***** Pin Function Number State J13A-5 Flameout N/A NC J23A-1 Carrier N/A NC J89-1 Purge N/A NC J23B-1 Unused N/A NC J23C-1 Unused N/A NC J23D-1 Low Std Samp N/A NC J23E-1 Low Samp N/A NC J23F-1 H2/N2 Press N/A NC Exit F1 F2 F3 F4 Figure 5-8. CHROMA BOARD DIGITAL INPUT SCREEN #2 4. If all entries are correct, press the F1 (Escape) soft key to return to the second Digital Configuration screen. If there are any errors on this screen, correct the errors and then press the F2 (Exit and Update) soft key to save the corrected data and return to the second Digital Configuration screen. Chroma Board 1 Output Table 1. After you cursor to Chroma Board 1 on the second Digital Configuration screen, press the F3 (Edit The Output Table) soft key OSM, F1 5-9

166 2. On the first Chroma Board 1 Digital Output screen, cursor to VistaII and press the F1 (Continue) soft key. 3. On the second Chroma Board 1 Digital Output screen (see Figure 5-9), verify each pin and function. ***** Chroma Board 1 Digital Output ***** Pin Function Number State J15A-1 Valve #1 NO J15A-2 Valve #2 NO J15A-3 Valve #3 NO J15A-4 Valve #4 NO J15A-5 Valve #5 NO J15A-6 Valve #6 NO J15A-7 Stream #1 NO J15A-8 Stream #2 NO More Below Exit F1 F2 F3 F4 Figure 5-9. CHROMA BOARD DIGITAL OUTPUT SCREEN #2 4. If all entries are correct, press the F1 (Escape) soft key to return to the second Digital Configuration screen. If there are any errors on this screen, correct the errors and then press the F2 (Exit and Update) soft key to save the corrected data and return to the second Digital Configuration screen. Digital Board 1 Input Table 1. After you cursor to Digital Board 1 on the second Digital Configuration screen, press the F2 (Edit The Input Table) soft key OSM, F1

167 2. On the Digital Board 1 Digital Input screen (see Figure 5-10), verify each pin and function. ***** Digital Board 1 Digital Input ***** Pin Function Number State TB6-1 VistaBasic #5 NO TB6-2 VistaBasic #6 NO TB6-3 VistaBasic #7 NO TB6-4 VistaBasic #8 NO TB6-5 VistaBasic #9 NO TB6-6 VistaBasic #10 NO TB6-7 VistaBasic #11 NO TB6-8 VistaBasic #12 NO More Below Exit F1 F2 F3 F4 Figure DIGITAL BOARD DIGITAL INPUT SCREEN 3. If all entries are correct, press the F1 (Escape) soft key to return to the second Digital Configuration screen. If there are any errors on this screen, correct the errors and then press the F2 (Exit and Update) soft key to save the corrected data and return to the second Digital Configuration screen. Digital Board 1 Output Table 1. After you cursor to Digital Board 1 on the second Digital Configuration screen, press the F2 (Edit The Output Table) soft key OSM, F1 5-11

168 2. On the Digital Board 1 Digital Output screen (see Figure 5-11), verify each pin and function. ***** Digital Board 1 Digital Output ***** Pin Function Number State TB5-18 Stream #11 NO TB5-19 Stream #12 NO TB5-20 Stream #13 NO TB5-21 Stream #14 NO TB5-22 Stream #15 NO TB5-23 Stream #16 NO TB5-24 Stream #17 NO TB5-25 Stream #18 NO More Below Exit F1 F2 F3 F4 Figure DIGITAL BOARD DIGITAL OUTPUT SCREEN 3. If all entries are correct, press the F1 (Escape) soft key to return to the second Digital Configuration screen. If there are any errors on this screen, correct the errors and then press the F2 (Exit and Update) soft key to save the corrected data and return to the second Digital Configuration screen. Digital Board 2 1. Cursor to Digital Board 2 on the second Digital Configuration screen. 2. To edit the input table, press the F2 (Edit The Input Table) soft key and follow the steps in "Digital Board 1 Input Table." 3. To edit the output table, press the F3 (Edit The Output Table) soft key and follow the steps in "Digital Board 1 Output Table." Chroma Board 2 1. Cursor to Chroma Board 2 on the second Digital Configuration screen. 2. To edit the input table, press the F2 (Edit The Input Table) soft key and follow the steps in "Chroma Board 1 Input Table." 3. To edit the output table, press the F3 (Edit The Output Table) soft key and follow the steps in "Chroma Board 1 Output Table." OSM, F1

169 Trend and Detector 1. Cursor to Other on the second Digital Configuration screen and press the F2 (Trend & Detector) soft key. 2. On the Trend And Detector Config screen (see Figure 5-12), verify each trend setting and detector configuration. ***** Trend And Detector Config ***** Trend Trend DETECTOR CONFIGURATION Chroma Board 1 Det # 1 None FID FPD T/C M1 M2 M3 2 None FID FPD T/C M1 M2 M3 More Below Escape Exit & Update F1 F2 F3 F4 Figure TREND AND DETECTOR CONFIGURATION SCREEN 3. If all entries are correct, press the F1 (Escape) soft key to return to the second Digital Configuration screen. If there are any errors on this screen, correct the errors and then press the F2 (Exit and Update) soft key to save the corrected data and return to the second Digital Configuration screen. BASIC COMMON! Size 1. Cursor to Other on the second Digital Configuration screen and press the F3 (BASIC COMMON! Size) soft key. 2. On the BASIC COMMON! Size screen, verify the COMMON! size. 3. If it is correct, press the F1 (Escape) soft key to return to the second Digital Configuration screen. If it is not correct, enter the correct size and then press the F2 (Exit and Update) soft key to save the corrected data and return to the second Digital Configuration screen. Final Steps After all configuration changes are complete, you must save the tables to E2PROM and reset the unit. 1. On the second Digital Configuration screen, press the F1 (Exit) soft key OSM, F1 5-13

170 2. On the screen with instructions on saving the tables, press any soft key. 3. On the Commands screen, cursor to STORAGE & CONFIG. and press the F2 (Save or Restore Tables) soft key. 4. On the Table Storage screen cursor to SAVE TABLES TO E2PROM and press the F2 (Save Tables) soft key. 5. When Are Your Sure? Y/N appears on the screen, press the Y key. 6. Press the F1 soft key as necessary to return to the Background screen. 7. On the Single Board Computer PCB, press and release the Reset switch. This resets the analyzer to use the data you just saved OSM, F1

171 TROUBLESHOOTING GUIDELINES SECTION 6. TROUBLESHOOTING This section provides troubleshooting information by category. Included in this information are symptoms, causes, and suggested tests for further fault isolation. These tests are described in Section 7, listed by Test Procedure (TP) number. BASELINE PROBLEMS Baseline or Signal Offset (TCD) Symptom: Baseline (detector signal) is continually offset to the positive or the negative with no short term drift up or down scale (see Figure 6-1). This is indicated on the graphic display, output recorder, and the detector signal. BASELINE TIME NORMAL BASELINE AMOUNT OF OFFSET TIME OFFSET Figure 6-1. EXAMPLE OF BASELINE OFFSET Background: A thermal conductivity detector (TCD) contains a measurement and reference filament detector configured in an electronic bridge circuit. With no sample eluting the column, both measurement and reference filaments are responding to carrier gas only. Therefore, the resistance of both the measurement and reference filaments should be within one ohm of one another (cold) and the detector in balance. Causes: 1. Temperatures incorrect. Perform Test Procedure 30 (Checking Temperature Table Values), steps 1 to 3, and 8 to 12 to verify or change temperature settings. 2. No carrier gases applied to analyzer. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies). 3. Large difference in reference and column carrier flow rate (example: reference 1 cc/min, column 20 cc/min). Perform Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments). 4. Column broken or connection in column train disconnected, restricted or leaking. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies) and Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments). If there is no carrier gas flow or the carrier gas flow is restricted, perform Test Procedure 7 (Column Train Problems). 5. Defective carrier regulator. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies), Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments), and Test Procedure 4 (Carrier or Makeup Gas Regulator), as applicable. 6. Column flooded with liquid sample. Perform Test Procedure 3 (Sample Valve Leaking/Column Flooding). 7. Detector balance adjustment needed. Perform Test Procedure 5 (TC Detector Balance) OSM, F1 6-1

172 8. A continuous presence of sample at the detector due to sample valve leakage. Perform Test Procedure 3 (Sample Valve Leaking/Column Flooding). 9. Filament failure. Perform Test Procedure 6 (Filament TCD Test). Cyclic Short Term Drift Symptom: Baseline (detector signal) is experiencing a cyclic short term drift (see Figure 6-2) indicated by detector signal, graphics display, or strip chart recorder (if used). If cyclic behavior is only present on strip chart recorder, verify recorder is functioning properly and that the recorder connecting wires are properly shielded. Ensure shield is connected to ground at only one end. BASELINE BASELINE TIME NORMAL TIME CYCLIC DRIFT Figure 6-2. CYCLIC SHORT TERM DRIFT At the extreme, the signal may indicate a cyclic behavior with the period of each cycle ranging from a few seconds to several minutes. Causes: 1. Short term drift, especially cyclic operation, could be due to temperature out of control at the TC detector or isothermal oven, dirty carrier, or defective flow controller. Perform Test Procedure 30 (Checking Temperature Table Values), steps 1 to 3, 8 and 9; Test Procedure 8 (Baseline Cyclic Temperature Controller (TCD)); Test Procedure 9 (Baseline Cyclic Carrier Regulator); or Test Procedure 10 (Baseline Cyclic Flow Controller), as applicable. 2. Another possible cause is cell vent back pressure changing. Disconnect vents to check. Perform Test Procedure 34 (Vent Back Pressure). Continuous Upward or Downward Drift Symptom: Baseline (detector signal) is slowly drifting upward or downward (see Figure 6-3) as indicated by the detector signal, graphics display, or strip chart recorder (if used). BASELINE BASELINE TIME TIME NORMAL UPWARD DRIFT Figure 6-3. CONTINUOUS UPWARD DRIFT Cause: This drift characteristic is generally related to detector response. Most common causes are temperature zone temperature drift, column flooding or contamination by a sample containing heavy hydrocarbons, leaking sample valve. Temperature zone drift normally occurs during temperature zone warm up. Column bleed is less pronounced in capillary columns than packed columns OSM, F1

173 Perform Test Procedure 3 (Sample Valve Leaking/Column Flooding); or Test Procedure 30 (Checking Temperature Table Values), steps 1 to 3, 8, and 9. Another possible cause could be detector filament deterioration. Baseline Continuous Noise Symptom: Baseline (detector signal) with no sample injection appears as noise similar in appearance to grass on a two dimensional drawing on the graphics display or strip chart recorder (if used), as shown in Figure 6-4. If it is present only on the strip chart recorder, verify the recorder is functioning properly and that the recorder connecting wires are properly shielded. Ensure recorder wire shield is connected to ground at only one end. NORMAL NOISE Figure 6-4. BASELINE NOISE Cause: Baseline or detector noise can result from contaminated carrier, makeup gas, tubing or regulators. This type of contamination is much less pronounced with a TCD than for an FID. Other causes include defective filaments (TCD), detector wiring, or electrical noise in the detector electronics or power supplies. Perform Test Procedure 11 (Common Usage of Gases); Test Procedure 12 (Utility Gas Contamination Procedure); Test Procedure 13 (Burner Air Catalytic Cleanup Unit), and Test Procedure 14 (Coaxial Cable), as applicable. Baseline or Signal Offset (FID) Symptom: Baseline (detector signal) is continually offset to the positive or the negative with no short term drift up or down scale (see Figure 6-5). This is indicated on the output recorder. BASELINE TIME NORMAL BASELINE AMOUNT OF OFFSET TIME OFFSET Figure 6-5. BASELINE OFFSET Cause: Baseline offset problems in an FID can be caused by the following: 1. Incorrect temperatures. Perform Test Procedure 30 (Checking Temperature Table Values), steps 1 to 3, 8, and 9. Inspect temperature settings and adjust if necessary. 2. Column flooded with liquid sample. Perform Test Procedure 3 (Sample Valve Leaking/Column Flooding). 3. Contamination can enter through the burner air, burner fuel, or carrier. Secondary sources are contaminated air, fuel, carrier lines, or regulators. a. Hydrocarbon contaminates in carrier gas, hydrogen fuel or air can cause the FID to produce an output signal as they are burned OSM, F1 6-3

174 b. The gases may be pure, but contaminated tubing or hardware components in the analyzer or cylinder regulator(s) contaminate the makeup gases as they pass through them. The FID detects theses contaminants, resulting in a noisy baseline. c. An FID is generally equipped with a catalytic air cleanup unit to remove hydrocarbon impurities from the burner air. If the air cleanup unit fails, the impurities in the burner air can appear as detector noise. 4. A continuous presence of sample at the detector due to sample valve leakage. Perform Test Procedure 3 (Sample Valve Leaking/Column Flooding). 5. Electronics circuit failure. Replace FID Amplifier Assembly. Baseline Signal Random Noise (FID) Symptom: Baseline characterized by random noise and/or spikes (see Figure 6-6). NORMAL NOISE Figure 6-6. BASELINE RANDOM NOISE Cause: FID noise is generally the result of electrical noise or contamination. 1. Electrical noise is usually isolated to a defective FID amplifier, defective coaxial cable or faulty electrical connections. a. Electrical noise from the FID amplifier could result from a noisy power supply or defective component of the PCB. b. Loose electrical connections can cause electrical signals to be sporadic. c. Since the FID amplifier input impedances are extremely high, low noise coaxial cable connects the detector and the FID amplifier. Defective coaxial cables or poor electrical connections are often sources of noise. 2. Contamination can enter through the burner air, burner fuel, or carrier. Secondary sources are contaminated air, fuel, carrier lines, or regulators. a. Hydrocarbon contaminates in carrier gas, hydrogen fuel or air can cause the FID to produce an output signal as they are burned. b. The gases may be pure, but contaminated tubing or hardware components in the analyzer or cylinder regulator(s) contaminate the makeup gases as they pass through them. The FID detects theses contaminants, resulting in a noisy baseline. c. An FID is generally equipped with a catalytic air cleanup unit to remove hydrocarbon impurities from the burner air. If the air cleanup unit fails, the impurities in the burner air can appear as detector noise. d. If water accumulates in the FID vent, the detector effluent flow can bubble through the accumulated water. This in effect back-pressures the FID, causing the flame intensity to fluctuate. This can appear as a noisy baseline as well OSM, F1

175 Perform Test Procedure 11 (Common Usage of Gases), Test Procedure 13 (Burner Air Catalytic Cleanup Unit), or Test Procedure 14 (Coaxial Cable), as applicable. Replace or clean the FID (see "FID REPAIR" in Section 8). Signal Offset (FPD) NOTE Because of the sulfur addition in the FPD detector, the FPD will always have a background level. The auto zero circuitry compensates for this. The background will usually use 15% to 80% of the available auto zero range. If the background uses less than 10% of the auto zero range, the flame detection electronics will assume the flame is out and the Flame Out LED will illuminate. Eluting peaks add to this background. Symptom: Detector signal is continually offset by a significantly different amount than when the detector was operating properly. Cause: Baseline offset problems in an FPD can be caused by the following: 1. Incorrect temperatures. Perform Test Procedure 30 (Checking Temperature Table Values), steps 1 to 3, 8, and 9. Inspect temperature settings and adjust if necessary. 2. Column flooded with liquid sample. Perform Test Procedure 3 (Sample Valve Leaking/Column Flooding). 3. A continuous presence of sample at the detector due to sample valve leakage. Perform Test Procedure 3 (Sample Valve Leaking/Column Flooding). 4. Electronics circuit failure. Replace FPD Amplifier Assembly. 5. Empty or leaking permeation device. Signal Random Baseline Noise (FPD) NOTE Because of the sulfur addition in the FPD detector, the FPD will always have a background level. The auto zero circuitry compensates for this. The background will usually use 15% to 80% of the available auto zero range. If the background uses less than 10% of the auto zero range, the flame detection electronics will assume the flame is out and the Flame Out LED will illuminate. Eluting peaks add to this background. Symptom: Baseline characterized by random noise and/or spikes (see Figure 6-7). NORMAL NOISE Figure 6-7. BASELINE RANDOM NOISE Cause: FPD noise is generally the result of electrical noise or contamination. 1. Electrical noise is usually isolated to a defective FPD amplifier, defective coaxial cable or faulty electrical connections OSM, F1 6-5

176 a. Electrical noise from the FPD amplifier could result from a noisy power supply or defective component of the PCB. b. Loose electrical connections can cause electrical signals to be sporadic. c. Since the FPD amplifier input impedances are extremely high, low noise coaxial cable connects the detector and the FID amplifier. Defective coaxial cables or poor electrical connections are often sources of noise. 2. Contamination can enter through the burner air, burner fuel, or carrier. Secondary sources are contaminated air, fuel, carrier lines, or regulators. a. Sulfur-bearing contaminates in carrier gas, hydrogen fuel or air can cause the FPD to produce an output signal as they are burned. b. The gases may be pure, but contaminated tubing or hardware components in the analyzer or cylinder regulator(s) contaminate the makeup gases as they pass through them. The FPD detects theses contaminants, resulting in a noisy baseline. c. If water accumulates in the FPD vent, the detector effluent flow can bubble through the accumulated water. This in effect back-pressures the FPD, causing the flame intensity to fluctuate. This can appear as a noisy baseline as well. Perform Test Procedure 11 (Common Usage of Gases) or Test Procedure 14 (Coaxial Cable), as applicable. Replace or clean the FPD (see "FPD REPAIR" in Section 8). ANALYSIS PROBLEMS No Peaks Symptom: No peaks are indicated on strip chart recorder, graphic display, or detector signal (see Figure 6-8). Missing Peaks BASELINE BASELINE TIME NORMAL TIME OFFSET Figure 6-8. NO PEAKS Cause: This generally indicates that either no sample was injected, or the injected sample is not being detected or processed. No peak detection could be caused by any one of the following: 1. Chroma not selected on manual control screen (affects recorder output only). 2. No sample flowing to the sample valve. Verify sample is flowing to the sample valve. 3. No carrier gas supplied to the analyzer. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies) and Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments). 4. No air to the sample valve actuator. Perform Test Procedure 18 (Sample Valve Actuation Air) OSM, F1

177 5. Baseline offset extreme. See "Baseline or Signal Offset (TCD)" or "Baseline or Signal Offset (FID)." 6. Column broken or connection in the column train disconnected. Perform Test Procedure 7 (Column Train Problems). 7. TCD Failure. Perform Test Procedure 5 (TC Detector Balance) and Test Procedure 6 (Filament TCD Test), as applicable. 8. FID Failure. Perform Test Procedure 17 (Verification FID Flame Is Ignited) and Test Procedure 15 (FID Reduced Sensitivity), as applicable. 9. FPD Failure. Perform Test Procedure 43 (FPD Gain Setting). 10. Low Zone Temperatures. See "TEMPERATURE CONTROL HARDWARE PROBLEMS" and Test Procedures 21 through Active stream is stream 9 (no inject occurs on stream 9). Change to correct active stream. 12. Check Method Table for correct entries. Perform Test Procedure 33 (Checking Method Table Configuration). 13. Sample Valve Failure. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies) and Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments), as applicable. Also see "Baseline or Signal Offset (TCD)" and "Baseline or Signal Offset (FID)." Repair sample valve (see "SAMPLE VALVE REPAIR" in Section 8). Check for correct stem volume and length. 14. Actuation solenoid valve vent is plugged or obstructed. Check and remove any obstruction. 15. Solenoid not moving. Replace solenoid valve, driver card, or Chroma I/O board. Double Sampling Symptom: The chromatogram peaks appear to have double apexes (see Figure 6-9). The trailing peak apex is generally smaller than the leading due to the first having the greater sample size. TIME TIME NORMAL DOUBLE SAMPLING Figure 6-9. DOUBLE SAMPLING Cause: Double sampling problems are isolated to the sample valve. Generally the first injection occurs when the valve is turned on (valve stem inserted into the injection chamber). The second injection is made when the valve is turned off (the valve stem is withdrawn from the injection chamber). Perform Test Procedure 19 (Double Sampling) OSM, F1 6-7

178 Additional Peaks of Unknown Origin (Mystery Peaks) Symptom: Chromatograph displays extra peaks or a noted difference in composite chromatograph appearance from that of the calibration (see Figure 6-10). Unknown TIME NORMAL TIME MYSTERY PEAKS Figure MYSTERY PEAKS Cause: If only present on calibration sample and not on process, verify that the correct calibration and proto fuel samples are being analyzed. Possibly a new calibration blend has been installed that contains a blending error. Perhaps the wrong calibration sample has been selected or incorrect analysis is attached to it. If mystery peaks are present on all process or calibration samples, the analyzer is experiencing a sampling problem. The sample valve seals may be leaking. The sample valve may be double sampling (see "Double Sampling"). The sample stem may be scratched or deformed. Peaks may also be originating from a previous analysis cycle. Check to ensure correct process stream is aligned with sample system. Perform Test Procedure 19 (Double Sampling), and Test Procedure 36 (Residual Sample), as applicable. Variable Sample Size Variable sample size can cause a nonrepeatability of peak concentrations if the peak area is varying (see Figure 6-11). TIME TIME ANALYSIS #1 ANALYSIS #2 Figure VARIABLE SAMPLE SIZE Symptom: Chromatogram area or height appears to change with each consecutive injection. Failure: The liquid sample volume is not consistent between consecutive injections. This can be related to sample flow, defective sample valve hardware, leaks in column train, or sample bubbling. Cause: Leaking sample valve seal can result in random bubbling of carrier into the sample chamber causing the sample size to vary. If the sample chamber pressure is such that the temperature is OSM, F1

179 above the bubble point of the sample, the sample will bubble in the sample chamber, causing an inconsistent liquid fill of the sample loop. This results in a continuously variable sample size. A defective sample valve stem or leaking seal(s) can also cause nonrepeatability. Perform Test Procedure 20 (Variable Sample Size). If necessary, replace the sample valve seals and stem (see "SAMPLE VALVE REPAIR" in Section 8). Variable Retention Times Variable retention times can result in nonrepeatability (see Figure 6-12). t 0 TIME t 0 t t 30 t 0 27 TIME TIME t 34 Figure VARIABLE RETENTION TIME Symptom: Retention times of calibration and individually gated process components change with each consecutive cycle. Parameters that affect retention times include the following: 1. Varying Carrier flow rate. Perform Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments). 2. Varying Isothermal Oven Temperature. Perform Test Procedure 30 (Checking Temperature Table Values). 3. Defective flow controller. Perform Test Procedure 10 (Baseline Cyclic Flow Controller) and Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments), as applicable. 4. Leak(s) in column train. Perform Test Procedure 7 (Column Train Problems). 5. Variable back pressure on FID vent or TCD measurement vent. Perform Test Procedure 34 (Vent Back Pressure). 6. Sample valve malfunction. Perform Test Procedure 11 (Common Usage of Gases) and Test Procedure 18 (Sample Valve Actuation Air), as applicable. See "SAMPLE VALVE REPAIR" in Section Contaminated Carrier or Makeup Gas. Perform Test Procedure 11 (Common Usage of Gases), Test Procedure 12 (Utility Gas Contamination Procedure), and Test Procedure 13 (Burner Air Catalytic Cleanup Unit), as applicable. Individual Peak Missing on Report Symptom: Chromatogram indicates all peaks are present; however, the data report shows the peak to be nonexistent or unknown OSM, F1 6-9

180 Cause: The gating in the method needs to be modified to ensure gating of the missing peak in the report. This can be done by modifying the gate ON/OFF time in the method table. See "PEAK DETECTION" in Section 4 for detailed instructions. Peak Inversion Symptom: The peaks on the strip chart recorder are reversed or negative (see Figure 6-13). Baseline offset adjusted up scale NORMAL OFFSET Figure PEAK INVERSION Cause: Negative peaks on the strip chart recorder could be due to reversed recorder wiring at the analyzer or at the recorder. Some recorders are equipped with polarity reversal. Ensure correct polarity setting on recorder. Other possible causes include reversal of sense and reference tubing connections or filament wiring if a TCD is used, or a grounded jet or missing jet voltage if a FID is used. 1. Check for reversed sense and reference filament wires. 2. Check for reversed sense and reference tubing connections to the detector. 3. Make necessary corrections. 4. Perform Test Procedure 28 (FID Polarizing Voltage Test). Chromatogram Oversized or Off Scale Symptom: The chromatogram or peak areas are excessively large. The condition may be severe enough that all peaks are off scale on the highest attenuation (see Figure 6-14). Chromatogram may go off scale at approximately the time of distillation on and not return to scale until time of distillation off. NORMAL PEAK OFFSCALE Figure CHROMATOGRAM OFF SCALE Cause: The attenuation could be set too low, making the chromatogram or peaks appear large (loss of polarizing voltage on FID). Another possible cause is the wrong carrier gas is being used (e.g. nitrogen used instead of helium) OSM, F1

181 The peaks may in fact be too large and saturating the detector or column. The splitter may be out of adjustment, or the liquid sample size may be too large. Possibly the detector gain jumper at the detector electronics is not setup correctly. The sample valve may be injecting an excessively large sample volume due to deformation or a scratch in sample stem or worn seals. WARNING Sample will spill or leak out during this procedure. Consult MSDS sheets on file at your location for safety requirements. 1. Perform Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments). 2. Perform Test Procedure 30 (Checking Temperature Table Values), steps 1 and 2, to check or modify attenuation value. 3. Check detector gain jumper and modify if necessary. 4. Repair sample valve (see "SAMPLE VALVE REPAIR" in Section 8). Check sample loop size. Reduced Detector Sensitivity Symptom: The chromatogram or peaks have reduced in size from that of a previous analysis. This is also characterized as a reduction in detector sensitivity. Cause: The attenuation could be set too high, making the chromatogram or peaks appear small. Another possible cause is the wrong carrier gas is being used (e.g. helium used instead of nitrogen). The peaks may be too small as a result of excessive sample splitting due to the splitter being out of adjustment, or a small liquid sample volume injection. The sample groove in the sample valve stem may be plugged or restricted. A programming error in sample valve on/off timing may not allow adequate time for a proper sample injection. Sample valve actuation malfunction can cause inadequate sample injection. Possibly the detector gain jumper configuration at the detector amplifier is not set up correctly. The sample valve may have a defective or wrong stem installed. Low polarizing voltage, defective Detector Amplifier, or dirty FID can also reduce sensitivity. 1. Perform Test Procedure 30 (Checking Temperature Table Values), steps 1 and 2, to check or modify the attenuation setting. 2. Perform Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments) to check carrier and splitter flow rates. 3. Perform Test Procedure 33 (Checking Method Table Configuration) to check sample on/off time. 4. Perform Test Procedure 28 (FID Polarizing Voltage Test) to check polarizing voltage. 5. Perform Test Procedure 15 (FID Reduced Sensitivity). 6. Check detector gain jumper and modify if necessary. 7. Repair sample valve (see "SAMPLE VALVE REPAIR" in Section 8). 8. Inspect sample valve stem to check for scratches, deformation and plugging. Check loop size and stem length OSM, F1 6-11

182 Peak Discrimination Symptom: Discrimination is the non linear unequal dilution of hydrocarbons in the column train. Typically the heavier components will tend to dilute more than the lighter components. Cause: Discrimination is usually the result of a leak or incorrectly adjusted sample splitter. The leak or split might cause more of the heavier components to be exhausted out the splitter vent or leak exit than the lighter components; thus, disproportionate dilution. Perform Test Procedure 32 (Peak Discrimination) to test for discrimination. TEMPERATURE CONTROL HARDWARE PROBLEMS The following alarm indicators help isolate hardware failures in the temperature controller. Temperature Probe Open Symptom: No heat to a specific temperature zone. Actual temperature as indicated in Manual Temperature Control Mode indicates greater than 500 deg C for a specific zone. Other zones actual temperature indicate low or ambient. At the temperature board in electronics enclosure, all LED s are off as the temperature control board shuts down. Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) Zone (#) (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Zone Specific *Analysis Shutdown *** TEMP ZONE (#) Alarm *** *Overtemp *Reasonableness Test *Probe Open/Shorted or TC Faulty *High Temp Failure: The failure is most likely isolated to the zone indicating a temperature greater than 500 deg C. The temperature sensor(s) is a 400 ohm platinum thermocouple probe. As the temperature of the probe increases, its resistance value increases. As the temperature of the probe decreases, the resistance decreases. The maximum temperature range measurable by the temperature controller is 500 degrees. An indication greater than 500 degrees corresponds to a high resistance value at the sensor input. The greatest resistance possible is an open circuit to the sensor input or open probe or connection. The least resistance would be a shorted probe or connection to the sensor input. Cause: The sensor to the zone input has possibly opened, or is no longer connected to the sensor input. Perform Test Procedure 21 (Open Temperature Sensor). Temperature Probe Shorted Symptom: No heat to a specific temperature zone. Actual temperature as indicated in Manual Temperature Control Mode indicates less than -200 deg C for a specific zone. Other zones actual temperature indicate low or ambient. At the temperature board in electronics enclosure, all LED s are off as the temperature board shuts down OSM, F1

183 Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) Zone (3) (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Zone Specific *Analysis Shutdown *** TEMP ZONE (#) Alarm *** *Reasonableness Test *Probe Open/Shorted or TC Faulty *Low Temp Failure: The failure is most likely isolated to the zone indicating a temperature less than -200 deg C. The temperature sensor(s) is a 400 ohm platinum thermocouple probe. As the temperature of the probe increases, its resistance value increases. As the temperature of the probe decreases, the resistance value decreases. The maximum scaled temperature range measurable by the temperature controller is -200 degrees. This corresponds to an extremely low resistance at the sensor input. The least resistance possible is a short circuit to the sensor input or shorted probe or connection. Cause: The sensor to the zone input has possibly shorted. Perform Test Procedure 22 (Shorted Temperature Sensor). Isothermal Oven Heater Thermocouple Faulty Symptom: At the temperature board in electronics enclosure, all LED s are off as the temperature control board shuts down. Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) *Temp Bd Alarm* (flashing) Temperature Board: Heater Barrel TC Faulty *Analysis Shutdown Failure: The isothermal oven heater temperature is greater than 500 degrees C. Cause: The sensor input from the isothermal oven heater temperature monitor has opened, or is no longer connected. Perform Test Procedure 24 (Isothermal Oven Overtemp Sensor Open). Temperature Control Micro #2 Symptom: Micro chip #2 monitors for over temperature conditions at the various temperature zones. No heat being applied to a specific temperature zone. Actual temperature as indicated in Manual Temperature Control Mode indicates greater than 500 deg C for a specific zone. At the temperature board in electronics enclosure, all LED s are off as the temperature control board shuts down OSM, F1 6-13

184 Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) Zone (#) (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Zone Specific *Analysis Shutdown *** TEMP ZONE (#) Alarm *** *Overtemp *Reasonableness Test *Probe Open/Shorted or TC Faulty Failure: The failure is most likely isolated to the zone indicating a temperature greater than 500 degrees. Cause: The sensor to the zone input for temperature monitoring has possibly opened, or is no longer connected. Perform Test Procedure 25 (Zone Input Sensor Open). Loss of Air Symptom: The isothermal oven (zone # 1) and programmed temperature oven (zone #2) are not being heated. The actual temperature reduces and eventually approaches ambient. These are the only temperature controllers that use air baths. Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Loss of Air Failure: Malfunction is related to application of oven air to air bath ovens. The air bath heater(s) will overheat and burn out if air is not applied to the heaters while power is applied. The air provides the heat to ovens by displacing heat from the heaters. The presence or lack of oven air is sensed by a pressure switch. If air is removed, the switch opens and power is removed from the air bath heaters. When air is applied the switch closes allowing the temperature controller to apply heat to the air bath heaters. Cause: The oven air has been shut off or reduced below air pressure switch setting. The oven loss of air pressure switch has failed or connection problem exists. Perform Test Procedure 23 (Loss of Oven Air). Triac Failure Symptom: The Actual temperature is indicating below set point for zone and alarm is indicating triac failure. Any one of the following alarm messages or conditions could be present: On Background Screen ***ALARM:*** (flashing) OSM, F1

185 On Manual Temperature Control Mode Screen On Alarm Screen Zone (#) (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Zone Specific *** TEMP ZONE (#) Alarm *** *Triac Failure Cause: The output of the triac is connected to the zone heater(s). An optical isolator connected parallel to the output senses the firing of the triac(s) as heat is applied to the heater(s). This output is monitored by the Temperature Control board. If the triac does not conduct when the gate signal is applied, the triac is diagnosed as failed. Problem could be associated with triac monitoring optical isolators on output board, or an open heater element. CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. Perform Test Procedure 26 (Open or Shorted Heater) to check for shorted heater. Replace Heater Output Board. T-Rating Disagreement Symptom: The temperature board has shut down and all the LEDs are off. The zone temperatures are reducing and will approach ambient. The T-Rating display is alternating between the two jumper settings. Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *T-Rating Disagreement *Analysis Shutdown possible Zone specific *Reasonableness Test If the T-Rating is in question, refer to final documentation provided with the chromatograph or contact the ABB Service Department. Remedy: The T-rating jumpers for Micro #1 and Micro #2 must be set up identically. Determine the correct setting and configure the jumpers for both identically OSM, F1 6-15

186 Exclusion Jumper Disagreement Symptom: The temperature board has shut down and all the LED s are off. The zone temperatures are reducing and will approach ambient. Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *T-Rating Disagreement *Analysis Shutdown possible Zone specific *Reasonableness Test Failure: Zones not used for temperature control are excluded to prevent operation. They are also set INACTive in the software. Cause: The exclusion jumper is not set up correctly. Remedy: Select correct exclusion jumper configuration. If in doubt contact ABB Service Department. Oven Temperature is Greater Than T-Rating Symptom: The temperature board has been shut down. If the trouble is in Micro #1 then all LED s are Off on the Temperature Control board and the zone temperature is greater than the T-Rating. If trouble is in Micro #2, then the top LED is ON and the actual temperature is greater than the T- Rating. Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen Alarm Screen ***ALARM:*** (flashing) Zone (#) (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Zone Specific *** TEMP ZONE (#) Alarm *** *Overtemp *High Temp Cause: The T-rating defines the maximum surface temperature allowed to prevent the ignition of the flammable liquids and gases. The over-temperature limit prevents the temperatures from reaching the T-rating limit. The over-temp must be less than the T-rating limit to prevent the temperature from reaching the T-rating ignition temperature. Remedy: Reconfigure T-Rating or upper limit to correct setting. To modify the temperature configuration table, refer to "DIGITAL TEMPERATURE CONTROLLER" in Section 4. Perform Test Procedure 30 (Checking Temperature Table Values). Reasonableness Symptom: Alarm Condition OSM, F1

187 Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) Zone (#) (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Zone Specific *** TEMP ZONE (#) Alarm *** *Reasonableness Test Cause: Micros #1 and #2 disagree by more than 30 deg C. Micro #1 monitors and controls the temperature control board. Micro #2 monitors for over-temperature conditions. The measurement of the two sensors must agree in order to ensure proper over-temp protection. Perform Test Procedure 30 (Checking Temperature Table Values), Test Procedure 21 (Open Temperature Sensor), Test Procedure 22 (Shorted Temperature Sensor), Test Procedure 25 (Zone Input Sensor Open), and Test Procedure 26 (Open or Shorted Heater), as applicable. AC Zero Crossing Loss Symptom: Alarm Condition. Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *No Zero Crossing The heater output board monitors the AC input with a comparator circuit. This determines the zero crossover point, which occurs when the magnitude of the AC signal is zero. This point occurs in both the positive and negative directions. The crossover point is used to coordinate application of power from the triac to the heating element. Power is applied as the zero crossover point occurs preventing unnecessary loading and surging on the temperature output circuitry. CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. Remedy: Replace Heater Output Control board. Over Temp Trial Test Fail Symptom: Alarm Condition OSM, F1 6-17

188 Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Overtemp Test Fail* possible zone specific Triac failures Cause: Temperature control did not detect over-temperature condition when tested. CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. Remedy: The over-temp micro has possibly failed, may require replacement of temperature control board or output board. Controller Housing Internal Temperature Greater Than 80 Degrees C Symptom: The temperature board has shut down and all LED s on temperature controller board are off. Actual temperatures are reducing, approaching ambient. Alarm condition present. Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Ambient Limit Exceeded Cause: The controller housing temperature is monitored to ensure that the temperature does not exceed 80 C. This is done to protect the associated heater electronics from high temperature operation. Excessive temperatures could cause electronics failure and runaway zone temperature control. CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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 OSM, F1

189 CAUTION See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. Install a temperature monitor and verify ambient temperature. Ensure air flow into the Controller housing. Set Point Unacceptable Symptom: Alarm Condition. Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) Zone (#) (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Zone Specific *** TEMP ZONE (#) Alarm *** *Set Point Failed To modify the temperature configuration table, refer to the "DIGITAL TEMPERATURE CONTROLLER" in Section 4. Reconfiguration Failure Symptom: Alarm Condition. Any one of the following alarm messages or conditions could be present: On Background Screen On Manual Temperature Control Mode Screen On Alarm Screen ***ALARM:*** (flashing) Zone (#) (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Zone Specific *** TEMP ZONE (#) Alarm *** *Reconfiguration Failed Remedy: Perform the temperature board reconfiguration procedure. Be certain to hold down the switch and respond by pressing Y. To modify the temperature configuration table, refer to the "DIGITAL TEMPERATURE CONTROLLER" in Section 4. Out of Control CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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 OSM, F1 6-19

190 CAUTION See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. The temperature controllers must be stable with respect to tracking the set point. Symptom: The actual temperature is not stabilizing at the set point temperature. This alarm occurs when the zone temperature has remained outside the operational band of the set point for more than 90 seconds. Any one of the following alarm messages or conditions could be present: On Background Screen ***ALARM:*** (flashing) On Manual Temperature Control Mode Screen On Alarm Screen Zone (#) (flashing) *Temp Bd Alarm* (flashing) Temperature Board: *Zone Specific *** TEMP ZONE (#) Alarm *** *Out of Control 1. Check to ensure proper sufficient heater air flow 2. Perform Test Procedure 21 (Open Temperature Sensor), steps 1-3, to check probe for stability. If not stable replace probe. 3. Replace applicable zone board. Check for stability. 4. Replace AC Conditioning board. Check for stability. Open or Shorted Heater Symptom: No heat to a specific temperature zone. Actual temperature is ambient, while set point is at normal setting. The analyzer may indicate out of control or low temperature alarm. Failure: The temperature controller and sensor input and heater output control board are functioning normally. An open heater will not supply heat to the temperature zone. Cause: The heater to the temperature zone is possibly open. Perform Test Procedure 26 (Open or Shorted Heater). Blown Fuse, AC Conditioning Board Symptom: No heat to any temperature zone. Failure: All temperature zone outputs share a common fuse. Cause: Open fuse causes power to be removed from zone heaters. The analyzer may indicate an out of control or low temperature alarm. Perform Test Procedure 27 (Open Fuse to AC Conditioning Board) OSM, F1

191 Low Oven Temperature CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. Symptom: Oven temperature is below the specified set point value. Cause: Low oven temperature can be caused by the following: 1. Low air pressure to analyzer ovens. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies) and make necessary adjustment at analyzer air regulator(s). 2. Loss of air pressure switch; wiring or connection is defective. Perform Test Procedure 23 (Loss of Oven Air). 3. Defective temperature probe. Perform Test Procedure 21 (Open Temperature Sensor), Test Procedure 22 (Shorted Temperature Sensor), Test Procedure 24 (Isothermal Oven Overtemp Sensor Open), Test Procedure 25 (Zone Input Sensor Open), Test Procedure 26 (Open or Shorted Heater), and Test Procedure 27 (Open Fuse to AC Conditioning Board), as applicable. 4. Heater orifice restricted by foreign matter. Check the heater orifice to ensure it is not restricted or plugged. High Oven Temperature Symptom: Oven temperature is above the specified set point value. Cause: High oven temperature can be caused by a runaway heater or defective temperature probe. Perform Test Procedure 22 (Shorted Temperature Sensor), Test Procedure 24 (Isothermal Oven Overtemp Sensor Open), Test Procedure 25 (Zone Input Sensor Open), Test Procedure 26 (Open or Shorted Heater), and Test Procedure 27 (Open Fuse to AC Conditioning Board), as applicable. Programmed Oven Temperature Not Cooling or Slow to Cool Symptom: Programmed temperature oven ramps to final set point, but will not cool to initial set point or is slow to cool to initial set point. Cause: Cool down is initiated by the selection of temperature control table entry #2 in the method tables. If this instruction is missing or incorrect values are placed in the temperature parameters, cool down will be effected and may not occur. Cool down causes a cool down solenoid to increase the cool air flow from the vortex cooler into the programmed temperature oven. If the cool down solenoid or vortex cooler fails, cool down will not perform as expected. If the air flow to the vortex cooler is inadequate, cool down will also be affected. A rate of 0.1 is needed to activate the cool down solenoid in the temperature control table entry #2. The following can cause problems with programmed temperature oven cool down. 1. An error has been made in programming the method table. Perform Test Procedure 30 (Checking Temperature Table Values) to verify all control parameters OSM, F1 6-21

192 2. Air supply pressure is low. Verify correct air pressures. If necessary make adjustment. 3. Vortex cooler not adjusted. Perform Test Procedure 41 (Programmed Temperature Oven Cool Down). 4. Listen for cool down solenoid to operate and introduce increased vortex cooler air flow. If this does not happen, perform Test Procedure 41 (Programmed Temperature Oven Cool Down). OUTPUT PROBLEMS Printer Not Generating Report Symptom: No reports or other printer response. Cause: The printer may be turned off or malfunctioning. The printer may have a blown fuse or be unplugged from power. The printer may be in alarm condition such as being out of paper. Wiring to printer may be disconnected or in error. Printer and analyzer output driver may be not be compatible or mismatched (RS-232). If no reports are generated the report option may be set to NONE. The post analysis calculations may still be in progress. If no report is generated before next analysis cycle begins, there is a problem. Perform Test Procedure 35 (Printer Test) to verify correct printer setup. Trend Output Not Functioning Correctly Symptom: There is no trend output at recorder or input device, or the trend output value is not correct. Cause: No trend output to an external device such as a recorder or DCS can be due to wiring, loss of loop power or, Trend Board failure. Incorrect trend output at the peripheral device could be due to loop power, input shunt resistance, Trend Board not scaled correctly, Trend Board malfunction, or incorrect trend table. Perform Test Procedure 37 (Trend Output) to test trend function. Digital PCB Malfunction Symptom: Valves do not switch and alarm digital output not functioning. Cause: Wrong assignment of valve or alarm digital assignment in method or Vista BASIC Program. Digital PCB malfunction or defect. Verify digital assignment (see "DIGITAL I/O OPTION" in Section 4). No Recorder Output Symptom: Strip chart recorder does not record chromatogram. Cause: The strip chart recorder may not be powered, or may be malfunctioning. A fuse may be blown at the recorder. Other causes include defective recorder cable, wiring error or loose connection. Possibly the wrong attenuation is selected at the recorder or the shunt resistor is not correct. The Manual Control Screen may not have the Chroma selection or the Chroma I/O board could be malfunctioning. The problem may be due to defective or damaged analyzer terminal connection, defective wiring or connection to the front jacks or backplane connector, or to defective electronics OSM, F1

193 No Analyzer Keypad Response Symptom: Pressing keypad on analyzer front panel produces no response on CRT or other analyzer output. Cause: No response by keypad could indicate defective keypad or malfunction or defect in keypad cabling from keypad to keypad assembly PCB. The CRT Control PCB or associated wiring or connections may be defective. The controller software may be locked up. LOCOM PCB Symptoms and Possible Causes Symptom: The CRT display indicates the message CANNOT CONTACT CONTROLLER when attempting to communicate with a remote analyzer. Cause: The remote analyzer switch address is incorrect. A remote analyzer cannot be contacted if it is not powered or connected to the network. It is also imperative that the network wiring be installed and wired correctly. Improper wiring may affect several analyzers simultaneously. To isolate the cause, perform the following: 1. Check remote analyzer address, power and wiring. Symptom: No communication or response from a remote analyzer or from a local analyzer front panel. Cause: The remote analyzer front panel address switch is not set correctly or the LOCK OUT REMOTE switch is set to On. 2. Check analyzer address switch setting. Symptom: Only local chromatograms are accessible at the local panel recorder output jacks. Remote chromatograms cannot be accessed. Cause: This feature can only be accessed when using the network. The jumper at JP5 located on the CRT controller may not be configured correctly. 3. Check and change if necessary Change Jumper JP5. Symptom: The Remote Front Panel Mode menu cannot be exited. Cause: The No Analyzer switch is ON. 4. Place NO ANALYZER Switch in OFF position. Symptom: No operation occurs when EXECUTE soft key is pressed in the Remote Front Panel Mode. Cause: The TEST HIGHWAY switch is On in one of the controllers connected to the front panel network. 5. Check TEST HIGHWAY in analyzers on network and set switch in OFF position. Symptom: Two or more controllers are responding to a remote command. Cause: LOCOM PCBs have identical address switch settings or defective LOCOM PCB. Check settings and correct. Then cycle power to the device in which the switch was modified OSM, F1 6-23

194 6. Replace LOCOM PCB (set-up address switch). Symptom: Cannot contact or use remote networking feature. Cause: Previous remote communication was not terminated. 7. Search for analyzer that is accessing another remote, or that is itself being accessed, then terminate the access. See "REMOTE GC OPERATION OPTION" in Section 4. Flame Out LED On Symptom: Flame Out LED indicates flame is out. Cause: The FID or FPD flame can be extinguished by insufficient burner fuel, air or column pressure surges, or plugged vent line (possibly moisture). The flame may in fact be burning and the thermocouple or the associated flame detection electronics may have failed to detect the flame on condition. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies), Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments), Test Procedure 29 ( Flame Out LED Remains On After FID Flame Ignition), and Test Procedure 34 (Vent Back Pressure), as applicable. If the flame will not light after repeated attempts to ignite it, go to the next paragraph. Flame Will Not Ignite (FID) Symptom: Flame Out LED on and continued attempts to light the flame have failed. Cause: Flame-out thermocouple and its electronics detect that flame is extinguished. The cause could be lack of or insufficient burner fuel, air, or in some cases carrier when hydrogen carrier is used. The jet may be plugged or restricted, preventing burner fuel from passing into the detector cell. The ignitor or ignitor electronics may be defective. The vent line may be plugged. Perform Test Procedure 17 (Verification Flame Is Ignited), Test Procedure 16 (FID Will Not Light), Test Procedure 31 (Plugged Jet or Breather), and Test Procedure 34 (Vent Back Pressure), as applicable. Flame Will Not Ignite (FPD) Symptom: Flame Out LED on and continued attempts to light the flame have failed. Cause: Flame-out electronics detects that flame is extinguished. The cause could be lack of or insufficient burner fuel, air, or in some cases carrier when hydrogen carrier is used. The jet may be plugged or restricted, preventing burner fuel from passing into the detector cell. The ignitor or ignitor electronics may be defective. The vent line may be plugged. Perform Test Procedure 17 (Verification Flame Is Ignited), Test Procedure 44 (FPD Flame Will Not Light), Test Procedure 31 (Plugged Jet or Breather), and Test Procedure 34 (Vent Back Pressure), as applicable OSM, F1

195 Low Carrier Pressure Hardware Alarm Symptom: Low carrier gas alarm. If carrier is in short supply and not corrected, carrier flow rates will reduce as the gas is depleted. Analyzer data will become erroneous as carrier pressure drops below the analyzer requirement. Causes: The following can be causes for low carrier pressure alarm. 1. Low carrier gas supply. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies). 2. Defective or incorrectly adjusted carrier pressure switch. Perform Test Procedure 39 (Low Carrier Pressure). 3. Inlet filter or restrictor for hydrogen is plugged. Low Sample Flow Hardware Alarm CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. Ensure adequate ventilation in analyzer shelter. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you read Section 4 completely and you understand and can perform the procedure requirements. Symptom: Rotometer and pressure gauge indications are below normal. Bubbles may be seen in analyzer effluent rotometer. Individual components, RVP and V/L calculation values are not repeating. Causes: The following can be causes for low sample flow alarm. 1. The sample booster pump is not operating or has failed. Check pump inlet and discharge pressure and power. 2. Defective or incorrectly adjusted sample flow switch. Perform Test Procedure 40 (Low Sample Flow Hardware Alarm). 3. Sample flow alarm checked during sample shutoff portion of analysis. Loss of Purge Air CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements OSM, F1 6-25

196 Symptom: If X purge system is installed, analyzer power will be removed and cannot be restored until purge air is restored. Causes: The following can be the causes of loss of purge. 1. Air supply to analyzer has been shut off. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies). 2. The purged sections in the analyzer have developed leak(s). Leak check with leak detector. 3. Purge air switches are defective. Replace purge switches. 4. Insect infestation or plugging of purge, atmospheric reference vent(s). Inspect and clear vent. 5. Tubing to and from pressure switches has disconnected or developed a leak. Inspect and replace if necessary. 6. The purge orifice is obstructed or plugged. Remove obstruction or plugging. Stream Not Selected Symptom: The steam is not selected for analysis. Cause: Possible causes include the following: 1. Stream of interest is inactive. 2. Stream is not assigned to the correct method table. 3. Stream is not included in the Random Stream Stepping Table. 4. Stream step instruction missing from method table. Perform Test Procedure 33 (Checking Method Table Configuration). 5. No activation air to actuator (pneumatic stream selection system). Perform Test Procedure 18 (Sample Valve Actuation Air). 6. Defective wiring or wiring connection to solenoid valve. 7. Defective solenoid drive PCB. 8. Defective Chroma I/O Board. Perform Test Procedure 42 (Stream Switching). Analyzer Will Not Power Up (X-Purge) CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. Symptom: Analyzer will not power up OSM, F1

197 Cause: Possible causes for analyzer not powering up are as follows: 1. If attempting to Override X-Purge, light intensity may not be sufficient to energize Override, or cover to X-Purge electronics housing is not removed. 2. Power is disconnected. Check power distribution circuit breakers and local disconnect switch. (Watch for lock-out tag-out). 3. No air or insufficient air supply at analyzer. An alarm should be present indicating the purge failure. 4. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies). 5. X-purge time-out not complete. 6. Air leak in purged analyzer housing preventing X-purge time from completing. See "Loss of Purge Air." 7. X-purge is locked out. Cycle power (10 seconds) to reset X-purge, and allow X-purge sequence to initiate OSM, F1 6-27

198 ELECTRONIC PRESSURE CONTROL TROUBLESHOOTING The Pressure Control Assembly (see Figure 6-15) requires special tools and equipment for repair. If you suspect a problem with this assembly please contact your ABB service representative. Figure EPC PRESSURE CONTROL ASSEMBLY OSM, F1

199 CONTROLLER PROBLEMS Input Power Input power is connected to one or more of the following locations on the Backplane PCB in the Controller Housing (see Figure 6-16): TB1, which is called VAC #1 J1A, which is called VAC #2 J1B, which is called VAC #3 TB1 TB1 J1A J1B J1A J1B Figure BACKPLANE PCB POWER CONNECTIONS Input power is 115VAC. This may be supplied directly as 115VAC or stepped down from a higher voltage. The input voltage may be conditioned or supplied from an uninterruptible power supply (UPS). Each of these choices, made at the time of sale, affects how the power is brought into the analyzer OSM, F1 6-29

200 Power Distribution The analyzer uses three power distribution circuits to route the power (see Figure 6-17): VAC #1, which provides heater power VAC #2, which powers the electronics through the Power Supply PCB VAC #3, which power the detectors, solenoid drivers, and EPC 115 to 230 VAC (Not Filtered or Conditioned) Hot Neut Gnd RFI Filter VAC #1 (to heaters) TB1 Jumpers installed when J1A does not have separate power source J1A to 230 VAC (Conditioned or UPS) Hot Neut Gnd VAC #2 (to electronics) Jumpers installed when J1B does not have separate power source J1B VAC (Autoformer) Gnd Neut Hot VAC #3 (to solenoids and detectors) Figure INPUT POWER DISTRIBUTION If all power supplied to the analyzer comes from a single source it will be connected to TB1. Instead of input cables there will be jumper plugs installed at J1A and J1B to connect their distribution circuits to the input power source. If unconditioned power is routed to TB1 and conditioned power to J1A, then J1B will have a jumper plug to connect its distribution circuits to J1A. If unconditioned power is routed to TB1 and an autoformer output is routed to J1B (with J1A not being connected to source power), then J1A will have a jumper plug to connect its distribution circuits to TB OSM, F1

201 When checking input power make sure to note the connections for source power to determine how power is routed. Poor Display Contrast If the analyzer is ON but it is difficult to read the LCD display, you may need to adjust the display. 1. Ensure the area is safe to open the analyzer. 2. Open the Controller Housing front door. 3. On the Front Panel PCB mounted on the door, locate the contrast adjustment. It is on the front side of the board, at the bottom center (see Figure 6-18). Front Panel PCB Contrast Adjustment Display Panel Figure LOCATION OF CONTRAST ADJUSTMENT 4. Adjust the contrast potentiometer clockwise a quarter turn to increase the contrast. 5. Verify the change in contrast by viewing the LCD display. 6. Repeat steps 4 and 5 as necessary to achieve the desired contrast. 7. Close and secure the Controller Housing front door. ALARMS The analyzer has different types and levels of alarms to help you resolve analyzer problems. You can review these alarms on the GCC display and on the customer's alarm indicators (when they are connected to the digital outputs of the GCC see "Alarm Common Output Connections") OSM, F1 6-31

202 When an alarm signal appears on the Background Screen, press the F4 (Alarms) soft key to display the ALARMS screen with the alarm message (see Figure 6-19). ****** ALARMS ****** ****** ALARM ****** Post Analysis Error: *Valve Manually Switched Exit Clear Alarms and Exit F1 F2 F3 F4 Figure ALARMS SCREEN When you finish with the alarm messages, press the F1 (Exit) soft key to return to the Background screen without deleting the alarms, or press the F2 (Clear Alarms and Exit) soft key to clear the alarms and return to the Background screen. Alarm messages are of two primary types: main alarms and subordinate alarms. Main alarms identify a major alarm category. These alarms appear on the alarm screen at the left margin (e.g., Post Analysis Error: in Figure 6-20). The main alarms are: Hardware Alarms Sensors Active: Sensors Held: Startup Hardware Problem Power Failed Flame Out Software Alarms Component High: Component Low: Clock Error: TCF Error: Post Analysis Error: Communications Error: Pressure Board: Temperature Board: Raw Chromatogram Storage: GCC is not Running an Analysis Basic Run Time Errors Basic Compilation Errors Subordinate alarms appear below the main alarms, indented and preceded by an asterisk (*) to show their subordinate status (e.g., *Valve Manually Switched in Figure 6-19). If a main alarm has subordinate alarms, the main alarm title will include a colon (:). The following subsections list the main alarms that have subordinate alarms, together with their associated subordinate alarms OSM, F1

203 Sensors Active When Sensors Active: appears as the main alarm, one or more sensor alarms appears below the main alarm. Sensors Active appears when an alarm is active at the time you look at the Alarms screen. Typical Sensors Active alarms and their descriptions are: NOTE Sensor Alarms 1 to 5 are application-specific alarms. Descriptions of their use are contained in the Data Package supplied with the analyzer. * Sensor 5 Alarm: [user entered name] * Sensor 4 Alarm: [user entered name] * Sensor 3 Alarm: [user entered name] * Sensor 2 Alarm: [user entered name] * Sensor 1 Alarm: [user entered name] * Purge Air activates when purge air is lost. After purge air is restored the alarm resets. * Carrier Gas activates when carrier gas is lost. After carrier is restored the alarm resets. * Low Oven Temp activates when oven temperature goes below the lower setpoint. When temperature comes back within the setpoints, the alarm resets. * High Oven Temp activates when oven temperature exceeds the upper setpoint. When temperature comes back within the setpoints, the alarm resets. * Low Standard Sample activates when standard sample is low or missing. When the standard sample is restored, the alarm resets. * Sample Flow activates when sample flow is lost. When the sample flow is restored, the alarm resets. * Low Fuel/N2/Dilution activates when fuel/n2/dilution is lost. When it is restored the alarm resets. Sensors Held When Sensors Held appears as the main alarm, one or more sensor alarms appears below the main alarm. Sensors Held appears when an alarm was active at some time during the analysis, but before you looked at the Alarms screen. Typical Sensors Held alarms are the same as those for Sensors Active. You can manually reset Sensors Held alarms by entering the Alarms screen (after the problem is corrected) and pressing the F2 (Clear Alarms and Exit) soft key. If you set Sensors Held to clear at the end of the analysis, they will do so if the Sensors Active have cleared. Component High When Component High: appears as the main alarm, one or more component alarms appears below the main alarm. Typical Component High alarms and their descriptions are: * Component High High activates when a component exceeds the "high high" setpoint. * Component High activates when a component exceeds the "high" setpoint but is within the "high high" setpoint OSM, F1 6-33

204 * Retention Time High activates when retention time exceeds the upper setpoint. * Response Factor High activates when response factor exceeds the upper setpoint. Component Low When Component Low: appears as the main alarm, one or more component alarms appears below the main alarm. Typical Component Low alarms and their descriptions are: * Component Low Low activates when a component is below "low low" setpoint. * Component Low activates when a component is below "low" setpoint but above "low low" setpoint. * Retention Time Low activates when retention time is below lower setpoint. * Response Factor Low activates when response factor is below lower setpoint. Clock Error When Clock Error: appears as the main alarm, one or more clock alarms appears below the main alarm. Typical clock alarms are: * No Active Streams activates when the status of all streams in the stream table has been set to inactive. To clear this alarm set at least one stream's status to active. * Memory Shortage < 20% activates when the GCC is short of memory. This is usually caused by chromatogram storage. To clear this alarm return all memory that is being used for chromatogram storage back to the operating system and reduce the number of points being saved by Chromatogram Storage function. * Auto Zero + Over Range activates when program is unable to autozero because the signal is out of range high. * Auto Zero - Over Range activates when program is unable to autozero because the signal is out of range low. * Bad Base Projection Forward activates when the beginning of a peak was not defined in the analysis. * Bad Base Projection Backward activates when the end of a peak was not defined in the analysis. * A/D Buffer Overrun activates when the analog-to-digital algorithm was unable to perform a conversion based on the analog signal provided. * A/D Conversion Error activates when the analog-to-digital algorithm was unable to perform a conversion. TCF Error When TCF Error: appears as the main alarm, one or more time-coded function alarms appears below the main alarm. These alarms are cleared by correcting the associated method entry designated by the alarm. Typical TCF alarms and their descriptions are: * Auto Zero During Noise activates when auto zero is performed during noise calculation. * Auto Zero During Gate activates when auto zero is performed during forced gate OSM, F1

205 * Auto Zero During Slope Detect activates when auto zero is performed during slope detection. * Gated During Noise activates when slope detection is turned on at the same time that a noise calculation is being performed. * Gated During Slope Detect activates when slope detection is turned on at the same time as a peak is being force gated. * Gate Switched Off w/o Gate On activates when a force gate is turned off without the force gate being turned on. * Noise During Gate activates when noise calculation is being performed at the same time as a force gate is turned on. * Noise During Slope Detect activates when noise calculation is being performed at the same time as slope detection. * Noise Off w/o Noise On activates when noise calculation is turned off but never turned on. * Not Enough Noise Points activates when Noise On and Noise Off are too close together in time to collect sufficient noise points to perform a calculation. * Invalid Peak Width activates when the peak setting in the TCF table is greater than 64. * Too Many Peaks in Analysis activates when there are more than 254 peaks in the analysis. Post Analysis Error When Post Analysis Error: appears as the main alarm, one or more post analysis alarms appears below the main alarm. Typical post analysis alarms and their descriptions are: * Invalid Peak End activates when the program is unable to define an end to a peak in the analysis (the peak did not end on a baseline or a valley point). * Cal Fail: RF Out of Range activates when calibration fails because the new response factor for a peak was out of the limits specified for the component. * Cal Fail: Missing Component activates when no peak appeared for a component in the calibration stream. * Missing Component activates when no peak was found that matches where a component was defined in the method. * Unknown Component activates when a peak was detected in the analysis and not defined in the method. * Analyzer Was Not Calibrated activates when an error occurs in the calibration cycle and the response factors are not updated. * Vista Basic Run-Time Error activates when an error occurs in the Vista Basic program when it runs. * Valve Manually Switched activates when a valve is switched from the Manual Control screen during the analysis cycle OSM, F1 6-35

206 Communications Error When Communications Error: appears as the main alarm, one or more communications alarms appears below the main alarm. Typical communication alarms and their description are: * Block not transmitted activates when a VistaNET message is passed to the Communication PCB and no acknowledgement is received. * Block dropped activates when VistaNET messages are being received from the Communication PCB faster than they can be processed. * No port to receive activates when there is not a port in the SBC software configured to receive the message. * Time out activates when a VistaNET message was not received or transmitted in the time allowed. * Unfinished multi-block activates when an incomplete multiblock message is received. * Unsolicited reply activates when a response message is received and there is no reply pending. * Unreachable destination activates when a message that requires a response has a return address that the GCC could not route the message to. * Socket purged activates when a VistaNET message is received in which there is no waiting task. Pressure Board When Pressure Board: appears as the main alarm, one or more pressure alarms appears below the main alarm. Pressure alarms are of two types, overall alarms and zone-specific alarms, with the zone-specific alarms subordinate to the overall alarms. Typical overall pressure alarms and their descriptions are: * ROM Checksum activates when the EPC Multibus PCB has failed. * Communications activates when communications between the SBC PCB and the EPC Multibus PCB have failed. * EPC Module Temperature High activates when the temperature in the EPC Module exceeds 68.2 C. * EPC Module Temperature Low activates when the temperature in the EPC Module goes below 59.9 C. * Zone Specific activates when one of the zone specific alarms is activated. If the *Zone Specific subordinate alarm appears, at least two additional lines appear below that. The first line identifies which zone produced the alarm and the second line identifies the specific alarm condition. Typical zone specific alarms and their descriptions are: * Zone Checksum activates when there is an EEPROM problem. * Out of Control activates when the ramp rate settings exceed an acceptable range or the analyzer is unable to maintain set point. * Zero Failed activates when the Zero pressure is not present, or the switch has not been depressed OSM, F1

207 * Set Point Failed activates when Zone is inactive; zone is SWITCH zone and switch not depressed or set point is greater than the configured pressure range. * Ramp Rate Failed activates when the ramp rate settings exceed an acceptable range. * Reconfiguration Failed activates when switch not depressed. * High Alarm activates when the maximum pressure limit set in configuration is too low. * Low Alarm activates when the minimum pressure limit set in configuration is too high. NOTE If either of the next two alarms occurs, information can be displayed and/or the analysis can be aborted, per the Pressure Check Table option selections. * Pressure Check Table * Entry 01, DILUTER > 600 psig (example) Temperature Board When Temperature Board: appears as the main alarm, one or more temperature alarms appears below the main alarm. Temperature alarms are of two types, overall alarms and zone-specific alarms, with the zone-specific alarms subordinate to the overall alarms. Typical overall temperature alarms and their descriptions are: * ROM Checksum activates when the DTC Backplane PCB has failed. * No Zero Crossing activates when there is loss of four or more consecutive AC line cycles. * Zone Specific activates when one of the zone specific alarms is activated. * Loss of Air activates when there is temporary loss of air to Zones 1 and 2 heaters. The analysis cycle aborts. When this alarm occurs, power will be removed from the heaters of air-operated zones for as long as the loss of air exists. When air pressure is restored, power is restored to the heaters. NOTE If one of the following alarms occurs, the analyzer will stop and power will be removed from all heaters. To resume operation, you must turn power OFF and back ON, and then restart the analysis. * Overtemp Test activates when the overtemp micro fails. It may signify a zone triac failure. * Communications activates when communications between the SBC PCB and the DTC Backplane PCB have failed. * Overtemp Triac activates when Micro 1 control triac fails during overtemperature test. * Ambient Limit Exceeded activates when the internal ambient temperature of 80 C is exceeded. * Heater Barrel TC Faulty activates when the heater barrel thermocouple is faulty. * T-Rating Disagreement activates when Micro 1 and Micro 2 T-Rating jumpers do not agree OSM, F1 6-37

208 * Analysis Shutdown activates when the Temperature Board alarm has signaled the SBC with information that will be used to determine whether to abort the analysis. If the *Zone Specific subordinate alarm appears, at least two additional lines appear below that. The first line identifies which zone produced the alarm and the second line identifies the specific alarm condition. Typical zone specific alarms and their descriptions are: * Reasonableness Test activates when probe and thermocouple disagree by more than 100 C. * Triac Failure activates when a control triac misfires consistently. * Zone Checksum activates when there is a EEPROM problem. * Out of Control activates when the ramp rate settings exceed an acceptable range or the analyzer is unable to maintain set point. * Zero Failed activates when Zero resistance is not 400 ohms, or the switch is not depressed (Zero is not required in the field). * Span Failed activates when Span resistance is not 1000 ohms, or the switch is not depressed (Span is not required in the field). * Set Point Failed activates when Zone is inactive; zone is SWITCH zone and switch not depressed or set point is greater than T-Rating. * Ramp Rate Failed activates when the ramp rate settings exceed an acceptable range (50 C per minute). * Reconfiguration Failed activates when switch not depressed. * High Alarm activates when the maximum temperature limit set in configuration is too low. * Low Alarm activates when the minimum temperature limit set in configuration is too high. NOTE If either of the next two alarms occurs, information can be displayed and/or the analysis can be aborted, per the Pressure Check Table option selections. * Temperature Check Table * Entry 02, PROG OVEN > 320 deg C (example) NOTE If one of the following alarms occurs, the analyzer will stop and power will be removed from all heaters. To resume system operation, turn the power OFF and back ON, and then restart the analysis. * Overtemp activates when the zone temperature has exceeded the displayed T-rating. * Probe Open/Shorted or TC Faulty activates when there is a defect in the zone sensor or interconnect OSM, F1

209 Raw Chromatogram Storage When Raw Chromatogram Storage: appears as the main alarm, one or more chromatogram alarms appears below the main alarm. Typical chromatogram alarms and their descriptions are: * Memory Below 20% activates when the memory pool used for chromatogram storage is below 20%. * No Memory Left activates when chromatogram storage has used all available memory. * Current Analysis Save Aborted activates when the GCC is unable to save the last chromatogram. * Could Not Save Analysis activates when the GCC is unable to save the last chromatogram. Alarm Mask The Alarm Mask screen has four selections for each alarm name: Alarm, Masked, Indicate, and Warning. Alarm When the Alarm Mask screen has "Alarm" selected for a given alarm, an alarm condition will: appear in the alarm pane of all connected RUIs; set the Modbus coil to active (if the alarm has a designated Modbus coil)and will set the associated Data Valid for reported stream to 0; report the alarm to VistaSTORAGE (if the GC is configured to send reports to VistaSTORAGE); report the alarm to VistaREPORTER (if the GC is configured to send reports to VistaREPORTER); report the alarm to the printer (if the GC is configured to send reports to a printer); report the alarm to the OPC Server (if the GC is configured to send reports to the OPC Server). The purpose of the Alarm setting is to invalidate the data and notify all users. Events suggested for this setting are Flameout, Sample Flow, Temperature Alarm, Pressure Alarm, and any event that would affect the accuracy of the analysis. Masked When the Alarm Mask screen has "Masked" selected for a given alarm, no alarm signals will be generated. The purpose of the Masked setting is to hide events considered to be a nuisance. Examples: (1) If a user has a sensor that has gone bad, the event can be masked out until the sensor can be replaced, or (2) if the user is getting communication alarms because an application is not running, the event can be masked out. Indicate When the Alarm Mask screen has "Indicate" selected for a given alarm, an alarm condition will: not appear in the alarm pane of all connected RUIs; set the Modbus coil to active (if the alarm has a designated Modbus coil)but will not set the associated Data Valid for reported stream to 0; report the alarm to VistaSTORAGE (if the GC is configured to send reports to VistaSTORAGE); 2000-OSM, F1 6-39

210 not report the alarm to VistaREPORTER (if the GC is configured to send reports to VistaREPORTER); not report the alarm to the printer (if the GC is configured to send reports to a printer); report the alarm to the OPC Server (if the GC is configured to send reports to the OPC Server). The purpose of the Indicate setting is not to invalidate the data but to notify the control system that the event has occurred. Events suggested for this setting are digital inputs from third-party analyzers that need to have their data passed to the control system but that should not affect the validation of the GC data. Example: an analyzer that has a common malfunction alarm that you want to pass to the control system using the GCC as a pass through device. Warning When the Alarm Mask screen has "Warning" selected for a given alarm, an alarm condition will: appear in the alarm pane of all connected RUIs; set the Modbus coil to active (if the alarm has a designated Modbus coil) but will not set the associated Data Valid for reported stream to 0; report the alarm to VistaSTORAGE (if the GC is configured to send reports to VistaSTORAGE); report the alarm to VistaREPORTER (if the GC is configured to send reports to VistaREPORTER); report the alarm to the printer (if the GC is configured to send reports to a printer); report the alarm to the OPC Server (if the GC is configured to send reports to the OPC Server). The purpose of the Warning setting is not to invalidate the data but to notify all users that an event has occurred in the GC that requires attention. Events suggested for this setting are low standard sample, communication errors, retention time and component concentration limits, and any event that requires user notification but does not invalidate analysis results. To verify or change the alarm mask settings: 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor to MISC. and press the F2 (Control Parameters) soft key OSM, F1

211 3. On the Control Parameters screen (see Figure 6-20), press the F3 (Alarm Mask) soft key. ***** Control Parameters ***** Analyzer Name: [ABB Analytical GCC ] Unknown Peak Alarm: No Yes Missing Comp Alarm: No Yes Update Trends on Alarm: No Yes Auto Update of RF: No Yes Max RF Variation: Unknown Peak RF: Unknown Peak Units: % ppm More Below Exit Alarm Common Escape and Mask Digital Update Out Mask F1 F2 F3 F4 Figure CONTROL PARAMETERS SCREEN 4. On the Alarm Mask, Main screen (see Figure 6-21), cursor down to the desired alarm name and verify the selection in the right-hand column. ***** Alarm Mask, Main ***** Active Sensors: (Expand) Alarm Component High: Alarm Component Low: Alarm Hardware: Alarm Power Fail: Alarm Unused: Alarm Idle: Alarm Flame Out: Alarm Clock: (Expand) Alarm More Below Exit Expand Mask F1 F2 F3 F4 Figure ALARM MASK MAIN SCREEN 5. To change the alarm mask setting, toggle the left or right cursor to obtain the desired selection (Alarm, Masked, Indicate, or Warning) OSM, F1 6-41

212 6. If the selected alarm has "(Expanded)" after the alarm name, the alarm has subordinate indicators. To view these subordinates, cursor to the desired alarm line and press the F2 (Expand Mask) soft key. 7. On the expanded alarm screen, repeat steps 4 and 5 to change a specific alarm's output. 8. Press the F1 (Exit) soft key to return to the Control Parameters screen. 9. Press the F2 (Exit and Update) soft key to save the new alarm data, or press the F1 (Escape) soft key to retain the original data. 10. Press the F1 soft key as necessary to return to the Background screen. Alarm Common Output Connections You can view analyzer alarms at the customer's alarm indicator when this indicator is connected to Hardware Alarm connector J111A and Software Alarm connector J111B on the GCC Backplane PCB (see Figure 6-22). TB1 J1A J111A J111A HARDWARE ALARM J1B 1 J111B 1 J111B SOFTWARE ALARM Figure BACKPLANE PCB DIGITAL ALARM CONNECTIONS Alarm Common Output Checks When the Common Digital Output Mask screen has "Common DO" selected for a given alarm, an alarm condition will illuminate the appropriate alarm LED on the GCC Front Panel (Hardware Fault OSM, F1

213 LED or Software Fault LED) and will send an alarm signal to the customer's alarm indicator (when that indicator is connected to J111A or J111B on the Backplane PCB). When the Common Digital Output Mask screen has "Masked" selected for a given alarm, no alarm signals will be generated. To verify or change the alarm common output settings: 1. On the Background screen press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor to MISC. and press the F2 (Control Parameters) soft key. 3. On the Control Parameters screen (see Figure 6-23), press the F4 (Common Digital Out. Mask) soft key. ***** Control Parameters ***** Analyzer Name: [ABB Analytical GCC ] Unknown Peak Alarm: No Yes Missing Comp Alarm: No Yes Update Trends on Alarm: No Yes Auto Update of RF: No Yes Max RF Variation: Unknown Peak RF: Unknown Peak Units: % ppm More Below Exit Alarm Common Escape and Mask Digital Update Out Mask F1 F2 F3 F4 Figure CONTROL PARAMETERS SCREEN 2000-OSM, F1 6-43

214 4. On the Common DO Mask, Main screen (see Figure 6-24), cursor down to the desired alarm name and verify the selection in the right-hand column. ***** Common DO Mask, Main ***** Active Sensors: (Expand) Common DO Component High: Common DO Component Low: Common DO Hardware: Common DO Power Fail: Common DO Idle: Common DO Flame Out: Common DO Clock: (Expand) Common DO Method Function: (Expand) Common DO More Below Exit Expand Mask F1 F2 F3 F4 Figure COMMON DO MASK MAIN SCREEN 5. To change the alarm common output, toggle the left or right cursor to obtain the desired selection (Common DO or Masked). 6. If the selected alarm has "(Expanded)" after the alarm name, the alarm has subordinate indicators. To view these subordinates, cursor to the desired alarm line and press the F2 (Expand Mask) soft key. 7. On the expanded alarm screen, repeat steps 4 and 5 to change a specific alarm's output. 8. Press the F2 (Exit and Update) soft key to save the new alarm data, or press the F1 (Escape) soft key to retain the original data. 9. Press the F1 soft key as necessary to return to the Background screen OSM, F1

215 SECTION 7. TEST PROCEDURES TP 1: CARRIER, MAKEUP AND UTILITY GAS SUPPLIES If you suspect a gas supply (flame, fuel, air) problem, perform the following test. 1. Stop Analysis at end of current analysis, and make no sample injection until procedure is completed. 2. Check gas supply pressures at the analyzer pressure gauges or EPC screens. Pressure indications should indicate normal operational values as indicated on the application data sheets or last valid record. 3. If values are low, check gas supply at source gauges. Verify gas cylinder valve(s) are open and that gas cylinder regulator(s) are adjusted for the correct outlet pressure. Verify isolation valves which supply carrier or makeup gases to the analyzer are open. Verify the cylinder gas supply is not depleted. Make necessary adjustments and replace empty gas cylinders with full ones. 4. Check the inlet filter or restrictor to ensure it is not plugged. NOTE Gas pressures include all carrier, hydrogen fuel, burner air and utility air supplies. TP 2: CARRIER AND MAKEUP GAS FLOW ADJUSTMENTS CAUTION When the carrier supply is turned on, if there is no pressure indicated on the carrier gauge, do not increase carrier flow. Leak check every connection outside the analyzer on the entire carrier flow path. Ensure adequate ventilation in analyzer shelter. 1. Stop Analysis at the end of the current analysis and make no injection until procedure is completed. 2. (FID or FPD) Extinguish flame by removing burner air and fuel. 3. Refer to the application data sheets supplied with your analyzer and verify correct reference and column carrier flow rates, correct hydrogen fuel and burner air flow rates (if FID or FPD), correct splitter adjustment, and correct air pressure adjustments. 4. (TCD) Make necessary adjustments and balance detector using Test Procedure 5 (TC Detector Balance). 5. (FPD) Make necessary adjustments using Test Procedure 43 (FPD Gain Setting). TP 3: SAMPLE VALVE LEAKING/COLUMN FLOODING WARNING Sample will spill or leak out during this procedure. Consult MSDS sheets on file at your location for safety requirements OSM, F1 7-1

216 CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. 1. Stop Analysis at the end of the current analysis, and make no sample injections until procedure is completed. 2. Isolate sample valve from the sample system using sample system isolation valves. 3. Take necessary environmental and personal safety precautions. Slowly disconnect sample inlet line and outlet lines at the sample valve and relieve sample pressure. Do not disconnect line until all pressure has relieved. Connect a short piece of stainless steel tubing to the sample valve outlet to a suitable approved waste collection container. 4. Using stainless steel tubing connect a source of 25 psig nitrogen directly to the sample valve inlet fitting (bottom). Purge all sample from the sample valve into the waste container via the short piece of tubing previously connected. When nitrogen purging is complete, (30 seconds), shut off nitrogen purge gas. 5. Raise the oven temperature to final set-point +20% and hold. Perform Test Procedure 30 (Checking Temperature Table Values), steps 1 to 3, 8 and 9, and observe the oven temperature (column). NOTE Steps 6 and 7 are optional. The existing column can be removed and another installed prior to performing step Observe baseline for two times the normal cycle time. If baseline offset is reduced, the sample valve is most likely leaking. 7. If little or no correction in baseline is seen, replace the column. If no column is available, leave overnight in this state. If the problem is due to column flooding, great improvement or elimination of offset should be apparent the next morning. If the column was flooded, repair the sample valve prior to applying sample to the sample valve or making an injection. TP 4: CARRIER OR MAKEUP GAS REGULATOR CAUTION When the carrier supply is turned on, if there is no pressure indicated on the carrier gauge, do not increase carrier flow. Leak check every connection outside the analyzer on the entire carrier flow path. Ensure adequate ventilation in analyzer shelter. 1. Stop Analysis at the end of current analysis, and make no sample injection until the procedure is completed. 2. Ensure carrier or makeup gas is applied to the analyzer by performing Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies). 3. No carrier or makeup gas pressure is indicated on analyzer gauges (regulator failed closed), large leak from regulator inlet to supply, gauge has failed, or tubing is restricted or plugged OSM, F1

217 4. Leak check every connection outside the analyzer on the entire carrier flow path. Perform step 5 only after step 4 has been completed and all leaks are repaired. 5. Loosen inlet fitting nut and check for presence of carrier or makeup gas using a leak detector solution. 6. If carrier or makeup gas is present, repair or replace the analyzer carrier or makeup gas regulator. If carrier or makeup gas is not present, check for the presence of carrier or makeup gas working back toward the gas supply. Loosen each fitting one-at-a-time. Check each fitting for the presence of gas using a leak detector. Once carrier or makeup gas is detected, the trouble is isolated between the present and last connection checked. Make necessary repairs. Tighten all fittings and check for leaks. 7. Adjust carrier or makeup gas pressure for pressure indicated on the analyzer carrier pressure gauge. If pressure adjusts to the correct value, stop this test and perform Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments) and, if the system has a TCD, perform Test Procedure 5 (TC Detector Balance). 8. If carrier or makeup pressure cannot be adjusted, repair or replace regulator. TP 5: TC DETECTOR BALANCE 1. Stop Analysis at the end of the current analysis and make no injection until procedure is completed. 2. On the Background screen press the F2 (Manual Control) soft key. 3. On the Manual Control Mode screen press the F2 (Detector and Graphics) soft key. 4. On the Chroma Board screen press the F3 (Manually Zero Baseline) soft key. The Detector Reading should change to a value of 2.00 mv ±0.05 mv. 5. On the Chroma Board screen note the Hardware Zero, Software Zero, and Detector Reading values. 6. Open the Controller front door and locate the Detector Amplifier on the left side wall of the Controller. 7. Adjust the TCD Adjust potentiometer (located on the Detector Amplifier) until the Detector Reading is equal to the sum of the Hardware Zero and Software Zero values noted in step Press the F3 (Manually Zero Baseline) soft key and recheck the readings. The detector is adequately zeroed when the Hardware Zero percentage is less than 10%. 9. Close and tighten the Controller front door. TP 6: FILAMENT TCD TEST CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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 OSM, F1 7-3

218 CAUTION See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Stop Analysis at the end of the current analysis cycle, and make no sample injection until procedure is completed. 2. Remove power from analyzer. 3. Shut off carrier to analyzer. 4. Open the Controller front door and locate the Detector Amplifier on the left side wall. 5. Remove the six thumb nuts, cover, and plastic shield from the Detector Amplifier. Then locate TB Disconnect the wires on TB 16 terminals 2 (red) and 8 (white). 7. Connect ohmmeter leads between TB16 terminal 7 and the white wire removed from terminal 8, and measure the resistance of the measure filament. 8. Connect ohmmeter leads between TB16 terminal 1 and the red wire removed from terminal 2, and measure the resistance of the reference filament. The measured values of the two filaments should be within one ohm of each other. 9. If the filaments are not within one ohm of each other, replace the filaments. See FILAMENT TCD REPAIR in Section Check filament to ground resistance with an ohmmeter. It should indicate an open circuit. 11. If filament resistance is within tolerance, Test Procedure 6 is complete. 12. Check all connections, then replace the Detector Amplifier plastic shield, cover, and thumb nuts. 13. Close and tighten the Controller front door. 14. Apply air and carrier to analyzer. 15. Apply power. 16. When analyzer temperature stabilizes, perform Test Procedure 5 (TC Detector Balance). TP 7: COLUMN TRAIN PROBLEMS CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements OSM, F1

219 1. Stop Analysis at the end of the analysis and make no sample injection until procedure is completed. 2. Reduce isothermal and programmed temperature oven air temperatures by reducing oven air pressures to zero psig. 3. Open Isothermal oven. 4. Inspect for disconnected or loose tubing connections or broken column in the column train from the carrier regulator outlet to the column vent. Reconnect or tighten all tubing fittings. Check for leaks and make necessary repairs. If corrections or repairs were made, proceed to step Loosen the fitting connecting the column to the LSV and verify carrier presence with a leak indicator solution. 6. If carrier flow is not present or is insufficient, continue disconnecting fittings at each connection in the column train working back toward the carrier supply one-at-a time, checking for the presence of carrier. When full or nonrestricted carrier flow is detected, the trouble has been isolated between the present and last connection checked. Make necessary repair(s). Reconnect or tighten all fittings and check for leaks. 7. If carrier flow is present and not restricted, reconnect the fitting to the LSV. Beginning at the column vent, work back toward the previously disconnected fitting, loosing each fitting in the column train one-at-a-time, checking each loosened fitting for the presence of carrier. When full or nonrestricted carrier flow is detected, the trouble has been isolated between the present and last connection checked. Make necessary repairs. Reconnect or tighten all fittings and check for leaks. 8. Check for correct carrier flow adjustment. Perform Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments), Test Procedure 5 (TC Detector Balance), and Test Procedure 44 (FPD Gain Setting), as applicable. TP 8: BASELINE CYCLIC TEMPERATURE CONTROLLER (TCD) 1. Refer to temperature control troubleshooting section and monitor temperature zones for stability and control from the manual temperature control screen. Alarms relating to unstable temperature may be present (Out of Control). 2. Check for sufficient oven air supply. 3. If temperatures are stable, temperature as a cause can be eliminated. TP 9: BASELINE CYCLIC CARRIER REGULATOR 1. Observe the carrier and column pressure gauges in isothermal conditions. Often contaminated, dirty or cyclic regulator performance can be observed as the carrier pressure oscillates between two pressure gauge indications. The gauge pointer movement can be as little as ±0.25 psig or as great as several pounds. 2. If the outlet pressure of the regulator is cyclic, replace regulator. 3. If performance is questionable, replace regulator. TP 10: BASELINE CYCLIC FLOW CONTROLLER 1. If the cyclic baseline is not a function of the isothermal oven temperature or the carrier regulator, and a flow controller is installed, the flow controller should be replaced OSM, F1 7-5

220 2. Perform Test Procedure 30 (Checking Temperature Table Values) and Test Procedure 9 (Baseline Cyclic Carrier Regulator), as applicable. TP 11: COMMON USAGE OF GASES 1. Are other analyzers serviced from the same burner air, carrier, or burner fuel source, experiencing noise? If Yes, then the noise problem is most likely related to a common utility gas, tubing, fitting, or regulator. 2. Perform Test Procedure 12 (Utility Gas Contamination Procedure). TP 12: UTILITY GAS CONTAMINATION PROCEDURE 1. Verify Burner Fuel is UHP Hydrogen (FID or FPD). If not, replace hydrogen cylinder with UHP Hydrogen. If noise is eliminated, this test is completed. If noise is still present, continue to step Verify carrier purity. If purity questionable, replace carrier gas cylinder. If noise is eliminated, this test is completed. If noise is still present, continue to step Replace burner fuel cylinder (FID or FPD). If noise is eliminated, this test is completed. If noise is still present, continue to step Replace carrier or burner fuel cylinder regulators. If noise is eliminated, this test is completed. If noise is still present, continue to step Replace or wash tubing from cylinder regulator to analyzer. 6. Disassemble and clean Detector (see FID REPAIR/Cleaning the Collector in Section 8). TP 13: BURNER AIR CATALYTIC CLEANUP UNIT 1. Determine if air cleanup unit is operational and at operating temperature. Perform Test Procedure 30 (Checking Temperature Table Values), steps 1 to 3, 8 and If available, connect high purity bottled air to burner air connection. If noise disappears, see METHANIZER/AIR CLEANUP REPAIR in Section If bottled air is not available, see METHANIZER/AIR CLEANUP REPAIR in Section 8. TP 14: COAXIAL CABLE CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Open isothermal oven door OSM, F1

221 2. Gently move or touch coaxial cable, while monitoring detector output on recorder. Some movement of signal is normal, but spikes of noise should not occur. 3. If noise spikes are systematically generated, check the coaxial cable connections. 4. If the connections are correct and tight, replace coaxial cable. TP 15: FID REDUCED SENSITIVITY CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Stop analysis at the end of the current cycle and make no sample injection until the procedure is complete. 2. Check analyzer attenuation in Manual Control Mode. Perform Test Procedure 30 (Checking Temperature Table Values), steps 1 and Verify sufficient sample flow to sample system. 4. Verify sample valve is functioning correctly. 5. Check to ensure correct carrier type: Helium, Nitrogen, etc. 6. Verify correct sample valve ON and OFF times in method table. Perform Test Procedure 33 (Checking Method Table Configuration). 7. Refer to the application data sheet supplied with your chromatograph and check carrier, makeup gases particularly splitter flow, and make any necessary adjustments. 8. If significant corrections were made in steps 2 through 7, run a single cycle analysis to determine if sensitivity has improved. If sensitivity is now satisfactory, Test Procedure 16 is complete. If sensitivity is still reduced, continue to step Verify detector gain jumper installed correctly. 10. Perform Test Procedure 28 (FID Polarizing Voltage Test). If sensitivity is normal, Test Procedure 15 is complete. If sensitivity continues to be reduced, continue to step Clean FID as described in FID REPAIR/Cleaning the Collector in Section Apply power and gases to analyzer. After temperature stabilizes, check sensitivity. If satisfactory, Test Procedure 15 is complete. If not, perform steps 13 through Replace electrometer and repeat step Replace coaxial cable and repeat step Replace FID and repeat step OSM, F1 7-7

222 TP 16: FID WILL NOT LIGHT CAUTION Do not ignite the FID flame if the temperature is below operational level. Low oven temperature will result in condensation damage to the flame cell. 1. Ensure burner air and burner fuel are adjusted to the values shown on application data sheets. 2. If flows and pressures cannot be adjusted, perform Test Procedure 31 (Plugged Jet or Breather) to test for jet or air restriction. 3. Remove power and open the Controller front door. Locate Detector Amplifier on the left side wall of the Controller and remove the six thumb nuts, cover, and plastic shield. 4. Turn power ON. 5. Connect AC voltmeter leads to TB16 terminals 3 and 4 on the Detector Amplifier. 6. On the Chroma Board screen, press the F4 (Manual Ignitor On) soft key to ignite the cell flame. The meter should indicate 1.2 to 1.5 volts AC. If voltage is not present, the ignitor could be shorted to ground, the auto ignite board could be defective, or wiring could be disconnected. If the voltage is present, the defect could be an open ignitor coil. 7. Turn off the burner fuel to extinguish the FID flame and then remove power from the analyzer. 8. Disconnect the wires from TB16 terminals 3 and 4. Connect an ohmmeter between these two wires to measure the resistance of the ignitor coil. 9. The resistance of the ignitor coil should measure 0.1 to 1 ohm. If an extremely high resistance is measured, and the ignitor coil is open, replace the ignitor. See FID REPAIR/Replacing the Ignitor Assembly in Section Connect the ohmmeter leads to one of the wires and chassis ground. 11. Measure the resistance of the ignitor coil to ground. If maximum ohms is not measured, the ignitor is shorted to ground. Replace the ignitor (see FID REPAIR/Replacing the Ignitor Assembly in Section 8). 12. Reconnect the ignitor wires to TB16 terminals 3 and If the ignitor coil was replaced, apply power to the analyzer. On the Chroma Board screen, press the F4 (Manual Ignitor On) soft key. If the FID ignites, proceed to step If the ignitor is operating properly and no voltage is present between TB16 terminals 3 and 4 when step 11 is performed, replace the Detector Amplifier. 15. Remove power and replace the Detector Amplifier plastic shield, cover, and thumb nuts. 16. Close and tighten the Controller front door. TP 17: VERIFICATION FLAME IS IGNITED One of the primary products of combustion is water. Water vapor produced by the flame is discharged from the FID/FPD vent. One way to verify the flame is ignited is to observe the condensation of the water vapor OSM, F1

223 1. Disconnect the cell vent and hold a reflective surface such as a mirror, wrench or other suitable object at such an angle that you can see the reflective surface. 2. If the flame is ignited, you will be able to see the condensed water vapor form on the reflective surface. TP 18: SAMPLE VALVE ACTUATION AIR CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Check valve assignment in method tables. 2. Verify actuation air is being applied to the sample valve. Gently loosen the two 1/8 inch fittings at the actuator. Apply Leak Tech, Snoop or other similar liquid leak detector to the back of the fittings. 3. From the background screen turn on valve 1. The outside actuation tube fitting should produce bubbles. Turn off valve 1. The bubbles should now be produced on the inside fitting. 4. If no air is present, check to ensure air is being applied to solenoid valve by loosening the solenoid air supply inlet connection and test for the presence of air with a leak detection solution. If air is applied to the solenoid valve, test to ensure that the solenoid actuation voltage is being applied. 5. Turn off purge air to analyzer. 6. Open the Controller front door. 7. Connect voltmeter leads across DC Solenoid Driver PCB S1 terminals 1 and 2. From the Background screen operate valve 1. The voltage to the 4-way solenoid valve should measure 110 Vdc when the valve is on and zero Vdc when the valve is off. 8. If the voltage is being applied, yet the valve is not switching, replace the solenoid valve. 9. If no voltage is present, remove power and disconnect both solenoid valve leads from S1 terminals Apply power and repeat step If no voltage is present, check the AC voltage to the DC Solenoid Driver PCB. Adjust the voltmeter to read 120 Vac. 12. Connect voltmeter leads between J9 terminals 1 and 2. If voltage is present, proceed to step If 120 Vac is not present, check the voltage at Solenoid #1 VAC J9A terminals 1 and 2. If voltage is present at J9A terminals 1 and 2, check the connections at both ends of the cable connecting J9A and J OSM, F1 7-9

224 14. Remove power and disconnect the cable between J9A and J9. Check continuity between J9A terminals 1, 2, and 3 and J9 terminals 1, 2, and 3, respectively. If any wires are open replace the cable, apply power and repeat step Apply power to analyzer and switch DC solenoid driver using procedure in step If voltage does not switch, replace DC solenoid valve driver PCB. 17. If voltage does not switch, replace Chroma I/O board. 18. Close and tighten the Controller front door. 19. Apply purge air and power. 20. Allow temperature to equilibrate. 21. Perform an analysis to verify analyzer operation. TP 19: DOUBLE SAMPLING 1. Request an analysis run on stream 10 (calibration). 2. Verify double apex peaks by analyzing calibration standard of individually resolved peaks. 3. When the analysis begins, stop the analysis at the end of the cycle. 4. Schedule Sample Valve Off at cycle time plus 20 seconds. 5. Run a second analysis. When the second analysis begins, stop analysis at the end of the cycle. If valve is double sampling, the peak shape will now be normal in most cases. 6. Schedule valve off at normal cycle time. 7. Manually switch the Sample Valve Off and observe the chromatogram. A second set of peaks may now appear. (This is another indication of double sampling.) 8. Turn off power, carrier, and sample supply to the analyzer. 9. Replace sample valve seals and stem (see SAMPLE VALVE REPAIR in Section 8). 10. Restore carrier, sample, and power. 11. Request calibration analysis to verify problem is solved. TP 20: VARIABLE SAMPLE SIZE 1. For a liquid sample valve, observe the analyzer effluent sample flow rotometer for the presence of bubbles. The sample pressure and temperature must be such that the sample pressure at the sample valve is 25 psig above the bubble point of the sample. 2. Ensure that the sample pressure at the sample valve is above the bubble point of the sample. 3. A booster pump may be necessary for process sample if the supply pressure is below the bubble point of the sample or the sample flow rate is not adequate at the supply pressure OSM, F1

225 4. Compare the temperature zone temperatures with those of your application data sheets sent with your chromatograph. Perform Test Procedure 30 (Checking Temperature Table Values) and make any necessary table corrections. Bubbles at the sample valve effluent generally indicate the sample temperature is above the bubble point of the sample. Carrier gas displacement of sample stem groove volume may be occurring due to leaking valve seals, causing varying sample size. 5. Increase sample flow and backpressure by adjusting metering valves at sample system. Perform an analysis and check repeatability. If the analyzer repeats, proceed to step For a vapor sample valve, ensure the sample valve effluent is referenced at atmospheric pressure. A sample shutoff valve may be required or is not operating or is not functioning properly. 7. Perform Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments). 8. Turn off power and air to the analyzer. 9. Open isothermal oven door and the programmed temperature cover (if applicable). Remove the cover to access the column. 10. Leak test column train. When complete, close ovens with reverse procedure of step If leaks were found, restore air and power. After temperatures stabilize, perform an analysis to test repeatability. If analyzer repeats, Test Procedure 20 is complete. 12. Repair sample valve, replacing stem and seals (see SAMPLE VALVE REPAIR in Section 8). 13. Apply air, carrier, sample, and power to the analyzer. Let temperatures stabilize and perform an analysis and check the repeatability. TP 21: OPEN TEMPERATURE SENSOR CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Remove power and purge air from the analyzer. 2. Let all temperature zones cool to ambient. 3. Open the Controller side door. 4. Disconnect the sensor and measure its resistance value. The resistance of the temperature probe should be approximately 440 ohms at 75 F (24 C). If open (extremely high), replace probe. The respective probes may be tested at the locations given below: 2000-OSM, F1 7-11

226 Temperature J48A Zone Board Terminals Assignment 1 4 & 5 Isothermal Oven 2 4 & 5 Programmed Temperature Oven 3 4 & 5 LSV 4 4 & 5 Detector 5 4 & 5 Methanizer/Air Cleanup 5. If temperature probe is open, replace the temperature probe. 6. Close and tighten the Controller side door. TP 22: SHORTED TEMPERATURE SENSOR CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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.. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Remove power from analyzer. 2. Let all temperature zones cool to ambient. 3. Open the Controller side door. 4. Disconnect the sensor and measure its resistance value. The resistance of the temperature probe should be approximately 440 ohms at 75 F (24 C). If shorted or considerable lower, replace probe. The respective probes may be tested at the locations given below: Temperature J48A Zone Board Terminals Assignment 1 4 & 5 Isothermal Oven 2 4 & 5 Programmed Temperature Oven 3 4 & 5 LSV 4 4 & 5 Detector 5 4 & 5 Methanizer/Air Cleanup 5. If temperature probe is shorted, replace the probe. 6. Close and tighten the Controller side door. TP 23: LOSS OF OVEN AIR CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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 OSM, F1

227 CAUTION See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Disconnect power and shut off air to analyzer. 2. Open the Controller side door. 3. Disconnect the oven air pressure switch by removing the connector from J42B on the DTC Backplane PCB (see Figure 7-1). J42B Figure 7-1. DTC BACKPLANE PCB 4. Connect an ohmmeter between the terminals of the connector removed from J42B. 5. Apply oven air pressure. 6. Unscrew the pressure switch slightly and check for leakage to ensure air is present at the switch. 7. Tighten pressure switch. 8. The switch should close. Remove air and the switch should open. If switch does not function as described, replace the oven air pressure switch. 9. Close and tighten the Controller side door OSM, F1 7-13

228 TP 24: ISOTHERMAL OVEN OVERTEMP SENSOR OPEN CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Remove power from the analyzer. 2. Let all temperature zones cool to ambient. 3. Open the Controller side door. 4. Check for loose connections at the specified terminal connections. 5. Disconnect the thermocouple sensor from J49A terminals 1 and 2 of the Zone 1 Temperature Zone PCB. 6. Connect ohmmeter leads between the two disconnected wires and measure the resistance value. If the resistance is extremely high, the thermocouple is open. Replace thermocouple. 7. After repairs, close and tighten the Controller side door. 8. Restore air and power. TP 25: ZONE INPUT SENSOR OPEN CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Remove power from the analyzer. 2. Let all temperature zones cool to ambient. 3. Open the Controller side door. 4. Check for loose connections at the specified terminal connections. 5. Disconnect the RTD sensor from J49A terminals 4 and 5 of the appropriate Temperature Zone PCB. 6. Connect ohmmeter leads between the two disconnected wires and measure the resistance value. Typical resistance will be approximately 430 to 450 ohms at ambient temperature. If resistance is OSM, F1

229 extremely high, the RTD is open. Replace the RTD. The respective probes may be tested at the locations given below: Temperature J49A Zone Board Terminals Assignment 7. Close and tighten the Controller side door. TP 26: OPEN OR SHORTED HEATER 1 4 & 5 Isothermal Oven 2 4 & 5 Programmed Temperature Oven 3 4 & 5 LSV 4 4 & 5 Detector 5 4 & 5 Methanizer/Air Cleanup CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Remove power from analyzer. 2. Open the Controller side door. 3. Locate heater terminal strip connections. Temperature Service Zone Board J49B Isothermal Oven Zone 1 1 and 2 Programmed Temp Zone 2 1 and 2 LSV (120 Vac) Zone 3 1 and 2, 5 and 6 LSV (220 Vac in, 120 V heaters) Zone 3 2 and 3, 4 and 5 LSV (220 Vac in, 220 V heaters) Zone 3 1 and 2, 5 and 6 Detector Zone 4 1 and 2 Methanizer/Air Cleanup Zone 5 1 and 2 4. Check for a loose connection at the defective temperature control circuit. 5. Remove one of the two wires to the defective temperature zone heater. Connect an ohmmeter across these heater wires and measure the resistance of the heater. 6. If open, the measurement will be extremely high. Typical resistance value is 10 to 120 ohms. Also check for shorted heater to ground. A shorted heater may have opened the heater fuse. 7. Perform Test Procedure 27 (Open Fuse to AC Conditioning Board). 8. If resistance indicates the heater is opened or shorted, replace the defective heater (see REPLACING HEATERS in Section 8) OSM, F1 7-15

230 9. Close and tighten the Controller side door. TP 27: OPEN FUSE TO AC CONDITIONING BOARD CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Remove power from analyzer. 2. Open the Controller side door. 3. Locate Fuses F1 and F2 on the AC Conditioning Board. 4. Remove the fuse(s) in question and test with an ohmmeter. The measurement should be approximately zero ohms. If the fuse is open, the measurement will be extremely high. 5. Replace blown fuse. Since a blown fuse may indicate other possible malfunctions or failures, continue with this procedure to verify the analyzer s operational status. 6. Test for shorted heater by performing Test Procedure 26 (Open or Shorted Heater). 7. Apply power to analyzer and determine if the fuse fails (opens). 8. If fuse fails, replace the AC Conditioning Board. 9. Close and tighten the Controller side door. TP 28: FID POLARIZING VOLTAGE TEST CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. CAUTION See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Stop the analysis. 2. Open the Controller front door. 3. Locate the Detector Amplifier on the left side wall of the Controller. Remove the six thumb nuts, cover, and plastic shield from the Detector Amplifier OSM, F1

231 4. Connect a DC voltmeter from Detector Amplifier TB16 terminal 5 to chassis ground. The meter should indicate -110 volts DC. If voltage is -110 VDC, Test Procedure 29 is complete. If the voltage is less than -110 VDC continue with step Disconnect the wire to the polarizer at TB16 terminal 5 and measure the voltage as in step If the voltage indication is below -110 VDC at the 110 volt power supply, replace the 110 volt power supply. 7. If the voltage is -110 VDC, remove power from the analyzer and shut down carrier and makeup gases. 8. Remove polarizer wire from TB16 terminal 3 and connect an ohmmeter between the disconnected wire and chassis ground. The meter should indicate an extremely high resistance (infinity), meter maximum. A lower resistance value may indicate a short, or presence of corrosion or water. The high value gives no assurance that the polarizer is contacting the jet. 9. If any repairs were made, the sensitivity should be checked by applying power to the analyzer and allowing temperatures to equilibrate. Balance detector per Test Procedure 5 (TC Detector Balance) and perform an analysis. If analysis demonstrates correct sensitivity, Test Procedure 28 is complete. 10. Remove power from the analyzer and shut down carrier and makeup gases. 11. Clean the detector cell. See Cleaning FID/Collector in Section Reconnect the wire to TB16 terminal 3 and apply power to the analyzer. 13. Measure with a DC voltmeter between the jet and chassis ground for -110 VDC. Once confirmed remove power for reassembling. 14. Complete FID assembly. 15. Close and tighten the Controller front door and the isothermal oven door. 16. Apply carrier, makeup gas, and power. 17. Allow temperatures to equilibrate and perform an analysis to confirm correct sensitivity and detector operation. TP 29: FLAME OUT LED REMAINS ON AFTER FID FLAME IGNITION CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. Do not ignite the FID flame if the isothermal oven temperature is below operational level. Low oven temperature will result in condensation damage to the flame cell OSM, F1 7-17

232 1. Stop Analysis at the end of analysis cycle and make no sample injections until procedure is completed. 2. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies) and Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments), if not previously checked. 3. Remove power from the analyzer. 4. Open the Controller front door. 5. Locate the Detector Amplifier on the left side wall of the Controller and remove the six thumb nuts, cover, and plastic shield from the Detector Amplifier. 6. Disconnect the thermocouple wires connected to Detector Amplifier TB16 terminals 1 and Connect an ohmmeter between the two thermocouple leads. The ohmmeter reading should indicate continuity. If it does not, the thermocouple is open. Replace the thermocouple (see FID REPAIR/Replacing the Thermocouple Assembly in Section 8). 8. Connect the ohmmeter between one of the thermocouple leads and chassis ground. The resistance should be high. If it is not high, the thermocouple may be shorted to chassis ground. Replace the thermocouple (see FID REPAIR/Replacing the Thermocouple Assembly in Section 8). 9. Reconnect the thermocouple wires. 10. Apply power to the analyzer. 11. Connect a digital voltmeter across capacitor C6 (see Figure 7-2). C6 Figure 7-2. FID AMPLIFIER SHOWING C6 LOCATION 12. Extinguish the FID flame. The Flame Out LED should illuminate. The DVM should indicate 2.5 mv or less. 13. Ignite flame and the LED should go out. The DVM should indicate 3.0 mv or greater. 14. If the electronics does not perform as described in steps 9 through 11, remove power and replace the Detector Amplifier OSM, F1

233 15. Perform FID cell maintenance for cleaning jet and flame out thermocouple (see FID REPAIR/Cleaning the FID Jet in Section 8). 16. Replace the plastic shield, cover, and thumb nuts on the Detector Amplifier. 17. Close and tighten the Controller front door. TP 30: CHECKING TEMPERATURE TABLE VALUES Verify that the software and hardware temperature parameter values are correct and have not been inadvertently changed. To perform this operation, it is necessary to access the temperature configuration table and the manual temperature control mode. 1. Press the F1 soft key until the Background screen is displayed (see Figure 7-3). ********** B A C K G R O U N D ********** ABB Analytical GCC Remote V029-1R (Std GCC) (C) 2001 **ALARM** **ALARM** 18-JUN-2002 TUE 08:16:01 **ALARM** Analysis Time :00114 Peaks Found:00 Cycle Time :00000 State:Idle Current Stream :01 Key Component: Purging Stream :01 none Method :01 entered Exit Manual Cur Report, To Control Basic I/O & Alarms Commands Options F1 F2 F3 F4 Figure 7-3. BACKGROUND SCREEN 2. On the Background screen press the F2 (Manual Control) soft key OSM, F1 7-19

234 3. On the Manual Control Mode screen (see Figure 7-4), press the F4 (Press. & Temp. Control) soft key. ****** Manual Control Mode ****** Valves: Time:00000 Enter Valve: [0] Cycle Time:00000 RECORDER: Chroma BD:1 Method Tbl: 000 Offset: 0% Stream: 01 Attn: 5 Purging: 01 Off Chroma Bar Trend Peaks: 00 PURGE SELECT: :0 State: Idle Start Crest End Peak Time Time Time Area Type Last: Val-Bas Bas-Val Exit Detector Manually Press. & To and Zero Temp. Bckgrnd Graphics Baseline Control F1 F2 F3 F4 Figure 7-4. MANUAL CONTROL MODE SCREEN 4. On the Pres & Temp Control screen (see Figure 7-5), cursor to TEMP CONFIGURATION. **** Pres and Temp Control **** TEMP CONTROL PRES CONTROL TEMP CONFIGURATION Names Zone and Controller Escape Config Limits Type F1 F2 F3 F4 Figure 7-5. PRESSURE AND TEMPERATURE CONTROL SCREEN OSM, F1

235 5. Press the F3 (Names and Limits) soft key to view the 5 Zone Names and Limits Table screen (see Figure 7-6). This table is factory set and is NOT intended to be field modified. In the unlikely event that one of the parameters was changed, the values should be compared to those in the table listing provided with the analyzer. **** 5 Zone Names & Limits Table **** Zone Low High Num Name Limit(C) Limit(C) 1 ISO-OVEN PROG. OVEN T/C CELL LSV TEMP ZONE Exit F1 F2 F3 F4 Figure ZONE NAMES AND LIMITS TABLE SCREEN 6. If the values shown in the table agree with those of the listing, there is no need for table modification. Exit this screen by pressing the F1 (Exit) soft key and go to step If the values do not agree, the values have been changed since the analyzer was shipped from the factory. The correct value(s) should be entered. To modify the temperature configuration table, refer to the DIGITAL TEMPERATURE CONTROLLER in Section Confirm the values of the Manual Temperature Control Mode table OSM, F1 7-21

236 9. On the Pressure and Temperature Control screen (Figure 7-5), cursor up or down until TEMP CONTROL is highlighted. Press the F2 (Manual Temp Control) soft key to access the Manual Temperature Control Mode screen (see Figure 7-7). **** Manual Temperature Control Mode **** Zone Config Actual SP Rate ISO-OVEN ISO 79.9C 80.0C 0.0 PROG. OVEN PROG/C 220.1C 220.0C 30.0 T/C CELL SWITCH 199.8C 200.0C 10.0 LSV ISO 199.9C 200.0C 10.0 Valve # : [0] Time : 0125 Zone # : 2 State : Pk Back Set Point: Ramp Rate: T-Rating Ver VALVES : T2 290C Accept Zero Span Escape Control All All Point Zones Zones F1 F2 F3 F4 Figure 7-7. MANUAL TEMPERATURE CONTROL MODE SCREEN 10. Compare the set point values of temperature zones 1 through 5 with those of the factory table listing that was provided with the chromatograph. If the values agree, there is no need to modify the table. Exit this screen by pressing the F1 (Escape) soft key and proceed to step If the values do not agree, the values have been changed since the analyzer was shipped from the factory. The correct values should be entered. 12. Return to the background screen by repeatedly pressing the F1 soft key until the Background screen is displayed. 13. From the Background screen press the F1 (Exit to Commands) soft key OSM, F1

237 14. On the Commands screen(see Figure 7-8), cursor up or down to highlight TABLE EDIT. Then press the F2 (Methods) soft key to access the methods tables. ****** COMMANDS ****** ANALYSIS CONTROL REPORTS TABLE EDIT PRINTER STORAGE & CONFIG. NAMES MISC. TESTING/SETUP SIM DISTILLATION Go to Other Background Methods Tables F1 F2 F3 F4 Figure 7-8. COMMANDS SCREEN 15. When the Method Table #?? screen appears, enter 1 for the method and then press the F2 (Edit the Table) soft key. 16. The Cal Define & Cycle Time screen appears. Press the F1 (Continue) soft key to display the first eight lines of Method Table # 01 (see Figure 7-9). ***** Method Table #01 ***** Time Function Value 0001 Temp. Contrl Two 0120 Noise Calc On 0125 Noise Calc Off 0128 Auto Zero N/A 0130 Skp, Nxt,Str= Nine 0132 Valve On One 0155 Valve Off One 0160 Distillation On More Below Exit Insert Delete Cal Define Line Line & Cycle Time F1 F2 F3 F4 Figure 7-9. METHOD TABLE SCREEN 2000-OSM, F1 7-23

238 17. Move the cursor up or down to highlight the time associated with Temperature Control Function Two. Then move the cursor to the right to highlight the value Two. The Temperature Control screen appears (see Figure 7-10). ***** Temperature Control ***** Entry Zone Set Point Ramp Rate C C/MIN 01 PROG. OVEN ISO-OVEN ISO-OVEN ISO-OVEN ISO-OVEN ISO-OVEN ISO-OVEN ISO-OVEN More Below Exit F1 F2 F3 F4 Figure TEMPERATURE CONTROL SCREEN 18. Compare the set point and ramp rate values with those in the factory table listings provided with your chromatograph. If they agree, press the F1 (Exit) soft key. If they do not agree, modify the Temperature Control screen as explained in DIGITAL TEMPERATURE CONTROLLER in Section Return to background screen by repeatedly pressing the F1 soft key until the Background screen is displayed. TP 31: PLUGGED JET OR BREATHER CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Remove power from analyzer. 2. If the jet is totally plugged, flame will be extinguished. If restricted, the flame could possibly still be burning at low intensity OSM, F1

239 3. Extinguish flame by reducing burner air, fuel and carrier to zero by rotating regulator adjustment counterclockwise until burner air fuel and carrier gauges indicate zero. When flame is out, the Flame Out LED will illuminate. 4. Connect flow meter (e.g. bubble tower) to FID vent. 5. Increase carrier pressure to value indicated on the application data sheets provided with the chromatograph. Both carrier pressure and carrier vent flow measurement at the FID vent should be the same as indicated on data sheets. If values are the same, jet and flame arrester are not plugged, Test Procedure 31 is complete. If values are low or nonexistent, the jet or flame arrester may be plugged. 6. Reduce the temperature programmed (if applicable) and isothermal oven air pressures to zero psig as indicated by their respective gauges. 7. Open the isothermal oven door. 8. If applicable, remove the temperature programmed temperature oven covers. 9. Disconnect the column fitting at the bottom of the FID. Connect the loose column end to a flow meter. 10. Measure the carrier flow. If flow is restored to the expected measurement, the jet or breather is plugged. Proceed to step 12. If flow is deficient, reconnect the column to the FID and perform step Perform Test Procedure 1 (Carrier, Makeup and Utility Gas Supplies), Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments), and Test Procedure 7 (Column Train Problems), as applicable. If flow is restored, Test Procedure 31 is complete. 12. Remove the breather and replace with a female connector. Attach the flow meter to the open end of connector. Measure the carrier flow. If flow is restored to normal, the flame arrester is plugged. Replace the flame arrester. 13. Repeat steps 4 and 5 above. If flow remains restricted, the jet is plugged. 14. Inspect jet by removing FID cap (see FID REPAIR in Section 8). If jet plugging can not be corrected by removing accumulated matter on jet tip, the FID must be replaced. The FID must be returned to the factor for jet replacement. See FID REPAIR in Section 8 for instruction on removing and reinstalling the FID. 15. Disconnect flow meter, reconnect and tighten all fittings, check for leaks, reattach programmed temperature oven cover and close isothermal oven door using reverse procedure of steps 7 and 8. TP 32: PEAK DISCRIMINATION 1. Request a calibration analysis. 2. Observe the peak areas and new response factors. If a greater percentage change has occurred in the peak height, peak area, and response factors in the heavier components than in the lighter, the presence of peak discrimination is apparent. 3. Perform Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments). 4. Perform Test Procedure 7 (Column Train Problems) OSM, F1 7-25

240 5. Routine validation comparisons will help in the early detection of discrimination. TP 33: CHECKING METHOD TABLE CONFIGURATION Verify the method configuration tables as follows: 1. Press the F1 soft key until the Background screen is displayed (see Figure 7-11). ********** B A C K G R O U N D ********** ABB Analytical GCC Remote V029-1R (Std GCC) (C) 2001 **ALARM** **ALARM** 18-JUN-2002 TUE 08:16:01 **ALARM** Analysis Time :00114 Peaks Found:00 Cycle Time :00000 State:Idle Current Stream :01 Key Component: Purging Stream :01 none Method :01 entered Exit Manual Cur Report, To Control Basic I/O & Alarms Commands Options F1 F2 F3 F4 Figure BACKGROUND SCREEN 2. On the Background screen press the F1 (Exit to Commands) soft key OSM, F1

241 3. On the Commands screen (see Figure 7-12) cursor to highlight TABLE EDIT. Then press the F2 (Methods) soft key. ****** COMMANDS ****** ANALYSIS CONTROL REPORTS TABLE EDIT PRINTER STORAGE & CONFIG. NAMES MISC. TESTING/SETUP SIM DISTILLATION Go to Other Background Methods Tables F1 F2 F3 F4 Figure COMMANDS SCREEN 4. When the Method Table #?? screen appears, enter 1 for the method number and then press the F2 (Edit the Table) soft key. 5. The Cal Define & Cycle Time screen appears. Press the F1 (Continue) soft key to display the first eight lines of Method Table # 01 (see Figure 7-13). ***** Method Table #01 ***** Time Function Value 0001 Temp. Contrl Two 0120 Noise Calc On 0125 Noise Calc Off 0128 Auto Zero N/A 0130 Skp, Nxt,Str= Nine 0132 Valve On One 0155 Valve Off One 0160 Distillation On More Below Exit Insert Delete Cal Define Line Line & Cycle Time F1 F2 F3 F4 Figure METHOD TABLE SCREEN 2000-OSM, F1 7-27

242 6. Refer to the table listings provided with your chromatograph. The function scheduling should be similar to the following: PROCESS STREAM METHOD TABLE Method Table #01 Time Function Value 0001 Temp. Contrl One 0128 Auto Zero N/A 0130 Skp, Nxt,Str= Nine 0132 Valve On One 0155 Valve Off One 0165 Baseline Proj Forward 0172 Forced Gate Valley 0175 Component One 0178 Forced Gate Valley 0179 Forced Gate Valley 0182 Component Two 0185 Forced Gate Valley 0186 Forced Gate Valley 0188 Component Three 0191 Forced Gate Valley 0205 Forced Gate Valley 0208 Component Four 0211 Forced Gate Valley 0212 Forced Gate Valley 0214 Component Five 0220 Forced Gate Valley 0244 Forced Gate Valley 0247 Component Six 0250 Forced Gate Valley 0259 Forced Gate Valley 0262 Component Seven 0265 Forced Gate Valley 0287 Forced Gate Valley 0290 Component Eight 0293 Forced Gate Valley 0710 Stream Step N/A 0768 Component Nine 0769 Component Ten 0770 Component Eleven 0771 Component Twelve 0772 Component Thirteen 0773 Component Fourteen 0774 Component Fifteen 0775 Component Sixteen 0776 Component Seventeen 0777 Component Eighteen 0778 Component Nineteen 0779 Component Twenty OSM, F1

243 CALIBRATION STREAM METHOD TABLE Method Table #10 Time Function Value 0001 Temp. Contrl One 0120 Noise Calc On 0125 Noise Calc Off 0128 Auto Zero N/A 0132 Valve On One 0155 Valve Off One 0160 Slope Detect On Now 0160 Peak Width Eight 0175 Component One 0175 Component One 0182 Component Two 0188 Component Three 0208 Component Four 0217 Component Five 0217 Baseline Valley 0247 Component Six 0262 Component Seven 0290 Component Eight 0290 Baseline Valley 0312 Component Nine 0312 Baseline Valley 0343 Component Ten 0343 Baseline Valley 0359 Component Eleven 0359 Baseline Valley 0390 Component Twelve 0390 Baseline Valley 0424 Component Thirteen 0424 Baseline Valley 0440 Component Fourteen 0440 Baseline Valley 0462 Component Fifteen 0462 Baseline Valley 0509 Component Sixteen 0509 Baseline Valley 0540 Component Seventeen 0540 Baseline Valley 0570 Component Eighteen 0570 Baseline Valley 0601 Component Nineteen 0601 Baseline Valley 0650 Slope Detect Off 0710 Stream Step N/A The various time coded functions are defined as follows. Section 4 contains more complete descriptions of these functions Temp. Contrl One This function ensures that the temperature of the isothermal oven is at the set point value prior to sample injection OSM, F1 7-29

244 0120 Noise Calc On 0125 Noise Calc Off This function samples the baseline to determine the random noise level of the baseline and is applicable only to slope detection Auto Zero N/A This function establishes a baseline zero reference point in the controller. It in effect compensates for the detector offset from electrical zero. Should this function fail or not be scheduled, errors could occur in gating, peak detection, post analysis calculations and peak concentration calculations as a result of errors in baseline correction Skp Nxt,Str= Nine The function at time 0130 causes the next timed function at 0132 to not be executed. Thus, when the next stream is stream 9 (a blank run), the sample valve on command will not occur and a sample will not be injected. Should this function not be scheduled, a whole chromatogram would be saved as a blank run. The result would be a total or near cancellation of the analysis in the post analysis calculation Valve On One This function causes the sample injection by inserting the sample volume contained in the machined groove in valve stem into the injection chamber of the sample valve. Once in the injection chamber, the liquid sample is vaporized and carried into the column train by carrier gas. Should this function fail or not be scheduled, no sample injection would occur Valve Off One This function withdraws the sample machined groove from the injection chamber into the sample chamber, where liquid sample continually flows across the stem in preparation for the next injection. Should this function fail or not be scheduled, only the initial sample injection would occur; the sample loop would never be refilled Baseline Proj Forward This function is used in baseline correction of individual gated peaks Forced Gate Valley This function immediately forces integration to begin and designates the peak topology for the start to be a valley, doing a perpendicular drop to the baseline Component One This function designates which component is being integrated at gate on command Forced Gate Valley This function immediately forces integration to stop and designates the peak end and topology to be a valley, doing a perpendicular drop to baseline. NOTE All other gate and component descriptions are similarly defined. TP 34: VENT BACK PRESSURE 1. Ensure FID or TCD detector vent is vented to atmospheric pressure. 2. Check for insect infestations in vent or atmospheric vent. 3. Replace flame arrester. Check for water in the detector. If necessary clean FID (see FID REPAIR/Cleaning the Collector in Section 8) OSM, F1

245 TP 35: PRINTER TEST 1. On the Background screen, press the F1 (Exit to Commands) soft key. 2. Cursor to PRINTER and then press the F2 (Test Printer) soft key. A string of characters should print. 3. If characters do not print, cursor to TESTING/SETUP and then press the F3 (Hardware Setup) soft key. 4. Match baud rate, parity, parity check and data bits to printer setup. 5. Check the power. The Disconnect switch or circuit breaker to printer must be ON. 6. Look for alarm lights and take corrective action. 7. Check serial cable connected to the printer input. 8. Ensure printer has serial interface installed and set up correctly, using the printer or interface operations manual. TP 36: RESIDUAL SAMPLE 1. Start sample analysis. 2. Observe the chromatogram. At the end of the cycle, stop the analysis NOW. 3. Perform Test Procedure 30 (Checking Temperature Table Values), steps 1 to 3 and 8, to access the Manual Mode. Reduce the attenuation for maximum sensitivity. 4. Observe baseline for additional peaks to elute. 5. If peaks elute, analyzer is experiencing a residual sample analysis. After all peaks have eluted, proceed to step 6. If peaks do not elute, Test Procedure 36 is complete. 6. Turn off power and sample to analyzer. Replace sample valve seals and O-rings (see SAMPLE VALVE REPAIR in Section 8). 7. Restore power and allow temperature zones to come to temperature and stabilize. 8. Perform two regular analyses. 9. In second analysis, determine if residual sample problem is repaired using steps 2 to 5. TP 37: TREND OUTPUT CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements OSM, F1 7-31

246 1. Remove power from analyzer. 2. Remove access cover to terminals on right hand side of electronics housing. 3. Verify if trend board output is set up for 4 to 20 ma or 0 to 5 VDC. 4. If current output, disconnect one wire from the output to be tested, and place the milliammeter in series with the load. See output terminal assignment below. 5. Turn analyzer power on. TREND OUTPUT TERMINAL ASSIGNMENT TREND CHANNEL TB7 + TB7 - SHIELD On the Background screen, press the F1 (Exit to Commands) soft key. 7. On the Commands screen, cursor down to TESTING/SETUP and then press the F2 (Diagnostic Tests) soft key. 8. On the Diagnostic Tests screen, cursor down to DIAGNOSTIC TOOLS and then press the F3 (Trend Output Test) soft key. 9. Enter the a trend test value. The output signal at the meter should respond to equivalent percentage of output. Test for low, middle, and high. 10. If output does not respond or does not reach the expected output value, check the following: a. Connect meter to the output terminal strip TB7 (see connection list in step 4) of the analyzer and repeat step 9. If functioning normally, problem is in loop wiring, connection, or input device and proceed to step 11. b. Check wiring from analyzer output to input of receiving device. c. Access Trend Table and determine if it is setup correctly. Make any necessary corrections. d. Substitute trend board. Existing board may be defective. 11. If board functions normal locally, but receiving device is not correctly reporting signal, check the following: OSM, F1

247 a. With authorized permission, remove one wire from input device of loop to be tested and connect the ammeter in series (voltage parallel). Perform step 9 to determine if loop wiring to input device is functional. b. Check and verify input device input requirement and configuration. c. Determine if an input shunt resistor is needed and determine value. d. Input device may need calibrated or rescaled. TP 38: DIGITAL I/O PCB CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. On the Background screen, press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor down to TESTING/SETUP and then press the F2 (Diagnostic Tests) soft key. 3. On the Diagnostic Tests screen, cursor down to DIAGNOSTIC TOOLS and then press the F2 (Digital Output Test) soft key and follow screen instructions. 4. Connect voltmeter between output terminal of Digital PCB and output common using proper polarity (these are transistor outputs). 5. If Digital I/O PCB functions, check for data entry. 6. If Digital I/O PCB does not function, it is defective. Replace the Digital I/O PCB. TP 39: LOW CARRIER PRESSURE CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. CAUTION See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Check to ensure that the carrier has not been shut off. If so, restore carrier supply. 2. Disconnect power and shut off air to analyzer OSM, F1 7-33

248 3. Disconnect oven carrier pressure switch at J23A terminals 1 and Connect ohmmeter leads between the two wires previously disconnected from J23A terminals 1 and Apply carrier pressure of at least 80 psi. 6. The switch contacts should close. Remove carrier pressure; switch contacts should open. 7. If switch does not function as described, remove carrier pressure and replace pressure switch. 8. If switch functions as described in step 7, but the alarm remains after the switch wiring has been reconnected and carrier applied, replace Chroma I/O PCB. TP 40: LOW SAMPLE FLOW HARDWARE ALARM CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Check to ensure that the sample flow has not been shut off. If so, restore sample flow. 2. Disconnect power to the analyzer. 3. Disconnect sample flow switch at J23E terminals 1 and Connect ohmmeter leads between these two wires. 5. With sample flowing, the switch should open. Stop sample flow and the switch should close. 6. If switch does not function as described, replace flow switch. 7. If switch functions as described in step 5, but the alarm remains after the switch wiring has been reconnected and sample flow established, replace Chroma I/O PCB. TP 41: PROGRAMMED TEMPERATURE OVEN COOL DOWN CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Stop Analysis at the end of this analysis cycle OSM, F1

249 2. Check air pressure for correct adjustment. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies). 3. Check all temperature control parameters. Perform Test Procedure 30 (Checking Temperature Table Values), and correct any errors. 4. Access the Manual Temperature Control Mode by performing steps 1 to 3, 8 and 9 of Test Procedure 30 (Checking Temperature Table Values). Change Zone 2 set point to 220 and rate to Monitor the actual zone 2 temperature. When it reaches 100 degrees, change the set point to the normal initial set point value and rate to You should hear the coolant solenoid valve operate and hear a sudden discharge of air into the programmed temperature oven. 7. If you do not hear the solenoid valve operate, override the X purge using the procedure given in Section 4. If you hear the solenoid valve switch, go to step Open electronics housing door. LED DS8 should be illuminated. If not, replace temperature control board. 9. Access the Manual Temperature Control Mode by performing steps 1 to 3, 8 and 9 of Test Procedure 30 (Checking Temperature Table Values). Change zone 2 set point to 220 and rate to Connect voltmeter leads across J42D terminals 1 and 2 and check for the presence of zero VAC. 11. Monitor the actual zone 2 temperature. When it reaches 100 degrees, change the set point to the initial set point value and rate to Connect voltmeter leads across J42D terminals 1 and 2 and check for the presence of 115 VAC. If voltage is present, replace the solenoid valve. 13. If no voltage is measured between J42D terminals 1 and 2, check for presence of 115 VAC between J42C terminals 1 and If voltage is not present at J42C terminals 1 and 2, check for 115 VAC at J46A terminals 1 and If voltage is present at J46A terminals 1 and 2, shut off power and replace motherboard. 16. If voltage is present at J46D terminals 1 and 2, remove power from the analyzer. 17. Disconnect the solenoid valve coil wires from J42D terminals 1 and 2 and connect an ohmmeter between the solenoid valve wire leads. The solenoid coil will have a small resistance. Check each lead to chassis ground. If shorted to ground or questionable, replace solenoid valve or coil. Inspect leads for bare insulation that could contact chassis or other grounded part and make necessary repairs. 18. Disconnect the solenoid valve coil wires from J42D terminals 1 and 2 and connect an ohmmeter between solenoid valve wire leads. If the coil resistance is extremely high or infinity, replace the solenoid valve or coil and fuse. Repeat procedure in step Apply power to the analyzer OSM, F1 7-35

250 20. Check vortex cooler efficiency as follows. Access the Manual Temperature Control Mode by performing steps 1 to 3, 8 and 9 of Test Procedure 30 (Checking Temperature Table Values). Change zone 2 set point to 0 deg and rate to Monitor the actual zone 2 temperature until temperature measurement is stable. WARNING Discharge air from the vortex cooler is extremely hot and can cause severe burns. 22. Protecting your hands with insulated gloves, adjust the vortex cooler at the discharge end for maximum cooling (minimum temperature) as indicated on actual zone temperature. 23. Enter set point at initial temperature. 24. Close and secure all doors and all covers. 25. Allow temperature to equilibrate. TP 42: STREAM SWITCHING CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. 1. Check valve assignment in method tables. 2. Verify stream is active. Make necessary changes. 3. If electric solenoid valve stream switching is used, proceed to step If air operated valves are used for stream switching, verify actuation air is being applied to the stream select valve actuator. Gently loosen the two fittings at the actuator. Apply Leak Tech, Snoop or other similar liquid leak detector to the back of the fittings. 5. Request an analysis for the steam in question. At stream step, the stream will begin to purge as indicated on the background screen. Actuation air will be applied to the respective actuator, producing bubbles at the loose fitting. When the next different stream is selected, bubbles should cease at the present actuation line. If the actuation is double acting, air will be present at the other actuation line and bubbles will be produced by the leak detector. All streams can be tested in this manner. Reconnect or tighten each fitting that was loosened. 6. If no air is present, check to ensure air is being applied to solenoid valve by loosening the solenoid valve air supply inlet connection. Loosen the inlet air fitting and test for the presence of air with a leak detection solution. 7. If air is applied to the solenoid valve, test to ensure that the solenoid actuation voltage is being applied. 8. Turn off purge air to analyzer and override X purge OSM, F1

251 9. Loosen the four screws that retain the front cover of the heater box. 10. Request an analysis for the stream in question. At stream step the stream will begin to purge as indicated on the background screen. Connect voltmeter leads across the stream switch soleniod valve (process) or the calibration solenoid valve (calibration). The voltage to the solenoid valve should measure 110 VDC when the valve is on and zero volts when the valve is off. If the voltage is being applied, yet the valve is not switching, replace the solenoid valve. 11. If no voltage is present, remove power and disconnect both solenoid valve leads. 12. Connect an ohmmeter between the two solenoid valve coil leads. If open, (extremely high resistance), replace the solenoid valve or coil. 13. Reconnect solenoid valve coil leads. 14. Apply power to analyzer and switch D.C. solenoid driver using procedure in step If voltage does not switch, replace D.C solenoid valve driver PCB. 16. If voltage does not switch, replace Chroma I/O board. 17. Reconnect and tighten all loose or disconnected fittings, and check for and repair any leaks. 18. Close and secure all doors and all covers. 19. Apply purge air and power. 20. Allow temperature to equilibrate. 21. Perform an analysis and verify analyzer operation. TP 43: FPD GAIN SETTING NOTE This test procedure is not normally required, unless the photomultiplier tube is changed. 1. Stop Analysis at the end of the current analysis and make no injection until this procedure is completed. 2. On the Background screen press the F2 (Manual Control) soft key. 3. On the Manual Control Mode screen press the F2 (Detector and Graphics) soft key. 4. On the Chroma Board screen press the F3 (Manually Zero Baseline) soft key. The Detector Reading should change to a value of 2.00 mv ±0.05 mv. 5. On the Chroma Board screen note the Hardware Zero, Software Zero, and Detector Reading values. The hardware zero should be 20 to 80 mv typical. On a clean system it should be 15 to 50 mv. 6. If the hardware zero reading is less than 15 mv, adjust potentiometer R71 on the FPD Electrometer PCB clockwise slightly. 7. Repeat steps 4, 5 and 6 until the hardware zero reading in step 5 is 20 mv OSM, F1 7-37

252 NOTE If the Photomultiplier Tube has very high gain, the reading of step 5 might not be adjustable to a value less than 80 mv. TP 44: FPD FLAME WILL NOT LIGHT CAUTION Do not ignite the FPD flame if the temperature is below operational level. Low detector temperature will result in condensation damage to the flame cell. Flame Out LED is lit. 1. Verify the flame is ignited by observing condensation of water vapor at the detector vent. 2. If there is no condensation, the flame is not lit; go to step 4. If condensation is present, check the detector offset (background). a. Disconnect the red coaxial lead from the photomultiplier tube (PMT). b. Connect a digital voltmeter (with 10 megohms input impedance) between ground and the center pin of the PMT coax connector. c. Record the meter reading. If it is less than 30 mv go to step 3. d. If it is more than 30 mv, the detector is normal. Replace the Electrometer PCB or Chroma I/O PCB. 3. Check the PMT supply voltage on the Electrometer. a. At pin A of the 3-pin connector on the PMT housing, you should get at least 40V + 4.5V per turn of the gain pot. b. If the voltage is too low, check the Electrometer PCB supply voltages, ± 15volts. c. If the Electrometer PCB supply voltages are correct, replace the Electrometer PCB. d. If the Electrometer PCB supply voltages are low or missing, replace the Power Supply PCB. 4. If the flame is not lit, perform the following steps. a. Ensure burner air and burner fuel are adjusted to the value shown on application data sheets. b. If flows and pressures cannot be adjusted, perform Test Procedure 31 (Plugged Jet or Breather). c. Jet is too high. d. Jet is broken. Flame Out LED is not lit. 1. Ensure burner air and burner fuel are adjusted to the value shown on application data sheets. 2. If flows and pressures cannot be adjusted, perform Test Procedure 31 (Plugged Jet or Breather) OSM, F1

253 TP 45: FLAME OUT LED REMAINS ON AFTER FPD FLAME IGNITION CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure requirements. Do not ignite the FPD flame if the isothermal oven temperature is below operational level. Low oven temperature will result in condensation damage to the flame cell. 1. Stop Analysis at the end of analysis cycle and make no sample injections until procedure is completed. 2. Perform Test Procedure 1 (Carrier, Makeup, and Utility Gas Supplies) and Test Procedure 2 (Carrier and Makeup Gas Flow Adjustments), if not previously checked. 3. Remove power from the analyzer. 4. Open the door on the right side of the analyzer. 5. Locate the FPD Zone Board. 6. Disconnect the thermocouple wires connected to J49A terminals 1 and 2 on the Zone Board (see Figure 7-14). J49A Figure FPD ZONE BOARD 7. Connect an ohmmeter between the two thermocouple leads. The ohmmeter reading should indicate continuity. If it does not, the thermocouple is open. Replace the thermocouple (see FID REPAIR/Replacing the Thermocouple Assembly in Section 8). 8. Connect the ohmmeter between one of the thermocouple leads and chassis ground. The resistance should be high. If it is not high, the thermocouple may be shorted to chassis ground. Replace the thermocouple (see FID REPAIR/Replacing the Thermocouple Assembly in Section 8). 9. Reconnect the thermocouple wires. 10. Disconnect the thermocouple wires connected to J49A terminals 7 and 8 on the Zone Board OSM, F1 7-39

254 11. Connect an ohmmeter between the two thermocouple leads. The ohmmeter reading should indicate continuity. If it does not, the thermocouple is open. Replace the thermocouple (see FID REPAIR/Replacing the Thermocouple Assembly in Section 8). 12. Connect the ohmmeter between one of the thermocouple leads and chassis ground. The resistance should be high. If it is not high, the thermocouple may be shorted to chassis ground. Replace the thermocouple (see FID REPAIR/Replacing the Thermocouple Assembly in Section 8). 13. Reconnect the thermocouple wires. 14. Apply power to the analyzer. 15. Connect a digital voltmeter betweenterminals7 and 8 of J49A. 16. Extinguish the FID flame. The Flame Out LED should illuminate. The DVM should indicate 2.5 mv or less. 17. Ignite flame and the LED should go out. The DVM should indicate 3.0 mv or greater. 18. If the electronics does not perform as described in steps 9 through 11, remove power and replace the Detector Amplifier. 19. Close and tighten the right side door OSM, F1

255 SECTION 8. REPAIR REPLACING HEATERS Refer to Figure 8-1 for component location when replacing heaters. Temperature Sensor Thermocouple Detector Methanizer Liquid Sample Valve Oven Heater Column Figure 8-1. ANALYZER OVEN COMPARTMENT CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See "AIR PURGING" in Section 4 for the X Purge override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure properly. Isothermal Temperature Oven Heater 1. Open the Controller front and side doors and the isothermal oven door. 2. On the Zone 1 PCB in the Digital Temperature Controller, disconnect J49B and remove the isothermal oven heater wires from pins 1 and On the Zone 1 PCB, disconnect J49A and remove the thermocouple wires from pins 1 and On the DTC Backplane PCB disconnect J42A and remove the thermocouple wires from pins 1 and Connect a small feeder wire (at least 36 inches long) to one of the heater wires. 6. In the isothermal oven disconnect the 1/4-inch fitting from the heater. 7. Extract the heater assembly from the clamp. 8. Withdraw the heater and wires from the feedthrough grommet and into the oven OSM, F1 8-1

256 9. Connect the wires from the new heater assembly to the feeder wire pulled through the tubing. 10. Install the new heater assembly using the reverse procedure, pulling the wires through the tubing. Sample Valve Heater WARNING Sample will spill or leak out during this procedure. 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 glasses. CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See AIR PURGING in Section 4 for the X Purge override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure properly. 1. Remove power, sample flow, and air from analyzer and allow to cool. 2. Open the Controller front and side doors, and the isothermal oven door. 3. Locate the Zone Sense Board and disconnect the LSV heater and sensor wires. 4. Withdraw the free end of the vaporizer cable from beneath the Card Cage into the Controller housing. 5. Inside the isothermal oven, loosen any cable clamps securing the vaporizer cable assembly and free the cable. 6. Disconnect all tubing connections to the LSV in the isothermal oven. 7. Disconnect the air lines from the LSV actuator. 8. Disconnect all tubing connections to the LSV in the isothermal oven. 9. Support the valve with your hand and remove the four Allen screws securing the valve to the analyzer. 10. Withdraw the sample valve body from the oven. 11. Remove the vaporizer assembly collar from the valve, separate the vaporizer halves, and remove the vaporizer. 12. Reassemble and connect the vaporizer using the reverse procedure OSM, F1

257 SAMPLE VALVE REPAIR The Liquid Sample Valve (LSV) utilizes two different connection methods for the sample lines. Earlier analyzers had these sample lines connected directly to the LSV, as shown in Figure 8-2. Putting a loop in the tubing or using flexible hose reduces any sideways force at the connection. Forcing the tubing into a position can exert a sideways force at the connection, causing valve leakage. INCORRECT CORRECT Figure 8-2. LSV CONNECTION METHODS, EARLY ANALYZERS New analyzers have the sample lines connected to a mounting plate attached to the LSV's mounting flange, as shown in Figure 8-3. Customer Connections Figure 8-3. LSV CONNECTION METHODS, NEW ANALYZERS You must take extreme care to avoid having the sample lines exert force on the sample connections of the Liquid Sample Valve. For example, if stiff 1/4-inch tubing or heat-traced lines are bent into position and attached to the valve or to the mounting plate, the force will cause premature failure of the valve and possibly bend the stem. A loop of 1/8-inch tubing or a flex hose is recommended between the valve and the sample line (this may be insulated if necessary). Figure 8-2 illustrates the incorrect and correct connection methods OSM, F1 8-3

258 It is also important to use two wrenches when tightening the sample line connections to the sample chamber. One wrench must be used to back up the force applied to tighten the fitting (direct wrench force will bend the stem). WARNING Sample will spill or leak out during this procedure. 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 glasses. CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See AIR PURGING in Section 4 for the X Purge override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure properly. NOTE To ensure the integrity of the components within the Liquid Sample Valve (LSV), use the tools in LSV Tool Kit 791K009-1 when assembling or disassembling the LSV OSM, F1

259 Disassembly on the Analyzer See Figure 8-4 for typical sample valve component location. Figure 8-4. LIQUID SAMPLE VALVE COMPONENT LOCATION 1. Stop the analysis at the end of a cycle. 2. Turn off power, carrier, sample, and air to the analyzer. 3. Open the isothermal oven door. 4. Label all tubing connections to the Liquid Sample Valve. 5. Disconnect all tubing from the Liquid Sample Valve. 6. Mark the analyzer and flange to ensure the flange is reinstalled in the correct orientation. 7. Remove the four screws holding the flange to the side of the analyzer. 8. Separate the LSV from the analyzer, being careful not to stress the vaporizer assembly cabling. 9. Remove the insulation cover and insulation from around the vaporizer assembly. 10. Remove the four screws that retain the two parts of the vaporizer assembly. 11. Separate the vaporizer assembly from the vaporizer chamber. 12. Remove the two cone point set screws from the cylinder. 13. Slide the cylinder off the piston and body. 14. Mark on the body the location of the sample chamber. 15. Using a hex key wrench, rotate the sleeve counterclockwise until it is loose. 16. Unscrew the body from the flange and vaporizer chamber OSM, F1 8-5

260 17. Remove the vaporizer chamber from the flange. 18. Slide the seal from the stem using the sample chamber. 19. Withdraw the piston and the piston rod from the sleeve. 20. This will free the seal from the stem. 21. Replace the seals. 22. Inspect the stem for visible imperfections. If imperfections are found, replace the stem. 23. Remove the rear valve seat from the body. 24. Remove the 15 Belleville springs from the body. 25. Inspect the body O-rings for visible imperfections. If imperfections are found, remove the body O-rings from the body and piston. 26. Unscrew the piston rod from the piston and extract the stem assembly from the piston rod. 27. Inspect the piston rod O-ring for visible imperfections. If imperfections are found, remove the piston rod O-ring from the piston rod. 28. Unscrew the sleeve from the body. 29. Inspect the sleeve O-ring for visible imperfections. If imperfections are found, remove the sleeve O-ring from the sleeve. Reassembly on the Analyzer NOTE In all steps the lubricant used is High Vacuum Grease, ABB part number Clean the seals with acetone and air dry them. 2. Clean the sample chamber with acetone and air dry it. 3. Lightly lubricate the sleeve O-Ring and the sleeve threads, internal threads and bore of the body with High Vacuum Grease. 4. Install the sleeve O-ring onto the sleeve. 5. Screw the sleeve into the body until the bottom of the sleeve grooves is flush with the ears on the back of the body. 6. Lightly lubricate the piston rod O-ring and the threads of the piston rod. 7. Install the piston rod O-ring onto the piston rod. Do not allow grease to enter the small hole through the center of the piston. 8. Insert the stem into the rear of the piston rod. 9. Screw the piston rod into the piston and tighten to in-lb. Do not overtighten or bend the rod or stem! Do not allow grease to contact the stem OSM, F1

261 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 Belleville springs onto the 1/4-inch thin wall plastic tubing, as shown in Figure 8-5. Figure 8-5. 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. Install the rear valve seat over the stem and let it rest against the Belleville springs. Do not allow the seat to scratch the stem. 16. Clean all the exposed area of the stem with acetone to ensure the stem and groove are free of grease and contamination. 17. Slide the first cleaned seal over the stem using the A end of Seal Insertion Tool TL-791A006B. The 30 angle (pointed end) of the seal must face the Belleville springs. 18. Slide the cleaned sample chamber over the stem onto the seal. 19. Slide the second cleaned seal over the stem using the B end of Seal Insertion Tool TL- 791A006B. The 30 angled (pointed end) of the seal faces out, away from the sample chamber. 20. Install the vaporizer chamber into the flange. 21. Lightly lubricate the threads on the body. 22. Retract the stem until it is flush with the front of the seal. 23. Screw the body into the flange against the vaporizer chamber until tight. 24. Push the stem into place OSM, F1 8-7

262 25. The sample chamber should be loose in the assembly at this point. If not, back out the sleeve until the sample chamber is loose. Use the end of a Allen wrench in the slot of the sleeve to adjust to the point of eliminating the longitudinal play of the sample chamber. 26. Tighten the sleeve in 24 1/4-turn increments (6 turns total) to preload the seals. 27. Lightly lubricate the inside bore of the cylinder. 28. Align the fittings on the cylinder with the sample chamber tubes, or with air lines if servicing. 29. Slide the cylinder onto the piston and the body. 30. Install two cone point set screws into the cylinder and tighten into the groove on the body. 31. Assemble the vaporizer assembly around the vaporizer chamber. 32. Insert the four screws that retain the two parts of the vaporizer assembly and tighten them. 33. Install the insulation around the vaporizer assembly. 34. Install the insulation cover over the vaporizer assembly and insulation. 35. Open the isothermal oven door. 36. Orient the flange so that the marks made at LSV removal are lined up. This should have the sample chamber vertical with the air connections at the top of the valve and the connection of the vaporizer chamber at the top. 37. Install the four flange screws and tighten them. 38. Reinstall tubing to the LSV, being careful to connect each line to the proper connection on the LSV. 39. Close the isothermal oven door. Removing the LSV from the Analyzer 1. Stop the analysis at the end of a cycle. 2. Turn off power, carrier, sample, and air to the analyzer. 3. Open the isothermal oven door. 4. Label all tubing connections to the Liquid Sample Valve. 5. Disconnect all tubing from the Liquid Sample Valve. 6. Mark the analyzer and flange to ensure the flange is reinstalled in the correct orientation. 7. Remove the four screws holding the flange to the side of the analyzer. 8. Remove the LSV from the analyzer. 9. Remove the insulation cover and insulation from around the vaporizer assembly. 10. Remove the four screws that retain the two parts of the vaporizer assembly OSM, F1

263 11. Separate the vaporizer assembly from the vaporizer chamber. 12. Remove the LSV to the workbench. Disassembly on the Workbench See Figure 8-6 for typical sample valve component location. Figure 8-6. LIQUID SAMPLE VALVE COMPONENT LOCATION 1. Perform Removing the LSV from the Analyzer. 2. Move the LSV to the workbench. 3. Remove the two cone point set screws from the cylinder. 4. Slide the cylinder off the piston and body. 5. Mark on the body the location of the sample chamber. 6. Using a hex key wrench, rotate the sleeve counterclockwise until it is loose. 7. Unscrew the body from the flange and vaporizer chamber. 8. Remove the vaporizer chamber from the flange. 9. Slide the seal from the stem using the sample chamber. 10. Withdraw the piston and the piston rod from the sleeve. 11. This will free the seal from the stem. 12. Replace the seals. 13. Inspect the stem for visible imperfections. If imperfections are found, replace the stem. 14. Remove the rear valve seat from the body OSM, F1 8-9

264 15. Remove the 15 Belleville springs from the body. 16. Inspect the body O-rings for visible imperfections. If imperfections are found, remove the body O-rings from the body and piston. 17. Unscrew the piston rod from the piston and extract the stem assembly from the piston rod. 18. Inspect the piston rod O-ring for visible imperfections. If imperfections are found, remove the piston rod O-ring from the piston rod. 19. Unscrew the sleeve from the body. 20. Inspect the sleeve O-ring for visible imperfections. If imperfections are found, remove the sleeve O-ring from the sleeve. Reassembly on the Workbench NOTE In all steps the lubricant used is High Vacuum Grease, ABB part number Clean the seals with acetone and air dry them. 2. Clean the sample chamber with acetone and air dry it. 3. Lightly lubricate the sleeve O-Ring and the sleeve threads, internal threads and bore of the body with High Vacuum Grease. 4. Install the sleeve O-ring onto the sleeve. 5. Screw the sleeve into the body until the bottom of the sleeve grooves is flush with the ears on the back of the body. 6. Lightly lubricate the piston rod O-ring and the threads of the piston rod. 7. Install the piston rod O-ring onto the piston rod. Do not allow grease to enter the small hole through the center of the piston. 8. Insert the stem into the rear of the piston rod. 9. Screw the piston rod into the piston and tighten to 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 OSM, F1

265 13. Stack the 15 Belleville springs onto the 1/4-inch thin wall plastic tubing, as shown in Figure 8-7. Figure 8-7. 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. Install the rear valve seat over the stem and let it rest against the Belleville springs. Do not allow the seat to scratch the stem. 16. Clean all the exposed area of the stem with acetone to ensure the stem and groove are free of grease and contamination. 17. Slide the first cleaned seal over the stem using the A end of Seal Insertion Tool TL-791A006B. The 30 angle (pointed end) of the seal must face the Belleville springs. 18. Slide the cleaned sample chamber over the stem onto the seal. 19. Slide the second cleaned seal over the stem using the B end of Seal Insertion Tool TL- 791A006B. The 30 angled (pointed end) of the seal faces out, away from the sample chamber. 20. Install the vaporizer chamber into the flange. 21. Lightly lubricate the threads on the body. 22. Retract the stem until it is flush with the front of the seal. 23. Screw the body into the flange against the vaporizer chamber until tight. 24. Push the stem into place. 25. The sample chamber should be loose in the assembly at this point. If not, back out the sleeve until the sample chamber is loose. Use the end of a Allen wrench in the slot of the sleeve to adjust to the point of eliminating the longitudinal play of the sample chamber. 26. Tighten the sleeve in 24 1/4-turn increments (6 turns total) to preload the seals. 27. Lightly lubricate the inside bore of the cylinder. 28. Align the fittings on the cylinder with the sample chamber tubes, or with air lines if servicing. 29. Slide the cylinder onto the piston and the body OSM, F1 8-11

266 30. Install two cone point set screws into the cylinder and tighten into the groove on the body. 31. Perform Installing an LSV on the Analyzer. Installing the LSV on the Analyzer 1. Open the isothermal oven door. 2. Install the vaporizer assembly around the vaporizer chamber. 3. Install the four screws that retain the two parts of the vaporizer assembly. 4. Install the insulation around the vaporizer assembly. 5. Install the insulation cover over the vaporizer assembly and insulation. 6. Install the LSV on the analyzer. 7. Orient the flange so that the marks made at LSV removal are lined up. This should have the sample chamber vertical with the air connections at the top of the valve and the connection of the vaporizer chamber at the top. 8. Install the four screws holding the flange to the side of the analyzer and tighten the screws. 9. Reconnect all tubing on the Liquid Sample Valve. 10. Close the isothermal oven door. Replacing the LSV Vaporizer Assembly 1. On the Manual Temperature Control Mode screen, note which zone has the LSV connection. 2. Stop the analysis at the end of a cycle. 3. Turn off power, carrier, sample, and air to the analyzer and allow it to cool. 4. Open the Controller front and side doors, and the isothermal oven door. 5. In the Digital Temperature Controller, locate the Liquid Sample Valve s Zone Board. 6. Disconnect the LSV heater and sensor wires, which make up the vaporizer cable. 7. Withdraw the free end of the vaporizer cable from beneath the Card Cage into the Controller housing. 8. Inside the isothermal oven, loosen any cable clamps securing the vaporizer cable assembly and free the cable. 9. Label all tubing connections to the LSV. 10. Disconnect all tubing connections to the LSV. 11. Mark the analyzer and flange to ensure the flange is reinstalled in the correct orientation. 12. Remove the four screws holding the flange to the side of the analyzer. 13. Separate the LSV from the analyzer OSM, F1

267 14. Remove the insulation cover from the vaporizer assembly. 15. Remove the insulation from around the vaporizer assembly. 16. Remove the four bolts fastening the two parts of the vaporizer assembly. 17. Remove the two parts of the vaporizer assembly. 18. Reassemble and connect the vaporizer assembly in the reverse order of disassembly. COLUMN INSTALLATION OR REPLACEMENT Refer to Figure 8-1 for column location. CAUTION 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. Column Removal 1. If analyzer is running and a column is to be replaced, stop the analysis. 2. Remove power from the analyzer. 3. Reduce Isothermal Oven temperature by reducing oven air pressure to zero psig. 4. Shut off carrier and other FID makeup gases (if applicable). 5. Open isothermal oven door. 6. To remove the column, loosen the fittings on both ends of the column and gently extract the column from the respective fitting connections. 7. Loosen any screw securing the column to the column mounting brackets and remove the column. Packed Column Installation 1. Install the column, orienting it in such a way that one end can be connected to the fitting at the LSV and the other into the bottom of the detector. 2. Fasten and secure column in place at the column mounting bracket with the retaining screws. 3. Insert the column end into the appropriate fitting connection and finger-tighten the nut. Then tighten it an additional 1/4 turn and test column for a secure connection. 4. Apply carrier gas and leak check. Further tighten the two fittings as required to ensure no leaks are present. 5. Close and secure the Isothermal Oven door. 6. Apply air and makeup gases OSM, F1 8-13

268 7. Allow zone temperatures to stabilize. 8. Check and adjust carrier and makeup gases flow rates. 9. Ignite FID (if applicable). Capillary Column Installation 1. 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 in "Cutting Capillary Columns." 2. Insert the end of the column through the back of the tubing nut. 3. Insert the column end through the new ferrule. 4. Slide the ferrule down the length of the column approximately three inches. 5. Insert the extended column length and the end of the ferrule into the appropriate tubing connection at the sample valve. 6. Connect the tubing nut and finger-tighten; then tighten it an additional 1/4-turn with an open-end wrench. 7. Test the column for a secure connection by gently pulling the column at the 1/8-inch tubing nut. Any withdraw should be corrected. Continue to tighten the nut until the column is securely connected at the fitting. 8. Repeat steps 1 through 7 for the other end of the column. 9. For columns connected to an FID, insert the column end into the FID analysis inlet connection until it stops against the jet. Then withdraw the column approximately 1/16-inch and tighten the nut finger tight. Tighten the nut an additional 1/4-turn with an open-end wrench, then check it for a secure fit. NOTE If a metal capillary column is used, particular care should be taken to ensure that the column does not contact the jet. The metal column will conduct electricity and could cause an electrical short at the jet. 10. Apply carrier gas and check for leaks. Further tighten the two fittings as required to stop any leaks. 11. Install all analyzer covers and doors. 12. Perform the analyzer startup procedure as described in Section 2. Cutting Capillary Columns The procedure for cutting glass or metal capillary columns is the same, except that a small sharp file may be used to score metal columns OSM, F1

269 NOTE Do not use high speed cutting wheels or grinders to cut capillary columns. This type of cutting generates heat that can damage the column and the resultant column cuttings could plug the column. 1. Use a diamond or ceramic scoring tool to score the surface of the outside tubing wall approximately one inch from the end of the column. Take care not to cut through the tubing wall. 2. Wipe the scored area clean to prevent material from entering the column. 3. Secure the column with your fingers 1/2-inch on each side of the score and gently bend the tubing at the score, in the direction opposite the score. When the score point opens, bend the tubing back towards the score. The tubing should make a clean break. 4. 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. 5. The column is now ready for installation. FID REPAIR Refer to Figure 8-8 for FID component location. Breather Adapter Microdot Connector Thermocouple Ignitor Polarizer Jet Figure 8-8. FLAME IONIZATION DETECTOR CAUTION This repair should only be attempted by people who are properly trained and posses the expertise for this repair. Before disposing of any residual insulating materials, ensure that disposal methods comply with all applicable regulatory restrictions OSM, F1 8-15

270 FID Cell Access CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See AIR PURGING in Section 4 for the X Purge override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure properly. The thermocouple, polarizer and ignitor assembly elements are fragile and can be easily damaged if not handled with extreme care. Do not touch the end of the elements. 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. Personal protective equipment such as goggles, face shield, lab coat and rubber gloves should be used while cleaning with solvents such as acetone. Cleaning with solvents should be done in a well ventilated area. 1. If power is applied to the analyzer, turn it off. 2. Turn off oven air to the Isothermal Oven and allow all temperature zones to cool. 3. Turn off carrier and other gases, as applicable. 4. Open the isothermal oven door. 5. For temperature programmed units, you must remove the insulated covers surrounding the FID cell body to access any of the FID cell internal components. Replacing the Breather 1. Disconnect the red coaxial cable located on the top of the detector. 2. Loosen the breather set screw using a inch Allen wrench, then extract the adapter fitting from the detector. 3. Using a 9/16-inch open-end wrench and a 1/2-inch backup wrench, disconnect 1/4-inch vent connection from breather. 4. Remove the breather with adapter fitting from the analyzer oven. 5. Remove adapter fitting from breather using 3/4-inch and 1/2-inch open-end wrenches. 6. Using a 3/4-inch open-end wrench and a 1/2-inch backup wrench, remove the 1/4-inch male connector from the existing breather. 7. Remove existing Teflon tape from the nipple of the adapter fitting and apply new tape. 8. Remove the existing Teflon tape from the male connector and apply new tape OSM, F1

271 9. Install the detector outlet adapter into the breather and finger tighten. Finish tightening using 3/4- inch and 1/2-inch open-end wrenches. 10. Install the 1/4-inch male connector into the breather using 3/4-inch and 1/2-inch open-end wrenches. 11. Connect the 1/4-inch detector vent tubing to the breather. Finger tighten, then tighten with a 9/16-inch open-end wrench and a 1/2-inch backup wrench. 12. Ensure the detector vent O-ring is in place in the adapter fitting. 13. Finish installing the breather by inserting the cylindrical end of the adapter fitting completely into the detector outlet and tightening the set screw with a inch Allen wrench. Note the set screw will fit into the groove of the adapter fitting when installed correctly. 14. Reconnect the red coaxial cable to the top of the detector. 15. Close and secure the isothermal oven door. Replacing the Thermocouple Assembly 1. Disconnect the red coaxial cable located on the top the detector. 2. Locate the thermocouple assembly as identified by the two red and black wires. 3. If applicable, remove any cable ties and free the wiring to expose the wire splices. 4. Cut and remove the heat shrink and glass tape from the red and black wires to expose the soldered connections. 5. Using a 40 watt soldering iron, disconnect the wiring splice. 6. Using a 3/8-inch open-end wrench, carefully remove the thermocouple. Note its location for reassembly. 7. Carefully insert the replacement thermocouple into the detector body and finger tighten, taking care not to damage it. Finish tightening using a 3/8-inch open-end wrench. 8. Roll each end of the red and black wires of the new thermocouple assembly between your forefinger and thumb, causing the wire ends to be tightly spiral wrapped. 9. Using the 40 watt soldering iron and approved high temperature solder, tin the wire ends. 10. Spread or expand the end of approved heat shrink to allow easy installation over the solder connection. 11. Install the heat shrink over each of the wires and slide it as far as possible from the connection. This will prevent premature shrinking of it when the connection is soldered. 12. Overlap the tinned ends of the red wire from the analyzer electronics and red element assembly wire, then solder the wires together using approved high temperature solder and the 40 watt soldering iron. 13. Repeat step 12 for the black wire. 14. Apply a short wrap of glass tape over each connection OSM, F1 8-17

272 15. Slide the heat shrink over the soldered connection and shrink it with a heat gun. 16. Reconnect the red coaxial cable to the top of the detector. 17. Close and secure the isothermal oven door. Accessing the Polarizer and Ignitor Elements 1. Disconnect the red coaxial cable located on the top of the detector. 2. Cut cable ties securing the detector element assembly wiring and straighten the wires to increase accessibility. 3. Remove the breather as described in "Replacing the Breather." 4. Visually trace the capillary tubing connections from the detector to the nearest unions. Place temporary tape labels on each side of the union tubing connections. 5. Disconnect the associated capillary connections at the unions. NOTE Steps 6 through 8 are required only for Temperature Programmed analyzers. 6. Rotate the detector cover latch counterclockwise until it is freed from the detector body. 7. Slide the detector cover from the detector heater housing and set aside. 8. Remove enough of the insulation from the detector heater housing to expose the polarizer and ignitor; retain it for later use. 9. Position the wiring and capillary tubing such that the housing can be lifted from the detector base up over the detector, then lift off the housing, fully exposing the detector body and elements. Replacing the Polarizer 1. After accessing the detector elements as described in "Accessing the Polarizer and Ignitor Elements," locate the polarizer as identified by the element with the single green wire. 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 green wire to expose the soldered connection. 4. Using a 40 watt soldering iron, disconnect the wire splice. 5. Using a 3/8-inch open-end wrench, carefully remove the polarizer assembly. Note its location for reassembly. 6. Carefully insert the replacement polarizer into the detector body and finger tighten, taking care not to damage it. Finish tightening using a 3/8-inch open-end wrench. 7. Roll each end of the green wire of the new polarizer between your forefinger and thumb, causing the wire ends to be tightly spiral wrapped. 8. Using the 40 watt soldering iron and approved high temperature solder, tin the wire ends OSM, F1

273 9. 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. 11. Overlap and solder the tinned ends of the green wire from the wiring harness and the green polarizer assembly wire using approved high temperature solder and 40 watt soldering iron. 12. Apply a short wrap of glass tape over the connection. 13. Slide the heat shrink over the taped connection and shrink it with a heat gun. 14. Close the detector as described in "Closing the Detector." Replacing the Ignitor Assembly 1. After accessing the detector elements as described in "Accessing the Polarizer and Ignitor Elements," locate the ignitor identified by the element with the two white 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 two white 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, continue loosening and carefully remove the Ignitor assembly. Note its location for reassembly. 6. Carefully insert the replacement ignitor into the detector body and finger tighten, taking care not to damage it. Finish tightening using a 3/8-inch open-end wrench. 7. Roll each end of the two white wires of the new ignitor between your forefinger and thumb, causing the wire ends to be tightly spiral wrapped. 8. Using the 40 watt soldering iron and approved high temperature solder, tin the wire ends. 9. Spread or expand the end of approved heat shrink to allow easy installation over the solder connection. 10. Overlap and solder the tinned ends of one white wire from the wiring harness and one white ignitor assembly wire and solder the wires together using approved high temperature solder and 40 watt soldering iron. 11. Repeat this operation for the remaining white wire. 12. Apply a short wrap of glass tape over each connection. 13. Slide the heat shrink over the taped connection and shrink it with a heat gun. 14. Close the detector as described in "Closing the Detector." Closing the Detector 1. Verify that all work inside the detector housing is complete OSM, F1 8-19

274 2. Route the wiring up through the top of the detector housing. NOTE Steps 3 through 6 are required only for Temperature Programmed analyzers. 3. Slide the housing down over the insulation and detector body onto the base. The housing must slide over the circular base and rest on the mounting bracket. 4. Bend the capillary tubing back into place, then route the wiring to the back of the detector housing and install insulation into the housing. 5. Install the detector cover by channeling the cover slot through the machined groove in the detector body, while sliding the cover into place. Note that the wiring exits through the slot in the cover, and that the capillary tubing exits the can through the sheared edge of the top cover. 6. Rotate the detector cover latch clockwise until is secured by the detector. Note the small slot in the latch also fits into the same machined groove the cover fits. 7. Install the breather as explained in "Replacing the Breather." 8. Using the previously installed temporary labels, connect the capillary tubes to their respective unions. 9. Remove the temporary labels. 10. Install cable ties to secure the detector wiring. 11. Install the red coaxial cable to the connector on top of the detector. 12. Close and secure the isothermal oven door. Cleaning the FID Jet NOTE Steps 1 and 2 are required only for Temperature Programmed analyzers. 1. Remove the three screws securing the detector can assembly, using a 9/64-inch Allen wrench or ball driver. 2. Extract the can from the isothermal oven. 3. 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). 4. On CENELEC AND CSA models, loosen the 7/16-inch packing adapter nut using a 7/16-inch open-end wrench, backed up with a 1/2-inch open-end wrench on the 1/2-inch packing adapter nut. Continue to loosen by hand until disconnected. 5. For all models, loosen the 1/2-inch packing adapter nut using a 1/2-inch open-end wrench with a 5/8-inch open-end back-up wrench. Continue to loosen by hand until disconnected. 6. Withdraw the column and associated ferrules and adapters from the detector. 7. Loosen the 5/8-inch adapter fitting from the bottom of the detector OSM, F1

275 8. Extract the jet with the adapter fitting from the jet cavity in the detector. 9. Inspect the end of the jet for damage. It should not be pitted or plugged. If pitted, replace with a new jet. 10. Insert a inch diameter piano wire into the jet and rod it out. If the piano wire will not pass through, replace the jet. 11. Using a syringe and protective equipment and clothing, flush the jet with a mild solvent such as acetone; then blow dry with 15 psig clean air, nitrogen or helium. 12. Use a 5/8-inch adapter fitting to insert the jet into the jet cavity. Finger tighten and finish tightening using a 5/8-inch open-end wrench. 13. Insert the column end, ferrule and adapter nut into the detector inlet and finger tighten; then loosen 1/8 turn. 14. If the ferrule was loose and slid any length on the column, continue to push the column into the detector analysis inlet until it stops. 15. Withdraw the column approximately one mm and tighten the 1/2-inch adapter nut finger tight. Tighten the nut 1/4 turn more with a 1/2-inch open-end wrench, then check it for a secure fit by gently attempting to pull the column slightly away from the detector. Carefully tighten the adapter until the column is secure. 16. For CENELEC and CSA models, slide the 7/16-inch packing adapter nut and ferrule toward the detector and install finger tight. Tighten the nut an additional 1/4 turn with a 7/16-inch open-end wrench. 17. For temperature programmed units, install the detector can assembly and secure it with the hex head screws using a 9/64-inch Allen wrench or ball driver. Be sure to align the three holes such that the edge of the can is parallel with edge of the temperature programmed oven. Cleaning the Collector 1. For temperature programmed units, remove the temperature programmed oven covers as described in "Cleaning the FID Jet." 2. Disconnect the column and remove the jet as described in Cleaning the FID Jet." 3. Remove the breather as described in "Replacing the Breather." 4. Remove the thermocouple as described in "Replacing the Thermocouple Assembly." 5. Access the detector elements as described in "Accessing the Polarizer and Ignitor Elements." 6. Remove the polarizer and ignitors described in "Replacing the Polarizer" and "Replacing the Ignitor Assembly." 7. Use a small stainless steel brush precleaned with acetone to remove chloride accumulations from the collector, by inserting the brush through the detector inlet connection and briskly scrubbing with an in-and-out motion. 8. Install the detector elements as described in "Accessing the Polarizer and Ignitor Elements." 9. Install the column as described in "Packed Column Installation" or "Capillary Column Installation." 2000-OSM, F1 8-21

276 10. For temperature programmed units, install and secure the temperature programmed oven covers. 11. Close and secure the isothermal oven door. Replacing the FID Cable Assembly NOTE This procedure requires a special tool, Insertion Tool ABB P/N TL799M013-1, to assist in passing the cable through the insulation between the Control Housing and the Oven. 1. Disconnect the Microdot connector located on top of the detector (see Figure 8-8). 2. Cut the cable just below where it passes through the Oven into the Control Housing and remove the cable from the Oven. 3. Disconnect the other end of the cable from the FID Amplifier Assembly and remove the cable from the Control Housing. 4. Remove the grommets from the grommet holes (located in the bottom of the Control Housing and the top of the Oven) that will accommodate the routing of the new cable. 5. The new FID Cable Assembly has a Microdot connector on one and and a BNC connector on the other end (see Figure 8-9). Screw the Microdot connector end of the new cable assembly into the Insertion Tool. Microdot Connector BNC Connector Figure 8-9. FID CABLE ASSEMBLY 6. Pass the Insertion Tool through the grommet holes from the Control Housing to the Oven. 7. Remove the Insertion Tool from the cable connector. 8. Make a slit in each grommet from the outer diameter to the inner hole. (This is necessary because the cable connector will not pass through the grommet.) 9. Position the cable in the grommets in the Control Housing and the Oven. 10. Push the grommets into the grommet holes. 11. Connect the cable connectors to their respective locations (BNC connector to the FID Amplifier Assembly and Microdot connector to the top of the detector) OSM, F1

277 FILAMENT TCD REPAIR Refer to Figure 8-10 for Filament Thermal Conductivity Detector (TCD) component location. Reference Filament Measure Filament Reference Vent Sample In Sample Vent Reference In TC Assembly Figure FILAMENT TC DETECTOR CAUTION This repair should only be attempted by people who are properly trained and possess the expertise for this repair. T/C Detector Access CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See AIR PURGING in Section 4 for the X Purge override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure properly. The filaments are fragile and can be easily damaged if not handled with extreme care. Do not touch the end of the elements. Caution should be used when working with a soldering iron. Safety glasses and protective gloves should be used to protect against hot molten solder and hot surfaces. Personal protective equipment such as goggles, face shield, lab coat and rubber gloves should be used while cleaning with solvents such as acetone. Cleaning with solvents should be done in a well ventilated area. 1. If power is applied to the analyzer, turn it off. 2. Turn off oven air to the Isothermal Oven and allow all temperature zones to cool. 3. Open the isothermal oven door. Removing the Filaments 1. Use a Phillips screwdriver to loosen the two Phillips head screws located on the front underside of the mounting bracket OSM, F1 8-23

278 2. Remove the mounting bracket cover by sliding it out and away from the detector assembly. 3. Remove the insulating material from the mounting bracket. 4. If they are not already labeled, label the wire pair connected to the measurement filament M and the wire pair connected to the reference filament R. 5. If the detector filament wiring connections are spliced, perform steps 6 through 8. If they are not spliced, go to step Position the detector wiring such that the wired splices can be accessed. 7. Cut and remove the heat shrink from each of the spliced filament wire connections to expose the soldered connections. 8. Using a 40 watt soldering iron, de-solder and disconnect the wire splices. 9. If the detector filament wiring connections are not spliced, cut the existing detector harness wires approximately three inches from the detector end. 10. Remove the harness retaining clamp and free the harness. 11. Clean the area around the two detector filaments to reduce the chance of foreign particles entering the detector cavity when the filaments are removed. 12. Loosen the two detector filament retaining gland nuts with a 3/8-inch open-end wrench. Continue to loosen by hand. 13. Carefully extract the filaments from the detector cell cavity. Installing the 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 marked M (measurement). 3. Slide the nut down the length of the wires to insert and align it with the measurement cavity. 4. Tighten the cable gland finger tight, then finish tightening with a 3/8-inch open-end wrench. 5. Insert the second pair of filament wires through the threaded end of the gland nut, then carefully insert the filament into the detector cell cavity marked R (reference). 6. Slide the nut down the length of the wires to insert and align it with the reference cavity. 7. Tighten the cable gland finger tight, then finish tightening with a 3/8-inch open-end wrench. 8. Using wire strippers, remove approximately 1/4 inch of insulation from the end of each detector filament wire OSM, F1

279 Filament Checkout 1. Obtain a multimeter and select the ohms function and a range capable of measuring 40 ohms. 2. Connect one multimeter lead to each wire of the measurement filament (installed in the detector cavity labeled M ). The resistance measurement should be approximately 40 ohms. 3. Connect one multimeter lead to each wire of the reference filament (installed in the detector cavity labeled R ). The resistance measurement should be within one ohm of the measurement filament resistance. 4. If the resistance measurements are not within one ohm of each other, ensure the multimeter is connected and functioning correctly, and that the correct meter function is selected. 5. If the detector filaments are not in tolerance, the detector filaments are defective. The filaments must be replaced and the checkout repeated. 6. Neither filament should contact the detector cell body. Connect the multimeter leads to one of the filament wires and the detector cell body. The meter reading should range from several hundred megohms to infinity. 7. Repeat this measurement for each of the other three filament wires. If all resistance measurements are correct, go to "Connecting the Filaments." If any resistance is too low, go to step If the resistance measurement is approximately 20 ohms, filament being tested is contacting the internal wall of the detector cell cavity. When this occurs, carefully loosen the gland of the suspect filament. Continue to loosen by hand and withdraw first the gland, then the filament from the detector cell body (taking care not to touch or damage the filament). 9. Inspect the filament for damage or bending. If it is damaged, the filament pair will have to be replaced. 10. If the filament is slightly bent, use small needle nose pliers to gently and carefully bend it straight. 11. If the filament orientation now appears to be correct, reinstall the detector filament and repeat the complete checkout. If it fails again, replace the detector filament pair and repeat the harness checkout. 12. If the filament is damaged during this attempted correction process, the filament pair will have to be replaced. Connecting the Filaments 1. Roll the ends of each stripped harness wire between your thumb and index finger to tightly spiral 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 OSM, F1 8-25

280 5. Slide the insulating sheath of each filament back to reveal the stranded wire, install approved heat shrink over each of the four filament wires, and slide it as far from the free wire end as possible. 6. Select a harness assembly wire with the R label designation and overlap the tinned ends of this harness wire with one of the reference filament wires. 7. Solder the wires using a 40 watt soldering iron and approved high temperature solder. Apply solder sparingly, allowing it to flow evenly. Do not overheat the solder or a high resistance connection could result. 8. Repeat steps 6 and 7 for the remaining harness wire labeled R and reference filament wire. 9. Repeat steps 6 through 8 for harness wires labeled M and the measurement wires. 10. Slide heat shrink over each connection and shrink with a heat source. Leak Test 1. Restore carrier to the analyzer and establish carrier flow to both the measurement and reference ports of the detector. 2. Verify carrier and reference flow using a flow meter. Typically the flows should be 30 to 40cc per minute if packed columns are used; 10 to 15 cc per minute if 0.53 mm ID capillary columns are used, and 3 to 5 cc per minute if 0.32 mm ID capillary columns are used. 3. Test for leaks around the detector filament gland nut with a nonconductive liquid leak detection solution. Correct all leaks before proceeding. 4. Shut off the carrier supply to the analyzer. 5. Gently remove any excess leak detection solution with a soft cloth or tissue and blow dry with 15 psig clean dry air, helium or nitrogen. Potting The Filaments (CENELEC and CSA Only) Perform this procedure if you know that your analyzer is constructed to CENELEC or CSA specifications or if the existing detector filament is potted. 1. Gently slide the insulation sheath out of and away from the gland nut. 2. Using a syringe filled with Silastic compound Dow 736 RTV, completely fill the gland cavity with the Silastic compound. 3. With the insulation still pulled away from the gland nut, use needle nosed pliers to install the wire spreader. 4. Separate and insert filament wires into the slots on either side of the spreader. The spreader should be positioned between the end of the sheath insulation and the back of the gland nut. 5. Press the spreader into the recess in the gland nut. The retainer must be installed such that it is not in anyway tilted. It is normal for the retainer to protrude slightly from the gland recess. 6. Slide the sheath insulation toward the wire spreader until it contacts the face of the spreader. 7. Replace the mounting bracket insulation OSM, F1

281 8. Install the mounting bracket cover and secure it with two Phillips head screws. 9. Close and secure the isothermal oven door. THERMISTOR TCD REPAIR Refer to Figure 8-11 for Thermistor Thermal Conductivity Detector (TCD) component location. Cable Top Sleeve Measure Thermistor Top Cover Standoffs Reference Thermistor Figure THERMISTOR TC DETECTOR CAUTION This repair should only be attempted by people who are properly trained and possess the expertise for this repair. T/C Detector Access CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See AIR PURGING in Section 4 for the X Purge override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure properly. The filaments are fragile and can be easily damaged if not handled with extreme care. Do not touch the end of the elements. Caution should be used when working with a soldering iron. Safety glasses and protective gloves should be used to protect against hot molten solder and hot surfaces. Personal protective equipment such as goggles, face shield, lab coat and rubber gloves should be used while cleaning with solvents such as acetone. Cleaning with solvents should be done in a well ventilated area. 1. If power is applied to the analyzer, turn it off. 2. Turn off oven air to the Isothermal Oven and allow all temperature zones to cool OSM, F1 8-27

282 3. Open the isothermal oven door. Removing the Thermistors 1. Use a Phillips screwdriver to loosen the two Phillips head screws located on the top cover. 2. Remove the top cover by sliding it out and away from the detector assembly. 3. Remove the top sleeve from the detector assembly. 4. If they are not already labeled, label the wire pair connected to the measurement thermistor M and the wire pair connected to the reference thermistor R. 5. Position the detector wiring such that the wired splices can be accessed. 6. Cut and remove the heat shrink from each of the spliced thermistor wire connections to expose the soldered connections. 7. Using a 40 watt soldering iron, de-solder and disconnect the wire splices. 8. Clean the area around the two detector thermistors to reduce the chance of foreign particles entering the detector cavity when the thermistors are removed. 9. If necessary, remove the two standoffs that hold the top cover in place and retain them for reinstallation. 10. Loosen the two detector thermistor retaining gland nuts with a 5/16-inch open-end wrench. Continue to loosen by hand. 11. Carefully extract the thermistors from the detector cell cavity. Installing the Thermistors Replacement thermistor installation kits are supplied with a matched pair of thermistor assemblies, high temperature solder, and heat shrink tubing. 1. Cut the four thermistor wires approximately the same length as the wires on the thermistors that were removed. 2. Insert one thermistor assembly into the detector cell cavity marked "M" (measurement) and screw the cable gland finger tight. 3. Finish tightening the cable gland with a 5/16-inch open-end wrench. 4. Insert the second thermistor assembly into the detector cell cavity marked R (reference) and screw the cable gland finger tight. 5. Finish tightening the cable gland with a 5/16-inch open-end wrench. 6. Using wire strippers, remove approximately 1/4 inch of insulation from the end of each detector thermistor wire. Thermistor Checkout 1. On a multimeter select the ohms function and a range capable of measuring 40 ohms OSM, F1

283 2. Connect one multimeter lead to each wire of the measurement thermistor (installed in the detector cavity labeled M ). The resistance measurement should be approximately 40 ohms. 3. Connect one multimeter lead to each wire of the reference thermistor (installed in the detector cavity labeled R ). The resistance measurement should be within one ohm of the measurement thermistor resistance. 4. If the resistance measurements are not within one ohm of each other, ensure the multimeter is connected and functioning correctly, and that the correct meter function is selected. 5. If the detector thermistors are not in tolerance, the detector thermistors are defective. The matched set of thermistor assemblies must be replaced and the checkout repeated. 6. Neither thermistor should contact the detector cell body. Connect the multimeter leads to one of the thermistor wires and the detector cell body. The meter reading should range from several hundred megohms to infinity. 7. Repeat this measurement for each of the other three thermistor wires. If all resistance measurements are correct, go to "Connecting the Thermistors." If any resistance is too low, go to step If the resistance measurement is approximately 20 ohms, the thermistor being tested is contacting the internal wall of the detector cell cavity. When this occurs, carefully loosen the gland of the suspect thermistor. Continue to loosen by hand and withdraw the gland and thermistor from the detector cell body (taking care not to touch or damage the thermistor). 9. Inspect the thermistor for damage or bending. If it is damaged, the matched set of thermistor assemblies will have to be replaced. 10. If the thermistor is slightly bent, use small needle nose pliers to gently and carefully bend it straight. 11. If the thermistor orientation now appears to be correct, reinstall the detector thermistor and repeat the complete checkout. If it fails again, replace the matched set of thermistor assemblies and repeat the harness checkout. 12. If the thermistor is damaged during this attempted correction process, the matched set of thermistor assemblies will have to be replaced. Connecting the Thermistors 1. Roll the ends of each stripped harness wire between your thumb and index finger to tightly spiral 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 thermistor 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 thermistor wire ends. 5. Install approved heat shrink over each of the four thermistor wires and slide it as far from the free wire end as possible OSM, F1 8-29

284 6. Select a harness assembly wire with the R label designation and overlap the tinned ends of this harness wire with one of the reference thermistor wires. 7. Solder the wires using a 40 watt soldering iron and approved high temperature solder. Apply solder sparingly, allowing it to flow evenly. Do not overheat the solder or a high resistance connection could result. 8. Repeat steps 6 and 7 for the remaining harness wire labeled R and reference thermistor wire. 9. Repeat steps 6 through 8 for harness wires labeled M and the measurement wires. 10. Slide heat shrink over each connection and shrink with a heat source. Leak Test 1. Restore carrier to the analyzer and establish carrier flow to both the measurement and reference ports of the detector. 2. Verify carrier and reference flow using a flow meter. Typically the flows should be 30 to 40cc per minute if packed columns are used; 10 to 15 cc per minute if 0.53 mm ID capillary columns are used, and 3 to 5 cc per minute if 0.32 mm ID capillary columns are used. 3. Test for leaks around the detector thermistor gland nut with a nonconductive liquid leak detection solution. Correct all leaks before proceeding. 4. Shut off the carrier supply to the analyzer. 5. Gently remove any excess leak detection solution with a soft cloth or tissue and blow dry with 15 psig clean dry air, helium or nitrogen. FPD REPAIR CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See AIR PURGING in Section 4 for the X Purge override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure properly OSM, F1

285 Replacing the Photomultiplier Assembly Refer to Figure 8-12 as you perform this procedure. FPD Electrometer (in Controller Housing) FPD Electrometer Cables Cables Photomultiplier Nuts Photomultiplier Nuts Early Version FPD Electrometer in Controller Housing Current Version FPD Electrometer in FPD Enclosure Box Figure FPD PHOTOMULTIPLIER ASSEMBLY END VIEW 1. Remove power from the analyzer. 2. Turn off oven air to the isothermal oven and allow all temperature zones to cool. 3. Turn off air supply to air cleanup unit. 4. Open the door on the left side of the analyzer. 5. Disconnect the cables to the Photomultiplier Assembly and set them aside. 6. Remove the four nuts securing the Photomultiplier Assembly to the analyzer, being careful to retain the nuts to reinstall the Photomultiplier Assembly. 7. Carefully pull the Photomultiplier Assembly straight out of the analyzer. 8. Reinstall the Photomultiplier Assembly in reverse order of removing it OSM, F1 8-31

286 Replacing the Burner Block Refer to Figure 8-13 as you perform this procedure. Vent Line Thermocouple Temp Sensor (804A005-3 only) H2 and/or Carrier Heater Mounting Screws Sample Thermocouple Heater Sulfur Addition Wafer 1. Remove power from the analyzer. Figure BURNER BLOCK 2. Turn off oven air to the isothermal oven and allow all temperature zones to cool. 3. Turn off air supply to air cleanup unit. 4. Open the isothermal oven door. 5. Disconnect the thermocouple leads from the Burner Block. 6. Disconnect the heater leads from the Burner Block. 7. Disconnect the temp sensor leads from the Burner Block, if installed. 8. Disconnect the sample line from the Burner Block. 9. Disconnect the vent line from the Burner Block. 10. Disconnect the hydrogen (H2) and carrier lines from the Burner Block. 11. Remove the bracket screws that fasten the Burner Block to the oven. 12. Slide the Burner Block off the end of the Photomultiplier Assembly and remove the Burner Block from the oven. 13. Install the new Burner Block in reverse order of removing it OSM, F1

287 Replacing the Burner Block O-Rings Refer to Figure 8-14 when performing this procedure. 1. Perform steps 1 through 4 of "Replacing the Burner Block." 2. To remove a particular O-Ring, carefully remove the associated connector and then remove the O-Ring. O-Ring O-Ring O-Ring O-Ring Figure BURNER BLOCK, SHOWING O-RINGS 3. Lubricate the new O-Ring with a slight film of silicone grease. 4. Insert the new O-Ring and reinstall the connector. Replacing the Jet Refer to Figure 8-15 when performing this procedure. Jet O-Ring Electrode Nut Figure BURNER BLOCK, SHOWING JET 1. Perform steps 1 through 4 of "Replacing the Burner Block." 2. Carefully remove the Electrode Nut. 3. If the Jet came out with the Electrode Nut, carefully remove the Jet from the Electrode Nut. 3. If the Jet did not come out with the Electrode Nut, carefully remove the Jet from the Burner Block by pulling it straight down. 4. Insert the new Jet into the Electrode Nut until it seats fully OSM, F1 8-33

288 5. Carefully install and tighten the Electrode Nut. METHANIZER/AIR CLEANUP REPAIR CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See AIR PURGING in Section 4 for the X Purge override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure properly. Let the Methanizer/Air Cleanup Assembly cool a minimum of 30 minutes prior to disassembly. Internal surface temperatures can cause severe burns if they are touched before they have cooled. No asbestos is used in any assembly or component part of the Methanizer/Air Cleanup Assembly. Therefore, all residual insulating materials may be disposed of without regulator restrictions. The high temperatures present under normal operating conditions can cause wiring insulation to become brittle and fragile. Ceramic temperature probes should always be considered fragile. When servicing the Methanizer/Air Cleanup Assembly, these component parts must be handled with great care to avoid damage. The analyzer uses two different types of Methanizer/Air Cleaner Assembly, Type 781 and Type 805. These are essentially the same except for appearance. The Methanizer/Air Cleanup Assembly comes from the factory supplied with both air cleanup and methanizer tubes. The larger tube is used for air cleanup and the smaller tube for the methanizer. If a tube is not being used, its inlet and outlet connections will be plugged. It is necessary to replace only the tube that is in use OSM, F1

289 Refer to Figure 8-16 for Methanizer/Air Cleanup Assembly component location. Removing the Methanizer/Air Cleanup Assembly 1. Remove power from the analyzer. 2. Turn off oven air to the isothermal oven and allow all temperature zones to cool. 3. Turn off air supply to air cleanup unit. 4. Open the isothermal oven door. 5. Label the tubing on both sides of the associated unions with temporary numbered tape labels. The labels are later used to ensure correct tubing connections when the air cleanup/methanizer is reinstalled. Harness Assy Air Cleanup Tube Methanizer Tube TYPE 781 TYPE 805 Figure METHANIZER/AIR CLEANUP ASSEMBLY 6. Using 7/16-inch and 5/16-inch open-end wrenches, disconnect the tubing connections from the reducing unions. 7. Disconnect any retaining clamps that are securing the harness. 8. Remove the four Phillips head screws attaching the support brackets to the isothermal oven wall. Secure the unit with your hand while removing the final top screws. 9. Lay the Methanizer/Air Cleanup Assembly on a suitable work surface within the constrained length of the heater harness. If only the catalytic tubes are to be replaced, the harness will not require further disconnection. 10. Type 781 only: Remove the four Phillips head screws attaching the support bracket to the top unit end caps and lay them aside OSM, F1 8-35

290 CAUTION Wait 30 minutes before proceeding to open the Methanizer/Air Cleanup Assembly. 11. Mark the top and bottom caps and housing with a grease pencil or permanent marker. When the caps are replaced with the marks aligned, the support bracket holes will be correctly aligned. 12. Using a 9/64-inch Allen wrench, remove the four Allen head screws attaching the air cleanup/methanizer top cap to the outer housing. 13. Grasp the housing and top cap. Withdraw the internal body assembly from the housing. 14. Using tweezers or a small screw driver, remove the insulation from around the body assembly. Retain it for later use. Removing the Catalytic Tubes 1. Using a 1/4-inch open-end wrench, disconnect the catalytic connections from the bottom side of the cap. 2. To remove a catalytic tube, remove the Phillips head screw and flat washer located in the center of the body at the opposite end from the harness. 3. Grasp the long coiled or pig tail end of the tubing and pull the short nutted end through the body assembly. 4. Repeat steps 2 and 3 for the second catalytic tube, if it is present. 5. Carefully rotate the body assembly and remove the Phillips head retaining screw and flat washer. 6. Note the location of the cartridge heater, temperature probes and thermocouple. Carefully extract cartridge heater, probes and thermocouple from air cleanup body. 7. Inspect the probe end of the wiring harness for damage. If any harness wiring or devices are damaged, replace the harness as described in "Packing the Housing" and "Installing the Methanizer/Air Cleanup Assembly." Installing the Catalytic Tubes 1. To install the air cleanup tube, insert the short end of the catalytic air tube through the larger tube passage of the body and align it with the inside air inlet port connection of the top cap. 2. To install the methanizer tube, insert the short end of the catalytic methanizer tube through the smaller tube passage of the body and align it with the inside methanizer inlet port connection. 3. Insert the tube fitting into the cap and tighten the inlet fitting nut finger tight. 4. Repeat step 3 for the second catalytic tube, if applicable. 5. Assemble the flat washer and screw. 6. Insert the flat washer retaining screw assembly into the center hole located in the end of the body assembly opposite the harness and tighten it with the Phillips screwdriver. 7. If a new tube is being installed, a small loop or pig tail should be coiled in the tubing to compensate for the excess tubing length. If installing an existing tube, the pig tail will already be present OSM, F1

291 8. Bend and position the coiled tubing such that the end fitting can be inserted into the corresponding air or methanizer outlet connection port located on the bottom of the top cap. 9. Tighten all inside catalytic tube inlet and outlet fittings, using a 1/4-inch open-end wrench. Packing the Housing 1. Pack a small amount of insulation around the probes, thermocouple, heater, and associated wiring of the body assembly and set the assembly aside. 2. Using a 9/64-inch Allen wrench, loosen and remove the four Allen head screws attaching the air cleaner/methanizer bottom cap to the outer housing. Separate and set the bottom cap aside. 3. Carefully insert and press the body assembly into the outer housing. 4. Align the top cap with the marks on the outer housing. This will align the mounting bracket holes in the top cap. 5. Install the four Allen head screws that secure the top cap to the outer housing and tighten with a 9/64-inch Allen wrench. 6. Place a small quantity of insulation into the housing cavity and gently pack it down using an object such as a screwdriver. Continue adding and packing in insulation until the cavity is filled, taking care not the damage any wiring. 7. Install the bottom cap, aligning the mark on the cap with the mark on the housing. This will align the bottom mounting bracket holes. 8. Install the four Allen head screws to secure the bottom cap to the housing, and tighten with a 9/64-inch Allen wrench. 9. Type 781 only: Install the two mounting brackets with four Phillips head screws. The mounting brackets should be aligned parallel to one another. Installing the Methanizer/Air Cleanup Assembly 1. Attach the Methanizer/Air Cleanup Assembly to the interior of the isothermal oven wall. Secure the air cleanup/methanizer with your hand while installing the four Phillips head screws through the support bracket holes and into the mounting holes located in the isothermal oven back interior wall. 2. Connect the tube connections to their respective reducing unions while matching the numbers on the temporary labels. 3. Remove the temporary tape labels. 4. Apply carrier and air to the Methanizer/Air Cleanup Assembly. 5. Using a liquid leak detection solution, test for leaks and make necessary repairs before proceeding. 6. Route the heater harness in the oven interior, following the same path as the original harness installation. 7. Connect heater one wires to J48E terminals 1 and 2, and connect heater two wires to J48E terminals 5 and OSM, F1 8-37

292 8. Connect the temperature sensor wires to terminals 1 through 6, as follows: Overtemp Thermocouple: yellow (+) to 1 Overtemp Thermocouple: red (-) to 2 RTD sensor: 4 and 5 Shield (individual): 3 Composite Shield: 6 9. Close and secure the isothermal oven door, and the Controller front and side doors. Air Cleanup Testing 1. Restore burner air to the cleanup unit by adjusting the burner air regulator for the correct burner air pressure as indicated at the burner air pressure indicator. 2. If a methanizer is used, restore carrier gas by adjusting the carrier regulator for the correct carrier pressure indication at the carrier pressure indicator. 3. Using a suitable liquid leak detection solution, test and repair any leaks that may be present in the connections loosened or disconnected during the maintenance procedure. 4. Close the isothermal oven door and secure the latch. 5. Restore carrier gas, oven air and fuel gas, if necessary, by adjusting the regulators for the correct indications at the pressure indicators. 6. After ensuring the area is safe, and the proper permits are in effect, apply AC power. 7. To check the temperature of the Methanizer/Air Cleanup Assembly, exit to the Background screen by pressing the F1 soft key. 8. Access the Manual Control Mode screen by pressing the F2 (Manual Control) soft key. 9. Access the Pressure and Temperature Control Mode by pressing the F4 (Press. and Temp. Control) soft key. 10. From the Pres and Temp Control screen, position the cursor up or down to highlight TEMP CONTROL and press the F2 (Manual Temperature Control) soft key to access the Manual Temperature Control Screen. 11. On the Manual Temperature Control screen observe the setpoint value. If necessary, change the setpoint of the air cleanup/methanizer temperature controller to 450 C. 12. The temperature of the Methanizer/Air Cleanup Assembly can also be monitored from this screen. The time required to achieve stability is two hours. 13. Press the F1 soft key as necessary to return to the Background screen. Air Cleanup Final Preparation 1. Restore all utility gases and verify that the pressures and flow rates are correct. These include oven air, purge air, carrier, burner fuel, and burner air. If the faces of the pressure gauges were previously marked and the marked location is known to be correct, simply adjust the pressure regulators until the gauge pointers are aligned with the pressure indicating marks. Refer to the engineering data package supplied with your analyzer for the correct values OSM, F1

293 2. After sufficient air purge time and when authorized by your safety administrator, apply power to the analyzer. 3. Verify that all Digital Temperature Control setpoint values are correct. Refer to the engineering data package supplied with your analyzer for the correct values. 4. Allow the temperature controlled zone temperatures to equilibrate. 5. Verify that sample is being introduced to and is sufficiently flowing through the analyzer sample valve. 6. Perform a minimum of three analyses to verify correct chromatographic response and analysis reports. Minor adjustments or calibration may be necessary to achieve desired analysis results. 7. Once analyzer operation and performance have been verified, place the analyzer back in service. REPAIRING THE CARRIER GAS PANEL (ANALOG) Removing the Carrier Gas Panel 1. Open the Control Housing access panel (see Figure 8-17). (1) Open Control Housing Access Panel (2) Remove Screw Figure CARRIER GAS PANEL FROM RIGHT SIDE 2. Remove the screw from the Carrier Gas Panel (see Figure 8-17). 3. Open the isothermal oven door OSM, F1 8-39

294 4. In the isothermal oven, remove tubing connections as shown in Figure (4) Remove tubing connections (2) unscrew feedthroughs Figure FRONT RIGHT SIDE OF OVEN 5. In the isothermal oven, unscrew the feedthroughs (see Figure 8-18) and pull them down approximately 0.5 inches; it is not necessary to completely remove them. 6. Open the Controller front door to gain access the mother board. 7. In the Control Housing access area, unplug the alarm switches from the mother board (see Figure 8-19). (7) Unscrew alarm switches (9) Remove plugs (10) Remove socket head screws Figure CONTROL HOUSING ACCESS AREA, RIGHT SIDE OF ANALYZER 8. In the Control Housing access area, unscrew the alarm switches from the manifold (see Figure 8-19). 9. In the Control Housing access area, remove the plugs from the manifold (see Figure 8-19). 10. In the Control Housing access area, remove the five socket head screws from the manifold (see Figure 8-19) OSM, F1

295 11. Carefully remove the Carrier Gas Panel. Replacing a Regulator 1. Remove the Carrier Gas Panel from the analyzer. 2. Disconnect the lines from the back of the regulator. 3. Remove the regulator adjusting knob. 4. Remove the nut securing the regulator to the panel. 5. Remove the regulator from the panel. 6. Remove the adjusting knob from the new regulator. 7. Insert the new regulator through the hole in the panel. 8. Fasten the nut securing the regulator to the panel. 9. Install the adjusting knob on the regulator. 10. Reinstall the lines on the back of the regulator. 11. Install the Carrier Gas Panel in the analyzer. Replacing a Gauge 1. Remove the Carrier Gas Panel from the analyzer. 2. Disconnect the line from the back of the gauge. 3. Loosen the screws on the plate that secures the gauge to the panel and then remove the plate. 4. Remove the gauge from the panel. 5. Insert the new gauge through the hole in the panel. 6. Install the plate that secures the gauge to the panel. 7. Tighten the screws holding the gauge and plate to the panel. 8. Reinstall the line on the back of the gauge. 9. Install the Carrier Gas Panel in the analyzer. Installing the Carrier Gas Panel 1. Insert the Carrier Gas Panel into the Control Housing access area of the analyzer controller. 2. In the Control Housing access area, install the five socket head screws into the manifold (see Figure 8-19), making sure the sealing gasket is in place. 3. In the Control Housing access area, install the plugs into the unused ports of the manifold (see Figure 8-19) OSM, F1 8-41

296 4. In the Control Housing access area, screw the alarm switches into the manifold (see Figure 8-19) and plug the wire harness into their original locations on the mother board. 5. In the isothermal oven, reinstall the feedthroughs (see Figure 8-18). 6. In the isothermal oven, reinstall tubing connections as shown in Figure Close the isothermal oven door. 8. Install the screw in the Carrier Gas Panel (see Figure 8-17). 9. Close the Control Housing access panel. 10. Close the Controller front door. REPAIRING THE EPC CONTROL ASSEMBLY Preparation NOTE To ensure the integrity of the components within the EPC, use the tools in EPC Service Tool Kit 801K005-1 when assembling or disassembling the EPC Control Assembly. CAUTION Before performing EPC repair, you must turn off power to the analyzer as described in the following steps. 1. On the Background screen, press the F1 (Exit to Commands) soft key. 2. On the Commands screen, cursor to ANALYSIS CONTROL, if necessary, and press the F2 (Start/Stop Analysis) soft key. 3. On the Start/Stop Analysis screen, cursor to End of Analysis? and press the F2 (Stop Analyzer) soft key. The analyzer will stop at the end of the analysis. 4. Remove power from the analyzer and ensure that power to the analyzer remains removed throughout the EPC repair process. 5. If an extended 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 OSM, F2

297 Removing the EPC Control Assembly CAUTION Be sure that the EPC Control Assembly has cooled to ambient temperature (approximately one hour) before proceeding. 1. Perform the Preparation procedure. 2. Open the Control Housing access panel. 3. Remove the two screws holding the EPC cover and remove the cover panel. 4. Remove the four screws holding the Purge Air Panel in place and carefully pull the panel forward and down. 5. On the side wall behind the Purge Air Panel remove the lock nut on the pipe nipple which retains the EPC Panel cables (see Figure 8-20). Lock Nut 6. Open the isothermal oven door. Figure EPC PANEL CABLE LOCK NUT 7. In the isothermal oven, disconnect the EPC feedthrough tube nuts. 8. In the isothermal oven, unscrew the feedthroughs and pull them downward approximately 0.5 inches; it is not necessary to remove them completely. 9. Open the Controller front door to gain access to the backplane board. 10. At the left side of the backplane r board, disconnect the EPC Control Assembly cable from J On the EPC Multibus PCB in the card cage, disconnect the EPC Control Assembly cable from J43 (near the bottom of the PCB). 12. In the Control Housing access area, unplug the alarm switches from the backplane board 13. Unscrew the alarm switches from the manifold OSM, F2 8-43

298 14. In the Control Housing access area, remove the plugs from the manifold. 15. In the Control Housing access area, remove the five screws from the manifold. 16. On the right side of the analyzer, remove the screw on the side of the EPC Control Assembly. 17. Carefully remove the Control Assembly. Installing the EPC Control Assembly 1. Carefully install the Control Assembly and its associated components. 2. On the right side of the analyzer, install the screw on the side of the EPC Control Assembly. 3. In the Control Housing access area, install and tighten the five screws holding the manifold. 4. In the Control Housing access area, install the plugs in the manifold. 5. In the Control Housing access area, install the alarm switches on the manifold. 6. Connect the alarm switches to the backplane board. 7. On the EPC Multibus PCB in the card cage, reconnect the EPC Control Assembly cable from J43 (near the bottom of the PCB). 8. At the left side of the backplane board, connect the EPC Control Assembly cable to J Close the Controller front door. 10. In the isothermal oven, screw the feedthroughs in place. 11. In the isothermal oven, reconnect the EPC feedthrough tube nuts. 12. On the side wall behind the Purge Air Panel insert the lock nut on the pipe nipple which retains the EPC Panel cables and tighten it (see Figure 8-20). 13. Position the Purge Air Panel and then install and tighten the four screws holding it in place. 14. Close the isothermal oven door. 15. Hold the EPC cover panel in place, then install and tighten the two screws holding the EPC cover. 16. Close the Control Housing access panel. Removing a Sensor PCB CAUTION Use an ESD Wrist strap and proper grounding procedures before handling any components in the EPC Control Assembly OSM, F2

299 CAUTION Be sure that the EPC Control Assembly has cooled to ambient temperature (approximately one hour) before proceeding. The Zones are arranged in the EPC Control Assembly enclosure with Zone one on the left and Zone 5 on the right (see Figure 8-21). Screw and Washer Proportional Valve, Zone 5 Sensor PCB, Zone 5 Proportional Valve, Zone 1 Heater Sensor PCB, Zone 1 Control PCB Figure EPC CONTROL ASSEMBLY COMPONENTS 1. Perform the Preparation procedure. 2. Remove the two screws holding the EPC cover and remove the cover panel. 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 explosionproof 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 to your left and out of the way (see Figure 8-22). AC Power Cable from Backplane PCB J44 Sensor PCB Cable, Zone 1 Sensor PCB Cable, Zone 2 Sensor PCB Cable, Zone 3 Large Ribbon Cable from EPC Multibus PCB Heater Cable Valve Cable, Zone 1 Valve Cable, Zone 2 Valve Cable, Zone 3 Valve Cable, Zone 4 Valve Cable, Zone 5 Sensor PCB Cable, Zone 4 Sensor PCB Cable, Zone 5 Figure EPC CONTROL PCB CABLING 2000-OSM, F2 8-45

300 5. Locate the Sensor PCB to be replaced. NOTE There are two types of Sensor PCBs: a square PCB assembly (old type) and PCB assembly that is at right angles to the sensor (new type). 6. Unplug the Sensor PCB from the Controller PCB. 7. To remove the old type Sensor PCB: a. Using a 1.5 mm hex socket wrench, remove the screws and plate that retain the Sensor PCB (older Sensor PCBs may not have the plate, but they are removed in similar manner, including standoffs if present). b. Grasp the Sensor PCB at opposite corners and gently remove it from the EPC Controller Assembly. c. Remove the O ring from the installation cavity. 8. To remove the new type Sensor PCB: a. Using a 1.5 mm hex socket wrench, loosen the screws that retain the Sensor PCB b. Slide the Sensor PCB out from under the mounting plate and remove it from the EPC Controller Assembly. Installing a New Sensor PCB NOTE If the old type Sensor PCB being removed is in any location other than the right-most zone in use, you will have to move the Sensor PCB that is in the right-most zone to where you have removed the old type Sensor. Then you can install the new type Sensor PCB in the right-most zone. Also, if more than one zone is replaced, they must be replaced starting with the highest numbered zone (right side) and proceeding to the lowest numbered zone (left side). 1. Place a Belleville washer on each mounting screw, with the rounded side toward the screw. 2. Place the screws through the holes in the mounting plate. 3. Place the gasket on the end of the two screws, with enough screw thread showing through the gasket to start the screws into the hole. 4. Insert the screws into the hole in the block, just far enough to hold them in place. 5. Place the Sensor PCB into position between the plate and the gasket, with the cable at the bottom right edge. 6. 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 OSM, F2

301 7. Tighten one screw, using torque limiting screwdriver ABB Tool 801Z003-1, set at 1 in.-oz. 8. Tighten the second screw to 2 in.-oz. 9. Retighten the first screw to 3 in.-oz. 10. Retighten the second screw to 4 in.-oz 11. 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 observe the precautions stated in the Note at the beginning of this procedure. 17. Reconnect the large ribbon cable to the Control PCB. 18. Reinstall the EPC Control Assembly cover and insert the ten screws and tighten them to 16 in.-lb, using ABB Tool TL1000/TL1002. 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 cover panel and insert the two holding screws. Removing a Proportional Valve CAUTION Use an ESD Wrist strap and proper grounding procedures before handling any components in the EPC Control Assembly. Be sure that the EPC Control Assembly has cooled to ambient temperature (approximately one hour) before proceeding. 1. Perform the Preparation procedure. 2. Remove the two screws holding the EPC cover and remove the cover panel. 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 explosionproof 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 to your left and out of the way (see Figure 8-22). 5. Locate the valve to be replaced (See Figure 8-21) OSM, F2 8-47

302 6. Disconnect the valve cable at the connector on the Control PCB. NOTE You may need to remove the Sensor PCB cable from the Control PCB to allow access to the connector of some zones. 7. Using 3 mm hex socket wrench ABB Tool TL1009, remove the screws and washers that secure the valve in place. 8. Firmly grasp the valve and remove it from the enclosure. Installing a New Proportional Valve 1. Before inserting the new valve, check the position of the o-ring on the valve. 2. If the o-ring is positioned at top of groove, use a solder aid or non-metal pick to roll the o- ring down to the bottom of the groove. The o-ring must not be twisted. 3. Insert the new valve into its position in the enclosure. The wires coming out of the coil should face the Control PCB (See Figure 8-21). 4. Assemble the spring or Belleville washer and hex socket head screw, ensuring that the concave side of the washer is facing away from the head of the screw. 5. Start the screw with the spring washer in the hole next to the valve. 6. Press down on the center of the valve and finish tightening the screw. 7. Insert and tighten the second screw and washer, if applicable. 8. Plug all cables back into their corresponding connectors on the Control PCB. 9. If another proportional valve needs to be replaced, repeat the appropriate steps to remove the old valve and install a new one. 10. Reinstall the EPC Control Assembly cover and insert the ten screws and tighten them to 16 in.-lb, using ABB Tool TL1000/TL1002. Ensure that the flame-proof or explosion-proof surfaces of the cover or the body of the Control Assembly are not damaged. 11. Reinstall the EPC cover panel and insert the two holding screws. Removing the Control PCB CAUTION Use an ESD Ground strap (wrist) and proper grounding procedures before handling any components in the EPC Control Assembly. Be sure that the EPC Control Assembly has cooled to ambient temperature (approximately one hour) before proceeding. 1. Perform the Preparation procedure. 2. Remove the two screws holding the EPC cover and remove the cover panel OSM, F2

303 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 explosionproof 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 to the left and out of the way (see Figure 8-22). 5. Unplug all valve, sensor PCB, and heater cables. 6. Using 2.5 mm hex socket wrench ABB Tool TL1007, remove four screws and washers (two from the triacs and two from the PCB mounting brackets). 7. Pull the Control PCB straight out of the enclosure toward you. 8. Remove fish paper isolator (do not throw away). 9. With a clean cloth, clean thermal joint compound off the enclosure. Installing a New Control PCB 1. On the new Control PCB, place a thin layer of thermal joint compound on all sides and the bottom of each RTD, and on the back of each triac. 2. Insert the Control PCB into enclosure with components and connectors facing up. 3. Align RTDs with the holes in the enclosure and ensure the RTDs are inserted in the holes flush with the enclosure. 4. Using 2.5 mm hex socket wrench ABB Tool TL1007, attach the Control PCB to the enclosure with four screws and washers. 5. Insert the fish paper insulator between the enclosure and the back side (solder side) of the Control PCB. 6. Plug all cables back into their corresponding connectors on the Control PCB. 7. Reinstall the EPC Control Assembly cover and then insert the ten screws and tighten them to 16 in.-lb, using ABBToolTL1000/TL1002. Ensure that the flame-proof or explosion-proof surfaces of the cover or the body of the Control Assembly are not damaged. 8. Reinstall the EPC cover panel and insert the two holding screws. Removing the Heater CAUTION Be sure that the EPC Control Assembly has cooled to ambient temperature (approximately one hour) before proceeding. 1. Perform the Preparation procedure. 2. Remove the two screws holding the EPC cover and remove the cover panel OSM, F2 8-49

304 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 explosionproof 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 to your left and out of the way (see Figure 8-22). 5. Locate the Sensor PCBs for Zones 1 and 2 (see Figure 8-21). 6. Using 1.5 mm hex socket wrench ABB Tool TL1001/TL1003, remove screws and plates that mount the Sensor PCBs and set these screws and plates aside for later use. 7. Remove the Sensor PCBs and set them aside for later reinstallation. Do not remove the Sensor cable connected to the Control PCB. 13. Unplug the heater connector from the Control PCB. 14. Carefully extract the heater from its cavity in the enclosure. 15. Remove the connector from the heater, using a small screwdriver. Installing a New Heater 1. With the new heater in hand, cut heater leads to 3-1/2 inches long. 2. Strip 1/8 inch of insulation off each heater lead. 3. Install the connector on the leads. 4. Place a thin layer of anti-seize compound 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. Reinstall the EPC Control Assembly cover and then insert the ten screws and tighten them to 16 in.-lb, using ABB Tool TL1000/TL1002. Ensure that the flame-proof or explosion-proof surfaces of the cover or the body of the Control Assembly are not damaged. 10. Reinstall the EPC cover panel and insert the two holding screws. CALIBRATING THE ELECTRONIC PRESSURE CONTROLLER The EPC should only require calibration if a component has been replaced. You should only need to calibrate the particular zone affected by the servicing. To calibrate a zone: 1. Determine the zone that needs calibration. 2. Open the isothermal oven door OSM, F2

305 3. Eliminate any back pressure to the zone by loosening the feedthrough fitting associated with the zone to be calibrated (see Figure 8-23). Figure LOCATION OF ZONE FITTINGS 4. On the Controller, verify the Background screen is displayed and then press the F2 (Manual Control) soft key. 5. On the Manual Control Mode screen press the F4 (Press. & Temp. Control) soft key OSM, F2 8-51

306 6. On the Pres and Temp Control screen (see Figure 8-24), cursor to PRES CONTROL and press the F2 (Manual Pressure Control ) soft key. ***** Pres and Temp Control ***** TEMP CONTROL PRES CONTROL TEMP CONFIGURATION Manual Pressure View Escape Pressure Config Alarms Control F1 F2 F3 F4 Figure PRESSURE AND TEMPERATURE CONTROL SCREEN 7. On the Manual Pressure control Mode screen (see Figure 8-25), enter the zone number of the zone you want to calibrate. **** Manual Pressure Control Mode **** Zone Config Actual SP Rate COLUMN ISO ANALYSIS ISO SELECTOR ISO ANALYSIS ISO COLUMN PROG Valve # : [0] Time : 0125 Zone # : 1 State : Idle Set Point : Ramp Rate : Ver A VALVES : Accept Calibrate Escape Control Zone Point F1 F2 F3 F4 Figure MANUAL PRESSURE CONTROL MODE SCREEN OSM, F1

307 8. Press the F3 (Calibrate Zone) soft key. The GCC displays Calibrate zone, hold switch on board. 9. Hold down the switch on the EPC Multibus PCB. The GCC displays Are You Sure? 10. Continue holding down the switch and press Y on the keyboard to save the new calibration. 11. When the GCC displays This zone has been calibrated, release the switch. 12. If the Set Point shows an unexpected value, enter the desired set point value. (The unexpected value is an offset corrected by the calibration; this is a software reporting function only, which is not used by the system.) 13. Retighten the fitting loosened in step 3. REPAIRING PURGE AIR PANEL COMPONENTS Removing the Purge Air Panel 1. Remove the four screws holding the panel in place (see Figure 8-26). 2. Carefully pull the panel forward. Replacing a Regulator Figure PURGE AIR PANEL FASTENERS 1. Remove the Purge Air Panel from the analyzer. 2. Disconnect the lines from the back of the regulator, using 1/2-inch and 9/16-inch open-end wrenches. 3. Remove the regulator adjusting knob. 4. Remove the nut and sealing gasket securing the regulator to the panel. 5. Remove the regulator from the panel. 6. Remove the adjusting knob from the new regulator. 7. Insert the new regulator through the hole in the panel OSM, F1 8-53

308 8. Install the sealing gasket and fasten the nut securing the regulator to the panel. 9. Install the adjusting knob on the regulator. 10. Reinstall the lines on the back of the regulator. 11. Install the Purge Air Panel in the analyzer. Replacing a Gauge 1. Remove the Purge Air Panel from the analyzer. 2. Disconnect the line from the back of the gauge, using a 9/16-inch open-end wrench. 3. Loosen the screws on the plate that secures the gauge to the panel and then remove the plate. 4. Remove the gauge and sealing gasket from the panel. 5. Insert the new gauge and sealing gasket through the hole in the panel. 6. Install the plate that secures the gauge to the panel. 7. Tighten the screws holding the gauge and plate to the panel. 8. Reinstall the line on the back of the gauge. 9. Install the Purge Air Panel in the analyzer. Installing the Purge Air Panel 1. Carefully put the panel back in place, aligning the mounting holes. 2. Install the four screws that hold the panel in place. SETTING JUMPERS The following paragraphs describe how to set the various PCB jumpers OSM, F1

309 Backplane PCB The Controller Backplane PCB has six jumpers to set up (see Figure 8-27). JP5 JP1 JP3 JP2 JP6 JP4 Figure BACKPLANE PCB JUMPER LOCATIONS Jumpers JP1 and JP5 are used to bypass pressure switch connection points for certain analyzer configurations. Since the purge switches are daisy chained in series, it is necessary to jumper across switches that are not connected. Jumper JP1 has its shunt installed between pins 1 and 2 for standard or Sparger oven usage; the shunt is installed between pins 2 and 3 for temperature programmed applications. Jumper JP5 has its shunt installed between pins 1 and 2 for single purge area; the shunt is installed between pins 2 and 3 for dual purge location applications. Jumpers JP2, JP3 and JP6 are associated with the purge alarm switch closures applied to the Chroma I/O PCB. Jumper JP2 has its shunt installed between pins 1 and 2 for X Purge applications only; the shunt is installed between pins 2 and 3 for Y or Z purge applications. Jumper JP3 has its shunt installed between pins 1 and 2 for standard analyzers; the shunt is installed between pins 2 and 3 for temperature programmed and Sparger applications. Jumper JP6 has its shunt installed between pins 1 and 2 for single purge configurations; the shunt is installed between pins 2 and 3 for dual purge applications. Jumper JP4 is used to connect two detectors to a single Chroma I/O PCB. The location of the jumper shunt depends on the revision of the Backplane PCB. Backplane PCBs that do not have JP5 and JP6 are artwork revision D or earlier, while those having JP5 and JP6 are artwork revision E or later. For revision D or earlier, the shunt is installed between pins 1 and 2 when the outputs of two detector amplifiers are applied to a single Chroma I/O PCB; the shunt is installed between pins 2 and 3 for normal operation (a Chroma I/O PCB dedicated to a single detector amplifier) OSM, F1 8-55

310 Revision E or later: the shunt goes between pins 1 and 2 for normal operation (a Chroma I/O PCB dedicated to a single detector amplifier); the shunt is installed between pins 2 and 3 when the outputs of two detector amplifiers are applied to a single Chroma I/O PCB. DTC Backplane PCB The Digital Temperature Controller (DTC) PCB has eight jumpers and one switch to set up (see Figure 8-28 for location). Switch SW1 is used to save configuration information to protected memory. Its use is described in DIGITAL TEMPERATURE CONTROLLER in Section 4, by the statement Hold down the switch on the DTC Backplane PCB. JP4 JP1 JP5 JP6 J2 JP3 JP2 SW1 JP3 SW1 J3 Figure DTC BACKPLANE PCB SWITCH AND JUMPER LOCATIONS Jumpers J2 and J3 are T-Rating jumpers. The jumper shunts must be installed exactly as shown below to ensure the temperature control operates properly. If they are set incorrectly, T-Rating disagreement alarms will result (0 = no jumper; 1 = jumper installed). Pins T5 T4A T4 T3B T3 T2C T2 T Shunts installed in these positions Zone allow set points (for the respective Zone zones) to be above the T-Rating, Zone for explosion proof zones only. Zone Zone OSM, F1

311 JP1 is the service diagnostics jumper. For normal operation the shunt is installed between pins 1 and 2. For service diagnostic screen use (only) the shunt is installed between pins 2 and 3. After servicing, the shunt must be reinstalled between pins 1 and 2. JP4 is the VAC Conditioning Board jumper. If the analyzer has one VAC Conditioning PCB installed, the shunt should be between pins 2 and 3. If the analyzer has two VAC Conditioning PCBs installed, the shunt should be between pins 1 and 2. JP2, JP3, JP5, and JP6 are the jumpers for the temperature zone boards. These jumpers are required for the software to recognize unused zones. Jumpers are installed from the even pins of unused zones to the even pins of used zones, for both Micro #1 (JP2 and JP3) and Micro #2 (JP5 and JP6). If all zones are in use, no jumpers are installed. Zone jumpers are identified as follows: Micro #1 Pin Micro #2 Pin Zone 1 JP3-2 JP5-2 Zone 2 JP3-4 JP5-4 Zone 3 JP3-6 JP5-6 Zone 4 JP2-2 JP6-2 Zone 5 JP2-4 JP6-4 Example: if Zone 5 is not used, one jumper must be run between JP2-4 and JP2-2 or one of the other pins listed under Micro #1 Pins, and a second jumper must be run between JP6-4 and JP6-2 or one of the other pins listed under Micro #2 Pins. DTC Zone PCB There can be up to five zone boards, one for each designated temperature zone. The only jumper on a zone board is JP1 (see Figure 8-29). How this jumper is set depends on the type of temperature sensor used for the zone. The jumper shunt should be between pins 1 and 2 for a 400 ohm platinum probe sensor; it should be between pins 2 and 3 for a thermocouple sensor. Figure DTC ZONE BOARD JUMPER LOCATION JP OSM, F1 8-57

312 VAC Conditioning PCB There can be either one or two VAC Conditioning PCBs, depending on the application. Each board has two jumpers to be set, JP4 and JP5 (see Figure 8-30). These jumpers are set according to the voltage supplied to the board, as follows (JP4 is the hot side and JP5 is the neutral side): Applied Voltage JP4 Shunt JP5 Shunt 32 VAC VAC VAC JP4 JP5 Figure VAC CONDITIONING BOARD JUMPER LOCATIONS Front Panel PCB There is one adjustment and three jumpers on this board (see Figure 8-31). The adjustment is potentiometer R56, which is used to set the display contrast for optimum viewing. JP7 JP6 JP5 R56 Figure FRONT PANEL PCB ADJUSTMENT AND JUMPER LOCATIONS The jumpers relate to the LOCOM option. JP5 has its shunt is between pins 1 and 2 for normal operation, between pins 2 and 3 for LOCOM installations. JP6 and JP7 have the shunts in place for normal operation and the shunts removed for LOCOM installations OSM, F1

313 FID Amplifier PCB The jumper on this PCB relates to intercolumn detector usage. For normal operation shunts should be installed in the first two positions at the right side of J18. These shunts are removed for an application using intercolumn detectors (see Figure 8-32). J18 Filament TCD Amplifier PCB Figure FID AMPLIFIER PCB JUMPER LOCATIONS The jumpers on this PCB relate to amplifier gain, single or dual carrier, temperature ranges, intercolumn detectors, and special testing (see Figure 8-33 for location). GAIN JUMPERS WT11 - WT13 CARRIER JUMPERS WT7 - WT10 TEMPERATURE JUMPERS WT1 - WT6 Figure FILAMENT TCD AMPLIFIER PCB JUMPER LOCATIONS The gain jumper is normally connected between WT11 and WT12. For high gain applications this jumper is connected between WT12 and WT OSM, F1 8-59

314 The carrier jumper is normally connected between WT9 and WT10 (single carrier). For dual carrier applications this jumper is connected between WT7 and WT8. The temperature jumpers are normally connected between WT1 and WT2 and between WT4 and WT5 (low temperature). For high temperature applications these jumpers are connected between WT1 and WT3 and between WT4 and WT6. For normal operation shunts should be installed in the first two positions at the right side of J18. These shunts are removed for an application using intercolumn detectors. The jumper between WT14 and WT15 must be in place for normal operation. It is only removed when hi-pot testing is to be performed. Thermistor TCD Amplifier Interface PCB The Thermistor Amplifier Interface PCB currently supports one or two Thermistor Amplifier PCBs (see Figure 8-34). AMPLIFIER #1 AMPLIFIER #2 FOR FUTURE EXPANSION FOR FUTURE EXPANSION JP JP JP1A JP2A Figure THERMISTOR AMPLIFIER INTERFACE PCB JUMPER LOCATIONS For single detector applications, one Thermistor Amplifier PCB is used, mounted in the Amplifier #1 position. Jumpers JP-1, JP-2, JP-1A and JP-2A all have their shunts between terminals 1 and 2. The output signal is routed through J13A. For dual detector applications, two Thermistor Amplifier PCBs are used, mounted in the Amplifier #1 and Amplifier #2 positions. Jumpers JP-1, JP-2 and JP-2A all have their shunts between terminals 1 and 2. Jumper JP-1A has its shunt between terminals 2 and 3. The output signal of Amplifier #1 is routed through J13A and the output signal of Amplifier #2 is routed through J13B OSM, F1

315 EPC Multibus PCB This board has one jumper and one switch to set up (see Figure 8-35). JP1 is the service diagnostics jumper. For normal operation the shunt is installed between pins 1 and 2. For installation and service the shunt is installed between pins 2 and 3. After installation or service, the shunt must be reinstalled between pins 1 and 2. Switch SW1 is used to save configuration information to protected memory. Its use is described in ELECTRONIC PRESSURE CONTROL OPTION in Section 4, by the statement Hold down the switch on the Electronic Pressure Control PCB. SW1 JP1 Figure EPC MULTIBUS PCB JUMPER LOCATION EPC Control PCB This board has a single jumper, JP2 (see Figure 8-36). For normal operation JP2 has a shunt between pins 2 and 3. For servicing of the block, the shunt is placed between pins 1 and 2 to turn off the heater. JP2 Figure EPC CONTROL PCB JUMPER LOCATION 2000-OSM, F1 8-61

316 Chroma I/O PCB (old type) CAUTION This board can only be used when the analyzer also has the old type Single Board Computer PCB (identified by a toggle Reset switch). This board, part number , has two jumpers which are mutually exclusive. When there is only one Chroma I/O PCB in the analyzer, or the board is used as Chroma I/O PCB #1 in a simultaneous dual detector analyzer, the jumper will be located between the terminals of JP1 (see Figure 8-37). This jumper is part of the printed circuit trace on this version of the Chroma I/O PCB. Jumper trace is on the circuit side of the board. Figure OLD CHROMA I/O PCB JUMPERS When a second Chroma I/O PCB is used, Chroma I/O PCB #2 must have the JP1 jumper trace cut and a jumper installed between the JP2 terminals. Chroma I/O PCB (new type) This board, part number 802A028D-_, has six jumpers, JP1 through JP6 (see Figure 8-38). Figure NEW CHROMA I/O PCB JUMPERS OSM, F1

317 JP1: When there is only one Chroma I/O PCB in the analyzer, or the board is used as Chroma I/O PCB #1 in a simultaneous dual detector analyzer, the shunt is installed between pins 1 and 2. When the board is used as Chroma I/O PCB #2, the shunt is installed between pins 2 and 3. JP2 through JP6: These jumpers are installed between pins 2 and 3 on the Chroma I/O PCB (later revisions of this board will have the jumpers hard-wired). VALCO DIAPHRAGM VALVE REPAIR The Valco DV22 ten-port diaphragm valve is used in some analyzers (see Figure 8-39). This procedure and the accompanying illustrations were reprinted with permission of VICI, Houston, TX, USA. Figure VALCO 10-PORT DIAPHRAGM VALVE Removing the Valve 1. Tag all valve connections. 2. Using a 1/4-inch wrench, remove the connections from the valve cap. 3. Using a 7/64-inch hex key wrench, loosen the clamp ring screw. 4. Remove the valve from the clamp ring and take it out of the analyzer. Repairing the Valve 1. Place the valve on a clean work surface. 2. Note the location of port 1 on the valve, opposite the air inlet (see Figure 8-40). Figure CAP ORIENTATION 2000-OSM, F1 8-63

318 3. Using a 9/64-inch hex key wrench, remove the screw from the valve cap (see Figure 8-41). Figure EXPLODED VIEW OF VALCO DIAPHRAGM VALVE 4. Carefully remove the valve cap from the two alignment pins. 5. Set the cap aside, with the polished side up so that it does not get scratched. 6. Remove the old diaphragm. 7. Remove the plungers. 8. Install new plungers, ensuring that the counterbored end is up toward the valve cap (see Figure 8-41). 9. Install new diaphragm, ensuring that the marking TOP is toward the valve cap. If there is no marking, ensure the indentation in the diaphragm is toward the valve body (see Figure 8-41). 10. Reinstall the valve cap, verifying that port 1 is correctly located. 11. Install the valve cap screw and tighten with a 9/64-inch hex key wrench OSM, F1

319 Reinstalling the Valve 1. Place the valve in the clamp ring and rotate it to the orientation of the valve that was removed. 2. Using a 7/64-inch hex key wrench, tighten the clamp ring screw. 3. Install the connections to the valve cap, matching the numbering on the valve to the tags on the connections. 4. Using a 1/4-inch wrench, tighten each connection. VISTANET DEBUG MONITOR Purpose The VistaNET Communications Board in the Card Cage has an on-board debug monitor that allows examination of the token bus communications. Several parameters accessible from the debug connector allow the technician to easily troubleshoot common problems. CAUTION You must work carefully with the Debug Monitor. Inserting erroneous information can cause networking problems. If such problems occur you must reset the network to reinstate proper operation. Making the Connections The VistaNET Communications Board has a connector that allows a serial cable to be connected to the board. ABB Aftermarket Spares can provide this cable (P/N ). The RS-232 communications protocol allows the use of a laptop PC for access. Included in Windows 95 is the Hillgraeve HyperTerminal Application, which emulates several popular devices. This cable should be connected to the Communications Board (see Figure 8-42) and to the appropriate COM port (Domain 1 or 2) on the laptop PC. On the laptop PC, set the terminal emulation to VT100, and the associated serial parameters to 9600 baud, 8 data bits, no parity, 1 stop bit, no handshaking. COMMUNICATIONS PCB J4 COMMUNICATIONS PCB DEBUG J3 DOMAIN 1 DOMAIN 2 J2 J1 Figure COMMUNICATIONS BOARD DEBUG CONNECTION 2000-OSM, F1 8-65

320 Startup When you have set up the terminal application and connected to the communications board, press <CTRL> A to invoke the Main Menu (see Figure 8-43). Vistanet Debugger - HyperTerminal File Edit View Cell Transfer Help VistaNet Monitor Firmware Rev 803V025-1CH IRQ: 5 Adapter Segment: C800H Dump Memory Write Memory Main Menu Dump History Fill Memory Read/Write Memory Promiscuous Mode Read Memory Show Registers Reset Statistics Dump Packet Ignore Token Reset state Globally Transmit Requests: Receives: Address: 199 Buffers Recycled: Errors: 10 Mode: 0600 Transmits: Last Error: 02 Input: 7 Transmit Errors: 5 Uploads: Output: 7 Retries: 10 Queued: Max Slack: 4 Collisions: 0 Dequeued: Gap Device: 229 Last Destination: 10 Backups: 0 Token Dest: 1 Tokens Issued: 1 Invalid: 0 Next Alive: 1 Tokens Dropped: 19 Tokens Received: Next Recvd: 1 Tokens Passed: Tokens Dumped: 4 Rate: Connected 0:00:27 VT N-1 Figure MAIN MENU When you exit the application, press <CTRL> Z to end the session. CAUTION Always end the session before exiting the monitor. While the monitor is intended to be non-invasive, it can affect operation over time. Some performance parameters are degraded by the monitor program. The Main Menu is divided into three sections: the Information Display at the top of the screen, Menu Items just below this information, and Statistical Data between the two horizontal lines. Information Display Firmware Revision: Indicates the part number and revision of the communications board firmware. The last digit of the revision indicates the position of the high-speed jumper on the board (L indicates low speed operation, H indicates high-speed operation). IRQ: Indicates 0 when the laptop PC is connected to the GC Communications Board. Adapter Segment: Indicates 000H when the laptop PC is connected to the GC Communications Board OSM, F1

321 Menu Items Dump Memory: Entered as DM XXXX where XXXX is the hexadecimal address to be examined. Memory is dumped by screen. Pressing the Enter key will scroll to the next block. The Escape key aborts the command. Figure 8-44 illustrates this screen. Vistanet Debugger - HyperTerminal File Edit View Cell Transfer Help BB B FF A A C 6D DA DE C 2D 2D 2D 2D 2D 2D 2D 2D D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D 2D D 2D 00 FF FF FF FF FF FF FF FE FF FF FF FF FF 0080 FF FF FF FF FF FF BF FF FF FF FF FF FF FF FF FF 0090 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF 00A0 FF FF FF FF FF FF 02 1A 5A A5 00B BB B C C7 02 1A 00C0 4C FF FF FF FF FF FF 4C 2E 2E 2E 2E 2E 2E 00D0 2E 2E 4C 2E 2E 2E 2E 2E 2E E 00 0F 00 00E0 00 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF 00F0 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF 0100 FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF FF 0110 FF FF FF FF FF FF FF FF FF FF FF FF 0B D BF E FA 00 0B 1B 5B B [......m B...q..1..e..u.., L.L..L......DM.n...p..[19;06f... Connected 0:00:27 VT N-1 Figure TYPICAL DUMP MEMORY SCREEN Fill Memory: Entered as FM XXXX YYYY ZZ where XXXX is the starting address, YYYY ending, ZZ pattern to be used to fill the memory block (all in hex). Read Memory: Entered as RM XXXX where XXXX is the hexadecimal address to be examined. Dump Packet: Entered as DP X where X = 0 to 16, indicating the buffer address of the packet to be examined (0 is the DP RAM buffer last uploaded to the host). Write Memory: Entered as WM XXXX YY where XXXX is the hexadecimal address to be written with pattern YY (all in hex). Read/Write Memory: Entered as RWM XXXX YY where XXXX is the hexadecimal addressed to be written with pattern YY, then read (all in hex) OSM, F1 8-67

322 Show Registers: Entered as SR (see Figure 8-45). The internal register contents of the 80C152 microcontroller are shown. Refer to the manufacturer s data sheet for an explanation of the contents. Type MM to return to the Main Menu. Ignore Token: Entered as IT, used for software loading tests. In this mode, the communications board remains part of the token bus, however tokens are merely passed, and no UDP packets are transmitted or received at this node. THIS COMMAND IS NOT TO BE USED IN THE FIELD. Main Menu: From the SFR display, this command returns to the main menu. Vistanet Debugger - HyperTerminal File Edit View Cell Transfer Help VistaNet Monitor SFR Display GSC ADR0:8E ADR1:01 ADR2:8E ADR3:01 BAUD:00 BKOFF:09 AMSK0:00 AMSK1:00 GMOD:1C IFS:65 MYSLOT:3F SLOTTM:01 TCDCNT:00 TSTAT:87 RSTAT:03 DMA BCRM0:02 BCRL0:0D DARH0:77 DARL0:C4 SARH0:00 SARL0:F4 DCON0:69 BCRH1:00 BCRL1:00 DARH1:00 DARL1:85 SARH1:03 SARL1:8B DCON1:00 INTERRUPT IE:F3 IEN1:C7 IF:E0 IPN1:C3 POWER CONTROL PCON:C0 LSC SCON:54 TIMER TCON:D0 TH0:D1 TL0:D8 TH1:FA TL1:FF TMOD: Connected 0:00:27 VT N-1 Figure TYPICAL SHOW REGISTERS SCREEN WARNING The Promiscuous Mode command is used only in the factory. Promiscuous Mode: Entered as PM, this command is used in software troubleshooting. In this mode, this node receives all UDP packets, whether destined for this station or not. Reset Statistics: Entered as RS, this command resets the cumulative statistics collected at this node. Reset stats Globally: Entered as RG, this command resets all cumulative statistics collected at all nodes by sending a reset statistics command to all nodes by transmitting a special token OSM, F1

323 CAUTION The Dump History command is rather invasive, and may cause this station to drop tokens. Dump History: Entered as DH, the history buffer maintained at this node is displayed (see Figure 8-46). Displayed are the source addresses of the last 255 stations to send a token on the wire. Note that the address of the station displaying this buffer is not seen. The location of the asterisks (***) shows the starting point of the display. The escape key will return you to the main menu. Pressing Enter will display the content of the next buffer captured. Vistanet Debugger - HyperTerminal File Edit View Cell Transfer Help A B C D E F *** A B C D E F Connected 0:00:27 VT N-1 Statistical Display Figure TYPICAL DUMP HISTORY SCREEN On the screen, several items of interest to the technician are displayed. The Statistical Display is divided, roughly, into three columns: Transmit, Receive and General Statistics. Following is an explanation of each screen element. Transmit Statistics Transmit Requests: Number of requests for UDP transmission from the host. Buffers Recycled: Number of requests for UDP transmissions processed by this board. Transmits: Number of UDP transmissions successfully made. Transmit Errors: Number of UDP transmissions not acknowledged by the destination (or acknowledgement was lost on line) OSM, F1 8-69

324 Retries: Number of UDP transmissions retried. Under normal conditions, such as a station off-line, this will be exactly twice the number of Transmit Errors. Collisions: Number of times this station has detected a loss of transmission on the wire due to collision with another station or overcome by noise. Last Destination: Address of the destination of the last UDP transmission. Tokens Issued: Number of times this station has detected a dead line and the slot assignment time has expired, resulting in an issuance of a token. Tokens Dropped: Number of times the token destination did not accept the token, or the token was lost. This indicates the number of times this station has seen a station go off-line, or line noise caused the packet to be corrupted. Tokens Passed: Number of tokens processed by this station. Receive Statistics Receives: Number of packets sent to this station. Errors: Number of unintelligible packets received by this station. Since there is an error condition, it is indeterminate whether this was a UDP packet or a token. Last Error: Encoded error condition indicating the failure detected by a receiver error, as follows: 1. Overrun - indicates a new character received before the last was processed. 2. Collision Abort - indicates a collision occurred during reception. 4. Alignment - indicates a new start of frame was detected before an end of frame. 8. CRC Error - indicates the CRC was in error. 16. Unknown - indicates more than one error condition existed during reception. 32. DMA Overrun - indicates the sending station attempted to send a packet larger than UDP size, 524 bytes. Uploads: Number of packets moved from the receive buffer pool into dual port memory for transfer to the host. Queued: Number of interrupts issued to the host to retrieve an uploaded packet. Dequeued: Number of interrupts issued to this board from the host indicating acknowledgement of a queued packet. Backups: Number of times this station has run out of receive buffers due to host interrupt latency. Invalid: Number of times the host issued unknown commands to this board. Tokens Received: Number of tokens received by this station. Tokens are broadcast objects, all tokens are seen by every station. Tokens Dumped: Number of tokens disposed of due to load at this station, or another station issued a token (indicating a receiver problem at that station). A token was seen on the wire while this station had a token OSM, F1

325 General Statistics Address: This station s wire address. Mode: Indicates the Software State of this station. These conditions are additive, bits encoded as follows: 1. Receive Request Pending - A UDP packet has been received and needs processing. 2. Receive Buffer Needed - The receiver buffer pool is full. When one is available, re-enable the receiver. 4. Transmit Requested - A UDP packet is in dual port memory and needs to be transmitted. 8. Transmit Completed - The last UDP transmission was successful, notify host. 16. Transmit in Error - The last UDP transmission was in error, notify host. 32. Upload Completed - The last DMA transfer to the host is completed, notify host a UDP packet has been received. 64. Initialization Requested - The host has requested the board reinitialize itself Line Timer Expired - The current transmission is taking too long, go into override mode. The communications board will attempt to clear line condition. (Caused by incorrect line biasing.) 256. Send Token - A token is ready to be sent to the next station in the token algorithm Terminal Input Pending - Carriage return pressed by debug operator, Process command Debug Mode - Update screen each pass through processing loop End of Interrupt - Send end of interrupt to host interrupt process Initialization Completed - Send initialization complete message to host. Input: Address of next buffer to fill in receive buffer pool. Output: Address of next buffer to empty into dual ported RAM. Max Slack: Maximum difference between input and output, or host efficiency (lag). Gap Device: Location of next device in gap search algorithm. Token Dest: Location of next non-gap update token. Next Alive: Address of next station detected on the line. Next Recvd: Address of the source address of the token seen on the wire subsequent to this station sending a token. Rate: Number of total detected errors per billion opportunities to generate errors OSM, F1 8-71

326 DUAL AIR CLEANUP REPAIR The Dual Air Cleanup Assembly appears in analyzers having two detectors. Refer to Figure 8-47 for Dual Air Cleanup Assembly component location. Harness Assembly Air Cleanup Tube #1 Air Cleanup Tube #2 Figure DUAL AIR CLEANUP ASSEMBLY CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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. See AIR PURGING in Section 4 for the X Purge override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure properly. Let the Dual Air Cleanup Assembly cool a minimum of 30 minutes prior to disassembly. Internal surface temperatures can cause severe burns if they are touched before they have cooled. No asbestos is used in any assembly or component part of the Dual Air Cleanup Assembly. Therefore, all residual insulating materials may be disposed of without regulator restrictions. The high temperatures present under normal operating conditions can cause wiring insulation to become brittle and fragile. Ceramic temperature probes should always be considered fragile. When servicing the Dual Air Cleanup Assembly, these component parts must be handled with great care to avoid damage. Removing the Dual Air Cleanup Assembly 1. Remove power from the analyzer OSM, F1

327 2. Turn off oven air to the isothermal oven and allow all temperature zones to cool. 3. Turn off air supply to air cleanup unit. 4. Open the isothermal oven door. 5. Label the tubing on both sides of the associated unions with temporary numbered tape labels. The labels are later used to ensure correct tubing connections when the air cleanup is reinstalled. 6. Using 7/16-inch and 5/16-inch open-end wrenches, disconnect the tubing connections from the reducing unions. 7. Disconnect any retaining clamps that are securing the harness. 8. Remove the four Phillips head screws attaching the support brackets to the isothermal oven wall. Secure the unit with your hand while removing the final top screws. 9. Lay the air cleanup assembly on a suitable work surface within the constrained length of the heater harness. If only the air cleanup tubes are to be replaced, the harness will not require further disconnection. CAUTION Wait 30 minutes before proceeding to open the Dual Air Cleanup Assembly. 10. Mark the top and bottom caps and housing with a grease pencil or permanent marker. When the caps are replaced with the marks aligned, the support bracket holes will be correctly aligned. 11. Using a 9/64-inch Allen wrench, remove the four Allen head screws attaching the air cleanup top cap to the outer housing. 12. Grasp the housing and top cap. Withdraw the internal body assembly from the housing. 13. Using tweezers or a small screw driver, remove the insulation from around the body assembly. Retain it for later use. Removing the Air Cleanup Tubes 1. Using a 1/4-inch open-end wrench, disconnect the air cleanup tube connections from the bottom side of the cap. 2. To remove an air cleanup tube, remove the Phillips head screw and flat washer located in the center of the body at the opposite end from the harness. 3. Grasp the long coiled or pig tail end of the tubing and pull the short nutted end through the body assembly. 4. Repeat steps 2 and 3 for the second air cleanup tube, if applicable. 5. Carefully rotate the body assembly and remove the Phillips head retaining screw and flat washer. 6. Note the location of the cartridge heater, temperature probes and thermocouple. Carefully extract the cartridge heater, probes and thermocouple from the air cleanup body. 7. Inspect the probe end of the wiring harness for damage. If any harness wiring or devices are damaged, replace the harness as described in "Packing the Housing" and "Installing the Dual Air Cleanup Assembly." 2000-OSM, F1 8-73

328 Installing the Air Cleanup Tubes 1. To install an air cleanup tube, insert the short end of the catalytic air tube through the larger tube passage of the body and align it with the inside air inlet port connection of the top cap. 2. Insert the tube fitting into the cap and tighten the inlet fitting nut finger tight. 3. Repeat steps 1 and 2 for the second air cleanup tube, if applicable. 4. Assemble the flat washer and screw. 5. Insert the flat washer retaining screw assembly into the center hole located in the end of the body assembly opposite the harness and tighten it with the Phillips screwdriver. 6. If a new tube is being installed, a small loop or pig tail should be coiled in the tubing to compensate for the excess tubing length. If installing an existing tube, the pig tail will already be present. 7. Bend and position the coiled tubing such that the end fitting can be inserted into the corresponding air or methanizer outlet connection port located on the bottom of the top cap. 8. Tighten all inside catalytic tube inlet and outlet fittings, using a 1/4-inch open-end wrench. Packing the Housing 1. Pack a small amount of insulation around the probes, thermocouple, heater, and associated wiring of the body assembly and set the assembly aside. 2. Using a 9/64-inch Allen wrench, loosen and remove the four Allen head screws attaching the air cleaner/methanizer bottom cap to the outer housing. Separate and set the bottom cap aside. 3. Carefully insert and press the body assembly into the outer housing. 4. Align the top cap with the marks on the outer housing. This will align the mounting bracket holes in the top cap. 5. Install the four Allen head screws that secure the top cap to the outer housing and tighten with a 9/64-inch Allen wrench. 6. Place a small quantity of insulation into the housing cavity and gently pack it down using an object such as a screwdriver. Continue adding and packing in insulation until the cavity is filled, taking care not the damage any wiring. 7. Install the bottom cap, aligning the mark on the cap with the mark on the housing. This will align the bottom mounting bracket holes. 8. Install the four Allen head screws to secure the bottom cap to the housing, and tighten with a 9/64-inch Allen wrench. Installing the Dual Air Cleanup Assembly 1. Attach the Dual Air Cleanup Assembly to the interior of the isothermal oven wall. Secure the air cleanup/methanizer with your hand while installing the four Phillips head screws through the support bracket holes and into the mounting holes located in the isothermal oven back interior wall OSM, F1

329 2. Connect the tube connections to their respective reducing unions while matching the numbers on the temporary labels. 3. Remove the temporary tape labels. 4. Apply carrier and air to the air cleanup assembly. 5. Using a liquid leak detection solution, test for leaks and make necessary repairs before proceeding. 6. Route the heater harness in the oven interior, following the same path as the original harness installation. 7. Connect heater one wires to J48E terminals 1 and 2, and connect heater two wires to J48E terminals 5 and Connect the temperature sensor wires to terminals 1 through 6, as follows: Overtemp Thermocouple: yellow (+) to 1 Overtemp Thermocouple: red (-) to 2 RTD sensor: 4 and 5 Shield (individual): 3 Composite Shield: 6 9. Close and secure the isothermal oven door, and the Controller front and side doors. Air Cleanup Testing 1. Restore burner air to the cleanup unit by adjusting the burner air regulator for the correct burner air pressure as indicated at the burner air pressure indicator. 2. Using a suitable liquid leak detection solution, test and repair any leaks that may be present in the connections loosened or disconnected during the maintenance procedure. 3. Close the isothermal oven door and secure the latch. 4. Restore carrier gas, oven air and fuel gas, if necessary, by adjusting the regulators for the correct indications at the pressure indicators. 5. After ensuring the area is safe, and the proper permits are in effect, apply AC power. 6. To check the temperature of the air cleanup assembly, exit to the Background screen by pressing the F1 soft key. 7. Access the Manual Control Mode screen by pressing the F2 (Manual Control) soft key. 8. Access the Pressure and Temperature Control Mode by pressing the F4 (Press. and Temp. Control) soft key. 9. From the Pres and Temp Control screen, position the cursor up or down to highlight TEMP CONTROL and press the F2 (Manual Temperature Control) soft key to access the Manual Temperature Control Screen. 10. On the Manual Temperature Control screen observe the setpoint value. If necessary, change the setpoint of the air cleanup/methanizer temperature controller to 450 C OSM, F1 8-75

330 11. The temperature of the air cleanup assembly can also be monitored from this screen. The time required to achieve stability is two hours. 12. Press the F1 soft key as necessary to return to the Background screen. Air Cleanup Final Preparation 1. Restore all utility gases and verify that the pressures and flow rates are correct. These include oven air, purge air, carrier, burner fuel, and burner air. If the faces of the pressure gauges were previously marked and the marked location is known to be correct, simply adjust the pressure regulators until the gauge pointers are aligned with the pressure indicating marks. Refer to the engineering data package supplied with your analyzer for the correct values. 2. After sufficient air purge time and when authorized by your safety administrator, apply power to the analyzer. 3. Verify that all Digital Temperature Control setpoint values are correct. Refer to the engineering data package supplied with your analyzer for the correct values. 4. Allow the temperature controlled zone temperatures to equilibrate. 5. Verify that sample is being introduced to and is sufficiently flowing through the analyzer sample valve. 6. Perform a minimum of three analyses to verify correct chromatographic response and analysis reports. Minor adjustments or calibration may be necessary to achieve desired analysis results. 7. Once analyzer operation and performance have been verified, place the analyzer back in service. REPAIRING THE CP VALVE This section describes how to replace the CP Valve slider, wedges, and o-rings. The material applies to both the 40 psig and 60 psig valves (see Figure 8-48). VALVE BODY VALVE PLATE CARRIER ASSEMBLY Preparation and Safety Figure TYPICAL M2CP VALVE CAUTION It is the customer s responsibility to ensure that the area is safe and and hazardfree, 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 OSM, F2

331 CAUTION See AIR PURGING in Section 4 for the X Purge override function. Do not perform override until you have read Section 4 completely and you understand and can perform the procedure properly. NOTE To ensure the integrity of the components within the CP Valve, use the tools in CP Valve Tool Kit 754K003-1 when assembling or disassembling the CP Valve. 1. Stop the analysis at the end of a cycle. 2. Turn off sample and air to the analyzer. NOTE 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. Replacing the Slider 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 Sheets supplied with your analyzer. To replace the slider: 1. Perform the "Preparation and Safety" procedure. 2. Open both Carrier Assembly latches by pulling down on the end of the latches. 3. Remove the Carrier Assembly from the Valve Plate and Valve Body, being careful to keep the latches in their open position. 4. Compare the old slider with the new slider to ensure they are the same. 5. Note the orientation of the slider s ports. 6. Remove the old slider from the Carrier Assembly. 7. Insert the new slider, ensuring that the ports are aligned in the same way as the old slider. 8. Wipe the bottom of the Valve Plate with methanol and a lint-free wipe to remove any slider residue or contamination. 9. Insert the Carrier Assembly on the Valve Plate. 10. Close the back Carrier Assembly latch. This ensures the Carrier Assembly is locked into the hole in the piston stem. 11. Close the front Carrier Assembly latch OSM, F2 8-77

332 Replacing the Wedges The four wedges (part number ), located on the Carrier Assembly, center the Valve Plate on the Carrier Assembly. To replace the wedges: 1. Perform the "Preparation and Safety" procedure. 2. Open both Carrier Assembly latches by pulling down on the end of the latches. 3. Remove the Carrier Assembly from the Valve Plate and Valve Body. 4. Remove the slider (see "Replacing the Slider"). 5. Note the orientation of the wedges and push out each wedge from the outside of the Carrier Assembly. 6. Insert the Wedge Insertion Tool (part of the CP Valve Tool Kit) part way onto the Carrier Assembly. 7. Insert two new wedges into the Wedge Insertion Tool and slide the Tool farther onto the Carrier Assembly. 8. Insert the other two new wedges into the Wedge Insertion Tool and slide the Tool fully onto the Carrier Assembly. 9. Put the Wedge Driver Tool (part of the CP Valve Tool Kit) into the v-slot of the Wedge Insertion Tool. 10. Tap the Wedge Driver Tool with a hammer to push the wedges into position, ensuring the back of each wedge is against the Carrier Assembly body. 11. Reinstall the slider. 12. Insert the Carrier Assembly on the Valve Plate. 13. Close the back Carrier Assembly latch. This ensures the Carrier Assembly is locked into the hole in the piston stem. 14. Close the front Carrier Assembly latch OSM, F2

333 Replacing the 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 8-49). The rework procedure is the same for both valves. PART NUMBER 40-PSIG KIT 764K001N-2 60-PSIG KIT 764K001N-1 DESCRIPTION (dimensions are in inches) O-Ring, Fluorocarbon, 1/4 x 1/8 x 1/ O-Ring, Fluorocarbon, 2 x 1-7/8 x 1/ O-Ring, Fluorocarbon, 1-3/4 x 1-1/2 x 1/ O-Ring, Fluorocarbon, 1-3/8 x 1-1/4 x 1/ O-Ring, Fluorocarbon, 1-1/2 x 1-3/8 x 1/ Grease, Molykote Figure O-RING KITS NOTE It is essential to the analyzer s operation that all valve ports remain correctly connected. To replace the o-rings: 1. Perform the "Preparation and Safety" procedure. 2. Tag each port connection to the valve, using the port numbers stamped on the Valve Plate. 3. Remove the port connections. 4. Remove the air connection on the Valve Body. (You do not have to remove the connection on the Mounting Plate that attaches to the analyzer.) 5. Using the 7/64- inch hex driver from the CP Valve Tool Kit, loosen the four screws that attach the Valve Body to the Mounting Plate. 6. Rotate the Valve Body counterclockwise and remove it from the Mounting Plate. 7. Open both Carrier Assembly latches by pulling down on the end of the latches. 8. Remove the Carrier Assembly from the Valve Plate and Valve Body. 9. Push the piston rod into the Valve Body to release the piston, being careful not to scratch any valve surfaces. 10. Remove the piston and piston rod from the Valve Body. 11. Remove the piston rod o-ring and the piston o-ring OSM, F2 8-79

334 12. Wipe all surfaces of the piston and piston rod to remove contamination. 13. Verify that the screw holding the piston rod to the piston is tight. 14. Lubricate one o-ring part number with Molykote Position O-Ring Tool part number over the piston rod (see Figure 8-50). PISTON PISTON O-RING SCREW LOCKWASHER PISTON ROD O-RING PISTON ROD INSTALLATION TOOL Figure INSTALLING THE O-RINGS ON THE PISTON ROD AND PISTON 16. Install the o-ring over the O-Ring Tool and into the o-ring groove on the piston rod. 17. Lubricate o-ring part number (40-psig valve) or (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 8-51). O-RING VALVE BODY Figure INSTALLING THE O-RING ON THE VALVE BODY 19. Wipe the inside of the Valve Body to remove contamination and old lubricant. 20. Inspect the piston rod bore to ensure the bore is clean. 21. Lubricate O-Ring part number (40-psig valve) or (60-psig valve) with Molykote 33 and install it in the o-ring groove in the Valve Body. 22. Lubricate the piston rod and the inside of the Valve Body (piston housing area) with Molykote OSM, F2

335 23. Insert the piston and piston rod into the Valve Body. Before seating the piston, ensure the flat surface on the piston rod is facing up. 24. Insert the Carrier Assembly into the Valve Plate. 25. Close the back Carrier Assembly latch. This ensures the Carrier Assembly is locked into the hole in the piston stem. 26. Close the front Carrier Assembly latch. 27. Install the Valve Body over the screws on the Mounting Plate and rotate Valve Body clockwise to seat it. The port connections must face the same direction as when it was originally installed. 28. Using the 7/64-inch hex driver from the CP Valve Tool Kit, tighten the four screws securing the Valve Body to the Mounting Plate. 29. Reinstall the air connection onto the Valve Body. 30. Reinstall the port connections, being careful to get each connection to the correct port. 31. Perform a leak check on the valve (see "Leak Check" in Section 2). 32. Turn on carrier, air and power. 33. Check the operation of the valve (see "Manual Operation of Valves" in Section 2) OSM, F2 8-81

336 ORDERING INFORMATION SECTION 9. REPLACEMENT PARTS NOTE Since the component parts specific to any given system are defined by the particular application, you should refer to the Recommended Spare Parts Lists in the Data Package supplied with the analyzer, to obtain the full and correct part number for the desired part or assembly. Equipment Identification The following information, found in the Data Package and on the analyzer nameplate, should be included in any communication concerning replacement parts or components: ABB Sales Order Number. Analyzer Model Number. Analyzer Part Number (P/N) and serial number. For serial numbered subassemblies such as PC boards, include the serial number and the part number (including dash number and revision letter) for the subassembly in the request. If a PC board requires conformal coating, prefix the PCB part number with the letters "CC." Applicable references from the Recommended Spare Parts List of the Data Package, included with each analyzer. Description of part. Hardware Configuration Identification The nameplate (see Figure 9-1), which is located on the right side of the Oven Compartment, lists the hardware configuration information. Sales Order No. ABB INC. LEWISBURG, WV MADE IN U.S.A ATEX MODEL: S.O. NO.: YEAR OF MANUFACTURE: II 2G EEx pde [ib] ib [ia] IIB+H2 T ATEX 6025X 0344 Model No. T-Rating Figure 9-1. TYPICAL NAMEPLATE The hardware configuration consists of the model number, sales order number, and T-Rating OSM, F1

337 Software Configuration Identification The software configuration appears at the top of the Background screen just below "ABB Analytical GCC." In Figure 9-2 the software configuration is 803V029-1G. Software Configuration ** B A C K G R O U N D ** ABB Analytical GCC Remote V029-1R (Std GCC) (C) 2001 **ALARM** **ALARM** 18-JUN-2002 TUE 08:16:01 **ALARM** Analysis Time :00114 Peaks Found : 00 Cycle Time :00000 State : Idle Current Stream :01 Key Component: Purging Stream :01 none entered Exit Manual Cur Report, To Control Basic I/O & Alarms Commands Options F1 F2 F3 F4 Figure 9-2. BACKGROUND SCREEN 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. When you order parts for replacement, use the list of parts included in the Engineering Data Package provided with your equipment to ensure you have the correct version of each part OSM, F1 9-2

338 GC CONTROLLER Back of Front Panel (see Figure 9-3) Description Part Number Kit, Front Panel PCB with LCD 81943A059-2 Lo Comm PCB 733A037D-1 Card Cage (see Figure 9-4) Figure 9-3. BACK OF FRONT PANEL Description Part Number Chroma I/O PCB (old type) _ Chroma I/O PCB (new type) 802A028D-_ Digital I/O PCB Analog Output PCB (Current) 733A096B-2 Analog Output PCB (Voltage) VistaNET Communication PCB 802A025B-1 VistaNET Interconnect PCB 802A015B-2 Ethernet PCB 802A034B-1 Electronic Pressure Control PCB 802A013B-1 Single Board Computer PCB (application dependent see Data Package) Figure 9-4. CARD CAGE COMPONENTS OSM, F2

339 GCC Chassis (see Figure 9-5) Description Part Number FID Amplifier (per application) 81943A040-_ Fuse for FID Amplifier (1 amp) Filament TCD Amplifier 81943A041-1 Fuse for TCD Amplifier (0.375 amp) Thermistor TCD Amplifier PCB 802A023B-1 Thermistor Amplifier Interface PCB 802A024B-1 RFI Filter (115 VAC) RFI Filter (220 VAC) Power Supply PCB 802A016B-1 Solenoid Driver PCB 802A001B-1 Relay/Solenoid Driver PCB 826A003B-1 Hydrogen Pressure Switch Pressure Sensor _ FPD Amplifier* *see "FLAME PHOTOMETRIC DETECTOR" for alternate location RFI Filter Power Supply PCB Pressure Sensors FID Amplifier and/or TCD Amplifier or FPD Amplifier Solenoid Driver PCB Hydrogen Pressure Switch Figure 9-5. CHASSIS COMPONENTS Components on Right Side Door (see Figure 9-6) Description Part Number Panel Assembly Kit 800K010-_ DTC Zone PCB 802A007B A 3AG fast acting Fuse amp Fuse, semiconductor type AC Conditioning PCB 802A009B-2 AC Conditioning PCB (has both fuses) DTC Zone PCB Panel Assembly Figure 9-6. RIGHT SIDE DOOR OF GCC 2000-OSM, F1 9-4

340 PURGE AIR PANEL (SEE FIGURE 9-7) Description Part Number Heater Air Pressure Switch /4-inch Tubing /8-inch Tubing Solenoid Valve Kit (vented) 800K005-1 Solenoid Valve Kit (non-vented) 800K005-2 See SOLENOID VALVES in Section 4 for information on the differences between types of solenoid valves Solenoid Valve Gasket Pressure Relieving Regulator, 0-40 psig Pressure Gauge, psi Regulator Gasket 81943D033-1 Gauge Gasket 81943D033-2 Figure 9-7. PURGE AIR PANEL ELECTRONIC PRESSURE CONTROL PANEL (SEE FIGURE 9-8) Description Part Number Proportional Valve O-Ring Kit 801K001-1 Control PCB 802A011B-1 Sensor PCB Kit 802A012B-2 Heater 81943A042-1 Metric Allen Wrenches TL161-1 EPC Service Tool Kit 801K005-1 Figure 9-8. ELECTRONIC PRESSURE CONTROL PANEL OSM, F1

341 CARRIER GAS PANEL (SEE FIGURE 9-9) Description Part Number Pressure Regulator, Pressure Regulator, Pressure Gauge, Pressure Gauge, Hydrogen Fuel Restrictor Carrier Gas Filter Figure 9-9. CARRIER GAS PANEL 2000-OSM, F1 9-6

342 ISOTHERMAL OVEN COMPONENTS (SEE FIGURE 9-10) NOTE Part Numbers are incomplete without dash numbers. See the Recommended Spare Parts List (in the Engineering Data Package) for application-specific information. Description Part Number Oven Heater Kit, 115 V 1000W 800K007-1 Oven Heater Kit, 230 V 1000W 800K007-2 Oven Heater Kit, 115 V 500W 800K007-3 Oven Heater Kit, 230 V 500W 800K007-4 Temperature Sensor, Platinum Makeup Valve Splitter Valve Metering Valve Restrictor Valve Liquid Sample Valve (see "Liquid Sample Valve") Flame Ionization Detector (see "Flame Ionization Detector") Filament Type TC Detector (see Filament Type Thermal Conductivity Detector") Thermistor Type TC Detector (see "Thermistor Type Thermal Conductivity Detector") M2CP Valve (see "M2CP Valve") 781 Methanizer/Air Cleanup (see "Type 781 Methanizer/Air Clean Up System") 805 Methanizer/Air Cleanup (see "Type 805 Methanizer/Air Clean Up System") Dual Air Clean Up (see "Dual Air Clean Up System") Figure ISOTHERMAL OVEN COMPONENTS OSM, F1

343 Liquid Sample Valve (see Figure 9-11) Description Part Number O-Ring Seal Kit 791K003N inch Stem (per application) 791A008B-_ inch Seal (per application) 791M001B-_ inch Stem (per application) 791A009B-_ 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 800K011-5 Figure LIQUID SAMPLE VALVE 2000-OSM, F1 9-8

344 Flame Ionization Detector (see Figure 9-12) Description Part Number Maintenance Kit 799K003-1 Jet Ignitor Assy 794A007B-2 Thermocouple Assy 794A008B-1 Polarizer Assy 794A009B-1 Column kits are application 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 Figure FID COMPONENTS Filament Type Thermal Conductivity Detector (see Figure 9-13) Description Part Number Filament Kit NEC 800K003-1 Filament Kit CENELEC/CSA 800K003-2 Figure FILAMENT TYPE TCD COMPONENTS OSM, F1

345 Thermistor Type Thermal Conductivity Detector (see Figure 9-14) Description Part Number Thermistor Assembly, matched pair 798A002B-1 Wire Splice Kit 800K001-1 M2CP Valve (see Figure 9-15) Figure THERMISTOR TYPE TCD COMPONENTS Description Part Number 10 port Slider (per application) 764M005-_ 6 port Slider (per application) 764M006-_ 8 port Slider (per application) 764M007-_ Fitting Kit 753K002N-11 O-Ring Kit, 40 psi Valve 764K001N-2 Carrier Assy SPV Wedge O-Ring Kit, 60 psi Valve 764K001N-1 Figure M2CP VALVE COMPONENTS 2000-OSM, F2 9-10

346 Type 781 Methanizer/Air Clean Up System (see Figure 9-16) Description Part Number Methanizer Tube 781A002C-1 Air Cleanup Tube 781A003C-1 115V Heater Kit 805K V Heater Kit 805K001-2 Sensor Kit 805K002-1 Crimper Harness Assy Air Cleanup Tube Methanizer Tube Figure TYPE 781 METHANIZER/AIR CLEAN UP SYSTEM Type 805 Methanizer/Air Clean Up System (see Figure 9-17) Description Part Number Methanizer Tube 805A017-1 Air Cleanup Tube 805A018-1 Heater Sensor Kit 805K002-1 Crimper Metric Hex Wrench TL-161 Air Cleanup Tube Methanizer Tube Figure TYPE 805 METHANIZER/AIR CLEAN UP SYSTEM OSM, F1

347 Dual Air Clean Up System (see Figure 9-18) Description Part Number Air Cleanup Tube 805A018-1 Heater Sensor Kit 805K002-1 Crimper Metric Hex Wrench TL-161 Valco Diaphragm Valve (see Figure 9-19) Figure DUAL AIR CLEAN UP SYSTEM Description Part Number Valve, 10-port Clamp Ring Diaphragm Kit Alignment Pin Air Fitting Connection Nut Connection Ferrule HEX HEAD SCREW CAP PLUNGER ENLARGED TO SHOW COUNTERBORED END DIAPHRAGM PLUNGERS ALIGNMENT PINS BODY Figure VALCO DIAPHRAGM VALVE 2000-OSM, F1 9-12

348 FLAME PHOTOMETRIC DETECTOR (FPD) Transformer and Photomultiplier Components (see Figure 9-20) Description Part Number Transformer Capillary Tubing, Burner Fuel (not shown) Coaxial Cable Assy Photomultiplier Assy 804A003-1 Solenoid, 3 Way (for X Purge) Pressure Sensor FPD Electrometer* 804A010-2 *see "GCC Chassis" for alternate location Burner Block (see "Burner Block Components") Pressure Sensor Solenoid Transformer FPD Electrometer 0 0 Coaxial Cable Photomultiplier Burner Block Figure PGC2000 SHOWING FPD COMPONENTS OSM, F1

349 Burner Block Components (see Figure 9-21) Description Part Number Burner Block Assy 804A005-1 Burner Block Assy with Temp Sensor 804A005-3 Heater Cartridge, 70W Thermocouple Assy Electrode Nut 804A004-1 Jet O-Ring 15/16-in OD, Fluorocarbon O-Ring 11/16-in OD, Teflon O-Ring 3/8-in OD, Fluorocarbon Breather Vent Breather Line Kit 804K002-_ Fitting 804M009-1 Sulfur Addition Wafer _ Breather Vent Temp Sensor (804A005-3 only) O-Ring O-Ring Sulfur Addition Wafer Fitting Breather Line O-Ring O-Ring Figure BURNER BLOCK COMPONENTS TEMPERATURE PROGRAMMED OVEN (SEE FIGURE 9-22) Description Part Number Heater Assy 806A034-1 Flame Ionization Detector with Heater Block 794A001B-2 Thermal Conductivity Detector with Heater Block 795A001B-2 Detector (FID shown) Heater Figure TEMPERATURE PROGRAMMED OVEN 2000-OSM, F1 9-14

350 Flame Ionization Detector with Heater Block (see Figure 9-23) Description Part Number Heater Block 795A002B-1 Flame Ionization Detector 799A001B-2 (see "Flame Ionization Detector" for FID component parts) Figure FID WITH HEATER BLOCK Filament Type TC Detector with Heater Block (see Figure 9-24) Description Part Number Heater Block 795A002B-1 Fialement Type Thermal Conductivity Detector 798A001B-2 (see "Filament Type Thermal Conductivity Detector" for Filament Type TCD component parts) Figure FILAMENT TYPE TCD WITH HEATER BLOCK OSM, F1