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A B B M E A S U R E M E N T & A N A LY T I C S | o p eratin g instructi o n

PGC5000 Series
Process gas chromatographs

Measurement made easy

Further information
Additional documentation on the PGC5000 process
gas chromatograph is available for download at
www.abb.com/analytical.
Alternatively simply scan this code.
The Company

We are an established world force in the design and manufacture of measurement products for industrial process control, flow
measurement, gas and liquid analysis and environmental applications. As a part of ABB, a world leader in process automation
technology, we offer customers application expertise, service and support worldwide. We are committed to teamwork, high quality
manufacturing, advanced technology and unrivalled service and support. The quality, accuracy and performance of the Company’s
products result from over 100 years of experience, combined with a continuous program of innovative design and development to
incorporate the latest technology.

Cyber Security Disclaimer

This product is designed to be connected to and to communicate information and data via a network interface. It is the Customer's
sole responsibility to provide and continuously ensure a secure connection between the product and Customer network or any other
network (as the case may be). Customer shall establish and maintain any appropriate measures (such as but not limited to the
installation of firewalls, application of authentication measures, encryption of data, installation of anti-virus programs, etc.) to protect
the product, the network, its system and the interface against any kind of security breaches, unauthorized access, interference,
intrusion, leakage and/or theft of data or information. ABB Inc. and its affiliates are not liable for damages and/or losses related to
such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.

Information for Users regarding the EU Directive 2012/19/EU on Waste Electrical and Electronic Equipment
(WEEE)

ABB Industrial Automation, Measurement and Analytics, product manufacturing unit located at 3567 Jefferson Street North in
Lewisburg WV 24901 USA, is committed to actively protecting the environment. The following product information is provided to the
user regarding instruction to not dispose of WEEE as unsorted municipal waste but rather to collect WEEE separately. The user’s
role in the management of WEEE is indispensable for the success of WEEE collection.

Such information necessitates the proper marking of Electrical and Electronic Equipment (EEE), referred to
herein as the product, which could end up in rubbish bins or similar means of municipal waste collection. The
product displays the crossed-out wheeled bin symbol, indicating a separate collection for the EEE and that the
product conforms to the directive for Waste of Electrical and Electronic Equipment (WEEE). End of life disposal
of the product is not intended for general household waste. Disposing of this product correctly will help save
valuable resources and prevent any potential negative effects on human health and the environment.

Regarding our sustainability strategy, the course of action when developing new products is to ensure wherever possible that any
and all national and international legal requirements, directives and standards of environmental protection and occupational safety
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knowledge.

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manufacture and use, the production of waste is reduced to a minimum. The environmentally friendly recovery and disposal of
waste created after their use is guaranteed, and measured through the sustainability group of ABB.

Information for treatment facilities shall be provided by ABB regarding the preparation for re-use and treatment of new EEE placed
for the first time on the European Union market. Such information may identify the different EEE components and materials, as well
as the location of dangerous substances and mixtures. This information shall be made available by ABB to centers which prepare
for re-use and treatment, and recycling facilities listed on the ABB website. Further information may be obtained through the local
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This document shall serve for informational purposes only, no legal obligations are substantiated by any regulations.

 
 
 
 
 
 
 

OI/PGC5000‐EN, rev D  2
PGC5000
PGC5000 Series Operating Instructions Contents

Contents
1 Glossary ..............................................................6 5.4 Starting the analyzer .............................................. 20
5.4.1 Leak check oven ........................................ 21
2 Safety and symbols .............................................7 5.4.2 Leak check carrier gas supply lines .......... 21
5.5 Calibrating the analyzer ......................................... 21
3 Introduction ........................................................8 5.6 Validation run......................................................... 22
3.1 General..................................................................... 8 5.7 Connecting to the network.................................... 22
3.2 Drawings .................................................................. 8 5.8 Using the access control list .................................. 24
3.3 Master controller..................................................... 8 5.8.1 Logging into PGC5000 analyzer ................ 24
3.4 Class B oven ............................................................. 8 5.8.2 Access levels .............................................. 24
3.4.1 Liquid version.............................................. 9 5.8.3 Subscriber list ............................................ 25
3.4.2 Vapor version.............................................. 9 5.8.4 Remote client ............................................ 25
3.5 Class C oven ............................................................. 9 5.9 Analyzer shutdown ................................................ 25
3.6 Air purge systems .................................................... 9
3.7 System variations .................................................... 9 6 Operation ..........................................................26
6.1 Introduction ........................................................... 26
4 Installation ........................................................10 6.2 Home tab ................................................................ 26
4.1 Safety considerations ............................................ 10 6.2.1 Chart sub-tab ............................................ 26
4.2 Analyzer location ................................................... 10 6.2.2 Status sub-tab ........................................... 27
4.2.1 Master controller ..................................... 10 6.2.3 Report sub-tab .......................................... 28
4.2.2 Ovens ........................................................ 11 6.2.4 Overlay sub-tab ......................................... 30
4.2.3 Precautions ............................................... 11 6.3 Status tab ............................................................... 31
4.3 Preparing for installation ...................................... 11 6.3.1 User configurable scopes ......................... 32
4.3.1 Installation tools and equipment............. 11 6.3.2 Configuring indicators............................... 33
4.3.2 Plumbing installation................................ 12 6.3.3 Status indicator reset................................ 33
4.3.3 Gas requirements ..................................... 12 6.4 Schedule tab ........................................................... 33
4.3.4 Calibration sample.................................... 12 6.4.1 Maintenance mode icon ........................... 34
4.3.5 Purge air alarm ......................................... 12 6.4.2 Power failure recovery icon ..................... 34
4.4 Equipment mounting ............................................ 12 6.4.3 Multiple oven & schedule relationship .... 35
4.5 Connections ........................................................... 12 6.4.4 Queue sub-tab .......................................... 36
4.5.1 Tubing ....................................................... 12 6.4.5 Step sub-tab .............................................. 37
4.5.2 Instrument air ........................................... 12 6.4.6 Time of day sub-tab .................................. 37
4.5.3 Carrier gas ................................................. 12 6.4.7 Demand sub-tab ....................................... 38
4.5.4 Burner fuel ................................................ 13 6.5 Analysis tab ............................................................ 38
4.5.5 Burner air .................................................. 13 6.5.1 Chart sub-tab ............................................ 39
4.5.6 Sample ...................................................... 13 6.5.2 Tabular editor sub-tab .............................. 40
4.5.7 Hydrogen gas ............................................ 13 6.5.3 Normalization............................................ 40
4.5.8 Vents ......................................................... 13 6.5.4 New analysis.............................................. 41
4.5.9 Liquid sample valve .................................. 13 6.5.5 Analysis error messages ........................... 42
4.6 Electrical ................................................................. 14 6.5.6 Loading an analysis from the library ........ 44
4.7 Setting up the master controller........................... 14 6.5.7 Running an existing schedule ................... 45
4.7.1 Single board computer pcb ...................... 14 6.5.8 Stopping or pausing schedules ................. 45
4.7.2 Purge air alarm ......................................... 15 6.5.9 Overlay sub-tab ......................................... 45
4.8 Setting up the ovens .............................................. 15 6.5.10 Chromatogram reprocessing.................... 45
6.6 Setup tab ................................................................ 46
5 Start-up .............................................................16 6.6.1 File management ...................................... 46
5.1 Introduction ........................................................... 16 6.6.2 System restore and recovery ................... 47
5.2 Master controller controls and indicators............ 16 6.6.3 System error messages ............................. 48
5.2.1 Touchscreen layout .................................. 16 6.6.4 Components .............................................. 49
5.2.2 Action items .............................................. 17 6.6.5 Streams...................................................... 50
5.2.3 Function/navigation buttons ................... 17 6.6.6 Master controller ...................................... 51
5.2.4 System information bar ........................... 18 6.6.7 Oven configuration ................................... 53
5.2.5 Naming conventions................................. 18 6.6.8 Oven buttons ............................................ 54
5.2.6 Keypad ...................................................... 19 6.6.9 Isothermal oven ........................................ 57
5.2.7 Keyboard ................................................... 19 6.6.10 Electronic pressure control ...................... 58
5.3 Oven controls and indicators ................................ 20 6.6.11 Detector amplifier..................................... 59

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PGC5000
PGC5000 Series Operating Instructions Contents

6.7 Subscriber tab ........................................................ 60 7.8.4 MODBUS slave communication ............... 83

6.7.1 Creating a new subscriber........................ 61 7.8.5 Client configurator .................................... 84
6.7.2 Adding an existing device ......................... 62 7.8.6 OPC communication ................................. 86
6.7.3 Subscriber events ..................................... 62 7.9 Input/output options ............................................. 86
6.7.4 Failover operation .................................... 63 7.9.1 Local input/output option ........................ 86
6.7.5 Modbus sub-tab ....................................... 63 7.9.2 Local output option setup ........................ 86
6.8 Program tab ........................................................... 65 7.9.3 Internal input/output option.................... 87
6.9 Manual mode tab .................................................. 65 7.9.4 Digital output ............................................ 88
6.10 Sample handling system........................................ 65 7.9.5 Digital input ............................................... 89
7.9.6 Analog input .............................................. 89
7 Technical description......................................... 66 7.10 External input/output option ................................ 89
7.1 Functional description ........................................... 66
7.2 Detectors ............................................................... 66 8 Operator troubleshooting ................................. 90
7.2.1 Flame ionization detector ........................ 66 8.1 Common issues ...................................................... 90
7.2.2 Thermal conductivity detector ................ 67 8.2 Oven LED indicators ............................................... 90
7.2.3 Flame photometric detector.................... 67 8.3 Indicator troubleshooting procedures .................. 90
7.2.4 Optional discharge ionization detector ... 68 8.4 Status indicators..................................................... 91
7.3 Peak detection ....................................................... 69 8.5 Diagnostic displays ................................................ 96
7.3.1 Classic method of peak detection............ 69
7.3.2 Min-max method overview ...................... 69 9 Scripting ............................................................99
7.3.3 Min-max examples ................................... 69 9.1 Introduction ........................................................... 99
7.3.4 Baseline correction, peak lumping .......... 71 9.2 Attachment to analysis elements ........................ 100
7.3.5 Baseline correction, tangent skim ........... 71 9.2.1 Creating a new script .............................. 100
7.4 Component detection (EZ peak) ........................... 72 9.2.2 Adding/running a script .......................... 101
7.4.1 EZ peak calculations ................................. 72 9.2.3 Adding a line to a script .......................... 101
7.4.2 Identifying peaks ...................................... 72 9.2.4 Deleting a line ......................................... 101
7.4.3 Single peak integration range .................. 73 9.2.5 Copying a line .......................................... 101
7.4.4 Multiple peak integration range .............. 73 9.3 Operators ............................................................. 101
7.4.5 Tangent skim ............................................ 74 9.4 Alphabetic listing.................................................. 102
7.4.6 Baseline drift ............................................. 74 9.4.1 ABSOLUTE VALUE function ..................... 102
7.5 Time-coded functions............................................ 74 9.4.2 ACTIVATE STREAM command ................ 102
7.5.1 Auto zero .................................................. 75 9.4.3 ACTUAL RETENTION TIME function ....... 102
7.5.2 Component min/max ............................... 75 9.4.4 ANALYSIS NAME function ....................... 102
7.5.3 Component RT (EZ peak).......................... 75 9.4.5 ASC function ............................................ 102
7.5.4 Digital input check .................................... 75 9.4.6 BENCHMARK CONCENTRATION fnctn ... 102
7.5.5 Do next if................................................... 76 9.4.7 BPRINT statement ................................... 102
7.5.6 Peak threshold .......................................... 76 9.4.8 CALIBRATION CONCENTRATION fnctn ... 103
7.5.7 Pressure check .......................................... 76 9.4.9 CANCEL REQUESTS command ................ 103
7.5.8 Pressure control ....................................... 76 9.4.10 COMPONENT CONCENTRATION fnctn ... 103
7.5.9 Pressure default ....................................... 76 9.4.11 CHR$ function ......................................... 103
7.5.10 Script control ............................................ 76 9.4.12 CLEAR INDICATORS command................ 103
7.5.11 Skip next if ................................................ 77 9.4.13 COMMON floating point array ............... 103
7.5.12 Stream step............................................... 77 9.4.14 COMMON$ string array .......................... 103
7.5.13 Temperature check .................................. 77 9.4.15 COMPONENT NAME$ function .............. 104
7.5.14 Temperature control ................................ 77 9.4.16 COMPONENT TYPE function ................... 104
7.5.15 Temperature default ................................ 77 9.4.17 COMPONENT UNITS function ................. 104
7.5.16 Unknown peak.......................................... 77 9.4.18 CURRENT STREAM function.................... 104
7.5.17 Valve on and valve off .............................. 78 9.4.19 DEACTIVATE STREAM function............... 104
7.6 Air purging ............................................................. 78 9.4.20 DIM statement ........................................ 104
7.6.1 Y and Z purge ............................................ 78 9.4.21 END statement ........................................ 105
7.6.2 X purge operation..................................... 79 9.4.22 END REPORT statement .......................... 105
7.6.3 X purge override option ........................... 80 9.4.23 EXPECTED RETENTION TIME function .... 105
7.6.4 X purge override contacts ........................ 80 9.4.24 EXPONENT function ................................ 105
7.7 Remote client......................................................... 81 9.4.25 FOR…NEXT statements ........................... 105
7.8 Remote communications overview ...................... 81 9.4.26 GOSUB statement ................................... 105
7.8.1 Subscriber tab configuration.................... 82 9.4.27 GOTO statement ..................................... 106
7.8.2 MODBUS overview ................................... 82 9.4.28 IF statement ............................................ 106
7.8.3 PGC5000 MODBUS configuration ............ 82 9.4.29 INDICATOR function................................ 106

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PGC5000
PGC5000 Series Operating Instructions Contents

9.4.30 INJECT TIME function ............................. 106 9.4.58 SCHEDULE NAME function ..................... 110
9.4.31 INTEGER TYPE conversion routine ......... 106 9.4.59 SCHEDULE RUN function ........................ 110
9.4.32 LENGTH function .................................... 106 9.4.60 SCHEDULE STOP command .................... 110
9.4.33 LOGARITHM BASE TEN function ............ 107 9.4.61 SET BASIC ALARM command .................. 110
9.4.34 LPRINT statement ................................... 107 9.4.62 SLEEP function......................................... 111
9.4.35 MID$ function ......................................... 107 9.4.63 SQUARE ROOT function .......................... 111
9.4.36 NATURAL LOGARITHM function ............ 107 9.4.64 START REPORT statement ...................... 111
9.4.37 NUMBER COMPONENTS function ......... 107 9.4.65 STREAM NAME function ......................... 111
9.4.38 OUTSTANDING REQUESTS function....... 107 9.4.66 STREAM STATUS function....................... 111
9.4.39 PEAK AREA function ............................... 107 9.4.67 TIME$ function ........................................ 111
9.4.40 PEAK CREST AMPLITUDE function ......... 108 9.4.68 TOTAL PEAK AREA function .................... 111
9.4.41 PEAK END AMPLITUDE function ............ 108 9.4.69 VALUE FUNCTION ................................... 112
9.4.42 PEAK END TIME function ........................ 108 9.4.70 VALVE command ..................................... 112
9.4.43 PEAK NEGATIVE AREA function ............. 108 9.4.71 WRITE ANALOG OUTPUT command ...... 112
9.4.44 PEAK POSITIVE AREA function ............... 108 9.4.72 WRITE DIGITAL OUTPUT command ....... 112
9.4.45 PEAK START AMPLITUDE function ......... 108 9.4.73 Y2X function ............................................ 112
9.4.46 PEAK START TIME function .................... 109 9.4.74 ZONE PRESSURE function ....................... 112
9.4.47 PURGING STREAM function ................... 109 9.4.75 ZONE TEMPERATURE command ............ 112
9.4.48 PUT COMPONENT CONCENTRATION .... 109
9.4.49 PUT PRESSURE OF A zone command ..... 109 10 Version upgrade .............................................. 113
9.4.50 PUT RESPONSE FACTOR command........ 109 10.1 Determining eqpt to be upgraded ......... 113
9.4.51 PUT TEMPERATURE OF A ZONE ............. 109 10.2 PC upgrading ........................................... 113
9.4.52 READ ANALOG INPUT function .............. 109 10.3 Gateway upgrading................................. 116
9.4.53 READ DIGITAL INPUT function ............... 110 10.4 Upgrading older PGC5000s..................... 119
9.4.54 REMARKS statement .............................. 110
9.4.55 REQUEST ANALYSIS command ............... 110
9.4.56 RESPONSE FACTOR function .................. 110
9.4.57 SCHEDULE ABORT function .................... 110

OI/PGC5000-EN, rev D 5
PGC5000
PGC5000 Series Operating Instructions 1 Glossary

1 Glossary
ACL Access Control List
ANSI American National Standards Institute
AOC Absence of Condtion
CAN Controller Area Network
Config Configuration
DSP Digital Signal Processing
DTC Digital Temperature Controller
EMC Electromagnetic Compatibility
EPC Electronic Pressure Controller
FID Flame Ionization Detector
FPD Flame Photometric Detector
FTP File Transfer Protocol
I/O Input/Output
IP Internet Protocol
IS Intrinsically Safe
ISA International Standards Association
LCD Liquid Crystal Display
LSV Liquid Sample Valve
LUI Local User Interface (operational software interface located on the Master Controller)
NIC Network Interface Connector
OC Oven Controller
OPC Open Productivity and Conductivity
OS Operating System
PC Personal Computer
PCB Printed Circuit Board
PIC Programmable Integrated Circuit
PM Preventive Maintenance
RT Retention Time
SBC Single Board Computer
SDRAM Synchronous Dynamic Random Access Memory
SHS Sample Handling System
SMART Oven Class B Oven or Class C Oven
TCD Thermal Conductivity Detector
USB Universal Serial Bus

OI/PGC5000-EN, rev D 6
PGC5000
PGC5000 Series Operating Instructions 2 Safety and symbols

2 Safety and symbols

The following symbols are used in this manual to alert the
user to possible hazards and to provide additional
information.

Indicates that the referred item can be Indicates that referenced items are
hot and should not be touched without susceptible to Electrostatic Discharge
care. (ESD) damage and should not be
touched without ESD safe handling
tools.
Indicates that a risk of electrical shock
and/or electrocution exists.

Alerts the user to pertinent facts and

conditions.
Indicates a potential hazard which could cause
serious injury and/or death, or indicates the
presence of a hazard which could result in
corruption of software or damage to
equipment or property.

OI/PGC5000-EN, rev D 7
PGC5000
PGC5000 Series Operating Instructions 3 Introduction

3 Introduction
3.1 General
The PGC5000 Series Process Gas Chromatograph (analyzer) separates and measures the individual components of gas or liquid
samples. It automatically samples and analyzes process streams, using the analyzer’s Master Controller to control analytical
functions.

The PGC5000 analyzer is compatible with early versions (before version 4) of the STAR Data Management System.

Each analyzer has a temperature code (T-Rating) listed on the nameplate. This T-Rating indicates the temperature classification
of the area in which the analyzer has been designed to operate. T-Ratings and area classifications for analyzer locations are
determined and supplied by the customer.

The analyzer consists of a Master Controller and associated ovens (see Figure 3.1).

Class C Class B
Oven Oven

Master
Controller

Fig. 3.1. Typical PGC5000 with Associated Ovens

An Important Documents CD-ROM comes with the analyzer. Included on this CD are data sheets, installation drawings, and
replacement parts lists needed to support installation and operation of the analyzer. This manual refers to these data sheets
and drawings as the “Data Package.”

3.2 Drawings
Since analyzer configuration depends on the particular application, this manual does not contain generic engineering drawings
and diagrams. You should utilize the drawings, diagrams and replacement parts lists provided on the Data Package supplied
with your analyzer to ensure you are using the correct ones for your system.

3.3 Master controller

The Master Controller can support up to four ovens, in any combination of Class B and Class C ovens, depending on detector
configurations. If internal I/O modules are utilized, the maximum number of ovens per Master Controller is limited to three.

The Master Controller contains a Card Cage with a Single Board Computer (SBC) PCB, a Power Supply, one or more Oven
Controller PCBs, and optional Wago input/output modules. The front panel assembly has a liquid crystal display (LCD), keypad,
and front panel board. Later versions of the front panel assembly have a touchscreen.

3.4 Class B oven

The Class B Oven, which comes in liquid and vapor versions, houses an isothermal oven which contains the analytical columns,
detector, detector amplifier, temperature controller, control valves, and sample valve. The Class B Oven has one detector and a
maximum of four valves.

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PGC5000
PGC5000 Series Operating Instructions 3 Introduction

3.4.1 Liquid version

The liquid version incorporates a liquid sample valve (LSV) as the input to the analysis. The duration of an analysis depends on
the application and consists of the following:

• The liquid sample valve injects a fixed volume of sample into a vaporizing chamber.
• “Sweep gas” transports sample out of the vaporizing chamber.
• Carrier transports the vaporized sample into the column.
• The column then separates the components and passes them into the detector.
• The detector measures the sample across the range of high to low concentration.

The liquid sample valve is externally mounted on the right side of the Oven Compartment and extends through the isothermal
oven, allowing direct injection. It is actuated by a solenoid valve located in the Oven Electronics Compartment. The liquid
sample valve captures a specific volume of liquid sample below its bubble point, injects it into a temperature controlled
(vaporizing) chamber of the LSV, which then sends the vaporized sample into the oven.

3.4.2 Vapor version

The vapor version has a vapor input to the analysis, so it does not require a liquid sample valve. The duration of an analysis
cycle depends on the applications and consists of the following:

• Carrier gas transports the vaporized sample through the columns.

• The column then separates the components and passes them into the detector.
• The detector measures the sample across the range of high to low concentration.

3.5 Class C oven

The Class C Oven contains the same components as the Class B Oven, but it has the capability to handle more oven
components. The Class C Oven has a maximum of two detectors and a maximum of six valves.

3.6 Air purge systems

The analyzer is suitable for a Class 1 Division 2 hazardous location, or an Ex Zone 2 area, without purge and pressurization
protection. Purge and pressurization protection of the electronics enclosure is required for a Class 1 Division 1 location, or an
Ex Zone 1 area. Refer to the analyzer nameplate for purge and pressurization specifications.

3.7 System variations

This manual supports the basic PGC5000 analyzer. An appendix to the main manual presents additional instruction for special
applications such as PGC5000TPGC (temperature programmed GC), PGC5007 (fuel sulfur GC), and PGC5009 (fast GC).

OI/PGC5000-EN, rev D 9
PGC5000
PGC5000 Series Operating Instructions 4 Installation

4 Installation
4.1 Safety considerations
Before starting to install the analyzer, read the safety information below.

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 the 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.

Before opening analyzer enclosure doors, be sure the area is safe from hazardous gases and will remain
so the entire time the analyzer is open.

When handling electronic parts and assemblies, it is necessary that proper electrostatic discharge (ESD)
precautions be taken (i.e., wear an ESD wrist strap with a grounding cable and use an ESD shielded bag to
protect items removed).

4.2 Analyzer location

The analyzer should be located as close as is practical to the sample stream. The analyzer must be installed in a shelter or area
protected from direct sunlight and harsh weather. It is recommended that a minimum clearance of six inches be allowed on
each side of the analyzer panel to allow for making the necessary connections.

The analyzer must be mounted so that it is level.

The analyzer should be adequately supported during mounting, since its approximate weight is 90 kg (200 pounds).
Connections should not be made to the analyzer until it is mounted securely in place.

The atmospheric exhaust (detector cell vent) must be an atmospheric vent.

4.2.1 Master controller

The Master Controller can be located up to 100 meters (305 feet) from the associated oven. The Master Controller
communicates with the oven through a fiber optic cable. The customer is responsible for locating the Master Controller in
accordance with the customer-specified area classification indicated on the nameplate.

When you are determining where to install the Master Controller, include the following location criteria:
• Installation must be a pollution degree 2 environment or better
• Electromagnetic compatibility
• Area classification indicated on the nameplate
• Equipment ingress protection is IP54
• Protection from rain, direct sunlight, temperature extremes
• Ambient operating temperature is 0 to 50 degrees C (32 to 122 degrees F)
• Avoiding exposure to corrosive gas
• Not intended for a combustible dust environment

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PGC5000
PGC5000 Series Operating Instructions 4 Installation

• Not intended for below surface mining applications

• Free from dust and static electricity
• Space of at least 152 mm (6 inches) to the right side of the Master Controller, if purge equipped
• Space of at least 610 mm (24 inches) in front of the Master Controller, for servicing
• Space of at least 279 mm (11 inches) above the Master Controller, if x-purge is utilized

4.2.2 Ovens
Locate the ovens as close as practical to the stream to be sampled. The customer is responsible for locating oven(s) in
accordance with the customer-specified area classification indicated on the nameplate.

When you are determining where to install the oven, include the following location criteria:
• Installation must be a pollution degree 2 environment or better
• Electromagnetic compatibility
• Area classification indicated on the nameplate
• Equipment ingress protection is IP54
• Protection from rain, direct sunlight, temperature extremes
• Ambient operating temperature is 0 to 50 degrees C (32 to 122 degrees F)
• Avoid exposure to corrosive gas
• Not intended for a combustible dust environment
• Not intended for below surface mining applications
• Free from dust and static electricity
• Space of at least 450 mm (18 inches) to each side of the oven for various customer connections and servicing
• Space of at least 406 mm (16 inches) in front of the oven, for servicing

4.2.3 Precautions
Review the following precautions during installation and before starting the analyzer.
• Temperature of protective air for purge/pressurization must not exceed 40 degrees C (104 degrees F).
• Inspection required for accumulated dust before applying electric power.
• Clean display with damp cloth only.
• Conduit entries not used must be sealed with an approved blanking plug.
• Main power supply must not exceed ±10% of the equipment rated voltage.
• Observe and take note of all caution tags attached to the analyzer.

4.3 Preparing for installation

Since Analyzer configuration depends on the particular application, this manual contains only generic engineering drawings and
diagrams. You should utilize the drawings, diagrams and replacement parts lists provided in the Data Package supplied with
your analyzer to ensure they are the correct ones for your system.

After unpacking the analyzer, inspect it for damage. Also check the packing list provided with the analyzer to make sure all
equipment is included. The packing list, which is taped on the box or crate, contains a list showing how many cartons were
shipped and what each box or crate contains.

4.3.1 Installation tools and equipment

The recommended standard tools and equipment for installation are:
• 5/32 inch hex key wrench (supplied)
• 5/16 inch hex key wrench (supplied)
• 7/16 inch open end wrench (2)
• 6 inch flat blade screwdriver
• 9/16 inch wrench
• 5/8 inch wrench
• 8 inch adjustable wrench
• Wire strippers
• Digital flow meter
• Leak detection solution

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PGC5000
PGC5000 Series Operating Instructions 4 Installation

4.3.2 Plumbing installation

All plumbing connections enter at the right side of the Oven and Master Controller cabinets. 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 PTFE tape or a suitable thread sealant. Make all connections
and then tighten them appropriately. Leak check each connection as described in the “Leak Check” paragraphs in Section 5.

4.3.3 Gas requirements

The following information represents general requirements. Due to differences in applications, refer to the Data Package for
application-specific requirements for each analyzer.
• Instrument air: instrument grade air
• Burner air: ISA hydrocarbon free grade with hydrocarbon content less than 1 ppm and dew point less than -40
degrees C (FID and FPD applications only).
• Carrier gases: varies with the application; the lower the levels of components being measured, the higher the
necessary carrier gas purity.
• TCD: for percent level measurements, gases of 99.99% purity; for ppm measurement ranges, 99.995% purity.
• FID: for measurements down to 5 ppm, gases of 99.995% purity; lower ranges require higher levels of purity.

4.3.4 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.

4.3.5 Purge air alarm

To meet Area Classification requirements, some analyzers are equipped with air purge. The analyzer system detects the loss of
purge at the Master Controller and/or oven(s) and generates alarm signals. The customer has the responsibility to connect the
purge alarm to a visual or audible enunciator located in a constantly monitored area, in accordance with the conformity
standard for purge and pressurization protection.

4.4 Equipment mounting

Depending on the configuration of the Oven, it can weigh from 80 to 120 pounds. You should have one or
more person help you lift it and move it.

Unpack the system 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 Master Controller and Oven dolly bolts. Secure wall-mounted units
appropriately. Refer to the Outline and Mounting Dimensions drawing in the Data Package for specific mounting information.

4.5 Connections

4.5.1 Tubing
Refer to the applicable drawings in your Data Package for specific tubing and connection information while observing the
following:
• Do not remove the tube caps, provided at the analyzer tubing ports to prevent deterioration of the columns, until
immediately before making each connection.
• Ensure use of proper size tubing and pipe; refer to the Outline and Mounting Dimensions Diagram contained in the
Data Package included with your equipment.
• Use tubing and fittings free of interior contamination from grease, oil or other substances. Before connecting these
lines, completely air-purge their interiors.
• After connecting the tubing, perform a leak check as described in the “Leak Check” paragraphs in Section 5.

4.5.2 Instrument air

The air supply is connected to the fitting marked Instrument Air Inlet.

4.5.3 Carrier gas

The carrier gas is connected to the fitting marked Carrier In.

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PGC5000 Series Operating Instructions 4 Installation

Carrier gas dryer is recommended for capillary column applications.

4.5.4 Burner fuel

The burner fuel, when used, is connected to the fitting marked Burner Fuel.

4.5.5 Burner air

The burner air, when used, is connected to the fitting marked Burner Air.

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

4.5.7 Hydrogen gas

Hydrogen is highly explosive. Follow applicable safety precautions and use extreme care in making
connections.

The analyzer uses hydrogen gas as a burner fuel with flame cell detectors (FID or FPD) and sometimes uses it as a carrier gas.
Verify that the hydrogen gas meets the criteria of the gas requirements listed in the Data Package. Also refer to the Data
Package for specific connection information.

4.5.8 Vents
All vent lines 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.

4.5.9 Liquid sample valve

The Liquid Sample Valve (LSV) is used only with liquid applications. The Oven Enclosure has sample lines connected to a
mounting plate attached to the LSVs mounting flange.

The LSV has the sample lines connected to the mounting plate attached to the LSVs mounting flange, as shown in Figure 4.1.

Sample
Line

LSV Body LSV Body

Mounting Mounting
Clamps Clamps
Sample
Line

Fig. 4.1 Liquid Sample Valve

It is important to use two wrenches when tightening the sample line connections at the LSV sample chamber. One wrench
must be used to back up the force applied to tighten the fitting (direct wrench force may bend the stem or damage the valve
seals).

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PGC5000 Series Operating Instructions 4 Installation

To ensure the integrity of the components within the Liquid Sample Valve, use the tools in LSV Tool Kit
791K009-1 when assembling of disassembling the LSV.

4.6 Electrical
The analyzer must be installed according to all applicable codes. If it is in a hazardous area, the wiring method must conform to
the applicable requirements.

Install signal wiring and power wiring in separate conduit pipes or cable trays to reduce noise and crosstalk.

A grounding (earthing) connection is required. Connect minimum 12 gauge (3.31 mm2) ground wire to the Earthing Connection
on the Oven Compartment and on the Master Controller.

4.7 Setting up the master controller

The Master Controller (see Figure 4.2) must be installed according to all applicable codes. If it will be in a hazardous area, the
wiring method must conform to the applicable requirements.
• Power wiring (circuit breaker protection must be supplied by the customer); refer to the installation wiring drawing
provided in the Data Package for details.
• Signal fiber between the Master Controller and the Oven(s).
• Alarm contact outputs; refer to the installation drawing in the Data Package for details.
• Ground (earth) connections must be at earth (0 volts) potential.

Failure to maintain earth (0 volts) potential at ground connection points constitutes a serious safety
hazard.

Wago I/O Single Board

Modules Computer PCB

Power Supply Oven Controller PCB

Figure 4.2. Inside the Master Controller

Refer to the applicable drawings in your Data Package for specific interconnection wiring information.

4.7.1 Single board computer pcb

This Single Board Computer (SBC) PCB, located inside the Master Controller, has built in redundant Ethernet Network Interface
Connections (NICs) located at the top right of the SBC.

The SBC has an Oven Controller Card for each oven, labeled 1 through 4 from right to left. This module communicates with the
oven via fiber optic cables attached to the board by two connectors. The fiber optic cables utilize two type ST connectors. The
customer is required to install all fiber optic connections.

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PGC5000 Series Operating Instructions 4 Installation

Sharp bends in a fiber optic cable can cause signal attenuation or the optical fiber to break.

The ST connectors have a bayonet mount and a long cylindrical 2.5 mm ceramic or polymer ferrule to hold the fiber. They are
spring-loaded and keyed with slots and alignment nubs. Always “Stab and Twist” to make sure the ST connectors seat properly.

If you have signal loss, remove and reconnect to see if this eliminates the problem.

Optical fiber consists of a core, cladding, and a protective outer coating, which guides light along the core by total internal
reflection.

4.7.2 Purge air alarm

The Purge Air Alarm must be monitored if the analyzer is equipped with pressurization protection. Connect the Purge Air Alarm
wiring to connector J19, pins 1 to 3, on the Single Board Computer. Refer to the Data Package for more detailed information.

The alarm contact is set in normally-open configuration for failsafe operation. The Purge Alarm input
must be configured to indicate a non-alarm condition when the contact is closed. The Purge Air Alarm is
a dry contact rated for a maximum of 5W at 30 Vdc or 0.25 A maximum.

The General Purpose alarm connections use J19 pins 4 to 6. Refer to the Data Package for more detailed information.

4.8 Setting up the ovens

Each oven must be installed according to all applicable codes. If it will be in a hazardous area, the wiring method must conform
to the applicable requirements.
• Power wiring (circuit breaker protection must be supplied by the customer); refer to the installation wiring drawing
provided in the Data Package for details.
• Signal fiber between the Master Controller and the Oven(s).
• Alarm contact outputs; refer to the installation drawing in the Data Package for details.
• Ground (earth) connections must be at earth (0 volts) potential.

Failure to maintain earth (0 volts) potential at ground connection points constitutes a serious safety
hazard.

Refer to the applicable drawings in your Data Package for specific interconnection wiring information.

Connect the oven purge alarm to connector J1 pins 1 (NC), 2 (C), and 3 (NO) on the DTC Digital PCB. Refer to the Data Package
for more detailed information.

The General Purpose alarm connections use pins 5 and 6 of the mating connector and connect to J1 pins 4 (NC), 5 (C), and 6
(NO) on the DTC Digital PCB. Refer to the Data Package for more detailed information.

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PGC5000 Series Operating Instructions 5 Start-up

5 Start-up
5.1 Introduction
The analyzer operates by separating the oven and controller functions. The application configured at the factory establishes
the operational baseline and expected results as requested by the customer. The analyzer can be controlled at either the Local
User Interface (LUI) or the Remote Client. While these interfaces can work simultaneously on an analyzer, they work
independently of each other. The last function to save data is the one effective on the analyzer.

5.2 Master controller controls and indicators

Normal operation of the analyzer is controlled from the Master Controller front panel (see Figure 5.1, which has the
touchscreen display and keypad.

Touchscreen Display Keypad

Fig. 5.1. Master Controller

5.2.1 Touchscreen layout

Figure 5.2 illustrates the basic Master Controller display layout and functionality.
1

2 4 3 5 6

Fig. 5.2. Basic Analyzer Screen Layout

1. Tabs – select a tab using the cursor to navigate between system operational and configuration displays.
2 Function Selectors – displays buttons and action icons relative to the selected tab.
3. Sub-tab Display Area – provides specific information relating to the tab and/or sub-tab selected.
4. Sub-tabs – each sub-tab displays additional information applicable for the main tab selected.
5. System Information Bar – displays current analyzer information.
6. Zoom Control – increases and decreases the scale of the display.

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5.2.2 Action icons

Action icons are small pictures that represent action commands. In this manual the text will utilize the meaning/function
shown below in referring to the icons. Figure 5.3 shows the action icons and provides a brief description of each one.

Icon Meaning/Function Icon Meaning/Function

Power Failure Recovery Setup USB Flash Drive Operation
(Schedule Tab) (Setup Tab)
Maintenance Mode (Schedule
Tab) Restore Settings (Setup Tab)

Schedule Abort (Schedule Tab) Start

Schedule Stop (Schedule Tab) Delete/Remove

Apply Response Factor (Setup

Save – Replaces saved Tab > Component)
information after editing
Pause – Pauses schedule
Save As – Saves as a new file execution
Routing Table Configuration
Add New – Creates new (Setup > Network Adapters)
Add – Adds existing item from Line Up; Page Up
library
Page Down; Line Down
Access Control List

Fig. 5.3. Action Icons

5.2.3 Function/navigation buttons

Function/navigation buttons complete an action. In this manual the text will utilize the meaning/function shown below in
referring to these buttons. Figure 5.4 shows the function/navigation buttons and provides a brief description of each one.

Icon Meaning/Function Icon Meaning/Function

Add to a scope (Status Tab) Run analysis on demand

Accept
Abort – Cancel Entry
Reset – Resets single indicator Reset – Reset all displayed indicators
Disconnect from remote Master Connect to a remote Master
Controller Controller
Go Back – Returns to the last Next
input
Shift Down – Virtual Keyboard Unlock a locked chromatogram
Control
Login to a Master Controller Lock a chromatogram

Fig. 5.4. Function/Navigation Buttons

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5.2.4 System information bar

The System Information Bar (see Figure 5.5), which is located along the bottom of the screen, gives a variety of information as
noted in the following list.

2 4

1 3 5

Fig. 5.5. System Information Bar

1. System Status Indicator – this light reflects indicators assigned to the overall health of the system. If the light is anything
other than green check the Status tab. The indicator colors signify the following:
Green = Normal
Yellow = Warning
Red = Alarm
Blue = Information Only
2. Network Connect Icon – this icon allows connecting to a Master Controller from the Remote Client or from the Master
Controller to another Master Control by entry of an IP address.
3. Security Login – provides means for logging into the analyzer.
4. Information Area – provides system messages.
5. Date and Time – shows date and time information used in reports.

5.2.5 Naming conventions

The following special characters MAY NOT BE USED in any software edit fields (e.g., component names, Master Controller
name):

Special
Character Identification
. Period
/ Forward Slash
\ Back Slash
& Ampersand
˜ Tilde
“ Double Quote (Quotation Mark)
‘ Single Quote (Apostrophe)
, Comma
? Question Mark
! Exclamation Point
@ At Symbol
$ Dollar Sign

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5.2.6 Keypad
The keypad is used for numerical input and cursor movement (see Figure 5.6). From this keypad, which is located to the right of
the display, navigation is accomplished by either pressing symbol keys or using the touch pad. The function of the keys is
explained below.

Fig. 5.6. Master Controller Keypad

1. Home – Returns to the default screen (Home tab).

2. Help – Jumps to the Quick Help screen.
3. Cursor Arrows – Move any direction on the sub-tabs.
4. Numeric Keypad – Inputs numeric data where needed.
5. Touch Pad – Moves the cursor on the screen (use a stylus or fingernail for best results).
6. Mouse Button – Indicates the mouse selection when needed.
7. Folder Selection – Moves left to right between screen tabs.
8. Destructive Backspace – Moves back one space at a time, deleting characters.
9. Virtual Keyboard – Displays the keyboard on the screen for inputting text characters.
10. Carriage Return – accepts data.

5.2.7 Keyboard
The virtual keyboard (see Figure 5.7), accessed from the keypad, allows text input from the Local User Interface. Use the touch
pad to select individual letters and numbers. Uppercase letters are available by pressing the Shift Up button on the left side of
the space bar. Press the Go Back button to delete characters. Press the Accept button to save the changes, or press the Abort
button to cancel. The number of characters differs depending on the field Max.

Shift Up Go Back

Fig. 5.7. Virtual Keyboard (lower case view)

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PGC5000 Series Operating Instructions 5 Start-up

5.3 Oven controls and indicators

Figure 5.8 shows the controls and indicators for a typical oven. Both the Class B Oven and the Class C Oven have the same
controls and indicators.
Gauges

Regulators

Indicator
Lights Gauge Regulator

Indicator
Lights

CLASS B OVEN CLASS C OVEN

Fig. 5.8. Typical Ovens

5.4 Starting the analyzer

1. Visually inspect the analyzer for inoperative or damaged gauges, loose or damaged connections, and overall condition.
2. Turn on the instrument air at its source.

Refer to the Data Package to ensure that air supply at the specified pressure is provided to the
INSTRUMENT AIR inlet. The purge air and heater air pressures should be as specified on the label below
the corresponding regulator.

3. Turn on carrier gas at its source.

Refer to the Data Package to ensure that the specified carrier gas is provided at the specified pressure to
each CARRIER inlet.

If the analyzer is equipped with enclosure purge, refer to the sales order tag for specified flow rate and
purge time before applying electrical power.

4. Turn the power ON at the external circuit breaker or switch.

5. Verify any auxiliary gases in the same manner as the Carrier gas.
6. Check for leaks. If a leak occurs during start-up, perform the leak checks described in paragraphs 5.4.1 and 5.4.2.
7. Allow sufficient time for oven warm-up. (Temperatures are set during installation). The oven should stabilize at the
temperature indicated in the Data Package. If adjustments are required, adjust the Digital Temperature Controller as
described on the Setup Tab > DTC “Digital Temperature Controller.”

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PGC5000 Series Operating Instructions 5 Start-up

5.4.1 Leak check oven

This is recommended at startup or if an internal carrier gas leak is suspected. Perform a simple leak check on the oven section
as follows (see Figure 5.9):

Fig. 5.9. Leak Check Oven Example

1. Plug all oven carrier gas vents as applicable: backflush vent(s), selector vent, detector vent(s) and splitter vent.
2. Under the Setup tab at the Master Controller, disable burner air and hydrogen fuel zones if applicable.
3. Set carrier pressure to factory settings.
4. Wait five minutes for pressure to equilibrate.
5. Set carrier pressure to zero psig.

You may observe an initial drop in pressure when setting the carrier pressure to zero psig. After the initial
drop record the reading and wait 30 minutes. The pressure should hold and any decline is excessive and
indicates a potential leak.

6. Check for leaks using a suitable leak detection solution. Starting at the inlet to the detector, work back to the carrier gas
supply, plugging the exit of each valve or column to locate the leak.

5.4.2 Leak check carrier gas supply lines

Check for leaks during initial installation by performing a simple leak check on the utility gases as applicable:
1. Ensure all power is off.
2. Pressurize all lines to 90 psig.
3. Wait five minutes for pressure to equilibrate.
4. Set supply regulator to zero (0) psi.
5. If pressure bleeds off, repeat steps 1 to 4 and use a suitable leak detection solution to check for leaks between carrier gas
supply and the ovens.

5.5 Calibrating the analyzer

Use the Setup tab to enter the calibration concentration for all components being calibrated. Follow the steps below to
calibrate using either the LUI or Remote Client.

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PGC5000 Series Operating Instructions 5 Start-up

1. Navigate to the Setup tab (see Figure 5.10).

Fig. 5.10. Setup Tab, Showing Calibration Concentration

2. Select the Components button from the Function Selectors list.

3. Verify that the Config sub-tab at the bottom of the screen is selected.
4. Select the component to calibrate from the COMPONENTS NAME drop down menu.
5. Enter the concentration and unit information into the CONCENTRATIONS CALIBRATION and UNITS fields. (Example: Enter
20 in the Calibration field and % in the Units field for 20%; ppm and ppb are also available).
6. Turn on the Calibration sample.
7. Select the Schedule tab and verify that the Demand sub-tab is selected.
8. Select the Run button to run the Calibration.
9. On successful completion, return to the Setup tab and select the Components button.
10. Ensure the current component name is selected; the PENDING RESP FACTOR appears.
11. Select the Apply Response Factor button (left arrow next to PENDING RESP FACTOR) to insert the pending response factor
as the current response factor.
12. To automatically update response factors, select the CALIBRATION AUTO UPDATE box.

5.6 Validation run

Follow the steps below to initiate a Validation Run, using either the LUI or Remote Client:
1. Navigate to the Schedule tab and select the Step or Demand Sub-tab.
2. Select the Add button.
3. On the drop down screen, choose the validation stream and select the Next button to continue.
4. On the drop down screen, choose the desired analysis and select the Next button to continue.
5. To confirm the choice select the Accept button. The validation analysis is now listed in the Step > Demand sub-tab.
6. Turn on the Validation sample and set the flow.
7. Either add to the schedule by selecting the analysis Active box in the Step sub-tab screen, or select the Start Schedule
button to execute one time.

5.7 Connecting to the network (optional)

The PGC5000 analyzer supports standard Ethernet connectivity. After the connections are physically attached and verified,
configure the analyzer in accordance with network policies.

A Master Controller’s Local Interface Unit (LUI) can be temporarily replaced with the Remote Client of another PGC5000
analyzer on the same network.

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PGC5000 Series Operating Instructions 5 Start-up

The Network Connect button is located in the system information bar at the bottom left of the display, showing two boxes
connected by a green line (see Figure 5.11). If you launch the Remote Client from STAR Client, the IP Address will appear in the
box next to the Network Connect button.

Network Connect Button

Fig. 5.11. Home Screen, Showing IP Address

If you call up the Remote Client by launching a file, you will get Local in the box next to the Network Connect button (see Figure
5.12).

Local

Fig. 5.12. Home Screen, Showing “Local”

If you then right click on the Network Connect button (with red X), you will get Local and a Logged Out message.

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PGC5000 Series Operating Instructions 5 Start-up

If you click on the Network Connect button again, you will get the IP Address Dialog Box, which will allow you to enter the
desired IP address (see Figure 5.13). After you enter the desired IP Address, click on Accept to save the entry or click on Abort
to retain the original settings.

Fig. 5.13. Home Screen, Showing IP Address Dialog Box

5.8 Using the access control list

5.8.1 Logging into the PGC5000 analyzer

Access to the analyzer is controlled by creating authorized user name with passwords. To log into the analyzer through the
Master Controller or the Remote Client, perform the following steps.

1. Log into the analyzer by selecting the Log In button and selecting a User name from the list (see Figure 5.14).

Log In
Button

Fig. 5.14. Selecting a User Name

2. Enter your assigned password and select the Accept button to accept.
3. The information bar at the bottom of the screen displays your access level.
4. The Log In button becomes a Log Out button upon log in. To log out, select the Log Out button.

5.8.2 Access levels (optional)

Access levels are set using the Master Controller, STAR Client, or optional VistaNET Name Service Application (VNSA) interface.
The user name/password information is maintained in a distributed Access Control List (ACL).

The ACL also stores the access level for each user of the analyzer and STAR Data Management System (STAR DMS). Refer to the
STAR Data Management System (DMS) Operating Instructions for a detailed description of ACL. There are three levels of
access:
• Supervisor: Can modify the ACL.
• Read/Write (Normal): Can modify all tables with the exception of the ACL.
• Read Only (Limited): Can view, but not modify, any table of any device.

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PGC5000 Series Operating Instructions 5 Start-up

All Supervisors have the ability to determine each user's required access level and enter the information into the ACL.

If the Information Bar states ‘Login access Unsecured,’ all users have full access (Supervisor level).

5.8.3 Subscriber list

The Subscriber Tab allows analysis results, status change and analyzer events reporting to the Reporter, the OPC, and the STAR
Server. Their addresses must be entered in the Subscriber List. Instructions for adding new or editing existing subscribers are
covered in the Operations section under the Subscriber Tab.

5.8.4 Remote client

Use the following procedure to connect remotely from a PC.
1. Install the Remote Client software on a Personal Computer (PC) attached to the same network as the Master Controller.
2. Launch the Remote Client from the STAR Client.

To launch the Remote Client from a shortcut:

1. Select the Network Connect button (see Figure 5.11).
2. When the Network Dialog Box appears, enter the IP address of the analyzer to observe and/or control (see Figure 5.13).
3. Select the Accept button to continue or select the Abort button to close the network box.

5.9 Analyzer shutdown

The Analyzer may need to be shut down for a variety of reasons: valve replacement, preventive maintenance, or temporary
plant shutdown.

The recommended steps for analyzer shutdown are:

1. Go to the Schedule Tab and stop all schedules (see Operation > Schedule Tab in Section 6 for instructions).
2. Block out and tag out sample to the ovens.
3. Purge sample from oven as necessary.
4. Decrease analytical oven temperature to ambient temperature (refer to Setup tab for instructions) and allow columns to
cool.
5. Block out and tag out carrier gases, burner air and burner fuel as necessary.
6. Lockout/tag out power to the oven.
7. Lockout/tag out instrument air supply.
8. Power down and tag out per company established safety procedures.

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PGC5000 Series Operating Instructions 6 Operation

6 Operation
6.1 Introduction
The PGC5000 analyzer operates from a series of tabs at the top of the screen. All functions of the analyzer are accessed from
these tabs and their sub-tabs, which are located at the bottom of the screen.

6.2 Home tab

The Home tab is the Master Controller’s default screen displayed when the system starts. It displays a quick overall health
status and performance snapshot of the analyzer. General features include:
• View current chromatograms
• Overlay chromatograms
• Zoom and pan chromatogram
• Color-coded Indicator Status Icons
• Reports

6.2.1 Chart sub-tab

The Home >Chart sub-tab displays the general operation overview and conditions of the analyzer (see Figure 6.1).

1 2

3
4

Fig. 6.1. Chart Sub-tab

1. Analysis Buttons –Displays the indicator level and analysis progress for all active analyses. The “Idle Stream” is included for
review of chromatograms or reports not currently running.
2. Analysis Graphics – Displays the currently selected analysis (button depressed at left) and overlays.
3. Chart Controls – Increase or decrease X & Y axes for viewing.
4. Sub-tabs – Displays information and setup relative to the selected analysis.

Selecting the chart controls allows zooming and/or panning of the current chromatogram.

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PGC5000 Series Operating Instructions 6 Operation

To zoom an area, use the cursor to select a point on the chart as a starting point (see Figure 6.2). Hold the mouse button down
and drag the box over the desired viewing area. Release the mouse button to complete the zoom. To return to the default view,
select the crossed arrow button, in the lower right corner of the screen.

Fig. 6.2. Zooming an Area

To zoom an area on the touchscreen at the LUI, use your finger (or other type of touchpad stylus) and touch the screen at the
starting point of where you want to have your zooming window begin. Keep your finger/stylus pressed gently on the screen
and drag the zooming box over the desired viewing area. Release your finger/stylus from the touchscreen to complete the
zoom. To return to default view, select the crossed arrow button.

6.2.2 Status sub-tab

The Home>Status sub-tab displays all triggered active assigned indicators for the selected analysis button, and the date and
time the indicator triggered (see Figure 6.3).

1 2

Fig. 6.3. Home>Status Screen

1. Indicator Reset – Reset one or all displayed indicators.

2. Indicator State – The triggered indicator's alert level: green (normal), yellow (warning), red (alarm), or blue (information
only).
3. Information Area – Date/time indicator triggered, indicator group and name.

Only triggered indicators assigned to a Stream, Analysis or Components are displayed. The colored dot
(light) represents the current indicator state and the date/time of indication.

To reset an individual indicator:

1. Locate the indicator to reset.
2. Select the Indicator Reset button to the left of the indicator to reset.

If the indicator stays the same color but the date matches the current analyzer time, the condition which triggered the indicator
may still be present.

To reset all triggered indicators currently displayed, select the Indicator Reset button in the header row.

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PGC5000 Series Operating Instructions 6 Operation

6.2.3 Report sub-tab

The Home>Report sub-tab displays the analysis information (see Figure 6.4).

1 2 3

Fig. 6.4. Home>Report Sub-tab

1. Analysis Buttons– Displays the indicator level and analysis progress for all active analyses. The “Idle Stream” is included for
review of analyses not currently running.
2. Report Type – Select Raw to display reports in raw data format. Select Previous to display last saved report for the
selected stream.
3. Report Selection Criteria – Select Stream.
4. Report Area – Report data displayed in the selected format.

The analyzer stores up to a week’s worth of analysis stream data for a standard application. Reports and Chromatograms for
each stream include the last five:
• Calibration stream reports and chromatograms.
• Validation stream reports and chromatograms.
• Alarm reports and chromatograms for each stream.

There is a “Locked” folder that can contain any number of Saved reports and chromatograms, and there are “Reprocessed” and
“alarm” folders that can contain the last five reports of each.

The operator has the option of viewing the previous report for the selected stream or any of the automatically saved reports.

Two report formats are available: Standard and Raw.

The report format selected also selects the type of report that can be sent to an optional Reporter.

The reports and chromatograms are stored on the RAM disk, allowing uninterrupted data collection. When the RAM disk is full,
the oldest files are removed to allow storage of new data, allowing continual data collection. The RAM disk stores data for a
maximum of 24 hours.

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PGC5000 Series Operating Instructions 6 Operation

1. The standard report (see Figure 6.5) displays inject time, sample stream, analysis name, report type, detector, component
Name / Retention Time / Concentration and validity of the component.

Fig. 6.5. Standard Report Format

2. The raw data report (see Figure 6.6) displays the actual value of software determined points on the chromatogram, in
addition to the information displayed in the standard report format. The times shown are in seconds from the start of the
method. The amplitudes are in 0.1 microvolt units. The Start of Baseline / End of Baseline amplitudes are relative to
electrical zero. The other amplitudes are relative to the computed baseline. Areas are in millivolt-sec units.

Fig. 6.6. Raw Data Report Format

Use the following steps to view the last saved report by stream.
1. Select the analysis from the list on the left.
2. Select the previous report box.
3. Select the stream.
4. View the report.
5. Select Raw to view in raw data format.

Use the following steps to view a stored report.

1. Ensure the Previous box is unchecked and select the RAW box if raw data is preferred.
2. Select the Stream from the first drop down list.
3. Select the timeframe from the second drop down list. Standard analysis data is saved in hourly folders in Year/Month/Day
and Hour format or alarm reports for the select stream.

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4. Select report inject time to view. Reports are saved by inject time in the following format:
TYPE/Year/Month/Day/Hour/Minute/Second (STD201507301629).
5. View the data (see Figure 6.6).

6.2.4 Overlay sub-tab

The analyzer supports the overlaying of stored chromatograms on the screen for use as a reference. A maximum of two stored
chromatograms can be viewed simultaneously on the Chart Sub-tab, plus the active stream.

If the analysis is not currently running, select ‘Idle Stream’ to retrieve data about that analysis.

The Home>Overlay sub-tab displays the choice of Overlay 1 and/or Overlay 2. Both overlays allow selection of chromatograms
saved on the Master Controller (see Figure 6.7).

2 3
1

4 5 6

Fig. 6.7. Home>Overlay Sub-tab

1. Active – Mark to make overlay viewable on chart screen.

Overlay 1 - Green
Overlay 2 - Red
2. Previous– Selects chromatogram from the selected stream’s last completed analysis.
3. Locked– If depressed, locks selected chromatogram (keeps chromatogram from being overwritten).
4. Stream Selection – Select stream to display: Calibration, Validation, or Named Stream.
5. Group Selection – Select locked, alarm, reprocessed, or by time frame.
6. File Selection – Select file by inject time.

To select a chromatogram to overlay:

1. Select the Home>Overlay sub-tab.
2. Either select Previous for the last completed analysis or unmark the Previous box to select a stored chromatogram.
3. Select the year (YYYY), month (MM), day (DD) and hour (HR). (Format: YYYYMMDDHR).
4. Select the File from the last drop down menu. (Format: YYYYMMDDHRXXXX where XXXX is the minute and second the
cycle started).
5. Mark the Active box.
6. Repeat steps for the second chromatogram, if desired.
7. Return to the Home>Chart sub-tab to view the overlays.

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Overlay 1 (top) displays in green; Overlay 2 (bottom) in red.

To turn off the overlay display, unmark the Active box on the Overlay Sub-tab.

The Master Controller stores analysis data continuously for a maximum of seven days. Report files are overwritten after seven
days or when the storage media is filled.

To manually save a chromatogram:

1. Select the Lock button above the chromatogram file name.
2. Unmark the Previous box and from the drop down menu select the ‘Locked’ item (see Figure 6.8).

Fig. 6.8. Locked Overlay

3. Select the desired chromatogram file from the third (rightmost) drop down menu.
4. Unlock the file by highlighting the file name and selecting the Unlock button above the chromatogram file name.

6.3 Status tab

The Status Tab screen (see Figure 6.9) displays a hierarchy of equipment levels and all indicators. Status alerts, such as overall
health, process limits, and alarms are visible through the color-coded Indicator Status icons.

1 1
2
3

Fig. 6.9. Status Screen Example

1. Scopes– Used to navigate between the All and the user configured scopes.

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2. Page Up/Down – Line Up/Down – Select buttons to move vertically through indicators. Depending on location or size of
list, movement arrows may not be shown. (Example: top of list, page up arrows will not be shown.)
3. Headings, from left to right of screen, are described in Figure 6.10.

Heading Function/Use
Reset all indicators and time stamps display. Reset single indicator and time stamp.

State The current state of the active indicator is represented by the color-coded status button.
Date/Time Displays date and time the indicator was triggered; date in Month/Day/Year format and time in 24 hour format.
Active User selectable; indicator is active if marked, inactive if not marked.
Hold User selectable; if marked, indicator holds value until manually reset; if not marked, indicator holds until the absence
of condition that triggered the indicator or until manually reset.
Group Name of indicator’s hardware or software group.
Name Name of the indicator.
Level User selectable level button: Red = Alarm, Yellow = Warning, Blue = Information Only.

Fig. 6.10. Status Tab Functions

4. Indicators– Display individual indicator information including current state, name, and group. The user can reset,
activate/de-activate indicators, set indicators to hold until manually reset and change alert level. All available indicators
are configurable to one or more of the Condition Monitoring System scopes. Indicator colors signify the status of the
indicator: green (normal), yellow (warning), red (alarm),or blue (information only).

The Status Tab gives access to configuration, evaluation, and monitoring of the PGC5000 Condition Monitoring System.

The Status Tab is used to collect additional information of the analyzer system’s Condition Monitoring
System. The analyzer system reports indicators through multiple means including: visual, color coded
indicator status icons, analysis reporting, OPC servers, and other communication media.

The All sub-tab is a complete listing of available indicators for that specific analyzer’s Condition Monitoring System. The four
remaining sub-tabs: Instrument, Stream, Analysis and Component are user configurable scopes.

6.3.1 User configurable scopes

The analyzer scopes represent a collection of indicators directly related to the hardware or software within the analyzer system
(see Figure 6.11). Each scope allows assignment of configurable indicators to optimize the Condition Monitoring System for
each installation. Indicators are assigned reporting levels depending on the user need. All Indicators can be set to Alarm,
Warning or Information Only levels. Indicators set to a Warning or Information Only level do not invalidate data reported to the
subscribers.

Scopes

Fig. 6.11. Scope Indicators

Instrument – The only scope where indicators set to an alarm level do not invalidate the reported data.
Master Controller Sub-scope – Any active, triggered, alarm-level indicator activates the common malfunction relay contact
closure for the Master Controller; it also sets the Master Controller rollup out to the Modbus link.

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Oven Sub-scope– Any active, triggered, alarm-level indicator activates the common malfunction relay contact closure for
the associated oven.
Stream – Any active, triggered, alarm-level indicator invalidates the analysis data reported to all subscribers for that stream.
(This may span multiple analyses.) It also sets the Is Valid indicator.
Analysis – Any active, triggered, alarm-level indicator invalidates the analysis data reported to all subscribers for the analysis. It
also sets the Is Valid indicator.
Component – Any active, triggered, set alarm-level indicator invalidates the component data reported to all subscribers for the
component to which it is assigned. It also sets the Is Valid indicator.

6.3.2 Configuring indicators

Figure 6.11 shows each scope with a color-coded indicator status icon. This icon represents the highest level triggered indicator
configured and activated for the scope. Indicators may be assigned to multiple scopes. Changes made to an indicator’s
activation criteria take effect immediately. To assign an indicator and level of an indication to a scope, follow these directions:

1. Locate the desired indicator in the All list.

2. Set the desired indicator level by selecting the appropriate indicator level (color) at the right of the screen.
3. Press the Add button at the right of the indicator.
4. Choose the scope and sub-scope categories.
5. Select the Next button to continue.

Instrument Scope will not invalidate data.

6. Verify choices and press the Add button to accept the changes, or press the Abort button to cancel the operation.
7. Select the Active Box. (Indicators must be marked Active to be monitored and reported.) Mark the Hold box to retain the
indicator's triggered level until manual reset.

6.3.3 Status indicator reset

To reset a single indicator state and date/time, press the Reset button at the far left of the indicator line. To reset the state and
date/time on all activate indicators shown on the displayed page, press the Reset All button at the top left of the indicator list.

If an indicator is persistent, clearing the indicator may appear as if not cleared (no color change), however
the time and date will change.

6.4 Schedule tab

The Schedule Tab allows the user to define the stream, Step order, TOD (time-of-day) requests, and Demand (Ad Hoc) requests.
Additionally, the user defines which analysis to use when analyzing a stream.

General functions include:

• A live list of analyses in Queue.
• Color-coded queued analyses identifying streams currently being analyzed, in purge, next to purge and pending.
• Option to Start, Stop, Abort, or Pause the schedule.

Schedule operation priorities:

1. Step Schedule Elements are the lowest priority and can be pre-empted by either Demand or TOD requests.
2. AdHoc requests pre-empt Step Schedule elements, but not TOD requests.
3. TOD requests pre-empt both Demand and Step table Schedule requests

No Schedule Element type can pre-empt its own type (e.g.: a TOD in the Schedule Queue can’t be pre-
empted by the next TOD Schedule Element added to the Schedule Queue).

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6.4.1 Maintenance mode icon

The Maintenance Mode icon sets the selected schedule's maintenance indicator. If desired, the maintenance mode indicator
may be placed in a scope at a level that invalidates reported data.

6.4.2 Power failure recovery icon

This software offers automatic, independent system control for planned or inadvertent power failure. This allows the user to
customize and control the process analyzer’s schedules, returning them to a ready state after an outage. These are used to:
• Protect the analytical hardware from introduction of process samples before the oven reaches its operational
temperature
• Separate and configurable power failure settings for all multiple oven configurations, including simultaneous and
parallel oven applications.
• Automatic synchronization of all analytical hardware to their operational state.

Power Failure Recovery defines a schedule's recovery mode after an unexpected power outage. These modes are defined as:
• Continue – Restarts the schedule at the last analysis that was running when power was lost.
• Restart – This mode can be configured to recover two ways.
1. Delete the analyses in the queue and Restart the schedule from the first active stream defined on the Step sub-
tab.
2. Delete the analyses in queue, run a “Clearing Analysis” and then restart the schedule. (The Clearing Analysis is an
optional analysis executed as the first analysis used to purge or condition the system if the analyzer comes up in
Restart mode. Each schedule has only one Clearing Analysis defined for the schedule.)
• Abort Mode– Stops the schedule and deletes all analyses in the queue.

To ensure that a Clearing Analysis is not defined, select ‘None' in the drop down list box (either the
Analysis Name or the Stream Name.)

Which mode the analyzer executes is determined by comparing the actual time the analyzer is ready to the user set times:
'Time Continue' and 'Time Restart.'
• Analyzer Ready is defined as the number of minutes from when the analyzer lost power until the time the schedule is
ready to run its first analysis for a given Schedule. (This includes analyzer boot time and time for oven(s) associated
with the analysis to reach the low temperature limit).
• Continue Time is the user defined time period, in minutes, in which the analyzer comes up in Continue mode.
• Restart Time is the user defined time period, in minutes, in which the analyzer comes up in Restart mode.
Additionally, this mode allows assignment of a Clearing Analysis. The Clearing Analysis is an optional analysis
executed as the first analysis used to purge or condition the system if the analyzer comes up in Restart mode. Each
Schedule has only one Clearing Analysis defined in that Schedule.

The Restart mode can be disabled by setting Time Restart to a value less than the value for Continue Time. If the Restart mode
is disabled, the Clearing Analysis is disabled.

If both values in the Power Failure Recovery Option are set to zero, the schedule restarts in an idle mode.

Upon recovery, the Master Controller compares the actual time to Analyzer Ready to the user defined values.

Modes are determined as follows:

• If the Analysis Ready time is less than the user defined Continue Time, then the analyzer comes up in Continue mode.
• If the Analysis Ready time is less than Time Restart and Time to Ready is greater than Continue Time, then the
analyzer comes up in Restart mode.
• If the Analysis Ready time is greater than Time Restart and Time Ready is greater than Continue Time, then the
analyzer comes up in Abort mode.
• If the Analysis Ready time is greater than Continue Time and Time Restart is less than Continue Time, then the
analyzer comes up in Abort mode.
• If the Time Continue and Time Restart = 0, then the Schedule comes up in the STOPPED/IDLE state.

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Figure 6.12 illustrates the determination of the schedule recovery modes.

Fig. 6.12. Power Recovery Options

6.4.3 Multiple oven and schedule relationship

Each schedule can use the oven hardware in more than one oven, allowing more than one oven association with a single
schedule. Each oven operates independently in the system. If an oven goes offline it impacts only the schedules associated with
the assigned oven. Figure 6.13 provides an example of a schedule/oven assignment and Figure 6.14 illustrates a typical multi-
oven and schedule relationship.

Schedule Oven 1 Oven 2 Oven 3 Oven 4

Assignment
Schedule 1 X X X
Schedule 2 X X
Schedule 3 X
Schedule 4 X

Fig. 6.13. Schedule/Oven Assignment Example

Fig. 6.14. Multi-Oven and Schedule Relationship.

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In each example, an X represents an offline oven (the offline condition may be initiated for maintenance, power failure or
possible associated equipment failure). In Example A, Oven 4 has gone offline. Only schedules 1 and 4 are impacted. In
Example B, Oven 2 is offline and impacts only schedules 1 and 2. These schedules react and restart as described in the Power
Failure recovery paragraph of this manual.

6.4.4 Queue sub-tab

The Schedule>Queue sub-tab displays the order of the current and upcoming analyses (see Figure 6.15). Schedules may be
created, started, stopped, paused or deleted.

3
2

Fig. 6.15. Schedule>Queue Display

1. Action Icons – Create, edit and control schedules (Table of Action Icons in Section 5 lists each icon).
2. Queue Display– Lists live analyses associated with selected schedule (left-hand column).
3. Schedule List – List of schedules.

A GREEN entry represents the current running analysis in the selected schedule. Total analysis time and time into analysis are
displayed under the TIME heading. A YELLOW entry identifies the sample that is purging for the next analysis. A BLUE entry
identifies the stream which is next to be purged. A WHITE entry identifies any additional Time of Day (TOD) or Demand request
in the order of analysis.

The TYPE of stream analysis displayed is defined as follows:

• Step – The sequence of stream analyses defined on the Step sub-tab.
• Time of Day (TOD) – Scheduled stream analyses defined on the TOD sub-tab.
• Demand (Ad Hoc) – Demand stream analysis requests.

Any stream analysis which is BLUE or WHITE can be deleted from the queue using the selection box and Delete button on the
right hand side of the screen.

When a Schedule goes off-line the associated Schedule button behaves as follows:
• STOPPED Schedules blink letters WHITE and RED; when the Schedule comes on-line the button letters turn RED.
• RUNNING Schedules blink letters WHITE and GREEN; when the Schedule comes on-line the button letters turn GREEN.
• PAUSED Schedules blink letters WHITE and YELLOW; when that Schedule comes on-line the button letters turn RED.

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6.4.5 Step sub-tab

Figure 6.16 shows the Step sub-tab display. It allows the user to add steps to a schedule.

1
3

Fig. 6.16. Schedule>Step Display

1. Schedule Select – Select schedule to show detail.

2. Add Action Icon – Select the Add icon to add an analysis.
3. Analysis Control Area – Add, Delete, Run and Activate.

The following illustrates the basic procedure for adding an analysis.

1. Select the Add icon.
2. Select the stream and press the Next button to continue.
3. Select the analysis and press the Next button to continue. Press the Go Back button to go back or press the Abort button
to cancel.
4. Press the Accept button to accept the selection. Press the Go Back button to go back or press the Abort button to cancel.

When accepted, the analysis will be added to the schedule on the Step screen. Mark the ACTIVE box with an X to activate.

6.4.6 Time of day sub-tab

The Schedule>TOD sub-tab displays the currently configured analyses, the streams they use, the frequency at which they run
and whether they are actively being used (see Figure 6.17). It allows frequency configuration at monthly, weekly, daily, hourly,
minute or second intervals.

1 3

Fig. 6.17. Schedule>TOD Display

1. Schedule Select – Displays Schedule detail.

2. Add Action Icon – Selects and adds streams by selecting the Add button.
3. Analysis Control Area – Add, Delete, Run and Activate.

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The TOD sub-tab sets scheduled validations, calibrations and stream analyses. The steps to add a TOD analysis are:
1. Select the Add button at the top of the sub-tab display and a selection list appears.
2. Select a stream from the list and press the Next button to continue.
3. Select the analysis from the list and press the Next button to continue. If needed, return to the previous screen by
pressing the Go Back button.
4. Select the frequency from the list and press the Next button to continue.
5. Depending on the last selection, select the day of the month or day of the week, and press the Next button ton continue.
6. Enter the time of day the analysis is added to the queue (hour and minute) and press the Next button to continue. (The
clock uses a 24-hour format.)
7. Review the information and press the Accept button to accept the entries, or press the Abort button to discard them. If
they are accepted, the analysis will be added to the TOD schedule. If needed, press the Go Back button to return to the
previous screen to change any information.
8. Activate the analysis by selecting the Active box.

6.4.7 Demand sub-tab

The Schedule>Demand sub-tab is used to develop analyses which a user wants to run at unspecified intervals. These analyses
may be used for maintenance, troubleshooting, validation and calibration. Select the Run button to add the analysis to the
queue manually. Figure 6.18 provides an example of the Demand Analysis Addition.

1
3

Fig. 6.18. Schedule>Demand Sub-tab

1. Schedule Select – Select Schedule to be displayed.

2. Add Action Icon – Select to add analyses.
3. Analysis Control Area – Add, Delete and Run Demand Analyses.

The steps for creating a demand analysis are:

1. Select the Add icon at the top of the sub-tab display and a selection list appears.
2. Select the desired stream from the list and press the Next button to continue.
3. Select the analysis from the list and press the Next button to continue. If needed, press the Go Back button to return to
the previous screen.
4. Review the information and press the Accept button to complete the request, or press the Abort button to discard. If
needed, press the Go Back button to return to the previous screen.
5. To add the analysis to the queue, press the Run Analysis on Demand button associated with the name of the analysis.

The analysis is placed as close as possible to the top of the queue. A Demand request does not replace the current or purging
stream analysis in a running schedule.

6.5 Analysis tab

The Analysis Tab presents the tools for creating and editing analyses by using either text or graphic techniques.

The Analysis Tab consists of three sub-tabs: Chart, Tabular Editor, Overlay and Report (only for reprocessed reports). It is the
focal point of building, editing and saving analyses and their building blocks.

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6.5.1 Chart sub-tab

The Analysis>Chart sub-tab is used to display and edit analyses graphically (see Figure 6.19). The parallel lines with the colored
symbols at the bottom of the chart screen graphically identify analysis objects.

Fig. 6.19. Analysis>Chart Sub-tab

The Chart sub-tab display consists of:

1. Action Icons – Used for retrieving saved analyses, and editing the displayed analysis.
2. Function Select Buttons – User created analysis objects.
3. Chromatogram Display – Displays current chromatogram and/or overlay.
4. Graphic Edit Area – Drag and drop objects to edit the selected object's timing.

Enable the graphical editor by selecting the Chart Sub-tab (see Figure 6.19). This editor allows analysis timing adjustment using
a pointing device with the drag and drop function. Refer to the Time Coded Function (TCF) section of the manual for a
complete list of TCFs and their functions.

To edit an analysis graphically:

1. Select the Add icon to load an analysis from the library. (The analysis is displayed in the Function Select buttons.)
2. If needed, select the detector from the drop down button at the top of the chromatogram display area.
3. Select an element of the analysis. (The symbol for the selected element is always displayed on the second horizontal line
from the top, below the chromatogram display area.)
4. Select the object to adjust by placing the cursor on the symbol.
5. Hold the cursor button at the LUI (left mouse button at the Remote Client) and move the object to the desired location
and release the cursor button.

To see the object’s timing represented numerically select the Tabular Editor sub-tab.

Use caution when editing preconfigured Analyses, Methods, and Sequences. “Save As” under a different
name prior to testing as changes made and saved affect all analyses, methods and sequences using that
named object.

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Figure 6.20 shows the corresponding placement of symbols on the Chart sub-tab in relation to the numbers entered from the
Tabular Editor sub-tab. Placement of the symbols can be edited from either sub-tab.

TIME OFFSET
CREST
185 BEGI N END
-3 2

START OF INTEGRATI ON
BEGI N END END OF INTEGRATION
-6 -2 BEGI N END
2 6

START OF BASELINE END OF BASELINE

BEGI N END BEGI N END

-12 -8 8 12

Fig. 6.20. Graphic Editor/Tabular Editor Map

6.5.2 Tabular editor sub-tab

The Analysis>Tabular Editor sub-tab is used to display and edit analytical data (see Figure 6.21).

Fig. 6.21. Analysis>Tabular Editor sub-tab

1. Action Icons – Create, Add, Delete or Save objects.

2. Function Select Buttons – User created Analysis objects
3. Editing Area – Used to display and edit selected object

Refer to the Time Coded Function (TCF) section of the manual for a complete list of TCFs and their functions.

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

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percentage of the sum of the areas of all the peaks. Normalization applies to analyses where the quantitative response of the
detector is the same for all the eluted components.

By default, the PGC5000 does not normalize component results. However, there is an option in the Analysis tab to normalize
the Analysis results. From the Analysis tab, load a saved Analysis and select the first tab of the Analysis on left hand side. Select
Tabular Editor at bottom of Analysis screen to setup the normalization feature (see Figure 6.21).

From this tab, you can set the Normalize option to Active by selecting the Normalize check box in middle of viewing window
(see Figure 6.22). This will normalize the Analysis results on the Report.

Fig. 6.22. Selecting the Normalize Option

You can also assign a component to display an un-normalized value for Analysis results in the Report. This is useful
to see the un-normalized total component concentration for all components as well as having the normalized
results displayed. You can assign the un-normalized results to an existing component, or create a new component
to display the un-normalized results (see Figure 6.23).

Fig. 6.23. Normalized Report

6.5.4 New analysis

The analyzer analyzes components by using established methods built from a sequence of TCFs such as valve functions.
Examples are:

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• Analysis - Consists of one or more methods (maximum of one per oven), which produces a measurable, displayable
chromatogram.
• Sequence - Consists of timed valve functions (On or Off), TCFs and sample injections. A sequence is under a method.
• Method- Consists of one or more sequences and may be assigned to an analysis. A method is under an analysis and
linked/tied to an oven.

Analyses, methods and sequences are created using menu selections. The following steps use the Analysis>Tabular Editor sub-
tab to create a new analysis including a method and a sequence. (A method and sequence is automatically generated when
creating a new analysis.)

When a new TCF or Add New option is selected, it is inserted below the highlighted tab in the Analysis
tab’s Function Select list.

1. Select the Add New icon when the New Object dialog box opens.
2. Choose the desired object to create and press the Next button to continue.
3. Confirm the information shown and press the Accept button to create the new Analysis. This automatically creates a new
Method and Sequence object under the analysis.
4. Select the Add New icon and define a startup purge time. (Purge Time is the amount of time the system purges the
sample prior to the initial start of an analysis, with a minimum equal to or greater than one second.)
5. Select the new Method under the new Analysis.
6. Assign a name and cycle time. (The description/name of the object should be something easily recognized for future
editing and must be unique to the system.)
7. Select the oven from the drop down list. (The oven name is assigned in the Setup Tab.)
8. Select the new Sequence button on the left (under the Method button) and assign a name and time offset. (The time
offset is start time in relation to the start of the method.)
9. With the Sequence button selected, select the Add New icon and choose Valve, then select the Next button to continue.
10. As needed, change the information in the description box, set the time offset and select the valve name from the drop
down list.
11. Next select the Add New icon from the Sequence scope.
12. Select a component.
13. Verify and save by pressing the Accept button.
14. Fill in the information completely.
15. Select the Add New icon.
16. Select TCF-Method Scope.
17. Select Stream Step.
18. Verify and accept by pressing the Accept button.
19. Fill in the Stream Step information.
20. Save the new analysis to Analysis Config. The Analysis button must be selected when saving.
21. Select the Save As icon to save as a new analysis.
22. Name and save to Analysis Config (for immediate use) and/or to Analysis Library for future use.

The Analysis must be saved to Analysis Config before it can be added to a schedule.

An analysis can be modified after it is saved. Select the object to modify, make the changes and save the analysis.

6.5.5 Analysis error messages

The following error messages display on screen when an error is found prior to the Master Controller sending the method to
the oven.

Message Issue / Fix

Analysis not found (e.g.: Name mismatch) An Analysis has a trailing space on the end of name that has gone
undetected. One example: Remove space at end of Analysis Name.

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Message Issue / Fix

TCF is outside Method A TCF non-End of Analysis script precedes the start of the first Method
defined in the Analysis
Component TCF - Begin crest time > 0 A Component TCF has a ‘Crest Begin' time offset that is less than zero
Component TCF - Begin time >= End time A Component TCF cannot have a 'Crest Begin’ time offset greater than
or equal to its 'Crest End’ time offset
Component TCF: 0 length Component Name A 'Component' TCF can’t have an empty Component Name
Bad oven address for [DeviceName] For a given TCF the associated oven name could not be found in the
device lookup collection
(Method's oven = [Oven_Id]) != (TCF Analysis has a Method assigned to one oven, containing a TCF referring
[Sbst].[Node] .[Type].[Chan]) to a device in another oven
Component TCF: 0 length Detector Name A 'Component' TCF can’t have an empty ‘Detector’ name
Non Sequence/TCF after DoNext/SkipNext Conditional TCF types must be followed by a legitimate TCF type (e.g.:
Not a Method or a Sequence)
DoNextIf is the last TCF in Analysis A 'Do Next' TCF type cannot be the last TCF in an Analysis
DoNextIf TCF precedes Component TCF A 'Do Next If' TCF cannot precede ‘Component’ TCF
DoNextIf TCF precedes DoNextIf TCF A ‘Do Next If’ TCF cannot precede another ‘Do Next If’ TCF
DoNextIf TCF precedes TcfSkipNextIf A ‘Do Next If’ TCF cannot precede a ‘Skip Next If’ TCF
DoNextIf TCF precedes StreamStep Tcf A 'Do Next If' TCF cannot precede ‘Stream Step’ TCF
DoNextIf TCF precedes UnknownPeak TCF A 'Do Next If' TCF cannot precede an ‘Unknown Peak’ TCF type
Duplicate Component found in same Method A Component with the same Component Name was found in the same
Method
Component TCF - End crest time < 0 A ‘Component’ TCF has a ‘Crest End’ time offset less than zero
[Num] Component TCFs, exceeds max Too many Components were specified in the Analysis
spec:[MaxNum]
Too many script TCFs in [Analysis Name] The count of the Script TCFs in this Analysis exceeds the maximum limit
Invalid min Method TCF StartTime=%d < 0 A TCF at Method scope was found to have a time offset of less than
zero seconds
Found more than one Stream Step TCF. Only one Stream Step is allowed in each Analysis

More than one Stream Step TCF in No Analysis can have more than one Stream Step
[AnalysisName]
Missing Stream Step TCF Every Analysis must have a Stream Step
NO TCFs in Analysis did not contain any TCFs
Analysis: "[AnalysisName]"
[Method Name] inside prev Method An Analysis was found containing a Method having no TCFs nor any
Sequences
[Sequence Name] in prev Sequence An Analysis was found containing a Sequence having no TCFs
All active STEP table items have a bad No Schedule Elements in the STEP table were found having a well-
["Analysis"] formed Analysis
[Component Name] - bad time values A part of the named 'Component' TCF is outside of its containing
Method
Malformed Method -> no oven assignment Every Method must have an Oven Name specified in that Method
Sequence.TimeOffset >= Method.CycleTime No Sequence start time can be greater than the containing Method's
CycleTime
SkipNextIf is the last TCF in Analysis A 'Skip Next' TCF type cannot be the last TCF in an Analysis
SkipNextIf TCF precedes Component TCF A 'Skip Next If' TCF cannot precede Component TCF
SkipNextIf TCF precedes DoNextIf TCF A ‘Do Skip If’ TCF cannot precede another ‘Do Skip If’ TCF
SkipNextIf TCF precedes TcfSkipNextIf A ‘Skip Next If’ TCF cannot precede a ‘Do Next If’ TCF
SkipNextIf TCF precedes UnknownPeak TCF A 'Skip Next If' TCF cannot precedes an ‘Unknown Peak’ TCF type
Malformed Analysis: Startup purge < 1 An Analysis's Startup Purge must be greater than zero
[Method Name]:Skip then StreamStep In the named Method, a skip occurs before the Stream Step
SkipNextIf TCF precedes StreamStep Tcf A 'Skip Next If' TCF cannot precede a ‘Stream Step’ TCF

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Message Issue / Fix

StreamStep TCF starts at time < 1 second A 'Stream Step' TCF cannot start at a time of less than one second into
the CycleTime
(MaxTcfEndTime = [Secs]) > (CycleTime= Some TCF in the Method exceeded this containing Method's CycleTime
[Secs])
Not all TCFs have a valid start time A TCF's time offset is configured at less than one second before the end
of the Cycle Time; Note: One exception: 'End-Of-Analysis' scripts
1st TCF not starting at reasonable time First TCF's time offset is configured to start before one second into the
Cycle Time
Invalid min Seq TCF StartTime = %d < 0 A TCF at Sequence scope has a time offset of less than zero seconds
[Description] TCF StartTime <= 0 No TCFs are allowed to start at a start time of <= '0' (Inside a Method /
Sequence)
Same oven address in 2 Methods found In one Analysis, two methods are configured to run in the same oven
Analysis: "[AnalysisName]"
Same Component in two different Methods The same Component Name is found in two different Methods

6.5.6 Loading an analysis from the library

The designed application analyses for the system are stored in the analyzer library and/or the analysis configuration.

Only analyses stored in Analysis Config can be added to a schedule.

The following steps present the instructions to retrieve an analysis from the library.
1. Select the Analysis>Chart sub-tab.
2. Press the Add to a Scope button and an object dialog box opens.
3. Select the Analysis Library.
4. Choose the desired analysis you want to load.
5. Press the Next button to continue.
6. Review the information listed at the top of the dialog box.
7. If the information is correct, press the Accept button to continue.
8. If the information is not correct, press the Go Back button to return to the previous dialog box, or press the Abort button
to cancel the operation.
9. Save the object to the Analysis Configuration for immediate use.

The chosen analysis appears on the left side of the screen, as shown in Figure 6.24.

Fig. 6.24. Library Stored Analysis

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6.5.7 Running an existing schedule

Please refer to the Schedule Tab for running a schedule.

6.5.8 Stopping or pausing schedules

Refer to the Schedule Tab for information concerning stopping or pausing a schedule.

6.5.9 Overlay sub-tab

The Analysis>Overlay function works exactly the same as the Home>Overlay screen. Refer to the Home>Overlay subsection in
this section for more information.

6.5.10 Chromatogram reprocessing

This allows the reprocessing of integration events on a completed (saved) Standard chromatogram report without re-running
the analysis (see Figure 6.25). The Active box on the left side of the display must be marked for the Reprocessing Action icon at
the right of the Analysis>Overlay sub-tab to display. Reprocessing is allowed on either overlay.

Active Reprocessing
Action

Fig. 6.25. Reprocessing Button

When the chromatogram data is reprocessed, using changed integration parameters, the reprocessed report can be compared
to the original report, showing any variation in peak results. If the integration change is satisfactory, the changes can be saved
to the analysis for later execution.

The reprocessed reports are saved on the Master Controller with a copy of the reprocessed report. Please note:
• Scripts contained in the analysis do not run during reprocessing.
• The reprocessed values are not reported to the OPC Server or any subscribers.
• Reprocessed reports are kept indefinitely; however, like the Alarm and Calibration folders, the folder is periodically
cleaned (every 10 minutes), leaving the last five files.
• Reprocessed reports are prefixed with “REP.”
• Reprocessed reports are backed up with all other available Stream Data by selecting the Copy Stream File Data to USB
Drive button on the File Management screen of the Setup tab.

Reprocessing existing chromatograms:

1. Go to the Analysis Tab>Chart sub-tab.
2. Select the Add icon and load an existing analysis.
3. Select the Overlay sub-tab.
4. On the Overlay sub-tab, mark the Active box for Overlay 1 or 2 and the Reprocessing Action icon appears. (If it does not
appear, refresh the screen by switching on another sub-tab and returning.)
5. Leave the Previous box checked and select the Reprocessing Action icon to reprocess the previous chromatogram data.
This uses the analysis data you loaded in step 2.

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6. Go to the Report sub-tab and note the data.

7. Go to the Chart sub-tab and adjust any of the integration parameters (retention time, baseline, etc.).
8. Return to the Overlay sub-tab and select the Reprocessing Action icon again.
9. Return to the Report sub-tab and note changes in the data displayed.
10. If the changes are acceptable, save the changes by selecting the Save icon. The modified analysis will load and run after
the next stream step occurrence.

6.6 Setup tab

The Setup tab allows the user to configure and modify elements of the analyzer (see Figure 6.26). Initial configuration is
completed and tested at the factory for application purposes. The Function Select list displays the top level of all objects
contained in the analyzer. Select an object button in this list to view and/or edit in the information area. If the object has sub
items, those items are displayed below the selected object button. Static and configurable information is displayed in the
information area on the right of the screen.

Fig. 6.26. Setup>Config Sub-Tab Example

1. Function Select list – List of all objects in the analyzer.

2. Object Configuration Information – Displays all information available for the selected list item. Including Action Icons (if
applicable) and Fields. (Editable fields display with a white background.)
3. Sub-tabs – Switch views by selecting the desired tab.

6.6.1 File management

The File Management button in the Function Select list allows the user to delete files from the analyzer libraries, restore the
analyzer to factory configuration, create a user restore point, restore the analyzer to the user created restore point, backup the
analyzer to a USB drive and backup ALL stream files to a USB drive and delete ALL stream files on the Master Controller

To delete files from the Analysis Configuration or system Libraries:

1. Press the Abort button to open a window displaying the system libraries.
2. Select the file location and press the Next button to continue.
3. Highlight the file and then press the Next button to continue.
4. Press the Accept button to confirm the deletion, or press the Go Back button to choose a different file, or press the Abort
button to cancel the operation.

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6.6.2 System restore and recovery

The analyzer has several recovery options and file transfer function available as shown in Figure 6.27. These options allow
restore point creation and/or chromatogram data file copy (for offline use) or deletion, as explained below.

Factory Restore
Access
Control List User Restore

User Save
USB Recovery Delete
USB Stream Diagnostics

Fig. 6.27. Recovery and Backup Options

If only option names show, you do not have enough rights to use the backup and restore options.

Stop all schedules before creating a recovery USB or backing up the stream files to a USB flash drive.

ACCESS CONTROL LIST – Selecting the Access Control List (ACL) icon displays a dialog box containing a list of users, passwords,
and access levels that is distributed, encrypted and persisted at each device. The ACL can be modified from a PGC5000
(LUI or Remote Client), VNSA, or a STAR Client. If the PGC5000 is secured, any user with supervisory rights can modify the
ACL. If the PGC5000 is unsecured, everyone has the ability to modify the ACL.

Stop all schedules before restoring from a recovery USB flash drive.

FACTORY - Selecting the Restore Settings icon restores the analyzer to the factory configuration. All user configuration changes
to the system will be lost.

USER – Selecting the Save Icon creates a User Restore point. The system copies all configuration files from the working
directory to the Restore directory on the analyzer. You should create a restore point prior to making any changes or
updates to the analyzer. Only one restore point is saved. Creating a second restore point will overwrite the initial store
point.

Selecting the Restore Settings icon restores the system to the user created restore point. It copies the configuration files
from the Restore directory to the Working directory of the Master Controller and restarts the system.

Creating the Recovery drive takes several minutes. Wait for the “Creation Complete” message before
removing the USB drive. Select the Eject USB icon on the Setup screen before removing the Recovery
drive. Store the Recovery drive in a safe place.

You must use a USB drive having 32 GB or less. If a USB drive larger than 32 GB is used, the system will
appear to write the data to the drive and give a “Creation Complete” message, but no data will be on the
drive.

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USB – Selecting the USB Flash Drive Operation Recovery icon creates a recovery drive on the USB flash drive inserted in the
Master Controller Single Board Computer (SBC). This operation takes up to thirty minutes to complete depending on
system configuration. The user restore directory is NOT saved to the Recovery drive.

To restore the system from an unrecoverable lockup or after replacing the Single Board Computer, install the USB flash
drive and apply power to the system. The Master Controller formats the flash memory and copies all of the files from the
USB flash drive to the system’s flash memory. Wait for the Upgrade Complete message to appear. Select the USB Eject
icon and wait for the Eject Complete message to appear. Remove the USB drive and cycle power on the Master Controller
to reboot.

Selecting the USB Flash Drive Operation Stream File icon copies all stored chromatogram files on the system to the flash
drive inserted in the Master Controller SBC board. Copying the data files will take several minutes. Wait for the Operation
Complete message to appear. Select the USB Eject icon and wait for the Eject Complete message to appear and then
remove the USB flash drive.

DELETE – Selecting the Delete icon deletes all saved chromatograms and report files on the system. It does not delete analyses
saved in the Analysis Config folder or Analysis Library folder.

DIAGNOSTICS – Selecting the Diagnostic Operation icon will copy all diagnostic files to a USB drive inserted in the Master
Controller SBC board. Diagnostic files are used to diagnose errors and events in software. These files are for factory use
and troubleshooting purposes. The copying of the files should take only a few minutes. Wait for the Operation Complete
message to appear. Select the USB Eject icon and wait for the Eject Complete message to appear and then remove the
USB flash drive.

Selecting the USB Action icon performs the functions listed above. Always wait for the Eject Complete message before
removing a USB drive.

6.6.3 System backup, restore and recovery error messages

The Backup/Restore and Recover options include error diagnostics. Figure 6.28 shows a sample message display.

Fig. 6.28. Error Popup Box

The following popup error messages display if an error is found during restore and recovery procedures.

Message Meaning / Issue / Fix

Factory Configuration Restore\Configuration Button pressed, but a Factory Configuration not found on
Missing! USB flash drive
Invalid Configuration Host Mismatch Warning! Host Name in the configuration does not match the Host
Name on the Master Controller: Call ABB support
Invalid Configuration Model Manager Task not There is an error in one of the configuration files: Call ABB
started support
Restore Point Configuration Capture Complete Restore Point has been written to the USB flash drive

Stream Data Files Capture Complete Backup of Stream Data is complete

Stream Data Files Delete Complete Stream Files Deleted

Stream Data Files No USB Drive Found No USB flash drive found. Insert USB flash drive in Master
Controller Single Board Computer (SBC) PCB
Updating Configuration.. Standby for System System is writing configuration files to USB flash drive
Restart

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Message Meaning / Issue / Fix

USB Recovery Drive Creation Complete Recovery data has been saved to the USB flash drive

USB Recovery Drive No USB Drive Found No USB flash drive found. Insert USB flash drive in Master
Controller SBC PCB
User Configuration Restore No Restore Point Found USB Flash drive has no Restore point files.

6.6.4 Components
The Components button in the Function Select list displays component information (see Figure 6.29). Components can be
added, deleted or edited.

Fig. 6.29. Setup>Components Configuration Display

To edit a component:
1. Navigate to the Setup Tab and select the Components button in the Function Select List.
2. Select the Config sub-tab at the bottom of the display.
3. Select the Component to edit from the Component Name drop down list.
4. Edit the component as necessary.

COMPONENT NAME - Component names must be unique to all configured components in the analyzer and are selectable from
the drop down menu.
CONCENTRATIONS
CALIBRATION – Numeric value representing the component's calibration concentration.
VALIDATION – Numeric value representing the component’s validation concentration.
UNITS – Unit of measure (%, ppm, ppb, calc, blank, none).
RESPONSE FACTOR – Response factor relative to the selected component (may be entered manually).
PENDING RESPONSE FACTOR – Calibration stream calculation. Use the Go Back button to manually replace the current
Response Factor with the calculated factor.
CALIBRATION AUTO UPDATE – If the box is marked, the Pending Response Factor automatically updates with the pending
response factor if it is within the drift limits entered.
CALIBRATION DRIFT LIMIT – The maximum amount the calibration can drift since the last calibration. The Response Factor will
not update if the pending response factor exceeds the drift limit.
VALIDATION LIMIT – Allowable percent of component concentration change during when running a validation.
RETENTION TIME LIMIT – Time into analysis (in seconds):
LOW – Low level limit, in seconds, that the peak crest can shift.
HIGH – High level limit, in seconds, that peak crest can shift
LIMITS – Concentration (Reported Component Values):
LOW-LOW – Sets the Low-Low indicator concentration limit
LOW – Sets the Low indicator concentration limit
HIGH – Sets the high indicator concentration limit

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HIGH-HIGH – Sets the high-high indicator concentration limit

The Status sub-tab displays component’s associated indicators, their state and allows reset. (The component indicators must
be marked active on the Status Tab to see state color.)

6.6.5 Streams
The Streams button in the Function Select list displays all streams configured for the analyzer (see Figure 6.30). Streams can be
created, configured and deleted from this display.

Fig. 6.30. Setup>Streams Configuration

STREAM LIST – Dropdown list of available streams.

STREAM NAME – Reference name of the stream.
STREAM ONLINE – Current status of Stream (Marked = Active/Online). Unmarking (Deactivating) triggers the ‘Offline’ Indicator.
STREAM VARIANT – Current variant of the stream being used.
RUNTIME TYPE – Dropdown list of selectable stream types.
VALVE NAME – Dropdown list of selectable valve types.
VALVE ADDRESS – Reference Address of the selected valve.

The Status sub-tab displays the configured indicator’s state and date and time of the selected stream.

To create a stream:
1. Navigate to the Setup Tab>Config sub-tab and select the Streams button in the Function Select list.
2. Select the Add New icon and enter a name and a variant for the new stream. (Stream names must be unique in the
analyzer.)
3. Confirm the stream creation by pressing the Accept button, or cancel the operation by pressing the Abort button.
4. Select the RUNTIME TYPE from the dropdown list.
5. Select the VALVE NAME from the dropdown list.
6. Select the STREAM ONLINE box to activate the stream in the schedule

To delete a stream:
1. Navigate to the Setup Tab>Config sub-tab and select the Streams button in the Function Select list.
2. Select the stream to delete from the STREAM LIST dropdown list.
3. Select the Delete icon.
4. Confirm the stream deletion by pressing the Accept button, or cancel the operation by pressing the Abort button.

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6.6.6 Master controller

Selecting the Master Controller button in the Function Select list displays the Config and Status sub-tabs and all associated
cards and peripherals (see Figure 6.31).

Fig 6.31. Master Controller Configuration

The associated items are shown in an indented list under the selected button in the Function Select list. If an associated item
or device contains or has a subset of parts or cards, those will be shown in an indented button list below that item or device.

Do not mark the SECURED box unless ACL contains at least one Supervisor user.

Setting Display Language: Select the desired language from the dropdown list. The display change is immediate to the user.

Multiple languages can be viewed at the same time from the Remote Client. However the last language
selected for display by either from the LUI or the Remote Client becomes the default display language
when the analyzer is restarted.

Status: This Status sub-tab displays the state of configured indicators. If triggered (state changed), it displays that event date
and time.
Master Controller Cards: As with the Master Controller button, each associated card in the list has two sub-tabs: Config and
Status. The Config sub-tab lists relevant or configurable information about the card, while the Status sub-tab is blank on
these items. The table below provides more information.

Button/Peripheral Config (Displays)

Power Supply Part number
Front Panel Part number
Purge Control Part number
Singe Board Computer (SBC) Serial and part number; Current version software
Network Adapters Network Address Settings: See Network Setup in this section
USB Hub User editable port identification for reference purposes
Clock System Time and Date Entry: See Clock Setup this section
Malfunction Alarm Allowsuser editable port identification for reference purposes
Purge Alarm Contact type and rating. Editable field for reference purposes
O/C Slots 1-4 Part number; occupied SBC slot

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Network Setup: The Network Address Settings are located under the SBC button of the Master Controller. The Master
Controller is equipped with dual 100 Network Interface Card (NIC) Ethernet jacks supporting redundant communications.
If applicable, configure the network address from the Setup>Master Controller>SBC>Network Adapters>Config Sub-tab by
entering the information in the appropriate areas. Figure 6.32 is an example Network Setup.

Fig. 6.32. Network Setup Example

HOST NAME – The network name of the Master Controller (the host name will be the same on both networks.
STAR Network Port – the port at which the STAR Network is located.
PRIMARY NIC and SECONDARY NIC addresses – Contact the network administrator for available IP Addresses, Subnet Masks and
Gateway Addresses.

The network configuration does not support Dynamic Host Configuration Protocol (DHCP.)

If you are configuring both NICs, the IP Address/Subnet Mask MUST ensure IP addresses are on different
subnets.

Check the connectivity of the system by loading the Remote Client and connecting to the Master Controller (see Remote Client
in Section 7). The Machine Address Code (MAC) address of each network adapter is shown, plus an editable text area for
reference purposes.

To set the network address and communication parameters:

1. Navigate to the Setup>Config Sub-tab.
2. Select Network Adapters from the Function Select list.

Since the HOST NAME and STAR Network Port are configured at the ABB factory, they should not be
changed.

3. Enter the Primary NIC and Secondary NIC addresses.

4. Set the Host Name.
5. Enter the Subnet Mask and Gateway addresses.
6. Enter Multicast addresses. Default Multicast addresses are provided.
7. Set up routing tables as needed.

The multicast addresses allow messages to be passed through network gear (switches/routers) from subnet to subnet.

Routers must enable multicasting for this functionality to work.

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Network Routing: The PGC5000 series has the ability to route through different networks using routing tables. Up to four
routes can be configured per network interface. Configure the routing tables by selecting the Routing Table Configuration icon.
The popup entry form allows the creation of a routing table for each network.

Network Addressing: Check with the network administrator to establish IP addresses and network masks to assign to the
analyzer. Ensure all network information needed for redundancy and routing, including the network gateways, are available.
Verify communication via the network. Refer to the Remote Client in Section 7.

Saving Network Settings: Saving Network settings will force the Master Controller to re-boot. The screen popup mesage in
Figure 6.33 will confirm the procedure.

Fig. 6.33. Saving Configuration Popup Message

1. Ensure all schedules are stopped.

2. Press the Save icon to save settings.

Clock Setup: The system clock is set in the Setup>Master Controller>SBC>Clock>Config Sub-tab (see Figure 6.34). The date is
displayed in Month/Day/Year format. The clock is displayed in the 24 hour format.

Fig. 6.34. Clock Set Example

To set the date and time:

1. Navigate to the Setup> Master Controller>SBC> Clock in the Function Select list.
2. Select the Config Sub-tab.
3. Adjust the date and time as necessary.
4. Save settings by selecting the Save icon at the top of the screen.

6.6.7 Oven configuration

Changing the name will affect OPC and Modbus reporting and any method running on the oven.

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Since there may be more than one oven, the Oven button in the Function Select list may indicate the oven number (i.e., Oven 1,
Oven 2). The Oven button displays information about the oven selected and lists the oven ancillary items including the Power
Supply, Purge Control, Digital Temperature Controls, Electronic Pressure Controller and the Detector Amplifier (see Figure 6.35).
If needed, change the oven name in the space provided, for easy reference.

Fig. 6.35. Setup Oven Configuration

To display information about the oven’s ancillary equipment select the associated button.

6.6.8 Oven buttons

As with the Master Controller button, the Oven buttons display each associated card. Each button has two sub-tabs: Config and
Status. Selecting the Setup>Oven button displays all configured associated cards and peripherals. These items are shown as
selectable buttons in an indented list under the selected button. The Config sub-tab lists relevant or configurable information
about the card, while the Status sub-tab displays all associated indicators and advanced troubleshooting information if
applicable.

Oven>Power Supply>Config displays the part number of the Oven Power Supply.

Oven>Purge Control>Config displays the part number of the purge switch assembly in analyzers with electronics purge.

Oven>DTC 1>Config displays the part number including the node ID number. All ancillary parts associated with the board are
displayed below this button.

Oven>DTC 1>Status displays the indicator state of software and hardware, T-Rating issues and the associated DTC zones.
Diagnostic information is also displayed. Refer to the PGC5000 Service Instructions SI/PGC5000 for more information.

Oven>DTC 1>Malfunction Alarm>Config displays the relay type, contact rating, and connection point.

Oven>DTC>Digital Inputs>Config displays a numerical list of the inputs. Each input is configurable, as indicated in the following
table.

Functions Option Results (When Triggered)

Not configured Blank (Nothing Shown) N/A
Indicator Editable Changes Indicator Status
Maintenance Available Schedules Sets Maintenance Mode indicator for selected
Schedule Run Available Schedules Runs Schedule
Stream Online Available Streams Activates Streams
Script Run Available Scripts Runs selected scripts

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Configuring digital inputs steps (see Figure 6.36):

1. Identify the digital input to configure.
2. Select DTC>Digital Inputs from the Function Select list.
3. Either enter text or select an option from dropdown list.

Fig. 6.36. Setup Digital Inputs

Digital Input Status: The digital input status sub-tab displays the current state of the inputs (see Figure 6.37). Some of the
inputs are used for factory configuration.

Fig. 6.37. Digital Input Status

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Oven>DTC 1>Pneumatic Actuator>Config displays the actuator part number (see Figure 6.38). All factory configured valve
outputs are displayed below the pneumatic actuator button, with the color coded indicators displaying the state of all
regulated and unregulated valves. Regulated valves are those inside the oven, while unregulated valves are external.

Fig. 6.38. Pneumatic Actuator Configuration

Oven>DTC 1>Pneumatic Actuator>Valve Driver(#)>Config displays the part and valve number (see Figure 6.39). It includes a
valve control button used to manually control the valve.

Fig. 6.39. Valve Driver Configuration

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Oven>DTC 1>Pneumatic Actuator/Valve Driver#>Valve(#)>Config displays the valve information related to the valve driver with
the same number. For internal valves (see Figure 6.40), this screen provides the specific information on the valve type and
the configuration of the analyzer. The name of the valve, which is used to identify the valve when creating an analysis, can
be changed for reference. The screens for external valves show only the name of the valve.

Fig. 6.40. Valve Configuration

6.6.9 Isothermal oven

Please note that the number of temperature zones is application dependent and each zone is independently listed as a button.
Zone temperature set points are set and verified under the Setup>Config Sub-tab. The temperature setup is configured from
the data sheets at the factory.

To configure the Isothermal Oven, enter THE NAME, SETPOINT, LOW LIMIT, HIGH LIMIT, ZONE TYPE and then mark ZONE
ACTIVE to activate the zone from this screen (see Figure 6.41). The real-time temperature associated with the oven is
displayed.

Fig. 6.41. Isothermal Oven Configuration Example

NAME –Since the name is factory configured, changing the name will cause the analysis to fail.
SETPOINT – Normal operating temperature.
LOW LIMIT – Minimum Alarm Level.
HIGH LIMIT – Maximum Alarm Limit.
ZONE TYPE – IsoThermal (set at factory).

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To adjust the oven temperature:

1. Select the Oven>DTC 1>Iso Oven>Config sub-tab.
2. On the Isothermal Oven screen, insert Setpoint and/or Limit values as appropriate.
3. Check and/or adjust the temperature configuration as necessary.

The Schedule will not start until the Low Temp Limit for the Isothermal oven has been met.

The Oven>DTC 1>Iso Oven>Status sub-tab displays the state and date/time of all active indicators in the DTC zone group.
Diagnostic information is also displayed.

6.6.10 Electronic pressure control

Please note that the number of pressure zones is application dependent and each zone is independently listed as a button.

The Oven>EPC>Config sub-tab allows viewing the EPC part number and also displays the NODE ID zone (see Figure 6.42).

Fig. 6.42. EPC Configuration Sub-tab

The Oven>EPC> Status sub-tab displays the state and date/time of all active indicators in the EPC zone's group of indicators (see
Figure 6.43). Diagnostic information is also displayed.

Fig. 6.43. EPC Status Sub-tab

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Zone # Configuration: This sub-tab displays the Zone ID, Name, Actual Pressure, Ramp Rate and Setpoint (see Figure 6.44).
Enter the NAME, SETPOINT, LOW LIMIT, HIGH LIMIT, ZONE TYPE and mark ZONE ACTIVE to activate the zone from this screen.

Fig. 6.44. EPC Zone 1 Configuration

NAME – Edit the name for easier reference (Function Selector button reflects new name).
SETPOINT – Normal operation pressure.
LOW LIMIT – Minimum Alarm Level.
HIGH LIMIT – Maximum Alarm Limit.
ZONE TYPE – Isobaric, Programmable (set at the factory).

The Status sub-tab displays the state and date and time of all active indicators in the EPC's group of indicators. Diagnostic
information is also displayed.

6.6.11 Detector amplifier

The Oven>DetAmp# sub-tab displays Serial Number, Part Number, amplifier ID, type and number of channels (see Figure 6.45).

Fig. 6.45. Detector Amplifier Configuration

The Oven>DetAmp#>FID Configuration sub-tab displays the Serial, Part, and Channel number (see Figure 6.45). It also displays
the Igniter, Polarizer, Gain factor and Output Voltage. A manual AUTOZERO button is provided. Set the AUTO-IGNITE ACTIVE
option and adjust the AUTO-IGNITE PERIOD (seconds) or select MANUAL IGNITE to ignite the detector manually from this
screen. The AUTO-IGNITE PERIOD is the time in seconds before you try to re-ignite the burner if the flame is out.

The Oven>DetAmp>FPD Configuration sub-tab display is similar to the FID display.

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The Oven> DetAmp> TCD> Configuration sub-tab displays the Serial, Part, and Channel number (see Figure 6.46). It also
displays the Filament Information, Gain factor and Output Voltage. A manual AUTOZERO button is provided. You can also edit
the input and output fields for easy reference from this screen.

Fig. 6.46. TCD Configuration

6.7 Subscriber tab

The Subscriber tab allows the user to designate information collection points for the analyzer information (see Figure 6.47). To
automatically send analysis results and analyzer events to network destinations, their addresses and names must be entered in
the Subscriber Tab. Use the Subscriber tab to edit the subscriber list from either the Master Controller’s front panel or PC
based Remote Client. The Subscriber tab has two sub-tabs: Str/Opc/Rd and Modbus.

2 3

Fig. 6.47. Subscriber Tab Display

1. Action Icons – Add existing or new subscriber.

2. Subscriber Information – Displays subscriber name & information.
3. Option Row – Mark the box(es) to activate and select the type of data to report, or Delete a subscriber as needed.

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Figure 6.48 describes the information provided on the Subscriber tab display.

Heading Description

Add Device – Provides a list of applications that can be subscribed.

Add New – Adds new subscriber. Name and IP addresses will have to be manually
entered.

NAME Configurable name of the reporting device.

TYPE The device type of receiver: OPC (ABB’s OPC Server), RD (Report Device) or STR
(STAR Server).

IP ADDRESS Primary IP network address of the report device.

SECONDARY Secondary IP network address of the report device.

IP ADDRESS

ACTIVE If the box is marked, defined reports are sent to the Subscriber list.

REPORT If the box is marked, defined report information is sent.

EVENTS If the box is marked, event information is sent to the list.

STATUS CHANGE If the box is marked, status change message is sent to that Subscriber.

Delete All/Delete – Choosing the top box will mark all demand configurations for
deletion. Choosing the lower box will mark that configuration for deletion.

Fig. 6.48. Subscriber Tab Display

6.7.1 Creating a new subscriber device (optional)

To add a new subscriber (see Figure 6.49):
1. Select the Add New icon.
2. Enter name and IP information.
3. Select TYPE and mark as active (as appropriate)
4. Press the Accept button to accept the configuration and add it to the list, or press the Abort button to cancel the add
operation.
5. Review and mark the appropriate options for the device.

10 1 0 201

10 2 0 201

Fig. 6.49. Adding a Subscriber Example

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6.7.2 Adding an existing device

To add an existing device to the subscriber list:
1. Select the Add Icon to open the device setup box.
2. Select the Device from the list.
3. Select the appropriate device type from the drop down list and press the Next button to continue.
4. Press the Accept button to accept the configuration and add it to the list, or press the Abort button to cancel the add
operation.
5. Review and mark the appropriate options for the device.

The check box action for each Subscriber Name allows specific reporting configuration features (see Figure 6.50). They are:
ACTIVE – whether it reports data.
REPORT – Sends Analysis data (RAW).
EVENTS –See the next paragraph).
STATUS CHANGE – Analysis status information is sent to subscriber (Analyzer, Stream and Sample Handling Status).

Fig. 6.50. Subscriber Added and Activated Example

6.7.3 Subscriber events

The following list identifies all events which trigger output to the defined subscriber lists.

Event Trigger/Origination Point Associated Indicator

Power Recovery: <DateTime> Analyzer completes power up sequence Report Only
Power Fail: <DateTime> Detects of loss of power MC: PowerFail
User Login: <Username> User logs in to the analyzer Report Only
User Logout: <Username> User logs out of the analyzer Report Only
Stream Online: <StreamName> Stream set online manually, programmatically StreamActive
(via scripting) or automatically (via DCS call
through OPC Server)
Stream Offline: <StreamName> Stream set offline manually, programmatically StreamActive
or automatically
Schedule Run: <ScheduleName> Resource Group has been activated manually, Report Only
programmatically or automatically
Schedule Stopped: Resource Group has been deactivated Report Only
<ScheduleName> manually, programmatically or automatically
Schedule Paused: Resource Group suspended manually, Report Only
<ScheduleName> programmatically or automatically
On-Line: <ScheduleName> Schedule runs Analyses OnLine
Idle: <ScheduleName> Schedule has no Analyses to Run OnLine
Calibration Started: Schedule starts calibration Calibrating
<ScheduleName>
Calibration Competed: Schedule completes calibration Calibrating
<ScheduleName>
Validation Started: Schedule starts validation Validating
<ScheduleName>
Validation Completed: Schedule completes a validation Validating
<ScheduleName>
Maintenance Started: Schedule Maintenance Starts: Maintenance Maintenance
<ScheduleName> Button Activated

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Event Trigger/Origination Point Associated Indicator

Maintenance Completed: Schedule Maintenance Ends: Maintenance Maintenance
<ScheduleName> Button deactivated
Step Table Changed An entry in a Schedule Step Table has been Report Only
altered
Time of Day (TOD) Table Altered An entry in a Schedule Time Of Day Table has Report Only
been altered
Ad Hoc Table Altered An entry in a Schedule Ad Hoc Table is altered Report Only
Scripting Error: <Script Name> An error occurs in a scripting program when ScriptError
run.
Network Communication When communication to a subscriber fails. CommError
Failure
CommFailureOven (1-4) Oven Controller Heartbeat fails (1-4 ) CommFailureOven (1-4)
On-Line After Auto-Calibration Associated with Simulated Distillation OnLine
On-Line After Blank Run Associated with OnLine
Simulated Distillation

6.7.4 Failover operation

The subscriber list supports failover (redundancy). If the secondary network interfaces are configured, the system switches to
the secondary network and continues to report data if the primary network fails (activates COM failure indicator).

IP addresses cannot be in the same network subnet.

If the Network is set up to provide data to both a STAR DMS Network and a DCS via Modbus, the STAR
DMS should be considered as the primary network, and the DCS Modbus connection as the secondary
network.

6.7.5 Modbus subtab

The Modbus subtab (located at the bottom of the screen) under the Subscriber tab allows the user to test the Modbus mapping
on the PGC5000 as well as change ranges in the Modbus map. Users can check/test the Instrument level data tags by selecting
which Instrument’s tags they want to view from the drop down selection box below the Instrument tab on top left hand side of
screen (see Figure 6.51). To test the Instrument level data tags, input a value into the SET VALUE text box on the right side of
the screen and that value will be sent over the network to the Master device. If the value received by the Master device
matches the value input into the SET VALUE text box, then Modbus is working for that data tag.

Fig. 6.51. Subscriber Tab, Showing Instrument Tag

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Stream level data tags can also be viewed/tested by selecting the Streams tab at top of screen (see Figure 6.52). Users can
check/test the Stream level data tags by selecting which Streams tags they want to view from the drop down selection box
below Stream tab at top of screen. Once the desired stream is selected, input a value into the SET VALUE text box at the right
side of the screen for the given address and the value will be sent over the network to Master device. If the user input value
matches the value received by the Master device, the Modbus mapping is working for the given Stream tag address.

Fig. 6.52. Streams Tab

The SET VALUE text box will not display the current contents of the given Modbus address. The SET
VALUE will be written to the internal register. If the PGC5000 overwrites the values prior to the Modbus
poll request, the value may not been seen by the Modbus Master.

Users also have the ability to change the ranges of any given Stream tag address. The LOW and HIGH range value for the
Modbus map can be changed at any given time. To change the range simply input a new range value into the LOW or HIGH text
box (see Figure 6.53).

Fig. 6.53. Streams Tab Low/High Ranges

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6.8 Program tab

The Program Tab gives the operator a means for programmatic control and calculations in addition to the built-in capabilities.
This provides the necessary support to customize operation of the analyzer to support unique requirements.

Section 9 provides detailed information on the scripting process.

6.9 Manual mode tab

The Manual Mode tab (see Figure 6.54) displays up to four hours of continuous chromatogram data. It also allows individual
manipulation of the valves and other specific elements of the analyzer.

Fig. 6.54. Manual Mode>Chart Example

1. Action Icons –Initiates the Chart Reset and /or Auto zero.
2. Valve List – Lists all available valves configured on the selected analyzer and enables manual control.
3. Chart Display Area – Displays current system results.
4. Zoom Controls – Allows detailed views of the analysis.
5. Setup Display Area – Displays objects from the setup sub tab (Future Use).

Select available valves from the valve list. The valve button depresses (becomes lighter) when active.

Manual Mode Action Icons are as follows:

Icon Meaning

Auto Zero – Sets current chart Y axis value to zero.

Chart Reset – Resets current chart X axis value to current time.

6.10 Sample handling system

The software controls and collects data from a modular, CANopen ANSI/ISA SP76.00.02-2002 standard SHS.

This software includes:

• Digital SHS Valve control with Alarm Status
• Sample Temperature Alarm Status
• Sample Pressure Alarm Status
• Sample Flow Alarm Status
• Filter Differential Pressure Alarm Status
• Reading Analog Inputs

All alarm indicators are configurable at the Master Controller for OPC and/or MODBUS data transmission to validate analyses
from the PGC and provide overall SHS health.

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7 Technical description
7.1 Functional description
Figure 7.1 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 DTC. 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, a plug of sample is swept by the carrier through the column train to the detector. In the backflush mode, the
carrier backflushes Column 1 to vent.

Fig. 7.1. Typical Analytical Flow System Diagram

The volume of sample is determined by the sample loop. When the valve switches, the sample passes into Column 1, to Column
2 and into the detector cell, where it is converted to an electrical signal. Column 1 performs preliminary separation to remove
the heavier non-measured components, which are then backflushed to vent. Column 2 separates the components to be
measured, which elute sequentially to the selector valve. 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 to Vent.

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.

The sample system, together with the PGC, controls the calibration sample input. The sample system flow and pressure control
depend on the sample system configuration.

7.2 Detectors
Standard detectors are the Flame Ionization Detector (FID), Thermal Conductivity Detector (TCD), and Flame Photometric
Detector (FPD). These detectors may be used separately, in combination, or as dual detectors. An optional Discharge
Ionization Detector (DID) is also available.

7.2.1 Flame ionization detector

The FID cell reduces the physical sample to an electrical signal. 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.

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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, igniter assembly, electrometer
amplifier, and associated circuitry. The power supply provides the necessary dc voltages for the FID Amplifier Assembly and
FID.

The igniter assembly provides control for the igniter 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 igniter 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.

7.2.2 Thermal conductivity detector

The Thermal Conductivity Detector (TCD) works on the principle that a heated body loses heat dependent on the composition
of the surrounding gas. Filaments sense the rate of heat loss so that any change in filament current results in a bridge output
proportional to the change. The TCD contains a reference filament and a measurement filament. 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.

A multiport version of the Thermal Conductivity Detector (MTCD) is available to achieve more measurements in a smaller
space.

7.2.3 Flame photometric detector

The Flame photometric detector (FPD) works on the principle that when sulfur is burned in a hydrogen-rich atmosphere,
luminescence (light) characteristic to sulfur is produced. The FPD cell consists of a 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.

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.

The FPD Electrometer PCB, located inside the electronics compartment of the oven, digitizes the detector output signal for
processing. This PCB assembly also provides energy for FPC flame sensing and ignition.

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7.2.4 Optional discharge ionization detector

The Discharge Ionization Detector (DID) consists of a detector unit and a power supply (see Figure 7.2).

Detector Unit Power Supply

Fig. 7.2. Discharge Ionization Detector

The DID is used in the ABB analytical process gas chromatograph for parts-per-billion (ppb) and parts-per-million (ppm)
measurements of the following:
• Impurities in high purity gases
• Halogenated hydrocarbons
• Impurities in ethylene
• Low levels of BTX
• Arsine and phosgene
• Ethylene oxide
• Formaldehyde
• Ammonia

A dielectric barrier discharge is a plasma discharge that is obtained using a high voltage alternating current applied to a gas such
as Helium or Argon as it flows through a dielectric material such as quartz glass. Two electrodes are arranged within the
detector so that when the high voltage is applied to the gas, a breakdown occurs with a subsequent discharge from one
electrode to the other. However, the presence of the dielectric barrier behaves as a capacitor in the localized region of the
discharge. The dielectric barrier stores a substantial amount of energy for each discharge. This results in the generation of
highly excited state molecules and atoms of Helium or Argon, which is referred to as the reaction gas. As the sample
components elute from the column they are ionized by the reaction gas. A second set of electrodes in the detector measure
the current generated from the ionized components. The output is sent to an electrometer, where it is amplified. Figure 7.3
illustrates this process.

-150 to -180V BIOS Amplifier

Zero Adjus t

He*
A
He in He* e- A+ e-
He*
Exh au st Tub e

Plasma

Colu mn In

Fig. 7.3. Typical DID Process

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7.3 Peak detection

The analyzer utilizes a new method of peak detection called “min-max” detection. In order to understand the new method, this
section first reviews the current, or classic, method of detection before explaining the min-max method.

7.3.1 Classic method of peak detection

In the classic mode, two methods of peak detection are offered: “forced gating” and “slope detect.” The forced gating method
requires the operator to take full control of the peak definition. The start and end times are manually entered, along with the
topology (baseline or valley). Forced gating method makes no assumptions about the shape of the peak, while the maximum
point between the start and the end is the “crest.” A single peak is assumed, whether the chromatogram results in a single
peak or multiple peaks.

The slope detect method assumes that all peaks meet certain criteria based on the slope of the signal. A peak must start with a
positive slope, crest and then finish with a negative slope that levels out. A quiet chromatogram is treated as a quiet signal and
only peaks meeting the necessary conditions are picked up. Slope detect determines peak crests, start and end times, and
topologies automatically.

Each method has pros and cons, but neither method satisfies all application requirements. Slope detect is the preferred method
when peaks meet at valley conditions or move around. Forced gating is the preferred method when the peaks are poorly
shaped or when slope detect will not give reliable results.

7.3.2 Min-max method overview

The ABB Min-Max method of chromatographic peak detection provides a higher level of accuracy than the classic method. The
ultimate goal of the PGC is to provide the end user with a repeatable and accurate determination of component
concentrations. Peak detection algorithms are used to scan the chromatogram to determine what part of the signal represents
the peaks of interest and their respective concentrations. Typically, this is a two-step process where the first step determines at
what times to start and stop integrating of the area under the peak. The second step is baseline correction where the method
determines what part of the peak’s area is due to not starting and ending at baseline.

7.3.3 Min-Max examples

The Min-Max method is a more reliable and accurate approach to measuring peak area. This method is closer to forced gating
than it is to slope detect. Each peak specification includes windows for crest time, start and stop of integration, start and stop
baseline correction (see Figure 7.4). The baseline correction window specifies the peak topology for the baseline and valleys.
The integration and crest windows allow for offset from a maximum in the analysis.

Fig. 7.4. Min-Max, Single Peak

The Min-Max method works strictly on finding minimums and maximums. The Identification Window (IW) area defines the
maximum point within the window and the time becomes the crest. The shape of the chromatogram inside the IW is not
considered. If the chromatogram shows multiple peaks within the IW, the maximum peak is the crest and only one crest can be
determined. The Start of Baseline (SB), End of Baseline (EB), Start of Integration (SI) and End of Integration (EI) areas define the

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minimum point within the window. The SI and EI determine the beginning and end of peak area integration, while SB and EB
determine the beginning and end of baseline correction.

Figure 7.5 is an example of the integration and the baseline correction windows for a peak doublet with a valley between,
where only one of the peaks is integrated. The SI and the SB were identical, but the EI and the EB are different. The second
peak is not required for the baseline correction of the first peak. In the Min-Max method, each peak is fully defined, so not
dependent on any other peak in the analysis.

Fig. 7.5. Min-Max, Multiple Peaks

Figure 7.6 defines the integration of two separate peaks and the windows for each peak separately.

Fig. 7.6. Min-Max, Separate Peaks

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7.3.4 Baseline correction, peak lumping

The Min-Max method completely defines the peak but requires careful placement of the windows to cover all situations. The
projection of a peak is used when either the SB or the EB are offset from each other, or when no stable place can be found for
one of them. A projection is accomplished by setting SB and the EB identically. If the windows occur before the IW, the
projection is forward (Figure 7.7, peak 1). If the windows occur after the IW, the projection is backward (Figure 7.7, peak 2).

Fig. 7.7. Baseline Correction, Peak Lumping

7.3.5 Baseline correction, tangent skim

A small shoulder on a much larger peak is a “tangent skimmed” peak. The main peak extends beyond the end of the skimmed
peak where part of the area under the skimmed peak actually belongs to the main peak. Treating the situation as two fused
peaks would give an unreasonably large area to the skimmed peak.

If the tangential skimmed peak were set up as shown in Figure 7.8, the standard baseline correction of drawing a line between
the SB and the EB would give the dashed line. This correction subtracts off the area above the chromatogram and if this
crescent shaped segment becomes large enough, the final peak area will go negative. Correct placement of the EB and the EI
can avoid the problem, but this is not always easily accomplished. Small movements of the tangential skimmed peak have a
large effect on the final peak area.

Fig. 7.8. Baseline Correction, Tangent Skim

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7.4 Component detection (EZ peak)

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

EZ Peak requires two Sequence Time-Coded Functions (TCF), Threshold and Component RT:
• The Threshold TCF provides the noise multiplier used to compute the noise threshold. This TCF appears only once
and must precede any Component RT TCF. It must be placed in a quiet zone of the signal at least two seconds after
an Autozero. At the time specified in the TCF, the threshold is computed from the previous 100 samples.
• The Component RT TCF defines an expected retention time and a window encompassing that time within which a
peak is expected. It provides the bounds for the crest only and needs to be wide enough to catch the crest. If there
are multiple peaks within the window, the algorithm selects the one closest to the user-defined retention time.

7.4.1 EZ peak calculations

Most chromatographic peaks take on the general form of a classical Gaussian curve and are analyzed mathematically. The
graph of a Gaussian curve is a characteristic symmetrical “bell curve” shape that quickly falls off toward plus/minus infinity. EZ
Peak detection utilizes a second derivative algorithm to detect the presence of a peak. Derivatives enhance the ability to
isolate regions in which peaks occur by allowing the algorithm to search for a change in sign.

While it is visually obvious, locating a peak is not a simple task for a computer. Signal noise complicates the decision of when
peaks, valleys, and return to baseline occur. The user sets up five separate windows for each peak: start of baseline, start of
integration, crest, end of integration, and end of baseline.

The second derivative measures how the rate of change of a quantity is itself changing and is set using a threshold value. At the
curve’s flex point on the leading side of the peak, the second derivative crosses from positive to negative, and at the flex point
on the trailing side, the derivative crosses from negative to positive. Between those points a single peak will be found. A curve
with multiple crests has two sets of crossover points.

An advantage of the second derivative approach is shoulder detection (i.e., a bump on the side of a large peak caused by an
underlying small peak – too small to form a valley between the two crests).

7.4.2 Identifying peaks

At some point, the signal emerges above the noise enough to signify a peak has started. The second derivative does not solve
the problem of knowing when the peak actually starts, but it gives a starting position to watch.

The second derivative algorithm measures the noise as a standard deviation in a quiet range of the signal over a one second
period (100 samples). The second derivative algorithm requires a minimum of ten consecutive samples above the threshold
before it is deemed a peak. As some noise may still stray above this threshold, the user is given the option to multiply this value
by a threshold factor. The result gives an envelope above which the second derivative algorithm decides that a peak may be
starting. The threshold factor TCF can be adjusted when the sequence TCF is entered. The larger the factor entered at the
setup screen, the larger a deviation from baseline is required before a peak is assumed.

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7.4.3 Single peak integration range

The integration range of a peak is defined to be the point at which the signal first emerges above the threshold and the point at
which it first disappears below the threshold (see Figure 7.9).

Integration Range
Threshold Envelope

Fig. 7.9. Single Peak

7.4.4 Multiple peak integration range

A multiple peak cluster is where the signal does not drop back to the threshold in the valley between peaks (see Figure 7.10).
The peaks are cleaved by a line dropped from the lowest point of the valley perpendicular to the baseline (perpendicular drop).
Integration for the first peak of the mountain range is from the emergence point to the first perpendicular drop. A middle peak
is integrated from its left perpendicular drop to its right perpendicular drop. The last peak is integrated from its left
perpendicular drop to the return to threshold.

Perpendicular
Drop

Peak Peak
Area Area
#1 #2

Fig. 7.10. Multiple Peaks

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7.4.5 Tangent skim

Whenever a bump or small peak appears on the trailing side of a much larger peak, the smaller peak can be cleaved from the
larger by a technique called tangent skim (see Figure 7.11). If a valley is present between the two peaks, a tangential line is
drawn from a point of the falling curve near the bottom of the valley before the smaller peak to the first point on the falling
curve after the smaller peak that would also be tangential. Tangent skimming is automatically chosen when the ratio of peak
heights from the bottom of the valley between them exceeds ten.

Tangent
Skim

Fig.7.11. Tangent Skim

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

7.4.6 Baseline drift

Baseline drift happens when the signal flat-lines at a level outside the threshold. Flat-lining is detected with the signal’s value
and its first derivative. If the derivative falls to 0 and the signal is outside the threshold, the baseline is re-anchored when this
condition exceeds 100 consecutive signal samples (one second). The peak detection threshold is now relative to the new
baseline. The baseline can shift higher or lower.

7.5 Time coded functions

A Time Coded Function (TCF) defines an action performed at a specified time in an analysis. The TCF parameters are the
specifications available to the function. TCFs are added to analyses, methods or sequence scopes when creating an analysis
using the Local User Interface (LUI) or Remote Client. Results of some TCFs may not be reported until the end of an analysis.

Entering a TCF in an analysis, method or script defines an action to perform (e.g. Valve ON) at specific time in the analysis. The
following table identifies the TCFs for each scope.

TCF Analysis Method Sequence

Autozero X
Component MinMax X
Component RT (EZ Peak) X
Digital Input Check X X
Do Next If X X
Peak Threshold X
Pressure Check X X
Pressure Control X X
Pressure Default X X
Script Control X X X
Skip Next If X X
Stream Step X
Temperature Check X X
Temperature Control X X
Temperature Default X X
Unknown Peak X
Valve On X
Valve Off X

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The following paragraphs list the functions (alphabetically) with descriptions. They include tables with the Parameter name,
acceptable Range and Units of measure values. This information is intended as a guide in properly configuring TCFs.

7.5.1 Auto zero

Auto zero supplies an offset which brings the raw baseline signal down to its most sensitive range. An offset voltage setting
that is out of range will set an indicator.

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Detector Channel Available from configuration N/A

7.5.2 Component min/max

There is only one TCF required for min/max detector signal integration. All timings are relative to the time offset.

The sequence offset + the Time offset + the gate value must be > 0 < the cycle time or 14400 (whichever is
smaller).

The min/max TCF has the following parameters:

Parameter Range Units

Time offset 0 to 14400 Seconds
Start Of Baseline Gate: Begin Time -14400 to 14400 Seconds
Start Of Baseline Gate: End Time -14400 to 14400 Seconds
End Of Baseline Gate: Begin Time -14400 to 14400 Seconds
End Of Baseline Gate: End Time -14400 to 14400 Seconds
Start Of Integration Gate: Begin Time -14400 to 14400 Seconds
Start Of Integration Gate: End Time -14400 to 14400 Seconds
End Of Integration Gate: Begin Time -14400 to 14400 Seconds
End Of Integration Gate: End Time -14400 to 14400 Seconds
Crest Gate: Begin Time -14400 to 14400 Seconds
Crest Gate: End Time -14400 to 14400 Seconds
Peak Type Positive, Negative, Tangent, Calculated N/A

7.5.3 Component RT (EZ Peak)

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Component Available from configuration N/A
Detector Available from configuration N/A
Peak Type Positive, Negative, Tangent, Calculated N/A
Crest Begin -14400 to 14400 Seconds
Crest End -14400 to 14400 Seconds

7.5.4 Digital input check

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Digital Input Available from configuration N/A
Action Ignore, Report, Skip, Abort N/A

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7.5.5 Do next if…

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

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Stream Available from configuration N/A

7.5.6 Peak threshold

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Threshold 1 to 99 (default 6) Numeric
Detector Channel Select from configuration N/A

7.5.7 Pressure check

Pressure check, which is part of the Electronic Pressure Controller, allows for pressure zone variances. A pressure value outside
the pressure limit range causes an alarm.

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Zone Available from configuration N/A
Action Ignore, Report, Skip, Abort N/A
Low Limit 0 to 100 PSI
High Limit 0 to 100 PSI

7.5.8 Pressure control

This feature of the Electronic Pressure Controller allows review or modification of the pressure zone set point and ramp rate.

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Zone Available from configuration N/A
Setpoint 0 to 100 PSI
Ramp Rate 0 to 1000 PSI/min

7.5.9 Pressure default

Returns zone to Setup Tab isobaric setpoint.

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Zone Available from configuration N/A

7.5.10 Script control

This allows running a programmed script at a defined time into the analysis, method or sequence. A script must be created
prior to adding this TCF.

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Script Name Available from configuration N/A

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7.5.11 Skip next if…

This allows skipping the next time-coded function when this stream value equals the stream number entered in the scheduler.
This function allows skipping a TCF on a particular stream, usually because that TCF does not apply to that stream.

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Stream Available from configuration N/A

7.5.12 Stream step

This 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.

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds

7.5.13 Temperature check

This evaluates temperature zone variances. A temperature value outside the zone limits initiates an action in response.

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Zone Available from configuration N/A
Action Ignore, Abort, Skip, Display N/A
Low Limit 0 to 1100 °C
High Limit 0 t0 1100 °C

7.5.14 Temperature control

This allows review or modification of the temperature zone set point and ramp rate at a specific time during the analysis.

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Zone Available from configuration N/A
Setpoint 0 to 1100 °C
Ramp Rate 0 to 1100 °C/min

7.5.15 Temperature default

This returns zone temperature to Setup Tab isothermal setpoint.

Parameter Range Units

Description User definable Text
Time Offset 0 to 14400 Seconds
Zone Available from configuration N/A

7.5.16 Unknown peak

This searches for an Unknown Peak in the specified area.

Parameter Range Units

Description User definable Text
Time Offset Begin 0 to 14400 Seconds
Time Offset End 0 to 14400 Seconds
Detector Channel Available from configuration N/A
Peak Type Positive/Negative N/A

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7.5.17 Valve on and valve off

Valve On and Valve Off control the operation of a selected valve. Each sequence should contain the valve on and off functions
required for the selected stream tap. The first “Valve On” time in an analysis is used in all reports as the “Sample Inject” time.

Parameter Range Units

Description User definable Text
Time offset 0 to 14400 Seconds
Valve Name Available from configuration N/A

7.6 Air purging

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.

7.6.1 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, 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.

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 60079-2:2001.

Purge time depends on the application. Refer to the analyzer label or Data Package for specific analyzer purge time.

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7.6.2 X purge operation

While X Purge (see Figure 7.12) 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.

OVERRIDE
PUSH BUTTON

Figure 7.12. 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.

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.

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7.6.3 X purge override option

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.

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 7.12) to apply power to the analyzer.

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.
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.

7.6.4 X purge override contacts

The X Purge housing has terminals for connecting an override jumper. 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.

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7.7 Remote client

The analyzer’s Remote Client provides remote access, across an Ethernet network, to a specified analyzer (see Figure 7.13). The
Remote Client functions are unique and are only applicable to the analyzer. The Remote Client also provides access to the
Report Viewer program (which is only in version 3 and earlier PGC5000 analyzers). This section provides basic guidelines
applicable to this Remote Client.

Fig. 7.13. Remote Client

Refresh the Remote Client screen to ensure all settings are displayed on the remote screen. Cycling
between tabs accomplishes this update.

For proper operation, ensure the Remote Client version number matches the version running on the analyzer (see Figure 7.14).
Locate the version number by selecting the ‘About’ window on the top menu bar of the Remote Client and on the Setup>
Master Controller> SBC Config sub-tab.

V4.2.98.1

Fig. 7.14. Version Number Comparison

7.8 Remote communications overview

The analyzer allows for communications (data transfer) by Ethernet TCP/IP. The analyzer can act as a Modbus Slave and send
data to a Modbus Master. Mapping of Modbus data is performed by using a Comma Separated Value file (.csv). The analyzer
can also send data to a STAR Server or an OPC Server.

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7.8.1 Subscriber tab configuration

Before the analyzer can communicate externally with a MODBUS client, OPC Server or STAR server, the Master Controller must
have a valid IP address entry in its Subscriber tab. This allows transmission of data to the Gateway and the OPC Server program.
The analyzer is configured to report to the OPCC Server as an OPC device type when added in the Subscriber tab (see Figure
7.15).

Fig. 7.15. Subscriber OPC Example

7.8.2 MODBUS overview

MODBUS is a communications protocol used with programmable logic controllers (PLCs). It is a de facto standard
communications protocol in industry, and is a commonly available means of connecting industrial electronic devices.
MODBUS allows for communication between many devices connected to the same network; for example a system that
measures temperature and humidity and communicates the results to a computer. MODBUS is often used to connect a
supervisory computer with a remote unit in supervisory control and data acquisition (Master/Slave).

7.8.3 PGC5000 MODBUS configuration

The MODBUS interface can be either TCP/IP or RS232, directly from the analyzer or from the Gateway server. The MODBUS
software translates data from the ABB analyzer system into the MODBUS RTU format recognizable by standard DCS gateway
devices.

It is beyond the scope of this manual to describe the MODBUS protocol. Consult your DCS documentation
for explanation of concepts and terminology that may be unfamiliar to you.

The MODBUS protocol provides a set of rules which allows data to be passed between any two compatible devices. The
protocol defines how the data is to be transferred but does not define the contents of the data. In order for the analyzer/DCS
interface to operate, both the Gateway (with MODBUS software) and the DCS must be configured to define the functions to
implement and the corresponding data addresses to use. The MODBUS interface provides analytical composition data from the
analyzer system to the DCS and various status information (e.g. data validity, analyzer and new data availability). The MODBUS
interface also accepts limited analyzer control functions from the DCS (e.g., request for calibration, stream activation, etc.).

The analyzer creates data tags supported by MODBUS interface and the OPC Server. The tags not added to the local MODBUS
include the string tags ANALYSIS_NAME, COMPONENT.NAME, etc. (shown below) as these strings do not fit within the MODBUS
structure of 16-bit data registers.

A .csv file used to map data points must be identical to the one used by the MODBUS client connected to the OPC Server. Each
line of the .csv file contains at least three entries, (tag name, MODBUS slave address, MODBUS point address). The MODBUS

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point address is a five-digit number which implicitly defines the MODBUS data type based on the most significant digit as
follows:

00001-09999 STATUS COILS

10001-19999 INPUT STATUS
30001-39999 INPUT REGISTERS
40001-49999 HOLDING REGISTERS

The MODBUS interface differentiates among the four different types of MODBUS data.

The MODBUS map is configured to overlay addresses. Two different data tags can map to the same address, but one tag cannot
map to two different addresses. If the latter is implemented, only the first tag in the map is updated. Most of the data tags
from the instrument are discrete indications mapped to either input coil or status coil addresses. Tags used for control purposes
must be mapped to a status coil address since the MODBUS master cannot write to an input coil. Analog values associated with
a component measurement, as well as temperatures, pressures, and set points available from the DTC and EPC, may be
represented to the MODBUS in one of four formats as described below:
• The integer portion of the analog value will be placed in a single MODBUS register.
• The IEEE floating-point format is used to store the value in two consecutive MODBUS registers.

The PGC5000 analyzer is a Big-Endian machine. The MODBUS Client operates on a Little-Endian machine,
meaning the most-significant and least-significant registers are reversed.

• In the Scaled0-9999 and Scaled0-4095 MODBUS data types, the analog value is scaled between two specified limits
and represented as a percentage of either 9999 or 4095 within a single MODBUS register.
• Specify the register format for each tag by appending the keyword followed by the optional scaling limits such as:
• Analyzer.Schedule.Process Stream.Propane.Concentration,01,31000,INTEGER
• Analyzer.Schedule.Process Stream.Methane.Concentration,01,31001,FLOAT
• Analyzer.Schedule.Process Stream.Hexane.Concentration,01,31003,Scaled0-9999,0.0,100.0
• Analyzer.Schedule.Process Stream.Isobutane.Concentration,01,31004,Scaled0-4095,0.0,100.0

The following analog tags are always represented as INTEGER values:

• Analyzer.Oven.DTC1.ZonesActive
• Analyzer.Oven.DTC2.ZonesActive
• Analyzer.Oven.EPC.ZonesActive
• Analyzer.Schedule.Stream.CycleTime
• Analyzer.Schedule.Stream.LastReportType
• Analyzer.Schedule.Stream.Component.UnitsOfMeasure

The "Analyzer.Schedule.Stream.SampleTime" tag is represented in two different formats by appending the keyword
"TIMESTAMP1" or "TIMESTAMP3" to the .csv entry. The "TIMESTAMP1" format uses a single MODBUS register containing the
hours in the high byte and the minutes in the low byte. "TIMESTAMP3" uses three registers with the first containing the hours,
the second containing the minutes, and the third containing the seconds.

The "Analyzer.Schedule.Stream.NewDataReady" tag is set whenever data is received for the specified stream. It is reset by the
MODBUS master prior to the next analysis becoming available or configured to automatically reset after a configured number
of seconds. To configure the tag to reset automatically, append a delay counter (in seconds) to the .csv entry.
• Example: Analyzer.Schedule.Stream.NewDataReady,01,11002,5. This results in the ‘NewDataReady’ bit to reset after
five seconds.

7.8.4 MODBUS slave communication

The Master Controller has the ability to run as a MODBUS slave for communication to Control Systems. This ability allows a DCS
to connect through Ethernet TCP/IP and retrieve MODBUS data on demand, directly from the Master Controller.
The communication connection is established by using the assigned TCP/IP (Port 502) address of the Master Controller and a
“MODBUS.csv“ file created by the user. The “MODBUS csv” file is created using the Client Configurator software program. The

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configured MODBUS .csv file is transferred to the analyzer’s operating system memory my means of File Transport Protocol
(FTP). The Remote Client includes an FTP program (Report Viewer).

7.8.5 Client configurator

Both the Gateway and the Master Controller use the Client Configurator software to map analyzer points to MODBUS coils and
registers. The .csv file used on the Gateway is modbus_client.csv and on the GC is MODBUS.csv. When creating the files using
the Client Configurator, the correct Protocol format option is selected at the top of the Client Configurator.

To create the modbus_client.csv file for the Gateway, the MODBUS option is selected. To create the MODBUS.csv file select the
PGC5000 option.

The Client Configurator’s main display is the Configuration Client (see Figure 7.16). From this screen and its subordinates you
can perform the entire MODBUS configuration. The 2.1.0.2 or greater version of the ABB Client Configurator includes specific
files needed for the Master Controller.

Fig. 7.16. Version 2.1.02 ABB Client Configurator

The Client Configurator is a part of the STAR Software suite. For complete information and instructions of setup and use, refer
to the latest STAR Data Management System (DMS) Operating Instructions.

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1. Create the MODBUS.csv file using the ABB Client Configurator (see Figure 7.17).

Fig. 7.17. MODBUS Configurator Example

Configuration information requires the following name(s):

• Master Controller
• Oven Name(s)
• Schedules
• Streams
• Component

2. Save the csv file on the Configurator system’s local PC drive or flash unit.
3. The csv file contains all of the information for the Control system (see Figure 7.18).

Fig. 7.18. CSV File Example

Transfer the file to the Master Controller. Reference the STAR Data Management System (DMS) Operating Instructions for
additional information.

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The Master Controller provides direct MODBUS TCP connection.

7.8.6 OPC communication

Analyzer Tag names used by the OPC Server represent data from the analyzer. For any given Master Controller, there may be
multiple analysis streams and/or components. The tag list defines the names used and the types of data available for the
device.

7.9 Input/output options

The analyzer offers input/output (I/O) options internal and external to the Master Controller. The local input/output is
available on the Single Board Computer PCB. Additional input/output modules can be mounted internally on the DIN rail in the
Master Controller.

An external input/output option is available if a very large number of inputs and/or outputs is needed. This external enclosure
also accommodates stream switching valves, if needed.

The input/output options are fully integrated with the analyzer’s local and remote user interfaces for direct operation and
programming.

7.9.1 Local input/output option

The local input option connections are Purge Air and Purge DPS (see Figure 7.18). These alarms are not customer configurable.

The local output option connections are located on the Single Board Computer (SBC) PCB. These connections provide the
primary analog and digital inputs and outputs.

7.9.2 Local output option setup

When the local output option is configured, the I/O Setup Tab displays the screen shown in Figure 7.19.

Fig. 7.19. Local I/O Setup Display

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

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Figure 7.20 illustrates the local output display. The editable areas are:
NAME - reference name, used for the button name
RANGE LOW - analog output low limit
RANGE HIGH - analog output high limit
COMPONENT - configured component dropdown list
SET VALUE - user set value, used to test the module

Fig. 7.20. Local Output Display

7.9.3 Internal input/output option

The Master Controller allows the placement of optional Wago input/output modules internally. This Internal input/output
option is mounted in the Master Controller in front of the Single Board Computer (see Figure 7.21) and accessed through the
front door.

Location of Input/Output Modules

Fig. 7.21. Location of Internal Input/Output Option

The internal I/O option connects to the SBC CAN Interface Card via an electrical cable. Configuration of the option is completed
and tested at the factory prior to shipment. The I/O option contains one Control Module, one End Module, and up to 18
input/output modules. The input/output modules are referred to in the manual and analyzer as Wago modules. The following
input/output modules are available (color code at the top of each module indicate the type of module):
• 2 channel analog output, 4 to 20 mA (blue)
• 4 channel analog output, 4 to 20 mA (blue)
• 4 channel analog output, ±10 V, 0 to 10 V (blue)
• 2 channel analog input, AC/DC 0 to 10 (green)
• 2 channel analog input, 4 to 20 mA (green)
• 4 channel digital output, 24 V, with low-side switching (red)
• 4 channel digital output, 24 V, with high-side switching (red)

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• 2 channel relay output, AC 230 V, DC 30 V (red)

• 4 channel digital input, DC 5 V, with high-side switching (yellow)
• 4 channel digital input, 24 V (yellow)

The Control Module (grey) is at the left end of the string of Wago modules and the End Module (grey) is at the right end. A high
quantity of Wago modules may require additional Control and End modules, which will be configured at the factory, as needed.

When the button for a specific I/O module is selected from the Function Select list, the appropriate Module Configuration
display appears (see Figure 7.22 shows the Digital I/O). Individual I/O channels are listed on the button below the I/O module
name. The button names can be edited for reference.

Fig. 7.22. Internal I/O Display

Input/output modules are shown in the following paragraphs, with the editable areas noted.

7.9.4 Digital output

Figure 7.23 illustrates the digital I/O display, with a digital output channel selected. The editable areas are:
NAME - reference name used for the button name
SET STATE - toggle switch used to set input On or Off
GROUP - indicator group assignment
NAME - assigned indicator name with the group

Fig. 7.23. Digital Output Display

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7.9.5 Digital input

Figure 7.24 illustrates the Digital I/O display, with a digital input channel selected. The editable areas are:
NAME - reference name used for the button name
STATE - echoes the installed module’s state (Red or Green indication is dependent on installation specifications)
FUNCTION - selected function (affected by state change)
ASSIGNMENT - assigned schedule for the selected function

Fig. 7.24. Digital Input Display

7.9.6 Analog input

Figure 7.25 illustrates the analog I/O display, with an analog input channel selected. The editable areas are:
NAME - reference name, used for the button name
RANGE LOW - analog input low limit
RANGE HIGH - analog input high limit

Fig. 7.25. Analog Input Display

7.10 External input/output option

The external I/O (EIO) option is housed in a separate enclosure and may include stream-switching valves. It communicates with
the Master Controller through a fiber optic CANbus communication link.

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8 Operator troubleshooting
This section contains operator troubleshooting for the PGC5000 analyzer Master Controller and attached ovens. For
maintenance, service and in-depth troubleshooting refer to PGC5000 Service Instructions SI/PGC5000.

8.1 Common issues

Most problems are the result of incorrect system and subsystem installations. To troubleshoot an installation problem,
perform the following checks in the order given:
1. Check all cable and power connections in the Master Controller, attached ovens, and optional equipment.
2. Verify all cables and boards are securely plugged in to the appropriate Master Controller.
3. Verify the Master Controller is configured properly and completes the Power On self-test.
4. Remove all options, including USB drives, one at a time, checking the effect on the Master Controller.
5. Disconnect the power, wait 60 seconds, reconnect the power and let the system restart.

If the Master Controller or oven does not power on, check for power related issues including loss of external power, fusing, and
breaker boxes for possible resolutions.

The Master Controller and oven may power on, but the schedule will not start until the oven has met the minimal temperature
requirements established in the Setup Tab. Refer to the Power Failure setup in the Schedule Tab section for more information
on restarts after power failure.

8.2 Oven LED indicators

The oven has three Light Emitting Diodes (LEDs) located on the left front of each unit. These LEDs indicate the current status of
the oven.
• If the LEDs are not lighted, check power to the unit.
• If the top LED is GREEN and flashing the system is initializing.
• For all other instances use the table below.

LED Red Amber Green

Top Oven Idle Future Use Executing Analysis
Middle DTC Malfunction Low Oven Air and/or Carrier Gas Alarm DTC Operation Normal
Bottom FID/FPD Flame Out Future Use FID/FPD Flame lit

8.3 Indicator troubleshooting procedures

Most system errors are identified by the Condition Monitoring System, resulting in indicator activation. If an indicator is placed
in one or more of the user defined Status Tab scopes, it reflects in the Master Rollup Indicator located at the bottom left corner
of the Local User Interface (LUI) or Remote Client display (see Figure 8.1).

Master Rollup Indicator

Fig. 8.1. Master Rollup Indicator

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Use the following steps to identify and correct issues.

1. If the Master Rollup Indicator is RED, YELLOW or BLUE (triggered), select the Home Tab and note the running analysis
button.
2. If an analysis button indicator light is not GREEN, select the Analysis button, then the Status sub-tab; locate the triggered
indicator(s) and identify the source and correct the issue(s). Refer to the Status Indicator table in this section for issue
resolution.
3. If all analysis button indicators are GREEN, go to the Status Tab. Check the scope sub-tabs (located at the top of the
display) for triggered indicators.
4. Select the scope displaying the triggered indicator and locate the activated indicator(s). Refer to the Status Indicator table
in the next paragraph for issue resolution.

Some Status Scopes have multiple sub-scopes to choose from or may require using the ‘Page Down’ icon
to view all indicators. If not assigned to a scope, ‘Triggered’ indicators on the Status Tab, (displaying red,
yellow or blue) are not reflected at the Master Rollup Status Indicator. It maintains a green (good) status.

Correct an issue by removing the condition which triggered the indicator. This includes removal and replacement of PCBs,
adjusting parameter limits or simply acknowledging the indicator by using the reset button. If the triggering condition still
exists, the indicator may not clear after pressing the Reset button.

8.4 Status indicators

The Status Indicator functions are an essential part of the User Interface of the analyzer (see Figure 8.2).

Fig. 8.2 Status Indicators

The Status Indicator table lists all available indicators under the Status Tab>All sub-tab. The table describes the triggering
condition and resolution to clear the condition. Where more than one indicator may be present a range is given; e.g. (1-4).
Refer to the glossary section for abbreviation explanations. The Reset column displays the means of reset; the AOC (Absence of
Condition) is the most common. The Source column identifies the group and most likely origination of the triggering condition.

Indicator Issue Resolution Reset Source

Master Controller Purge fails for this zone Correct purge issue. Absence of MC
(MC) - Purge Fail Condition (AOC)
MC - Power Fail MC resets from power Reset Indicator at Status Tab. Manually MC
failure
Comm Failure Oven Controller (OC) # Check power to board. Check CAN AOC MC
Oven (1-4) Heartbeat fails connections. Check config files.

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Indicator Issue Resolution Reset Source

Network Comm Communication to an Active Ensure Subscriber communication path AOC MC
Failure Subscriber fails is complete, IP address correct and the
subscriber is powered on. Check routing
tables if applicable.
POST Failure Power On Self-Test fails Cycle power. If POST error persists, note AOC MC
error and contact ABB Support.
DTC Failure DTC board indicates a fault; Check power to board and CANBus AOC Oven
communication with the connections. Follow DTC card check
DTC board fails procedures in Service Instructions.
EPC Failure EPC board indicates a fault Check power to board and connections. AOC Oven
or communication with EPC Follow EPC card check procedure in
board fails Service Manual.
Extended I/O Error Condition detected on Refer to external I/O documentation. AOC Oven
Fault the External I/O controller
Oven - HighTemp Oven temperature out of Check High limit from Setup tab. Adjust AOC Oven
range (high) as necessary.
Oven - LowTemp Oven temperature out of Check Low limit setting from Setup tab. AOC Oven
range (low) Adjust as necessary.
Oven - Purge Fail Purge fails for this zone Correct purge issue. AOC Oven
Software Error Rollup of software faults at Check Oven Group indicators to refine AOC Oven
the OC search.
DTC Zone (1-3) Zone 1 Controller card fails Replace Card. AOC OVEN.DTC1
Hardware Error Rollup of hardware Check the DTC and DTC Zone Indicators. AOC OVEN.DTC1
diagnostics at the DTC
Software Error Rollup of software faults at Check the DTC and DTC Zone Indicators. AOC OVEN.DTC1
the DTC
T-Rating Conflict DTC T-Rating does not Possible Configuration Error, contact AOC OVEN.DTC1
match As-Built T-Rating ABB for more information.
High Temperature Temperature out of range Check setting at Setup Tab>Oven>DTC# AOC DTC Zone
(high) Button. Adjust as needed.
Low Temperature Temperature out of range Check setting at Setup Tab>Oven>DTC# AOC DTC Zone
(low) Button. Adjust as needed.
Out of Control Temperature deviates > Check analysis temperature control TCF AOC DTC Zone
±10° from setpoint settings. Check Zone indicators &
Diagnostic Displays.
Over temp Temperature exceeds Max Defective temperature sensor. Contact AOC DTC Zone
limit for T-Rating ABB for more information.
Ramp Out of Temperature deviates > Check analysis temperature control TCF AOC DTC Zone
Control ±10° from setpoint during settings. Check Zone indicators &
(Future Use) Temperature Ramp Diagnostic Displays.
Temperature Temperature Measurement From the Setup Tab check the AOC DTC Zone
Sensor Fault out of valid range temperature settings. Replace
temperature sensor if needed.
DTC Digital Input Low oven purge air Check purge pressure setting at ovens AOC Ovn#DTC#.1
1 pressure. Open on alarm. front panel gauge. Adjust as necessary.
Check instrument air supply pressure.
Check oven purge pressure switch.
DTC Digital Input Optional Hardware inputs; Verify option input device is function AOC Ovn#DTC#.2
2-14 Open on alarm properly. -14
Common Alarm Open input overrides the Verify proper operation of common AOC Ovn#.DTC#.
Relay Override common alarm output alarm override switch. D1
DigIn 16

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PGC5000
PGC5000 Series Operating Instructions 8 Operator Troubleshooting

Indicator Issue Resolution Reset Source

Hardware Error Rollup of hardware Check the EPC and EPC Group Zone AOC Ovn#.EPC
diagnostics at the EPC indicators.
Software Error Rollup of software faults at Check the EPC and EPC Group Zone AOC Ovn#.EPC
the EPC indicators.
EPC Zone One(1- Rollup of Zone (1-10) Check EPC Zone specific indicators and AOC EPC Zones
10) Indicators correct as necessary.
Pressure Sensor Defective pressure sensor Replace Pressure sensor if needed. AOC Ovn#.EPC.PZ
Fault .#
Low Alarm Pressure out of range (low) Adjust pressure zone's low limit under AOC Ovn#.EPC.PZ
the Setup Tab. Verify supply pressure to .#
the zone. Correct as necessary. Replace
EPC sensor or solenoid valve as
necessary.
High Alarm Pressure out of range (high) Adjust pressure zone's high limit under AOC Ovn#.EPC.PZ
the Setup Tab. Replace EPC sensor or .#
solenoid valve as necessary.
Ramp Out of Pressure deviates > ±x psi Check analysis pressure control TCF AOC Ovn#.EPC.PZ
Control from setpoint during settings. Check Zone indicators & .#
Pressure Ramp Diagnostic Displays.
Out of Control Pressure deviates > ±x psi Check analysis pressure control TCF AOC Ovn#.EPC.PZ
from setpoint settings. Check Zone indicators & .#
Diagnostic Displays.
Software Error Rollup of software faults at Check indicators and Diagnostic AOC Ovn#.DTM#
the Det Amp Displays at Detector Amplifier.
Hardware Error Rollup of hardware Check indicators and Diagnostic AOC Ovn#.DTM#
diagnostics at the Det Amp Displays at Detector Amplifier.
Detector Fault Rollup of channel Check Diagnostics Display on Status AOC Ovn#.DTM#.
diagnostics Sub-tab. TCD.#
Flame Out FID or FPD flame not Check utilities, igniter including AOC Ovn#.DTM#.
detected. fuel, burner, connection verify FID/FPD#
flows, burner air.
Autoignite Limit Retry of Automatic Ignites Check utilities, igniter including fuel, AOC Ovn#.DTM#.
has been exceeded burner, connection verify flows , burner TCD.#
air.
Autozero Conflict Autozero attempted during Move autozero TCF to a time into When reported. Ovn#.DTM#.
peak measurement analysis when a component is not being TCD.#
measured.
Offline Stream in offline state Information Only. AOC Stream
(Calibration, Validation,
'Stream Name")
Low Concentration is below Low Information Only. Adjust Limits under When reported Component
Concentration Setpoint but above Low- the Setup tab as needed.
Low Setpoint
Low–Low Concentration is below Low- Information Only. Adjust Limits under When reported Component
Concentration Low Setpoint the Setup tab as needed.
High Concentration exceeds the Information Only. Adjust Limits under When reported Component
Concentration High Setpoint but below the the Setup tab as needed.
High-High Setpoint
High–High Concentration exceeds the Information Only. Adjust Limits under When reported Component
Concentration High-High Setpoint the Setup tab as needed.
Response Factor Measurement out of range Information Only. Adjust Limits under When re- Component
(RF) Low Limit (low) (% of deviation from the Setup tab as needed. calibrated
previous RF)

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Indicator Issue Resolution Reset Source

RF High Limit Measurement out of range Information Only. Adjust Limits under When re- Component
(high) (% of deviation from the Setup tab as needed. calibrated
previous RF)
Retention Time Retention time exceeds the Information Only. Adjust Limits under When reported Component
High High Setpoint the Setup tab as needed.
Retention Time Retention time is below Low Information Only. Adjust Limits under When reported Component
Low Setpoint the Setup tab as needed.
Validation Measurement out of range Information Only. Adjust Limits under When re- Component
(% of deviation from known the Setup tab as needed. validated
standard)
Missing No peak found matching a Information. Edit analysis as needed. When reported Analysis
Component component defined in the
method
Unknown Peak detected in the See Unknown Component TCF. When reported Analysis
Component analysis and not defined in
the method
Sample Flow Lost Future functionality: Sample Restore Sample flow. Replace sample AOC Script
flow is lost flow switch as necessary.
Script Error Script fails to operate within Use Program Tab to edit script to meet When cleared in Analysis
parameters existing criteria of the system. script

Analysis Aborted 1. Analysis does not 1. Check Pressure, Temperature and/or AOC. Analysis
complete analysis due to Digital Inputs. Correct problem
temperature, pressure accordingly.
and/or digital input 2. User controlled.
programmed command. 3. Check oven related indicators for
2. User intervention using more information.
Stop Now command.
3. Related oven issues.
Invalid Analysis Analysis failed validation 1. From Analysis Tab edit Analysis to AOC Analysis
meet requirements.
2. User controlled.
DigIn Check TCF Programmable Input See Digital input TCF. AOC Script
checks.
Prsr Check TCF Pressure Check failed See pressure check TCF. AOC Script
Offline Schedule Offline: Oven is Information Only. Resets when oven AOC Schedule
powered down power is restored.
Idle Schedule Stopped or paused Information Only. AOC Schedule
Calibrating Schedule running an Information Only. AOC Schedule
analysis on Calibration
Stream
Validating Schedule running an Information Only. AOC Schedule
analysis on a Validation
Stream
Maintenance Schedule set in Information Only. AOC Schedule
Maintenance State
Compile Error Syntax errors in Script From Program Tab check script syntax. Next Run Script
Runtime Error Script encountered error From Program Tab check script objects. Next Run Script
during execution
Script Not Found Script specified in TCF Ensure Script is in the Script library. Next Run Script
cannot be located
Missing Report Script can’t find the report Edit the analysis under the Analysis Tab. Next Run Script
to be modified Script TCF must have a time greater
than the analysis cycle time.

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PGC5000
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Indicator Issue Resolution Reset Source

Run Time Script exceeded allotted From Program Tab, Check script logic, Next Run Script
Exceeded runtime increase Max Runtime variable.
User Error #1 - 10 Script Asserts Error #1 - 10 User programmable indicators. Next Run Script
Information only.
Node Loss Device no longer reachable Check cables & communication path on AOC SHS
on SHS CAN bus SHS CANBus
New Node Device added to SHS CAN Information Only. AOC SHS
bus
Address Conflict Two devices with same Check SHS Node Id on device. AOC SHS
address on SHS CANbus
Invalid State Combination of valve states Correct Valve conflicts. AOC DVM
not allowed
Vol Flow Low Low Volumetric Flow lower than Information Only. AOC ARV
Low Low Limit
Vol Flow Low Volumetric Flow lower than Information Only. AOC ARV
Low Limit
Vol Flow High Volumetric Flow exceeds Information Only. AOC ARV
High Limit
Vol Flow High Volumetric Flow exceeds Information Only. AOC ARV
High High High Limit
Pressure Low Low Pressure lower than Low Information Only. AOC ARV
Low Limit
Pressure Low Pressure lower than Low Information Only. AOC ARV
Limit
Pressure High Pressure exceeds High Limit Information Only. AOC ARV
Pressure High Pressure exceeds High High Information Only. AOC ARV
High Limit
Temp Low Low Temperature lower than Information Only. AOC ARV
Low Low Limit
Temp Low Temperature lower than Information Only. AOC ARV
Low Limit
Temp High Temperature exceeds High Information Only. AOC ARV
Limit
Temp High High Temperature exceeds High Information Only. AOC ARV
High Limit
Vol Flow Low Low Volumetric Flow lower than Information Only. AOC FastLoop
Low Low Limit
Vol Flow Low Volumetric Flow lower than Information Only. AOC FastLoop
Low Limit
Vol Flow High Volumetric Flow exceeds Information Only. AOC FastLoop
High Limit
Vol Flow High Volumetric Flow exceeds Information Only. AOC FastLoop
High High High Limit
Pressure Low Low Pressure lower than Low Information Only. AOC FastLoop
Low Limit
Pressure Low Pressure lower than Low Information Only. AOC FastLoop
Limit
Pressure High Pressure exceeds High Limit Information Only. AOC FastLoop
Pressure High Pressure exceeds High High Information Only. AOC FastLoop
High Limit
Temp Low Low Temperature lower than Information Only. AOC FastLoop
Low Low Limit
Temp Low Temperature lower than Information Only. AOC FastLoop
Low Limit

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Indicator Issue Resolution Reset Source

Temp High Temperature exceeds High Information Only. AOC FastLoop
Limit
Temp High High Temperature exceeds High Information Only. AOC FastLoop
High Limit
Loop DP Low Low Loop Differential Pressure Information Only. AOC FastLoop
lower than Low Low Limit
Loop DP Low Loop Differential Pressure Information Only. AOC FastLoop
lower than Low Limit
Loop DP High Loop Differential Pressure Information Only. AOC FastLoop
exceeds High Limit
Loop DP High High Loop Differential Pressure Information Only. AOC FastLoop
exceeds High High Limit

The # is used in place of numbers to eliminate repeats in multiple card and oven systems. "Information
Only" signifies the set indicator is activated in response to the setup criteria. It does not necessarily
identify a fault.

8.5 Diagnostic displays

Diagnostic displays (indicator boxes) are displayed from the Setup Tab>Status sub-tab (see Figure 8.3). The associated boxes,
when filled (black), indicate the named action is active. Not all indicators boxes denote issues with the system, but they
represent processes in action.

Fig. 8.3. Diagnostic Display Example

The following table gives a resolution to the issue where applicable.

Source Group Issue Resolution

Missing Device Oven Board did not report to Oven Check power to board. Check CAN
Controller (OC) at startup. connections. Contact ABB.
Mismatched Device Oven Board identity does not match Contact ABB. Check config file.
config file.
Inaccessible Device Oven Board communication not Check CAN connection to Wago module.
viable. Refer to Wago documentation.
Duplicate Device Oven Two devices have the same CAN Correct by changing the node ID of one of the
node ID. duplicate boards. Refer to Service Manual

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PGC5000 Series Operating Instructions 8 Operator Troubleshooting

Source Group Issue Resolution

Extra Device Oven A board that responded to the Contact ABB for more information. Remove
OC is not listed in the system board.
configuration.
PIC Comm Error DTC# DSP and PIC supervisor have Replace DTC Digital card. Refer to the Service
(Hardware Error) stopped communicating. Manual.
Broken valve DTC# Valve failed start-up test. Check solenoid block cable. Replace faulty
(Hardware Error) solenoid if problem persists.
AC fault (Hardware DTC# DTC did not detect AC or power Check AC connections to DTC assembly. T-
Error) to heater failed. Rating faults can also cause this symptom.
Current out-of-range DTC# Internal power test failed. Check heater(s) to verify proper resistance.
(Hardware Error) Check heater connections.
CAN Node Not Found DTC# Device did not communicate Check board LEDs for error. Refer to the
with OC or go online. Service Manual.
Lost CAN Heartbeat DTC# Device stopped communicating. Check board LEDs for error. Check CAN bus.
Refer to the Service Manual.
Code Download Error DTC# Failed to send executable code Check board LEDs for error. Refer to the
to device. Service Manual.
Unexpected Heater DTC#.IsoThrml Internal power test failed. Can occur as a result of PIC supervisor
Voltage Oven shutdown or T-Rating failure. Verify heaters
and temperature feedback. Check for other
faults.
T-Rating mismatch DTC#.IsoThrml System information does not Contact ABB.
Oven match DTC internal setting.
Low Prsr-Air/Carrier DTC#.IsoThrml Air or carrier pressure switch is Verify proper air/carrier pressure and
Oven open. increase if necessary. If pressure is correct,
replace switch.
Temp Reading Invalid DTC#.IsoThrml DTC unable to read Replace temperature probe. Possibly replace
Oven temperatures. DTC Digital. Refer to the Service Manual.
CAN Node Not Found EPC Device did not communicate Check board LEDs for error. Refer to the
with OC or go online. Service Manual.
Lost CAN Heartbeat EPC Device stopped communicating. Check board LEDs for error. Check CAN bus.
Refer to the Service Manual.
Code Download Error EPC Failed to send executable code Check board LEDs for error. Refer to the
to device. Service Manual.
Barometric pressure EPC Status Only. Not Applicable.
low
Barometric pressure EPC Status Only. Not Applicable.
high
Ambient temperature EPC Status Only. Not Applicable.
low
Ambient temperature EPC Status Only. Not Applicable.
high
Zone plateau EPC.Carrier# Status Only. Not Applicable.
Zone In Band EPC.Carrier# Status Only. Not Applicable.
Zone Fail Zero EPC.Carrier# Status Only. Not Applicable.
Zone Enabled EPC.Carrier# Status Only. Not Applicable.
Can Node Not Found Ovn.DetAmp# Device did not communicate Check board LEDs for error.
with OC or go online.
Lost CAN Heartbeat Ovn.DetAmp# Device stopped communicating. Check board LEDs for error. Check CAN bus.
Refer to the Service Manual.

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Source Group Issue Resolution

Code Download Error Ovn.DetAmp# Failed to send executable code Check board LEDs for error. Refer to the
to device. Service Manual.
RTC Failure Ovn.DetAmp# RTC signal missing or irregular. Check CAN connections. Check power and
ground connections. Check chassis ground
connection to Oven Electronics Door.

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PGC5000 Series Operating Instructions 9 Scripting

9 Scripting
9.1 Introduction
The analyzer has programmatic control and calculation in addition to the built-in capabilities. The Program Tab provides the
means to customize analyzer operation to support most requirements (see Figure 9.1).

1 2

Fig. 9.1. Scripting Example

The scripting language has the capability to invoke a script upon the completion of an analysis providing any necessary
calculations to support, for example, BTU calculations. The scripting language supports invoking a script during or upon the
method or sequence completion. It also supports the means to invoke a script as a Time Coded Function (TCF) and as a
schedule entry.

1. The Program Tab icons control the system scripting actions. To edit the scripts use the script editing icons.

Icon Function Icon Function

Create new script Load existing script

Clear script Save and Save As

Run Script

2. The script editing icons are used to create and change script functions.

Field \ Icon Function Field \ Icon Function

Blank = OFF / Marked = Maximum time (in
ON. Runs continuously seconds) script has to
from startup of the complete execution
Master Controller before aborting
Add / Insert Line Cut line

Copy line Paste line

Delete line

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3. Script editing area.

The script editing area has two major sections:

1. The Line # section is a non-editable region containing auto-generated line numbers:
• When a statement is added, a line number is assigned and displayed.
• When a statement is moved, the line numbers are re-assigned.
• When a statement is deleted, the line numbers are re-assigned.

2. The statement section is the editing region contained the script:

• One statement is allowed per line.
• The script editor allows up to 999 statements.
• The script editor allows lines up to 99 characters.

The statement section has horizontal grid lines to separate statements. This allows scrolling in horizontal and vertical
directions. The control icons manipulate the script, the statements and the file.

9.2 Attachment to analysis elements

The scripting language supports the capability to have a script be invoked upon the completion of an analysis, a method, a
sequence or attached as a TCF providing any necessary calculations to support, for example, BTU calculations.

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

The time offset of a script, which script is an End-Of-Analysis type, does nothing more than to cause that script to be identified
as an End-Of-Analysis script by comparing its time offset with the Cycle Time.

The End-Of-Analysis scripts are simply executed in bulk, in no particular order. The following are End-of-Analysis scripting rules
for Analysis, Method scoped and Sequence scoped Scripts.
• All “Analysis Scoped” scripts are EOA scripts and must have an execution time greater than the maximum Cycle Time
of all contained Methods within that Analysis.
• Any scripts at the Sequence and Method scope are EOA scripts if their execution time exceeds the Cycle Time of the
longest (e.g.: maximum Cycle Time) Method. Scripts at Sequence or Method scope having an execution time less
than the longest Method's Cycle Time and greater than the Cycle Time of the Method that contains it are considered
being in error.
• A script at the Sequence or Method scope whose execution time is less than the Cycle Time of the Method that
contains it are allowed.

This type of script cannot perform the functions of an End-Of-Analysis script, because it runs within the
Cycle Time of the Method containing it. It will not be able to operate on or query the Analysis Report
because that report does not exist until after the Analysis has been completed.

• When an Analysis completes all EOA scripts executed irrespective of the execution time defined.
Example: An Analysis has two EOA scripts. Their execution times resolve to 181 and 182 seconds respectively. The
analysis contains a Method with a maximum Cycle Time of 180 seconds. In this scenario, there is no guarantee as to
which script gets executed first.

Line numbers are updated after a statement is added or deleted, if the statement is not the last statement in the script.

9.2.1 Creating a new script

1. Select the Program tab to open the script editor.
2. Select the Create New Script icon.
3. Enter the name in the area provided.
4. Press the Accept button and the script input page appears.
5. Enter lines of script (see Figure 9.1).

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PGC5000 Series Operating Instructions 9 Scripting

6. Enter MAX TIME and (if applicable) choose AUTO RUN.

AUTO RUN starts the script at initial Master Controller power up and runs the script continuously.

7. Save the script by clicking the Save icon.

9.2.2 Adding/running a script

1. Select the Analysis tab.
2. Open an existing analysis by selecting the Add icon.
3. Choose location and press the Next button.
4. Choose the analysis name and press the Next button.
5. Confirm selections by pressing the Accept button.
6. To select the script insertion point, select the button. (The script TCF appears below the selected button.)
7. Select the Add New icon.
8. Choose TCF – Sequence Scope and press the Next button.
9. Choose Script and press the Next button to continue.
10. Confirm selections by pressing the Accept button.
11. Select the newly added script button.
12. Select the Tabular Editor sub-tab.
13. Enter a DESCRIPTION and a TIME OFFSET.
14. Select SCRIPT NAME from the drop down list.
15. Select the Save icon or the Save As icon to save the modified analysis.

9.2.3 Adding a line to a script

The Insert Line icon adds a new statement to the script. When a line is added to the script, it is inserted above the current
selected statement. If no statement is selected, the statement is added after the last statement in the script. When adding a
statement to the script, the new statement becomes the currently selected statement. If a statement is inserted within the
script, the line numbers are updated.

To add a line (see Figure 9.1):

1. Select a line by pressing the number button on the left. The new line will be inserted above this line.
2. Select the Insert Line icon.
3. Insert the desired script in the blank line.
4. Select the Save icon to save the modified script, or select the Save As icon to save it as a new script.

9.2.4 Deleting a line

To delete a line from a script:
1. Select the line by pressing the number button on the left.
2. Select the Delete Line icon.
3. Select the Save icon to save the modified script, or select the Save As icon to save it as a new script.

9.2.5 Copying a line

To copy a line in a script:
1. Select the line by pressing the number button on the left.
2. Select the Copy Line icon.
3. Identify the location where you want to copy the line.
4. Select the line below the desired location by pressing the number button on the left.
5. When the blank line appears, select the Paste Line icon.
6. Select the Save icon to save the modified script, or select the Save As icon to save it as a new script.

9.3 Operators
The following operands are available for use in the scripting language:
Precedence “(“ Floating “<>” // Comparison
Precedence “)” Floating “<” // Comparison
Floating “=” // Assignment Floating “>” // Comparison

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Floating “+” Floating “<=” // Comparison

Floating “-“ Floating “>=” // Comparison
Floating “*” String “=” // Comparison
Floating “/” String “<>” // Comparison
Boolean “AND” String “+” //Concatenate
Boolean “OR” String “=” //Assignment
Floating “=” // Comparison

9.4 Alphabetic listing

9.4.1 ABSOLUTE VALUE function

Description: Returns the absolute value of a floating point expression.
Syntax: ABS ( fp )
Comments: fp is a floating point expression.

Example: 0010 A = ABS( A )

Takes the absolute value of the expression stored in variable A and assigns it to variable A.

9.4.2 ACTIVATE STREAM command

Description: Sets the state of a Stream to ONLINE. Makes all uses of the Stream in the Schedule ACTIVE.
Syntax: ACTIVATE_STREAM( stream$ )
Comments: stream$ is a string variable (or constant) containing the stream name of the stream to be activated.
Example: 0010 ACTIVATE_STREAM( “CalStrm1” )

9.4.3 ACTUAL RETENTION TIME function

Description: Returns the component’s actual retention time.
Syntax: ACTUAL_RT( component$ )
Comments: component$ is a string variable (or constant) containing the component name.
Example: 0010 A = ACTUAL_RT( “Methane” )
Gets the actual retention time of component named Methane and assigns to floating point variable A.

9.4.4 ANALYSIS NAME function

Description: Returns the method for the stream that has just been analyzed.
Syntax: ANALYSIS_NAME$
Example: 0010 A$ = ANALYSIS_NAME$

9.4.5 ASC function

Description: Returns the ASCII code value for a character.
Syntax: ASC( string$ )
Example: 0020 CKS = 0
0030 REM CALCULATE CHECKSUM OF A$
0040 FOR J = 1 TO LEN( A$ )
0050 CKS = CKS + ASC( MID$( A$, J , 1 ) )
0060 NEXT J

9.4.6 BENCHMARK CONCENTRATION function

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

9.4.7 BPRINT statement

Description: Functions identically to LPRINT except BPRINT converts numeric values into a string and places it in a string
variable. See LPRINT statement for all options.
Syntax: BPRINT TO string var$ [USING format$;][expression list]

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PGC5000 Series Operating Instructions 9 Scripting

Comments: string_var$ is a string variable.

format$ is a string constant or string variable whose value specifies the format for conversions as defined
for LPRINT.
Example 1: 0010 BPRINT TO A$ USING “%3D;” 0,-1, 10,100
Puts the following into A$: 000 0-1 010 100
Example 2: 0010 BPRINT TO A$ USING “%9.2R;”-0.12,100.23
Puts the following into A$: - 0.12 100.23

9.4.8 CALIBRATION CONCENTRATION function

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

9.4.9 CANCEL REQUESTS command

Description: Removes all pending requests (uncommitted) from the designated Schedule Queue.
Syntax: CANCEL_REQUESTS( schedule$ )
Comments: schedule$ is a string variable (or constant) containing the schedule name for which to clear the schedule
queue.
Example: 0010 CANCEL_REQUESTS (“ScheduleA”)

9.4.10 COMPONENT CONCENTRATION function

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

9.4.11 CHR$ function

Description: Converts a value to its corresponding ASCII character.
Syntax: CHR$( code )
Comments: “code” is a number between 0 and 255.
Example: 0010 A$ = "AREA MONITORING REPORT:"
0020 REM TACK ON SOME LINE FEEDS
0030 A$ = A$ + CHR$( 10 ) + CHR$( 10 )

9.4.12 CLEAR INDICATORS command

Description: Clears all the alarms.
Syntax: CLEAR_INDICATORS
Example: 0020 CLEAR_INDICATORS

9.4.13 COMMON floating point array

Description: This represents a global pre-declared array of floating point storage shared among all BASIC programs. A
reference to a particular element of COMMON by any of the BASIC programs accesses the same locations in
memory. Values can be stored in COMMON by a BASIC program and then be accessed by another BASIC
program. This array shall provide for the storage of 4096 floating point values.
Syntax: COMMON( I )
Comments: “I” is an index into the array.
Example: 0010 FOR I = 1 TO 3048
0020 COMMON( I ) = I
0030 NEXT I

9.4.14 COMMON$ string array

Description: This represents a pre-declared array of string variables shared between all BASIC programs. A reference to
a particular element of COMMON$ by any BASIC program accesses the same locations in memory. Values
can be stored in COMMON$ by a BASIC program and then accessed by another BASIC program. The

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COMMON$ array passes strings between BASIC programs. This array shall provide for the storage of 128
character strings of length 128.
Syntax: COMMON$( I )
Comments: “I” is an index into the array.
Example: 0010 A$ = "ALARM HAS OCCURRED"
0020 B$ = "NO ALARMS"
0030 IF ALARM THEN
0040 COMMON$( I ) = A$
0050 ELSE
0060 COMMON$( I ) = B$
0070 ENDIF

9.4.15 COMPONENT NAME$ function

Description: Returns the name of the nth component in the analysis report.
Syntax: COMPONENT_NAME$( n )
Comments: n is the nth component in the analysis report
Example: 0010 LPRINT COMPONENT_NAME$( 1 )

9.4.16 COMPONENT TYPE function

Description: Returns a value representing the type of the component (Measured or Calculated).
Syntax: COMPONENT_TYPE( component$ )
Comments: component$ is a string variable (or constant) containing the component name.
Return values:
0 = Measured
1 = Calculated
Example: 0010 IF COMPONENT_TYPE( "N2" ) <> 0 THEN
0020 LPRINT COMPONENT_CONCENTRATION( "N2" )
0030 ENDIF
If the Component Type of the component named “N2” is calculated, print the component’s value.

9.4.17 COMPONENT UNITS function

Description: Returns the Units Of Measure of the named component.
Syntax: COMPONENT_UNITS$( component$ )
Comments: component$ is a string variable (or constant) containing the component name.
Example: 0010 LPRINT COMPONENT_UNITS$( “Methane” )

9.4.18 CURRENT STREAM function

Description: Returns the stream currently under analysis. (Evaluate adding function to return purging Stream)
Syntax: CURRENT_STREAM$( schedule$ )
Comments: schedule$ is a string variable (or constant) containing the schedule name for which the current stream is
desired.
Example: 0010 IF CURRENT_STREAM$( “Schedule 1” ) = “ST506” THEN
0020 GOSUB HydrogenStream:
0030 ENDIF

9.4.19 DEACTIVATE STREAM command

Description: Sets the state of a Stream to OFFLINE. Makes all uses of the Stream in the Schedule INACTIVE.
Syntax: DEACTIVATE_STREAM( stream$ )
Comments: stream$ is a string variable (or constant) containing the stream name of the stream to be deactivated.
Example: 0010 DEACTIVATE_STREAM( “CalStrm1” )

9.4.20 DIM statement

Description: Allocates storage for an array of variables.
Syntax: DIM variable(extent)[,variable(extent)]....
Comments: variable is the variable name of the array.
extent is the number of elements in the array.
Notes: a) Only one dimension is allowed.
b) Array subscripts must be from 1 to the array dimension (extent).

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c) To use a variable as an array, it must be declared before use in the DIM statement.
Example: 0020 DIM A(N_COMP(1)),B$(10),C%(50)
This statement declares an array A of floating point variables with as many elements as there are
components in analysis 1, array B$ of 10 strings, and array C% of 50 integer variables.

9.4.21 END statement

Description: Indicates that program execution is complete.
Syntax: END
Comments: END is a statement that may appear anywhere in the program; if not, it is implied to follow the last
statement of the program.
Example: 0010 IF ALARM( FLAME_OUT ) THEN
0020 END
0030 ENDIF
For this example, when an alarm condition exists, program execution terminates.

9.4.22 END REPORT statement

Description: Terminates a report group for sending to Reporter. All LPRINT content is grouped together in one
block starting with the START_REPORT statement.
Syntax: END_REPORT
Example: see START_REPORT

9.4.23 EXPECTED RETENTION TIME function

Description: Returns the component’s expected retention time.
Syntax: EXPECTED_RT( component$ )
Comments: component$ is a string variable (or constant) containing the component name.
Example: 0010 A = EXPECTED_RT( “Methane” )
Gets the expected retention time of component named Methane and assigns it to floating point variable A.

9.4.24 EXPONENT function

Description: Returns e (i.e., 2.71828) raised to the power of the floating point expression.
Syntax: EXP( fp )
Comments: fp is a floating point expression.
Example: 0010 A = EXP( T )
Raises e to the power of floating point variable T and assigns it to floating point variable A.

9.4.25 FOR...NEXT statements

Description: Does an iteration loop.
Syntax: FOR variable = initial x TO y [STEP z]
NEXT [variable, variable]
Comments: variable is an integer used as a counter.
x is the initial value of the counter.
y is the final value of the counter.
z is the increment for the counter.
Example: 0010 FOR I = 100 TO -100 STEP -2
.
.
0020 NEXT
Executes loop 101 times with loop counter values of 100, 98, …, -98, and -100.

9.4.26 GOSUB statement

Description: Branches to subroutine.
Syntax: GOSUB Line
RETURN
Comments: line is the statement number for the subroutine.

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Example: 0010 GOSUB 100

0020 END
.
.
0100 RETURN
Branches to subroutine at statement 100. Subroutine returns execution at statement 20 which ends
execution.

9.4.27 GOTO statement

Description: Branches to label.
Syntax: GOTO ProgramLabel:
Comments: Program Label: is the label where execution will continue.

9.4.28 IF statement
Description: Allows for alternative paths of execution based on the evaluation of an expression.
Syntax: IF expression THEN
statements
ELSE
statements
ENDIF
Comments: expression is a logical expression whose result is TRUE or FALSE.
statements is a single or multiple statement.
Example: 0010 IF A = 1 AND B = 2 THEN
0020 LPRINT “ONE”
0030 ELSE
0040 LPRINT “TWO”
0050 ENDIF
If the expression is true, “ONE” is printed otherwise “TWO” is printed.

9.4.29 INDICATOR function

Description: Returns the Boolean state of a GC Indicator Group. Individual indicators can be selected by Bitwise mask.
I.e. value returned is the IndicatorGroup & mask.
Syntax: INDICATOR( IndicatorGroup$, mask )
Comments: IndicatorGroup$ is a string variable (or constant) containing the name of the indicator group.
Example: 0010 FLAMEOUT = 16384
0020 IF INDICATOR( “Oven1.DTM1.FID.1”, FLAMEOUT) THEN
0020 LPRINT( “Flame Out!” )
0030 ENDIF

9.4.30 INJECT TIME function

Description: Returns a string with the sample inject date and time using the same format as TIME$.
Syntax: INJECT_TIME$
Example: 0010 A$ = INJECT_TIME$
String variable A$ gets inject time and date for the current analysis report.

9.4.31 INTEGER TYPE conversion routine

Description: Returns the integer value of an expression.
Syntax: INT( fp )
Comments: fp is a floating point expression.
Example: 0010 I = INT( A )
Converts the value of floating point variable A to an integer and assigns it to integer variable I.

9.4.32 LENGTH function

Description: Returns the number of characters in a string.
Syntax: LENGTH( string$ )
Comments: string$ is any string expression.

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Example: 0010 A$ = “1234567890”

0020 N = LENGTH( A$ )
Variable N gets the number of characters (10) in string variable A$.

9.4.33 LOGARITHM BASE TEN function

Description: Returns the Logarithm to base ten of an expression.
Syntax: LOG( fp )
Comments: fp is a floating point expression.
Example: 0010 A = LOG( 10.123 )
The logarithm to base ten of 10.123 is assigned to floating point variable A.

9.4.34 LPRINT statement

Description: Prints to the line printer.
Syntax: LPRINT [USING format$;][expression[,expression]...]
Comments: format$ is a string constant or variable that specifies the printout format
Note: Start/End Report is required to obtain output from LPRINT (see Start Report).

9.4.35 MID$ function

Description: Return a substring of a string
Syntax: MID$( “ABCDEFGHIL”, 2, 3)
Comments: first parameter is a string
second parameter is index to start substring
third parameter is length of substring
Example: 0010 A$ = MID$( “ABCDEFGHIL”, 2, 3)
Contents of A$ will be “BCD”

9.4.36 NATURAL LOGARITHM function

Description: Returns natural Logarithm (to the base e) of floating point expression.
Syntax: LN( fp )
Comments: fp is a floating point expression.
Example: 0010 A = LN( 2.71828 )
The natural logarithm (logarithm to the base e) of 2.71828 is assigned to floating point variable A.

9.4.37 NUMBER COMPONENTS function

Description: Returns the number of components in an analysis report.
Syntax: NUMBER_COMPONENTS
Comments: Analysis% is the Analysis ID
Example: 0010 FOR CompID = 1 TO NUMBER_COMPONENTS
0020 LPRINT COMPONENT_NAME$( CompID )
0030 NEXT CompID
For every component in analysis method one (statement 10), component name is printed (statement 20).

9.4.38 OUTSTANDING REQUESTS function

Description: Returns the number of uncommitted pending requests in Analysis Request (Schedule) Queue.
Syntax: OUTSTANDING_REQUESTS( schedule$ )
Comments: schedule$ is a string variable (or constant) containing the schedule name.
Example: 0010 IF OUTSTANDING_REQUESTS( “ScheduleA” ) > 0 THEN
0020 CANCEL_REQUESTS(“ScheduleA”)
0040 ENDIF
All uncommitted requests are deleted if there are any requests in the Analysis Request Queue.

9.4.39 PEAK AREA function

Description: Returns the peak’s corrected area
Syntax: PEAK_AREA( component$ )
Comments: component$ is a string variable (or constant) containing the component name.

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Example: 0010 FOR I = 1 TO NUMBER_COMPONENTS

0020 LPRINT PEAK_AREA( COMPONENT_NAME $( I ) )
0030 NEXT I
The example prints the area under each peak.

9.4.40 PEAK CREST AMPLITUDE function

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

9.4.41 PEAK END AMPLITUDE function

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

9.4.42 PEAK END TIME function

Description: Returns the end time for the peak.
Syntax: PEAK_END_TIME( component$ )
Comments: component$ is a string variable (or constant) containing the component name.
Example: 0010 FOR I = 1 TO NUMBER_COMPONENTS
0020 LPRINT PEAK_END_TIME( COMPONENT_NAME$( I ) )
0030 NEXT I
Prints the time of each peak’s end.

9.4.43 PEAK NEGATIVE AREA function

Description: Returns the peak’s negative area.
Syntax: PEAK_NEG_AREA( component$ )
Comments: component$ is a string variable (or constant) containing the component name.
Example: 0010 FOR I = 1 TO NUMBER_COMPONENTS
0020 LPRINT PEAK_NEG_AREA( COMPONENT_NAME$( I ) )
0030 NEXT I
Prints the uncorrected area of each peak.

9.4.44 PEAK POSITIVE AREA function

Description: Returns the peak’s positive area.
Syntax: PEAK_POS_AREA( component$ )
Comments: component$ is a string variable (or constant) containing the component name.
Example: 0010 FOR I = 1 TO NUMBER_COMPONENTS
0020 LPRINT PEAK_POS_AREA( COMPONENT_NAME$( I ) )
0030 NEXT I
Prints the uncorrected area of each peak.

9.4.45 PEAK START AMPLITUDE function

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

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9.4.46 PEAK START TIME function

Description: Returns the start time for the peak.
Syntax: PEAK_START_TIME( component$ )
Comments: component$ is a string variable (or constant) containing the component name.
Example: 0010 FOR I = 1 TO NUMBER_COMPONENTS
0020 LPRINT PEAK_START_TIME( COMPONENT_NAME$( I ) )
0030 NEXT I
Prints the time at the start of each peak.

9.4.47 PURGING STREAM function

Description: Identifies the stream currently purging for the given Schedule.
Syntax: PURGING_STREAM$( schedule$ )
Comments: schedule$ is a string variable (or constant) containing the schedule name.
Example: 0010 ST$ = PURGING_STREAM$(“Schedule1”)
Requests the name of the stream currently purging stream for Schedule1.

9.4.48 PUT COMPONENT CONCENTRATION command

Description: Updates the component concentration.
Syntax: PUT_CONC(component$, concentration )
Comments: component$ is a string variable (or constant) containing the component name. Concentration is the new
concentration for the specified component.
Example: 0010 PUT_CONC( “Methane”, 10.1234 )
The concentration of 10.1234 is stored in the concentration for the component named “Methane” in the
current report and analyzer Component Configuration.

9.4.49 PUT PRESSURE OF A ZONE command

Description: Updates the isobaric set point of the specified pressure zone.
Syntax: PUT_PRESSURE( ovenaddress$, setpoint )
Comments: ovenaddress$ is a string variable (or constant) containing the address of the zone, e.g. “Oven1.Epc.PZ.1”
setpoint is the desired pressure value.
Example: 0010 Z1 = ZONE_PRESSURE( “Oven1.Epc.PZ.1” )
0020 PUT_PRESSURE( “Oven1.Epc.PZ.2”, Z1 )
Gets the actual pressure of oven 1, pressure zone 1 and sets it as the setpoint value for oven 1, pressure
zone 2.

9.4.50 PUT RESPONSE FACTOR command

Description: Updates the response factor for a particular component.
Syntax: PUT_RF( component$, response_factor )
Comments: component$ is a string variable (or constant) containing the component name.
response_factor is the new response factor for the specified component.
Example: 0010 PUT_RF( “Ethane”, 0.98 )
The value of 0.98 is stored in the response factor for component named “Ethane”.

9.4.51 PUT TEMPERATURE OF A ZONE command

Description: Updates the isothermal set point of the specified temperature zone.
Syntax: PUT_TEMPERATURE( ovenaddress$, setpoint )
Comments: ovenaddress$ is a string variable (or constant) containing the address of the zone, e.g. “Oven1.DTC1.TZ.1”
setpoint is the desired temperature value.
Example: 0010 Z1 = ZONE_TEMPERATURE( “Oven1.DTC1.TZ.1” )
0020 PUT_ TEMPERATURE( “Oven1.DTC1.TZ.2”, Z1 )
Gets the actual temperature of oven 1, temperature zone 1 and sets it as the setpoint value for oven 1,
temperature zone 2.

9.4.52 READ ANALOG INPUT function

Description: Returns the value of an Analog Input.
Syntax: READ_ANALOG( ovenaddress$ )
Comments: ovenaddress$ is a string variable (or constant) containing the address of the input, e.g. “EXIO1.WAGO1.AI.1”

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Example: 0010 AN1 = READ_ANALOG ( “EXIO1.WAGO1.ANAIN.1” )

9.4.53 READ DIGITAL INPUT function

Description: Returns the state ( 0 or 1 ) of the digital input addressed.
Syntax: READ_DIGITAL( ovenaddress$ )
Comments: ovenaddress$ is a string variable (or constant) containing the address of the input, e.g. “EXIO1.WAGO1.DI.3”
Example: 0010 D1 = READ_DIGITAL( “EXIO1.WAGO1.DIGIN.3” )

9.4.54 REMARKS statement

Description: Used for placing remarks in the BASIC program.
Syntax: REM remark
Example: 0010 REM CLEAR OUT COMMON(1)
0020 COMMON(1) = 0.0

9.4.55 REQUEST_ANALYSIS command

Description: Requests an analysis of a stream.
Syntax: REQUEST_ANALYSIS( stream$, analysis$ )
Comments: stream$ is a string variable (or constant) containing the name of a Stream
analysis$ is a string variable (or constant) containing the name of an Analysis
Example: 0010 REQUEST_ANALYSIS( “CalStream”, “AnalysisH7” )
Note: Stream/Analysis element must exist in the Demand table of an active schedule.

9.4.56 RESPONSE FACTOR function

Description: Returns the component’s response factor.
Syntax: RESPONSE_FACTOR( component$ )
Comments: component$ is a string variable (or constant) containing the component name.
Example: 0010 A = RESPONSE_FACTOR( “Ethylene” )
Gets the response factor of component named Ethylene and assigns it to floating point variable A.

9.4.57 SCHEDULE ABORT function

Description: Issues a schedule STOP IMMEDIATE command to the designated schedule.
Syntax: SCHEDULE_ABORT( schedule$ )
Comments: ‘schedule$’ is a string variable (or constant) containing the schedule name.
Example: 0010 SCHEDULE_ABORT( “Schedule1” )

9.4.58 SCHEDULE NAME function

Description: Returns the schedule name analyzed in last analysis cycle.
Syntax: SCHEDULE_NAME$
Example: 0010 IF SCHEDULE _NAME$ = “Schedule1” GOTO 100

9.4.59 SCHEDULE RUN function

Description: Issues a schedule RUN command to the designated schedule.
Syntax: SCHEDULE_RUN( schedule$ )
Comments: schedule$ is a string variable (or constant) containing the schedule name.
Example: 0010 SCHEDULE_RUN( “Schedule1” )

9.4.60 SCHEDULE STOP function

Description: Issues a schedule STOP command to the designated schedule.
Syntax: SCHEDULE_STOP( schedule$ )
Comments: schedule$ is a string variable (or constant) containing the schedule name.
Example: 0010 SCHEDULE_STOP( “Schedule1” )

9.4.61 SET BASIC ALARM function

Description: Sets the User Error indicator specified in the current script’s Indicator group
Syntax: SET_BASIC_ALARM( UserAlarm )
Comments: UserAlarm is an integer from 1-10.
Example: 0010 SET_BASIC_ALARM( 3 )

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9.4.62 SLEEP function

Description: Pauses execution of the script for the designated number of seconds
Syntax: SLEEP( seconds )
Example: 0010 SLEEP( 3 )
Execution suspended for 3 seconds.

9.4.63 SQUARE ROOT function

Description: Returns the square root of a floating point expression.
Syntax: SQRT( fp )
Comments: fp is a floating point expression.
Example: 0010 A = SQRT( A * 100 )
The square root of the quantity 100 times the value of floating point variable A is assigned to floating point
variable A.

9.4.64 START REPORT statement

Description: Starts a report group for sending to Reporter. All LPRINT content is grouped together in one block
until the END_REPORT statement is reached.
Syntax: START_REPORT
Example: 001 START_REPORT
002 LPRINT “First line of report”
003 LPRINT “Second line of report”
004 END_REPORT
Note: Start/End Report is required to obtain output from LPRINT.

9.4.65 STREAM NAME function

Description: Returns the stream number analyzed in last analysis cycle.
Syntax: STREAM_NAME$
Example: 0010 IF STREAM_NAME$ = “ST506” GOTO 100
When stream analyzed in previous cycle (analysis data currently being computed) is number three, branch
to statement 100.

9.4.66 STREAM STATUS function

Description: Returns the active/inactive status of the stream.
Syntax: STREAM_STATUS( stream$ )
Comments: stream$ is a string variable (or constant) containing the name of a Stream
0 = Offline ( Inactive )
1 = Online ( Active )
Example: 0010 IF STREAM_STATUS( “CalStream” ) = 0 THEN
0020 LPRINT “CALIBRATION STREAM OFFLINE”

9.4.67 TIME$ function

Description: Returns a string containing the date and time in the following format: hh:mm:ss Day DD Mon YYYY
(e.g., 17:46:31 Mon 6 Nov 1989)
Syntax: TIME$
Example: 0010 A$ = TIME$
The string variable A$ gets the time and date.

9.4.68 TOTAL PEAK AREA function

Description: Returns the total area value for all the peaks detected in an analysis.
Syntax: TOTAL_PEAK_AREA
Example: 0010 FOR I = 1 TO NUMBER_COMPONENTS
0020 LPRINT PK_AREA( COMPONENT_NAME( I ) )
0030 NEXT I
0040 LPRINT TOTAL_PEAK_AREA
For each component, print the area of the peak, then the total peak area of all components.

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9.4.69 VALUE function

Description: Returns a floating point number that is the result of a conversion of the string passed.
Syntax: VALUE( string$ )
Comments: string$ is any string expression. If a valid conversion can’t be performed, VALUE returns zero. Leading non-
numeric characters will cause an invalid conversion.
Examples: 0010 A = VAL( “-10. 3” )
The value of floating point variable A is set to -10.3.

9.4.70 VALVE command

Description: Turns valve On or Off.
Syntax: VALVE( ovenaddress$, state )
Comments: ovenaddress$ is a string variable (or constant) containing the address of the v, e.g. “Oven1.DTC1.REG.2”.
state: 0 = valve Off, 1 = valve On.
Example: 0010 VALVE( “Oven1.DTC1.REG.2”, 0 )
Turns Analytical valve 2 in Oven 1 off.

9.4.71 WRITE ANALOG OUTPUT command

Description: Sets the specified analog output to the level desired in engineering units. The range is specified in Setup of
the Analog Output.
Syntax: WRITE_ANALOG( ovenaddress$, value )
Comments: ovenaddress$ is a string variable (or constant) containing the address of the output
(e.g. “InIo.Wago1.AnaOut.1”)
value is the trend output value.
Example: 0020 WRITE_ANALOG( “InIo.Wago1.AnaOut.1”, 37.0 )

9.4.72 WRITE DIGITAL OUTPUT command

Description: Specifies the state of Extended Digital Outputs.
Syntax: WRITE_DIGITAL( ovenaddress$, state )
Comments: ovenaddress$ is a string variable (or constant) containing the address of the output
(e.g. “InIo.Wago1.DigOut.3”
state <> 0 asserts the output, state = 0 de-asserts the output.
Example: 0020 WRITE_DIGITAL( “InIo.Wago1.DigOut.3”, 0)

9.4.73 Y2X function

Description: Returns the value of Y raised to the X power.
Syntax: Y2X( fpbase, fpexp )
Comments: fpbase, fpexp are floating point expressions.
Example: 0010 LPRINT Y2X( 2, 10 )
Prints the value of 2 raised to the power of 10 ( = 1024 ).

9.4.74 ZONE PRESSURE function

Description: Returns the actual pressure of the specified zone.
Syntax: ZONE_PRESSURE( ovenaddress$ )
Comments: ovenaddress$ is a string variable (or constant) containing the address of the zone, e.g. “Oven1.Epc1.PZ.1”
Example: 0010 Z1 = ZONE_PRESSURE( “Oven1.Epc1.PZ.1” )
Returns the actual pressure of zone 1 in EPC1 in Oven 1.

9.4.75 ZONE TEMPERATURE command

Description: Returns the actual temperature of the specified zone.
Syntax: ZONE_TEMPERATURE( ovenaddress$ )
Comments: ovenaddress$ is a string variable (or constant) containing the address of the zone, e.g. “Oven1.Dtc1.TZ.1”
Example: 0010 Z1 = ZONE_TEMPERATURE( “Oven1.Dtc1.TZ.1” )

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10 Version upgrade
10.1 Determine equipment to be upgraded
The first step in upgrading your system is to identify the equipment to be upgraded and determine if the PCs and Servers (i.e.
Gateways) are new enough to be upgraded. PCs running windows XP or older cannot be upgraded and Gateways running
Windows 2000 cannot be upgraded. In these cases the Hardware and Operating system must be replaced with a newer model.
You may refer to each section below for more detail on upgrading.

A PGC5000 running software before Version 3.x.x.x, cannot be upgraded without first contacting ABB Lewisburg support
([email protected]).

Prior to performing the upgrade, you should create a recovery USB stick in the event that there is an issue with the upgrade.
1. To create a recovery USB stick, insert a clean, blank USB stick into the USB port at the left side of the Single Board
Computer PCB inside the Master Controller.
2. Navigate to the Setup>File Management screen.
3. Press the Recovery button.
4. Wait for the message that the process is complete.
5. Remove the recovery USB stick and store it in a safe location.

10.2 PC upgrading
If the PC has no VistaNET software installed, please refer to the STAR Data Management System (DMS) Operating Instructions.
If there are existing PGC5000s Version 3.x.x.x in the system that will be running an older version of the Remote Client, then the
files and GCHelpfiles folder (see Figure 10.1) will need to be copied to a temporary folder and then copied back after the
VistaNET Core software is uninstalled.

Fig. 10.1. GCHelpfiles Example

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In order to determine if the PC has a previous VistaNET software install, navigate to the Control Panel/Programs/Uninstall a
Program per Figure 10.2.

Fig. 10.2. Control Panel/Uninstall

If you have a previous install you will see Figure 10.3.

Fig. 10.3. Previous Install Screen

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The old version of the VistaNET core software must be uninstalled before you can install the new version. Double left clicking
on the VistaNET name will bring up Figure 10.4.

Fig. 10.4. Removing Old Software

Be sure to select Remove before selecting Next.

There will be a series of screens after this process. Select OK or Next at all of them, when prompted. After the process has
completed, verify that the VistaNET software is no longer appearing in the Control Panel/Programs.

After the old version of the VistaNET software has been uninstalled, if you plan to use an older version of the Remote Client
with an existing PGC5000 then you will need to copy the files and folder that were copied to the temporary folder above back
to C:\\Program Files\ABB\VistaNET 2.0.

At this point installation of the STAR software can be performed on the PC per section 4 of the STAR Data Management System
(DMS) Operating Instructions. After successful installation of the STAR core software, the Control Panel/Programs section
should show Figure 10.5.

Fig. 10.5. Programs and Features Screen

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10.3 Gateway upgrading

During the upgrade process of the Gateway communications to the DCS will be interrupted.

The first step is to determine if the Gateway you have can be upgraded. The following models of Gateway cannot be
upgraded:
• Power Edge 350
• Power Edge 650
• Power Edge 750
• Power Edge 850.

These Gateways must be replaced in order to work with version 4 of the PGC5000. The Gateway will only need upgrading if you
intend to receive data from a PGC5000 running version 4 to it.

It is recommended to make an image of the Gateway with the disk imaging software provided in case something goes wrong in
the upgrade process.

On the Gateway to be upgraded, locate and save the following files (note: some may not exist) to a secure location so that they
can be copied back on to the Gateway in a later step:
• Modbus_Client.csv
• VNSA.CFG (if VNSA is running on this Gateway)
• VNOPCTags.txt
• Any PGC5000 tag files for PGC5000s that will be left in the system running version 3; these files will have the GC name
and a .tag file extension.
If there are existing PGC5000s running Version 3.x.x.x in the system that will be running an older version of the Remote Client,
then the files and GCHelpfiles folder shown in Figure 10.6 will need to be copied to a secure location and then copied back after
the VistaNET Core software is uninstalled.

Fig. 10.6. GCHelpfiles Folder

The next step is to uninstall the following applications:

• VistaNET 2.0 OPC Applications
• VistaNET
• OPC Core Components Redistributable (x64)

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These can be accessed thru the Control Panel/Programs/Uninstall a Program (see Figure 10.7).

Fig. 10.7. Uninstall Screen1

Restart the server as prompted during the uninstall process.

At this point installation of the STAR software can be performed on the Gateway per Section 4 of the STAR Data Management
System (DMS) Operating Instructions. After a successful install of the STAR core software, the Control Panel/Programs section
should be as shown in Figure 10.8.

Fig. 10.8. Uninstall Screen2

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Next perform an install of the OPC Server Version 4 software by running the Setup.exe file on the OPC Server installer CD and
following the prompts. After the install of the OPC Server, the Control panel of installed programs will show Figure 10.9.

Fig. 10.9. Control Panel Screen

If you are installing the OPC Server on Windows Server 2003, the OPC DCOM settings need to be modified. From the command
prompt, run “DCOMCNFG” and browse to the Component Services screen (see Figure 10.10) and view the “Properties” of the
“ABB VistaNET Process Analyzer OPC Service” Component Service.

Fig. 10.10. Component Services Screen

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PGC5000 Series Operating Instructions 10 Version upgrade

The “Authentication Level” must be set to “None” on the “General” tab, as shown in Figure 10.11.

Fig. 10.11. General Tab/Authentication Level

Copy the files that were saved before the uninstall, to a secure location back on to the Gateway. The Modbus_Client.csv will
need to be copied back to the folder that it was copied from, usually Program Files (x86)\ABB\VistaNet 2.0. VNSA.CFG (if VNSA
is running on this Gateway) will need to be copied to the ABB\Analytics folder, as this will be the new location of the version 4
compliant VNSA application.

VNOPCTags.txt and any PGC5000 tag files for PGC5000 devices that will be left in the system will need to be copied to the
ABB\Analytics folder, as this will be the new location of the OPC service. If a different install folder was specified during the
installer process, then the files will need to be copied to the folder that was specified.

If there are existing PGC5000s in the system that will be running an older version of the Remote Client, then the files and
GCHelpfiles folder copied from above will need to be copied back to the folder that it was copied from, usually Program
Files\ABB\VistaNet 2.0.

10.4 Upgrading older PGC5000s

If the PGC5000s in the existing system are running a version of software that starts with 1 or 2, then please contact the factory
as the Configuration files will need to modified by the factory in order for the upgrade to be performed.

To upgrade from Version 3.x.x.x of the PGC5000 to Version 4.x.x.x:

If the PGC5000 is in the “VistaNET Device Definition Table” of the VNSA, you must remove the entry from
the VNSA or you will get a name conflict when the converted PGC5000 analyzer restarts.

1. The upgrade kit should contain 2 USB drives:

• A “Recovery” drive which is shipped blank – the user should insert the drive into the SBC of the analyzer to be
upgraded and perform a Make Recovery USB.
• An “Upgrade” drive which contains the proper V4 software and help files in a /format folder and the necessary
UPGRADE.BIN on the root.
2. After the recovery drive has been created, mount both USB drives on a PC that has the XML_VersionConverter application
installed.

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PGC5000 Series Operating Instructions 10 Version upgrade

3. Launch the converter and Figure 10.12 should appear.

Fig. 10.12. XML Dialog Version Converter Box

4. For Source, browse to the “Recovery” USB drive and select the “\format\Configuration” folder.
5. For Destination, browse to the “Upgrade” USB drive and select the “\format” folder.
6. Press “Convert.”
7. If there are no problems, a “Completed Successfully!” dialog will appear.
8. The “Upgrade” drive will now be ready to apply to the analyzer.
9. Turn analyzer power OFF and insert the “Upgrade” drive in the SBC.
10. Turn analyzer power ON.
11. Wait for all files to install and the “Upgrade Complete” message to appear.
12. Turn analyzer power OFF.
13. Remove “Upgrade” drive.
14. Turn analyzer power ON.
15. Once the Analyzer has rebooted, ensure the LUI is operating properly by noting Date/Time seconds are incrementing as
expected.
16. Go to “Setup>Master Controller” screen and note the analyzer NAME.
17. Go to “Setup>Master Controller>SBC>Network Adapters” and enter the analyzer NAME in the HOST NAME field exactly as
it appeared on the Master Controller screen.
18. Press the Network Save button (Disk Icon above the HOST NAME caption). All configuration and network Information will
be refreshed and the system will reboot.
19. At this point the upgrade should be complete.

To repeat the process, remove all the files from the recovery drive and remove the Configuration folder from the upgrade drive.

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NOTES

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NOTES

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—
ABB Inc.
Measurement & Analytics
3567 Jefferson Street N
Lewisburg, WV 24901
USA
Tel: +1 304 647 4358
Fax: +1 304 645 4236
Mail: [email protected]

abb.com/measurement

OI/PGC5000-EN Rev. D  06.2018

—
We reserve the right to make technical changes or modify the contents of this document
without prior notice. With regard to purchase orders, the agreed particulars shall prevail.
ABB does not accept any responsibility whatsoever for potential errors or possible lack of
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