PACS Software for FRP-4

Software Manual

Version 1.0.1.
23.08.2004
Before installing and operating the system, please read this software manual and the
operating instructions carefully. BARTEC BENKE cannot accept liability for injuries or
damages caused by failure to observe the software manual and the operating instructions
and safety precautions.

We have checked the information in this document carefully to ensure its completeness
and correctness. However, as alterations may occur due to technical improvements, we
cannot accept liability for complete consistency. This software manual does not constitute
any obligation or guarantee of performance on the part of BARTEC BENKE.

The software manual and the operating instructions were compiled according to the
requirements defined in the EU Directive 94/9/EG, Appendix II.

For translations into other languages, the German version is to be regarded as the original
document.

If you have any problems or questions, please contact:

BARTEC BENKE GmbH

Borsigstraße 10
21465 Reinbek/Hamburg
Germany

Tel.: +49 (0) 40 - 72703 - 0

Fax: +49 (0) 40 - 72703 - 363
E-Mail: [email protected]

© 2004 BARTEC BENKE GmbH, Reinbek. All rights reserved.

This software manual is copyrighted. This document may not be reproduced or

transmitted, neither whole nor in parts, by any electronic, mechanical or other means,
without prior written permission from BARTEC BENKE GmbH. The manufacture of any
component with the aid of this manual without prior written permission is also prohibited.
Contents I

Contents
1 Introduction to PACS..........................................................................1
1.1 Application Area and Properties ......................................................................... 2
1.2 Analysis Procedure ............................................................................................. 3
2 First Steps with PACS ........................................................................9
2.1 Starting PACS................................................................................................... 10
2.2 Watchdog Module ............................................................................................. 11
2.3 Exiting PACS .................................................................................................... 12
2.4 Changing the User Level .................................................................................. 13
2.5 Changing the Expert Password ........................................................................ 14
3 PACS Overview .................................................................................15
3.1 The PACS Main Window .................................................................................. 16
3.2 The PACS Menu ............................................................................................... 20
4 The IO Menu ......................................................................................21
4.1 Overview ........................................................................................................... 22
4.2 Testing Inputs and Outputs............................................................................... 22
4.3 Configuring Inputs and Outputs ........................................................................ 25
4.4 Modbus ............................................................................................................. 30
4.5 Interface to the Controlling System .................................................................. 30
5 The Configure Menu .........................................................................33
5.1 Overview ........................................................................................................... 34
5.2 Configuring General Parameters ...................................................................... 35
5.3 Configuring Product-Specific Parameters ........................................................ 36
5.4 Checking and Viewing Alarms .......................................................................... 38
6 The Report Menu...............................................................................39
6.1 Overview ........................................................................................................... 40
6.2 History Table..................................................................................................... 40
6.3 Viewing the LogBook ........................................................................................ 41
6.4 Viewing the Alarm Table................................................................................... 42
7 The Help Menu ..................................................................................43
7.1 Overview ........................................................................................................... 44
8 Troubleshooting................................................................................45
8.1 Error Monitoring in PACS ................................................................................. 46
8.2 List of Error Messages ...................................................................................... 47
9 Program Parameters.........................................................................59
9.1 List of Parameters............................................................................................. 60

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

II Figures

Figures
Figure 1.1: Process diagram.......................................................................................... 4
Figure 2.1: Watchdog Module...................................................................................... 11
Figure 3.1: PACS Main Window ................................................................................... 16
Figure 3.2: PACS - Graphical Display of the Measuring Results ...................................... 17
Figure 4.1: PACS – IO Menu........................................................................................ 22
Figure 4.2: PACS - Testing Digital and Analog Inputs and Outputs................................. 22
Figure 4.3: PACS - Configuring Digital and Analog Inputs and Outputs........................... 25
Figure 4.4: PACS - Modbus Data.................................................................................. 30
Figure 5.1: PACS - Configure Menu.............................................................................. 34
Figure 5.2: PACS - Configuration of General Parameters ............................................... 35
Figure 5.3: PACS - Configuration of Product-Specific Parameters ................................... 36
Figure 5.4: PACS - Defining a New Product .................................................................. 37
Figure 5.5: PACS - Alarm Table ................................................................................... 38
Figure 6.1: PACS - Report Menu .................................................................................. 40
Figure 6.2: PACS - History Table.................................................................................. 40
Figure 6.3: PACS - LogBook ........................................................................................ 41
Figure 6.4: PACS - Alarm Table ................................................................................... 42
Figure 7.1: PACS - Help Menu ..................................................................................... 44
Figure 7.2: PACS - Manuals ......................................................................................... 44
Figure 7.3: About PACS............................................................................................... 44

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Introduction to PACS 1

1 Introduction to PACS

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

2 Introduction to PACS

1.1 Application Area and Properties

PACS (Process Analyzer Control Software) is a software application for BARTEC BENKE
process analyzers. It is designed for automatic control of the process flow in which a
certain product property (here: the freezing point) is analyzed. With the aid of the sensors
and actuators of the specific analyzer, PACS controls the process flow and displays the
process status and the results of the analysis, e.g. in the form of a history.

A so-called Watchdog module supervises PACS and, in case of an error, resets the
analyzer. Optionally, communication with the process control room and transmission of the
results can be carried out via a module (e.g. Modbus) which is connected to the field bus
interface.

Software Properties

PACS is based on Microsoft Windows operating systems (Windows NT or Windows 2000)

and is installed on a PC that complies with industry standard. By means of its adjustable
parameters, PACS can be configured for every specific application. Before delivery, the
system is installed and configured for the specific application by BARTEC BENKE.

It is advisable to install a software application for remote maintenance of the system via
network, modem/ISDN or serial interface. This optional interface allows the user and the
manufacturer to access the system convieniently, if required, to facilitate maintenance,
configuration and system diagnosis.

Hardware Properties

PACS is installed on a PC that complies with industry standard and the current technical
development. Depending on the specific application and customer requirements, various
hardware interfaces (network, modem/ISDN, etc.) are implemented.

The industry standard PC must meet the following minimum requirements:

• Pentium II, 133MHz
• 32 MB RAM
• min. 40 MB available hard disk space
• ISA-slot

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Introduction to PACS 3

Term Definitions

• Cloud Point: This term is not used in the narrow sense of the corresponding
industrial standards but in a more general sense, i.e. as the temperature at which
clouding by paraffin crystals sets in.

• Streams are physically connected product lines which feed the product into the
measuring cell. Optionally, these product lines can be equipped with valves. PACS
Freezing Point supports the use of two streams plus one validation stream.

• A product is here defined as a liquid hydrocarbon with a limited scope of physical

properties. To this product, a set of parameters is assigned in order to optimize the
analytic process with reference to those properties.

• Mode Local/Remote describes the operating mode. The user operates the
functions, such as selecting streams and starting and stopping the process flow, either
at the main screen (local) or by using a so-called Distributed Control System (DCS) via
a control interface (remote). (For further information on the interface, please refer to
chapter 4.5.)

• Parameters are values which can be adjusted in order to set up the system,
depending on device or product properties. There are two types of parameters:
general parameters and product-dependent parameters (see chapters 5.2 and 5.3).
The values are referenced by the parameter names.

1.2 Analysis Procedure

The following sections describe the process flow of the Freezing Point Analyzer, i.e. the
program steps which the Freezing Point Analyzer carries out during the analysis (cycle).
The process flow is controlled by the PACS software and displayed in the main window.

Note: The process flow is influenced strongly by the configuration of parameters,

products and alarms. For further information, please refer to chapter 5.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

4 Introduction to PACS

The following figure shows the sequence of process steps. (The description refers to the
measuring cell, which operates by transmission detection.)

RESET /
SHUTDOWN

Process Run Time>TimeOutFreez

or
after FRP
Detection
Time>Flushing Time1

Initialize Freez Point Detection

Flushing/
Time > FlushingTime1 &
Heating TempProduct<WCellStart
or Detector 1. derivate < SwitchOffFreezDer
FlowCheck < Temp. Product <MaxInlet & Flowcheck>TempProduct &
TempCell > WCellStart >MaxInlet Time<CoolTime3
&
Time < FlushingTime1 Time >
CoolTime3

Flushing Cooling3

SwitchPointCool23+LastFreezPoint>TempProduct
Time > FlushingTime2 &
Time<CoolTime2
or
Time >
Detector 1. derivate <SwitchoffFreezDer
CoolTime2
ProductTempLow>ProductTemp
Sample Check or
Cooling2
ProductTemp>ProductTempHigh

ProductTempLow<ProductTemp TempPre-Stage-TempProduct>DiffTempCellCooler
& &
ProductTemp<ProductTempHigh Time<CoolTime1
Photodetector not OK ! Time >
CoolTime1

Dead Time Alignment Cooling1

Time >DeadTime Photodetector OK !

Figure 1.1: Process diagram

Note: If the system is switched to "Reset" following an alarm, the cycle is restarted. If
the alarm is configured as "Shutdown" (see alarms in chapter 5.4), the process
flow must be restarted. (For further information, please refer to chapter 3.1.)

Program Start

After starting the program, PACS loads the configuration parameters and those settings
(selected product, process run/stop, local/remote control) which were active at the
previous program session. These settings are always used at the start of the analysis
process. If the measuring process was not active at program shutdown (button Reset not
active, or no stream selected – buttons StreamX – and button AutoSwitch is in state
“Stop”), the program remains in the state “Do Nothing” (waiting loop). Otherwise, the
measuring cycle begins with the program step Reset.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Introduction to PACS 5

Reset

The process flow proceeds to the step Reset after the program is started, or if the button
PressToReset in the main program window (see chapter 3.1) is clicked (state changes to
Reset), or if the reset line is activated, or if an alarm occurs during the analysis cycle. The
valves, controls, etc. are set to their initial position, and the state changes to Initialize.

Shutdown

The process step Shutdown is indicated after an alarm occurs which is configured
accordingly (see chapter 5.4). The valves, controllers etc. are switched to their home
position or reset following the error. After the problem has been solved, the process must
be restarted (button Reset).

Initialize

The Freezing Point Analyzer continues its program by initializing the hardware. The Ready
signal and the alarm signal are reset, and a sample or validation cycle are started, as
requested by the user. The photo detector is activated (the light source is switched on),
but it is not calibrated. If the intermediate stage has not yet reached the target
temperature (CntrPre-StageW), it is heated exactly to the target temperature of 3°C.

The program records the start of an analysis cycle by means of a protocol entry in the
History table (with date and time). The program then switches to the step Flushing
Heating.

Flushing Heating

The Freezing Point Analyzer checks whether the cell temperature lies below the parameter
value “TMaxInlet”. If the temperature is higher, the alarm TA_TH_CELL is triggered. If the
measuring cell is colder than the intermediate stage, the cell is heated to the temperature
of the intermediate stage. Then the valve Product Inlet opens and, depending on the
selected stream, either the valve Y-Product (1/2) or the valve Y-Validation. A check for
product flow is carried out. If the product temperature does not reach the value of
"FlowCheck" during the time defined in "StartHeatTime", the alarm TA_NF_CELL is
triggered. Afterwards, the cell is tempered to the threshold value "WCellStart". As
reference value for the controller, a ramp with the gradient "HeatingRamp" is generated.
While the temperature is being adjusted, flushing of the cell is interrupted. As soon as the
value "WCellStart" is reached, the program proceeds to the step Flushing. The duration
of the program step is monitored ("FlushingTime1").

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

6 Introduction to PACS

Flushing

The measuring cell is rinsed. The old product sample is removed from the system by a
new sample. The duration of this rinsing process is defined in the product-dependent
parameter "Flushing Time". The time setting must be sufficiently long. The program then
proceeds to the step Sample Check.

Sample Check

In this step, the product temperature is checked (temperature of the product from the
production process). Only if this temperature lies within the range defined by the product-
dependent parameters "ProdTempLow" and "ProdTempHigh", the program proceeds to
the step Dead Time. Otherwise, the alarm TA_TH_PRODUCT or TA_TL_PRODUCT is
triggered.

Note: For further information on alarms and on troubleshooting, please refer to

chapters 5.4 and 8.

Dead Time

The valve Product Inlet and, depending on the selected stream, either the valve Y-Product
(1/2) or the valve Y-Validation is closed. There is a waiting period for the duration of
"DeadTime" (product-dependent parameter). This program step allows the product sample
to rest, so that suspended particles can sink to the bottom and gas bubbles can rise to
the top. After the "DeadTime" has elapsed, the program proceeds to the step Alignment.

Alignment

During the program step Alignment, the detector is balanced and the light sensor is
checked. The current detector value (intensity value for clear product) is normalized to the
value 1 (100%). With the following program step Cooling 1 the cooling of the product
starts.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Introduction to PACS 7

Cooling 1

During the first cooling phase, the Peltier elements are tested by measuring the increasing
difference in temperature between the test cell and the intermediate stage. If the
difference in temperature does not exceed the minimum defined in "DiffTempCellCooler"
after the time "CoolTime1" has elapsed, the alarm TA_TG_COOLING1 is triggered. The
temperature gradient of the cooling process can be set in "GradientCool1".

The program switches from Cooling 1 to Cooling 2 when the temperature difference
"DiffTempCellCooler" between test cell and intermediate stage has been reached.

Cooling 2

The product in the measuring cell is cooled down further until its temperature almost
reaches the last measured freezing point ("_lastFreezPoint" + "SwitchPointCool23"). The
next program step is Cooling 3. The controller uses "GradientCool2" as reference value. It
is monitored whether the cloud point is already detected in this program step (see
Cooling3). In this case, the alarm TA_CF_COOL12 is triggered, and the program proceeds
to the step Cooling3. If the duration of the program step Cooling2 exceeds the time in
"CoolTime2", the alarm TA_TO_COOL2 is triggered.

Cooling 3

To determine the cloud point and the freezing point, either the transmission mode
(diffusion and absorption of light at the paraffin crystals) or the polarization mode (rotation
of the plane of polarization at the paraffin crystals) can be used. The mode is selected with
the button Transmission/Polarisation in the main window. The polarization method
requires different hardware (polarization filter).

1) Transmission Mode

The cloud point is the product temperature at which the first derivative of the photo
detector signal falls below the threshold value "SwitchOffFreezDer".

2) Polarization Mode

The cloud point is the product temperature at which the first derivative of the photo
detector signal exceeds the threshold value "PolDetection".

The measuring cell is cooled further at the rate defined in the temperature gradient
"GradientCool3", until the cloud point is detected. If this is not achieved within the time in
"CoolTime3", the alarm TA_TO_COOL3 is triggered. Otherwise, the program step
FreezPointDetection follows.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

8 Introduction to PACS

Note: As reference value for the parameter "SwitchOffFreezDer", it is recommended

to leave the default value unchanged (see list of parameters in chapter 9.1).
This value is determined empirically and applies to most products.

Freezing Point Detection

This is the last program step in the analysis cycle. Cooling of the Peltier elements is
deactivated, and the current product temperature in the measuring cell (= cloud point) is
measured. The product is then reheated with the cooling gradient "GradientCool3". The
product will cloud even further at first and then will clear up again slowly.

The freezing point is detected when the normalized detector signal reaches the value of
the cloud point plus the product-specific parameter "FreezPointDet". The corresponding
temperature is displayed in the main window as Last Freezing Point. The detected
freezing point is also shown graphically and recorded in the History table, and is output as
a 4-20 mA signal together with the digital "Ready" signal (digital output) for the time
defined in "ReadyTime" in seconds.

Afterwards, the measuring cell is heated to the temperature of the intermediate stage, and
the process cycle starts again with the step Initialize.

Note: As reference value for the parameter "FreezPointDet", it is recommended to

leave the default value unchanged (see list of parameters in chapter 9.1). This
value is determined empirically and applies to most products.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

First Steps with PACS 9

2 First Steps with PACS

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

10 First Steps with PACS

2.1 Starting PACS

To start PACS, proceed as follows:

• Switch on the analyzer, as described in the operation manual.

The computer for data analysis (ACU) boots up and starts the operating system, and the
PACS process software starts automatically.

Only in some cases, it may be necessary to start manually. To do this, proceed as follows:

• In the Windows Start menu under Programs – Bartec Benke, select the PACS
program symbol.

Note: PACS always starts on the Operator user level, using the same settings as
were stored during the last session. If the analysis process was active when
the program was ended, it will now be started again. Otherwise, only the
outputs will be initialized with their starting values and the safety monitoring
program will be started.

After starting PACS, the Watchdog module starts automatically (see chapter 2.2), and also,
if required, the communication module (Modbus).

Additionally, if installed, the remote maintenance software starts.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

First Steps with PACS 11

2.2 Watchdog Module

After starting PACS, the Watchdog module starts automatically. The Watchdog module
shows whether particular applications which are necessary for correct system operation
are active (e.g. PACS, Modbus, etc.). These applications are registered by the Watchdog
module, and they are then polled in turn. If a registered application does not react to the
polling request, all applications and the operating system are shut down. After a delay
time, the Watchdog triggers a system reset which restarts the operating system and the
PACS software.

Figure 2.1: Watchdog Module

The LED WD shows the status of the Watchdog hardware. If the LED is grey, the
hardware is inactive. If it is green, the hardware is active.

The LED CON shows the available connections. If at least one application is registered and
polled by the Watchdog module, the LED is green. If no application is registered, the LED
is grey. The registered applications are shown in the center of the Watchdog window
under "Connections".

The LED TRIG changes color from blue to orange. While the Watchdog module is
checking if the connected applications are active, the progress bar shows the current
status of the polling process. If all connected applications are active, the hardware is
triggered, and the LED is orange. If not all applications are active, the hardware is not
triggered, and the LED remains blue. The Watchdog module then resets the system within
the next few seconds, i.e. it stops all active applications, shuts down the operating system,
resets the hardware and restarts.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

12 First Steps with PACS

The Watchdog window contains information on the software version and the
manufacturer.

To close the Watchdog module, click on Quit.

Note: If the Watchdog module is closed while registered applications are still running,
the correct function of the applications can no longer be checked.

If you click on Reset, a system reset will be carried out. This should only be
done in exceptional cases and for test purposes, as any changes in the
system configuration which were not previously stored will be lost.

2.3 Exiting PACS

Before you exit PACS, close all dialog windows. There are several ways of exiting the
program:

• Select Exit form the File menu.

• Press Alt-F4.

• Double-click on the program icon in the top left corner of the main window .

• Click on the "Close" symbol in the top right corner of the main window .

The current settings for the software configuration are stored and will be loaded
automatically at the next system start.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

First Steps with PACS 13

2.4 Changing the User Level

In PACS, there are three user levels: Operator, Expert, and Manufacturer.

Operator The Operator level is the online level for operators on-site. This level
offers system check functions as well as product stream switching and
product selection. This is the usual level for routine operation.
Expert The Expert level allows you to define product streams and to organize
data collection.
At Expert level, you have access to all software functions, except:
- controller settings in the menu Configure – Parameters
- settings in the fields Scan Parameters and Channel in the menu
IO – Configure
- operation of the digital and analog outputs during the measuring
process in the menu IO – Test
Manufacturer At Manufacturer level, you have unlimited access to all functions of the
software. The Manufacturer level allows you to configure the hardware.
These settings are generally configured by BARTEC BENKE. They are
instrument-specific and should not be changed.

To change to a highter user level, e.g. from Operator to Expert level, proceed as follows:

• Click on Level in the center of the main window.

A drop-down menu opens from which you can select the desired user level.

• For example, select the user level Expert.

A dialog window appears in which you are required to enter the password for the user
level.

On delivery, the password benke is pre-set for the Expert level. In order to
prevent unauthorized access to the system, you should change this
password as soon as possible. For details on changing the Expert password,
please refer to chapter 2.5.

• To change to Expert level, enter the password in the dialog window, and click on OK.

Note: No password is needed to change to a lower user level, e.g. from Manufacturer
or Expert level to Operator level.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

14 First Steps with PACS

2.5 Changing the Expert Password

On delivery, the password benke is pre-set for the Expert level. You should change this
password as soon as possible.

To change the Expert password, proceed as follows:

• Change to Expert level, as described in chapter 2.4.

• Select Password – Configure.

A dialog window opens.

• Enter a new password with at least 5 characters, and, to confirm, enter it again in the
second line.

Note: For the passwort, only characters from the internation ASCII code can be used,
no blanks or special characters are allowed. A password must have at least 5
characters. Please note that the program distinguishes between upper case
and lower case letters.

• To save the new password, click on OK.

To keep the old password, click on Cancel.

The new password is active immediately. The next time you log in on Expert level, you will
have to enter the new password.

For safety reasons, treat passwords as confidential and change them

regularly in order to prevent unauthorized access to the system!

Note: The password for the Manufacturer level cannot be changed. If you require the
password for maintenance purposes, please contact BARTEC BENKE service.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

PACS Overview 15

3 PACS Overview

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

16 PACS Overview

3.1 The PACS Main Window

The PACS main window displays the status of sensors and actuators, the process state and
the measuring results.

The top bar of the main window is the title bar. It shows the program name and the
Windows symbols:

Minimize window to icon.

Minimize and adjust window size.
Close window and exit program.
Program symbol, provides access to all screen display options.

Below the title bar, there is the menu bar (see chapter 3.2).

Figure 3.1: PACS Main Window

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

PACS Overview 17

In the upper part of the main window, four sections show the most important inputs
and outputs. They are, from left to right: "Digital Outputs", "Digital Inputs", "Analog
Outputs", "Analog Inputs".

In the center part of the main window, the streams are displayed with their assigned
products and the most recent measuring results.

In the right part of the main window (center and top), the current process status and
the most important process values are displayed. The most important control
elements are also located here.

In the lower part of the main window, the measuring results are displayed
graphically. The section History shows the date and time as well as the freezing point at
the current cursor position. Additionally, the time scale for the display can be selected (2,
4, 8, 12, 24, or 48 hours).

Inputs and Outputs

The section "Digital Outputs" (valves, Peltier control, control of the light sensor, alarms /
status, ..), "Digital Inputs" (remote control signals, Peltier status, ..) and "Analog Inputs"
(temperatures and detector signal) shows the current status of the sensors and actuators.

In the section "Analog Outputs", the value of the two analog outputs (4-20mA) is
displayed. The first analog output shows the freezing point, the second shows the signal
assigned to it from a list.

The signal selected for the second output can be displayed as a graph over time by
clicking the button SelectGraph (in the History section in the lower part of the main
window).

Figure 3.2: PACS - Graphical Display of the Measuring Results

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

18 PACS Overview

Process-Relevant Parameters and Controls

In the top center of the main window, the most important process-relevant parameters
and controls are displayed. Temperature Setpoint shows the current setpoint for
controlling the product temperature in the measuring cell. Temperature Gradient shows
the current set rate of heating or cooling in degrees [K] per second. Depending on the
current program step (Cooling 1..3), this field shows the different values. Controller
shows the current set value [%] of the controller (performance of the Peltier elements).
Detector shows the current value of the light sensor detector after normalization to 1.
The field Detector (1st Derivative) shows the first derivative, on a time basis, of the
normalized detector signal. The LED Light detection indicates the correct function of the
light sensor after the Alignment process step.

Streams and Product Assignment

The stream sections in the center part of the main window are each equipped with a
button for product selection (e.g. Kerosin LightFuel). The selection Not Active means:
no product is selected. (Products can be defined in the menu Configure - Products.) To
start an analysis, a product must be selected, and the product-dependent parameters
must have been entered.

Two streams and an additional validation stream can be assigned. With the buttons
Stream 1 and Stream 2 (states "Stop" and "Run") and with the button
Stream/Validation, the streams can be selected directly. If the process is activated by
clicking on one of these buttons, the respective stream with its assigned product is used
until a different stream is activated, or until the button is clicked again. By selecting a new
stream or by selecting automatic stream switching, the active measuring cycle is not
aborted but finished regularly. The new stream selection becomes active in the state
Initialize.

The Stream/Validation button allows you to start a validation cycle. It corresponds to

the Validation digital input being activated in Remote mode. Pressing and releasing the
button initiates the number of validation cycles specified in "Passes" of the third stream.
The analyzer then returns to product analysis. If the button remains pressed, validation
cycles are carried out until the control button is reset. If the parameter
"ValidationCycleBreak" is set, the active cycle is stopped immediately, and the validation
cycle is started.

An active cycle is always indicated by a green label for the two streams or by a yellow
label for the validation stream with the respective product on the stream (e.g. "Kerosin" in
the example above) It is also indicated by color, with which button the cycle was started
(here: "Stream 1 Run").

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

PACS Overview 19

Process States and Controls

You can use the Level control button in the top right part of the main window to switch to
a different user level (see chapter 2.4).

The button Auto-Switch (state "Stop" or "Run") in the top right part of the main window
is used for automatic stream switching. With this function, the system switches between
stream 1 and stream 2 automatically. On each stream, the number of cycles defined in
"Passes/Cycle" is carried out on one stream, and the stream is then switched. The display
Actual Passes in the top right part of the window shows the number of cycles that are
still to be carried out before switching.

The Transmission (Polarization) button is only active on Manufacturer level. It is used

to switch between the "Polarization" and "Transmission" detection modes. (This requires
additional hardware.)

If the Local button is clicked, the display changes to Remote (available from Expert
level), and the analyzer can then only be remote controlled via the digital inputs. In
Remote mode, the control elements in the main window are inactive, except for changing
back into Local mode, the mode in which the digital inputs are not active. There are thus
two possibilities to run the analyzer: via the display in Local mode, using the mouse, or via
an external computer in Remote mode.

Clicking the Press to Reset control button in Local mode has the same effect as
activating the digital input Reset in Remote mode. If the button remains active, the
process is cancelled and the system changes to the state "Do Nothing". It will remain in
this state until the button is reset (hold function). If the button is clicked and reset
immediately, the current cycle is aborted and a new cycle is started via the program step
"Reset".

On the right, the field Time shows the current date and time, the field Error shows if
there are any error messages (see chapter 8). If there is no error, the field is grey.

In the State field, the current process state is shown. In the field State Time, the
duration in seconds of the current process state is displayed. In the field Cycle Time, the
time elapsed in the measuring cycle is displayed.

The Vali-Cycle field shows how many validation cycles remain to be carried out after the
validation request has been received. The number counts down from the number of
validation cycles entered in "Passes". If the validation request remains active, the system
counts down to 1 and carries out another validation cycle. If the validation request is only
activated briefly, the system counts down to 0 and switches back to the active product
stream automatically.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

20 PACS Overview

On Manufactuerer level, three additional buttons are available in the right part of the main
window. These buttons are reserved for particular manufacturer tests and should be used
only by BARTEC BENKE service personnel:

• The Arrow button switches to the next process step without waiting for the
current step to finish.

• The Stop State button (OFF / STOP Timer) prevents timer-contolled switching to the
next process step.

• The button Debug On is used to record data for error analysis in the file
.\data\TempDebug.txt. This can only be activated if the window SelectGraph is
open. The following information is recorded continually at two second intervals:
TimeStamp, Temperatuer Heatexchanger, Temperature Prestage, Temperature
Product, Detector Signal, and additionally the detection of the freezing point:
CloudPoint, FreezPoint, FreezPointDet, SwitchOffFreezDer. To stop recording, close
the SelectGraph window or click on Debug Off.

3.2 The PACS Menu

Overview of the menu bar:

File IO Configure Report Password Help

1 2 1
Exit Test Parameters History Table Configure Manual(s)
2 1
Configure Products LogBook About
3
Modbus Alarms Add Message
Alarm Table
1
write access only on Manufacturer and Expert level
2
unlimited write access only on Manufacturer level
limited write access on Expert level
3
write access only on Manufacturer level

Note: For further information on the individual menu functions, please refer to the
following chapters.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The IO Menu 21

4 The IO Menu

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

22 The IO Menu

4.1 Overview

The options in the IO menu allow you to carry out a hardware test. All outputs can be
switched, and the input values are displayed. Each input and output can be configured and
calibrated.

Figure 4.1: PACS – IO Menu

4.2 Testing Inputs and Outputs

To open the dialog window Input/Output Test, select IO – Test. The following screen
appears:

Figure 4.2: PACS - Testing Digital and Analog Inputs and Outputs

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The IO Menu 23

Note: Depending on the user level, this dialog offers different functions. For further
information on the user levels, please refer to chapter 2.4.
Do not change the settings in this dialog unless you are well
acquainted with the functions! Operating errors can cause damage!

All analog and digital inputs and outputs are displayed with their current value or switch
status. When the digital inputs and outputs are switched, the adjacent LED or switch
button becomes green, otherwise it remains grey.

The digital outputs, e.g. those which switch a single valve, can be switched manually for
testing by clicking on the switch button. Similarly, the values for the analog outputs can be
changed.

Note: If you change the digital outputs during an analysis cycle, you may affect the
process and the results.

In the Modulator field you can change the settings for a modulator implemented in the
system as a power regulator for the heating and cooling control. The modulator controls
the Peltier elements of the measuring cell. With the digital output Heat/Cool, the polarity
of the Peltier elements is reversed. Before you do this, make sure that the modulator is
switched off.

The On/Off switch allows you to switch the modulator on (switch position right) or off
(switch position left).

The LEDs Upper Limit and Lower Limit are red if the measuring cell temperature
exceeds or falls below the threshold values. They change back to grey as soon as the
temperature returns to a value within the limits.

The LED Lockout lights in the OK state (inverse operation) and is extinguished if the
temperature is exceeded. Additionally, the alarm TA_LOCKOUT is triggered. The LED must
be reset with LockOut Reset (+G2-SH2) in the electronics housing G2. The LED
LockOutReset lights briefly to confirm the action.

Caution!
An explosive atmosphere can be a danger to your life!
While the EEx p system is under electric current, it must be opened by
specially qualified and instructed personnel only!
Always observe the safety precautions and the instructions in the operation
manual for the analyzer!

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

24 The IO Menu

The average power output from the modulator is compared with the set value. If it is
above or below the set value limits the LEDs Modulator In or Modulator Out light up in
red and so indicate the corresponding power adjustment.

Note: The modulator should not be operated manually during normal operation.
Should this be necessary: Observe the temperature closely in order to prevent
damage to the Peltier elements.

The lower bar and the Power field next to it show the power target value [%] of the
modulator. You can change the set value with the arrow buttons next to the Power field,
or by moving the slide.

To close this dialog, click Cancel.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The IO Menu 25

4.3 Configuring Inputs and Outputs

Note: Depending on the user level, this dialog offers different functions. For further
information on the user levels, please refer to chapter 2.4.
Do not change the settings in this dialog unless you are well
acquainted with the functions! Operating errors can cause damage!

To configure the digital and analog inputs and outputs and to calibrate and set other
process parameters, select IO – Configure. The following dialog window appears (Note:
These signals are generally configured by BARTEC BENKE before delivery of the system):

Figure 4.3: PACS - Configuring Digital and Analog Inputs and Outputs

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

26 The IO Menu

By clicking the button labeled Tag, you can select a digital output in the section Digital
Output. A drop-down menu opens with the names of all configured digital outputs. Click
on one of these outputs. The name will then be displayed on the button under Name.

To change the name, click on Rename and enter a new name for the selected tag in the
dialog. The name can be up to 15 characters long. Click on OK.

In the Channel field you can assign a channel on the I/O board to the currently selected
digital output. This is only accessible at Manufacturer level, as changes in this
configuration can result in hardware errors.

The checkbox Invert allows you to invert the state of the channel (negative / positive
logic). The checkbox Init determines which value will be used to initialize the digital
output after starting the program, before the first analysis cycle. If the check box is
selected, outputs are switched to active status.

To configure the digital inputs in the section Digital Input, proceed as described above
for the section Digital Output. There is no initialization value for inputs.

In the section Analog Output, select a channel of the I/O board. The name will then be
displayed on the button under Name. To change the name, click on Rename and enter a
new name, as described above for the section Digital Output.

To change the name, click on Rename and enter a symbolic name for the corresponding
property name. The name can be up to 15 characters long. Click on OK.

The field Init shows the start value for initializing the outputs, as described for the section
Digital Output.

The names of the analog and digital inputs and outputs are shown in the window Input /
Output Test.

The channels for the analog input values are set in the section Analog Input. To
configure the analog input, select a channel on the I/O board and assign a symbolic name
to it which stands for the corresponding input value. The name can be up to 15 characters
long (as described above for the digital outputs).

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The IO Menu 27

Calibration Process for Analog Channels

The property values are output as analog signals via the analog output to which a 4-20 mA
sensor is connected. Therefore, the physical range of each channel must be adjusted by
calibration to match the digital range.

The range for the analog input values must also be adjusted. For temperature
measurement, PT 100 sensors are used whose resistance varies as a function of
temperature in accordance with DIN 43760 / IEC 571.

Generally, a calibration is the interrelation of measured values or signals with known

properties (e.g. value table: temperature, current) which is described by a mathematical
model. This mathematical model can then be used to analyze unknown signal values.

The analog inputs and outputs normally use a 2-point calibration; i.e. the relationship
between the physical property and the value in the AD or DA converter is assumed to be
linear. If two values are known, their relationship can be described in a linear equation.

An exception is the measurement with PT 100 sensors, which is carried out by the
transmitter integrated with the I/O board. External PT 100 transmitters are assumed to be
linear. The IO card transmitters feed constant current into the PT 100 sensor. The voltage
drop, and thus the value from the converter, is thus proportional to the resistance, not the
temperature. To determine the temperature accurately, first the resistance must be
measured, then the temperature is calculated using a standard formula (according to DIN
43760 / IEC 571). For this purpose, the selection Conversion must be changed from
"linear" to "PT 100".

Note: These settings are factory-set and must not be changed! If a calibration should
become necessary due to an error, the measuring process must be aborted
first.
Temperature values can be output in Celsius or Fahrenheit. This is configured
by BARTEC BENKE during installation and first startup. It is not possible to
make alterations during program run, or to configure other measuring units.

Two examples of analog input and output calibration now follow, with different sensors:

PT 100:

• Select an Analog Input, e.g. "T_PRODUCT", and set the Conversion to "Pt-100".

• Instead of the PT 100 sensor, connect a potentiometer.

• Determine the calibration points (e.g. – 50 °C and + 50 °C), and enter these values in
the fields Convert Value Low and Convert Value High. The required resistance
values can now be read from the fields Physical Value Low and Physical Value
High.

• Set the resistance to the value in Physical Value Low. The value in field Digital
Value Current changes accordingly.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

28 The IO Menu

• Select this value with the arrow button to the left of field Digital Value Low.

• Set the resistance to the value in Physical Value High. The value in field Digital
Value Current changes accordingly.

• Select this value with the arrow button to the right of field Digital Value High. The
calibration is now complete. To save the changes, click Save, to exit without saving
the changes, click Cancel.

• After calibration, reconnect the sensor to the input.

Note: If you have the relevant resistance values available, during calibration you can
specify the "Physical Values" and read off the resulting "Converted Values", i.e.
the temperature, from the display fields.

4 – 20 mA:

• Select an Analog Output, e.g. "Freezing Point".

• Disconnect the output wiring and connect an ampere meter.

• Determine the range to be measured and enter it into fields Physical Value Low and
Physical Value High (you can also enter the range later).

• Copy the value in Physical Value Low into field Physical Value Current, using the
arrow button on the left. The output current should now be about 4 mA.

• Set the output current to 4 mA by changing the value in Digital Value Current, and
transfer this value into the field Digital Value Low with the arrow button on the left.

• Copy the value in Physical Value High into field Physical Value Current, using the
arrow button on the right. The output current should now be about 20 mA.

• Set the output current to 20 mA by changing the value in field Digital Value Current
and transfer this value into the field Digital Value High using the arrow button on
the right. The calibration is now complete. To save the changes, click Save, to exit
without saving the changes, click Cancel.

• After calibration, reconnect the output wiring.

Note: The physical range of the analog outputs can be changed at any time. The
calibration to the analog range of 4-20 mA is retained.

In the field Scan parameters the scan rate (Scan-Interval), filter constant (Filter-
Constant) and derivative constant (Deriv) for the analog inputs are set.

Note: These settings are factory-set and must not be changed!

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The IO Menu 29

In the File menu, you can load a software configuration (Load) or save a configuration
under a different name (Save As).

Select File – Load to load a software configuration. A dialog appears from which you can
select the required file. The standard path is
C:\Programs\BBS\Freezing Point\config. Click Load to load the selected
configuration file.

To save a configuration you have changed under a different name, so that it can be
reactivated later, select File – Save As. A dialog appears from which you can select the
file name and path for saving the configuration file. The standard path is
C:\Programs\BBS\Freezing Point\config.

Note: It is recommended to save a backup copy of the config directory. The

directory contains all PACS program settings, such as parameters, products,
alarms, and IO settings. For further information, please refer to chapter 5.

As soon as you have made a change, the Save button becomes active. To save the
changed settings, click Save, and then click Cancel to close the window. To close the
window without saving the changes, click Cancel.

Note: When the program starts, settings are always retrieved from the file conf.io.
The menu described above serves to save various configuration settings.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

30 The IO Menu

4.4 Modbus

As an addition or a substitute for the physical interface (analog outputs, digital outputs,
digital inputs) to the control system (DCS), an optional Modbus interface module can be
installed. This module is described in a separate manual (Modbus Interface Description
FRP-4).

To put this module into operation, the necessary hardware and software must be installed
and configured, and the parameter "ModbusActive" must be set to 1 (0 = inactive).

Select IO – Modbus from the menu to open the following window:

Figure 4.4: PACS - Modbus Data

The LED Active indicates the status of the connection to the master (DCS).

The remaining LEDs indicate the states of the digital inputs (Modbus) as monitored by the
analyzer. The inputs Analyse Reset, Validation RQ, Stream1/2 and Stream Auto
correspond to the digital inputs with the same name (physical, discrete connections).

4.5 Interface to the Controlling System

The following signals (partly optional) are part of the interface to the controlling master
system – in most cases, this is the Distributed Control System (DCS). They allow you to
transfer data, such as measuring results or alarm and status messages, and also serve to
operate the analyzer by remote control.

Instead of using an interface equipped with discrete signal lines, as described, the same
functionality can be achieved by using a field bus interface (option) with a Modbus
protocol.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The IO Menu 31

Analog Outputs (4..20mA)

• Measured value (FreezingPoint)

• Selected Signal (internal signal which can be selected in the PACS main window)

Digital Outputs

• Sumalarm: digital output for a sum alarm

• Ready: digital output which indicates the process state Ready (pulse duration can be
configured in the software).

• Validation ID: digital output for the validation cycle; this output is active when a
validation cycle is in progress.

• ParaSet_12: Depending on the selected product and its assigned parameter

"ParaSet", the digital output is set.

Digital Inputs

The digital inputs Analyse Reset, Validation RQ, and Stream 1/2 (option) are also
external connections to the control system. These inputs can be operated externally by
the user, if the option Remote is activated in the main window (only available at Expert
level or higher).

• If the input Analyse Reset is operated, the current analysis cycle is interrupted (the
same result can be achieved by clicking on Press to Reset in the main window). As
long as the input is kept active, the analysis process remains in the state "DoNothing"
(standby).

• If the input Validation RQ is operated, the current measuring cycle is finished

without interruption, if the parameter "ValidationCycleBreak" has the value 0.
Otherwise ("ValidationCycleBreak" = 1), the measuring cycle is aborted immediately.
Afterwards, the number of validation cycles specified in the parameter
"ValidationCycleNo" is carried out. As long as the input is still active, the validation
cycles continue until the input is reset.

• The input Stream 1/2 is used to select the product in remote operation.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

32 The IO Menu

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The Configure Menu 33

5 The Configure Menu

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

34 The Configure Menu

5.1 Overview

The options in the Configure menu allow you to set the values for process parameters,
products and alarms.

Figure 5.1: PACS - Configure Menu

For the process run, PACS requires a number of settings for the configuration parameters.
Some of these parameters are of general scope and are valid for the instrument,
independently of the product. Other parameters are product-specific. These settings can
be defined in the Configure menu.

Parameter.. :
• general settings, independent of the product
• file: .\config\conf.par

Products.. :
• product-specific settings
• file: .\config\conf.pro

Alarms.. :
• software-specific settings
• file: .\config\conf.al

IO (access via IO – Configure):

• general settings, independent of the product
• file: .\config\conf.io

Note: It is recommended to save a backup copy of the config directory. The

directory contains all PACS program settings, such as parameters, products,
alarms, and IO settings. The standard path is
C:\Programs\BBS\Freezing Point\config.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The Configure Menu 35

5.2 Configuring General Parameters

To define the process parameters, select Configure – Parameters... The following

window appears:

Figure 5.2: PACS - Configuration of General Parameters

The window header shows the path and name of the file which contains the PACS process
parameters.

In this window, you can set two types of parameters. In the upper section of the window
(section General), general process parameters and their values are set, such as a time
("ReadyTime") or a temperature limit ("TmaxInlet") for the maximum product
temperature. These general process parameters refer to all products.

To define a general parameter, click on Parameter Name in the section General. A

drop-down menu opens with the parameters you can select by clicking. A Value is
assigned to each parameter. You can change the parameter value by using the arrow
buttons next to it, or by typing the new value directly into the field.

In the central section of the window (Controller), you can configure the controller
parameters, in this case for a PID controller. You can view and change the values as
described above. A set of parameters is assigned to a controller. To change a parameter of
a controller, first select the controller with the button Controller Name, and then select
the parameter with the button Parameter Name. You can now change the value of the
parameter in the field Value.

Note: All parameters are preset by the manufacturer before delivery. If adaptation to
the product is required, only the general process parameters (General) should
be changed.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

36 The Configure Menu

From the File menu you can load a set of parameters (Load) or save a it under a different
name (Save As).

Select File – Load to load a set of parameters which was saved previously. A dialog
appears from which you can select the required file. The standard path is
C:\Programs\BBS\Freezing Point\config. Click Load to load the selected
configuration file.

To save a changed set of parameters under a different name, so that it can be reactivated
later, select File – Save As. A dialog appears from which you can select the file name and
path for saving the file. The standard path is
C:\Programs\BBS\Freezing Point\config.

As soon as you have made a change, the Save button becomes active. To save the
changed settings, click Save, and then click Cancel to close the window. To close the
window without saving the changes, click Cancel.

5.3 Configuring Product-Specific Parameters

A product is here defined as a liquid hydrocarbon with a limited scope of physical

properties. To this product, a set of parameters is assigned in order to optimize the
analytic process with reference to those properties.

Select Configure – Products.. to create or delete products and to edit the product-
specific parameters.

Figure 5.3: PACS - Configuration of Product-Specific Parameters

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The Configure Menu 37

In the field Product, select the product whose parameters you want to edit.

Use Delete to delete the product shown under Product, unless it is currently active in the
analytic process, and unless it is the only product in the list.

Use New.. to create a copy of the parameter set shown under Product. If less products
are defined than licensed, a pop-up window appears in which you must enter the name of
the new product:

Figure 5.4: PACS - Defining a New Product

In the field Product depending Parameter, a set of product-dependent parameters is

defined, such as the DeadTime or the FlushingTime for the product shown under
Product. The values are displayed under Value. They can be edited at Expert level.

As soon as you have made a change, the Save button becomes active. To save the
changed settings, click Save, and then click Cancel to close the window. To close the
window without saving the changes, click Cancel.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

38 The Configure Menu

5.4 Checking and Viewing Alarms

Select Configure – Alarms.. to view the alarms triggered by PACS in the event of an
error.

Figure 5.5: PACS - Alarm Table

The error message is displayed under Message. The reaction to the errors is preset or
changed by the manufacturer. There is a difference between alarms and warnings.
Warnings generally indicate only minor deviations in the process flow, e.g. inaccurate
measuring results. Alarms are severe errors which cause an interruption of the process or
a system shutdown. This is indicated by a 1 in the line for the resulting response to the
error. Additionally, if mA 0 is marked with a 1, the analog outputs will also be initialized.

For a list of errors and necessary steps for troubleshooting, please refer to section 8.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The Report Menu 39

6 The Report Menu

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

40 The Report Menu

6.1 Overview

In the Report menu, you can view the protocol entries of the last n days (n being the
number defined in the parameter "_historylen"). Earlier protocol entries are saved in the
subdirectory \Freezing Point\data\Archive, if the size of the archive directory
does not exceed 1 MB.

Figure 6.1: PACS - Report Menu

6.2 History Table

To open the History Table, select Report – History Table.

Figure 6.2: PACS - History Table

The History table contains the measuring results of the last n days (n being the number
defined in the parameter "_historylen") with the date and time of the entry ("Date",
"Time"). Additionally, the table records the stream from which the measuring result was
obtained ("Str."), and whether the cycle was a validation cycle ("Val.").

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The Report Menu 41

6.3 Viewing the LogBook

The LogBook records different types of events chronologically (for types, see ID). To view
the LogBook, select Report – Logbook from the menu.

Figure 6.3: PACS - LogBook

The window contains the protocol entries of the last n days (n being the number defined
in the parameter "_historylen"). Each entry contains the date and time of the entry
("Date", "Time"), an ID which classifies the type of entry ("ID"), and a message which
contains further information ("Message"). There are the following ID types:

A (Action): Action during the process flow, e.g. program start ("StartProgram")
E (Error): Error messages
N (Note): Operator's comments
R (Result): Measured result
W (Warning): Warning messages

Adding Protocol Entries

To add an entry to the LogBook, select Report – Add Message. A window appears
where you can enter the required information. When finished, click Enter. The entry will
be added to the LogBook, together with the current date and time, and marked with the
ID N (Note).

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

42 The Report Menu

6.4 Viewing the Alarm Table

To view the Alarm Table, select Report – Alarm Table.

Figure 6.4: PACS - Alarm Table

The Alarm Table contains the alarms of the last n days (n being the number defined in
the parameter "_historylen") with the date and time of the entry ("Date", "Time").
Additionally, the alarm configuration is displayed in coded form under A/W.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

The Help Menu 43

7 The Help Menu

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

44 The Help Menu

7.1 Overview

The Help menu offers help for working with PACS.

Figure 7.1: PACS - Help Menu

Select Help – Manual(s) to access the system documentation as a PDF file. A dialog
window opens in which you can select the required document.

Figure 7.2: PACS - Manuals

Select Help – About for information on the manufacturer and the software version. This
information is useful if you need to contact the manufacturer.

Figure 7.3: About PACS

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Troubleshooting 45

8 Troubleshooting

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

46 Troubleshooting

8.1 Error Monitoring in PACS

PACS constantly monitors key system functions and issues error messages when a fault
occurs.

There are four basic error types:

• Errors in the start-up program (StartUp-Error), which are displayed as soon as the
program is started.

• Real-time or program faults (Internal CVI Error), which can occur during operation.

• Errors in the analyzer, which are generated based on constant monitoring. They are
displayed in the Report – Alarm Table menu and in the Error field in the main
window.

• Error messages from the analysis process, which are generated independently from
the process state. They are displayed in the Report – Alarm Table menu and in the
Error field in the main window.

Note: If the program terminates, the Watchdog will be activated, i.e. a system reset
will be carried out and the program will be restarted. In this case, the
LogBook contains the comment "Start_after_abnormal_Termination".

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Troubleshooting 47

8.2 List of Error Messages

The following list of error messages gives you information on the cause of the problem
and the necessary steps to be taken.

General Errors

Error Message Cause / Result Troubleshooting

Error, Freezing Point is The analyzer program can

already running ! No only run once.
Duplicate Allowed.

Errors in the StartUp Program

Error Message Cause / Result Troubleshooting

StartUp-Error, Unable to The UIR file is not available Check that the file exists in
load MAIN PANEL ! or damaged, or there is a the UIR subdirectory. It may
memory problem. be necessary to reinstall the
StartUp-Error, Unable to
program. If you reinstall the
load History Table !
program, the conf.* files
StartUp-Error, Unable to must not be overwritten, or
load About Panel ! the original files must be
copied back into the
StartUp-Error, Unable to
config directory. Restart
display Selectout Graph !
the program.
StartUp-Error, Unable to
load MAIN MENU BAR !

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

48 Troubleshooting

Error Message Cause / Result Troubleshooting

StartUp-Error, Unable to The UIR file is not available Check that the file exists in
display MAIN PANEL ! or damaged, or there is a the UIR subdirectory. It may
memory problem. be necessary to reinstall the
StartUp-Error, Unable to
program. If you reinstall the
load IO_Test PANEL !
program, the conf.* files
StartUp-Error, Unable to must not be overwritten, or
load IO_Config PANEL ! the original files must be
copied back into the
StartUp-Error, Unable to
config directory. Restart
load IO Menue !
the program.
StartUp-Error, Unable to
load Parameter PANEL !
StartUp-Error, Unable to
load Parameter Menue !
StartUp-Error, Unable to
load Alarms")
StartUp-Error, Unable to
load Alarms PANEL !
StartUp-Error, Unable to
load Alarms Menue !
StartUp-Error, Unable to
load Alarm Table !
StartUp-Error, Unable to The UIR file is not available Check that the file exists in
load Product PANEL ! or damaged, or there is a the UIR subdirectory. It may
memory problem. be necessary to reinstall the
StartUp-Error, Unable to
program. If you reinstall the
load Password Panel !
program, the conf.* files
must not be overwritten, or
the original files must be
copied back into the
config directory. Restart
the program.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Troubleshooting 49

Error Message Cause / Result Troubleshooting

StartUp-Error, Unable to The configuration file is not Check that the file exists in
load conf.io ! Check if the available or damaged, or the config subdirectory
file is present and isn’t there is a memory problem. and that it is not being used
occupied by another by another program (e.g.
application. Notepad). If necessary,
replace missing files with
StartUp-Error, Unable to
backup files. Restart the
load conf.par ! Check if the
program.
file is present and isn’t
occupied by another
application.
StartUp-Error, Unable to
load conf.pro ! Check if the
file is present and isn’t
occupied by another
application.
Unable to access IO-board ! The IO board is not Check the supply voltage for
Continue without available, i.e. the IO board, the IO board, the
connection ? the ISA board or the connectors, the cable and
connection cable are missing the correct location of the
or defective. ISA board.

Real-time / Program Errors

Error Message Cause / Result Troubleshooting

Internal CVI-Error, Unable to There is a memory problem Restart the program or the
display About Panel ! or a program fault. entire system. Check for
possible memory errors.
Internal CVI-Error, Receiver
Panel not open !
Internal CVI-Error, Unable to
display Panel for
IO-Test !

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

50 Troubleshooting

Error Message Cause / Result Troubleshooting

Internal CVI-Error, Unable to There is a memory problem Restart the program or the
display Panel for Parameter- or a program fault. entire system. Check for
Configuration ! possible memory errors.
Internal CVI-Error, Unable to
display Panel for Product-
Configuration !
Internal CVI-Error, Unable to
display Panel for Password !
Internal CVI-Error, Unable to
display Panel for History !
Unable to display Panel for
Alarm-Configuration !
Unable to display Panel for
LogBook !
Unable to display Selectout
Graph!

Process State Errors

Note: These errors are displayed in the Alarm Table and in the Error section in the
main window. Since the error messages can be configured, depending on
language, the error TAGs are relevant.

Error Message / (TAG) Cause / Result Troubleshooting

Heating Time too long ! StartTemperature Click on Press to Reset.

(WcellStart =
(TA_TT_HEATING) Check the parameters:
CellTemperature) was not
settings for controller,
reached within time
parameters FlushingTime1,
FlushingTime1 in program
WCellStart.
step Flushing/Heating.
Check Peltier elements and
replace, if necessary.
May indicate that product is
too cold.
Cell too hot for Product Before product enters, the Check the cell temperature
Inlet ! system checks if the cell is and the parameter
too hot. TmaxInlet !
(TA_TH_CELL)
Click on Press to Reset or
activate the reset line.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Troubleshooting 51

Error Message / (TAG) Cause / Result Troubleshooting

Lower Limit Temperature In the program step Sample Check parameter

Product ! Check, the product was too ProductTempLow, check
cold. product temperature!
(TA_TL_PRODUCT)
Click on Press to Reset or
activate the reset line.
Upper Limit Temperature In the program step Sample Check parameter
Product ! Check, the product was too ProductTempHigh, check
hot. product temperature! Click
(TA_TH_PRODUCT)
on Press to Reset.
Process in Unknown State Undefined process state! Correct / repair external
fault.
(TA_UK_STATE) Caused only by external
fault, e.g. power failure. Click on Press to Reset or
activate the reset line.
Process received unknown Process received an Correct / repair external
Command! undefined command. fault.
(TA_UK_CMD) Caused only by external Click on Press to Reset or
fault, e.g. power failure. activate the reset line.

Alignment NOT OK ! Detector could not be Check the parameter

balanced. "DetectorTest"!
(TA_AL_MEAS_OUT)
IR diode or LED faulty or If required, re-calibrate the
open circuit. IR light sensor.
Detector signal is lower than Click on Press to Reset or
parameter "DetectorTest" activate the reset line.
IR light sensor is calibrated
incorrectly
Switch over Point from Temperature difference Check the parameter values!
Cooling 2 to Cooling 3 too between start of Cooling2
Click on Press to Reset or
early ! and freezing point detection
activate the reset line.
is too low (should be about
(TA_SW_COOL23EARLY)
10 - 12°C)
Temperature Gap prestage/ Temperature difference Check the parameters:
cell in step Cooling 1 ! (DiffTempCellCooler) - DiffTempCellCooler
between intermediate stage
(TA_TG_COOLING1) - GradientCool1
and cell is not attained
during step Cooling1 - CoolTime1

Incorrect parameter settings Check

- Peltier elements
Possible defects:
Peltier element, controls, or - the corresponting controls
PT 100 - and PT 100
Click on Press to Reset or
activate the reset line.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

52 Troubleshooting

Error Message / (TAG) Cause / Result Troubleshooting

Cloud Point Found in Warning ! Check the product-

Cooling 1 or Cooling 2 ! dependent parameter
Cloud Point was detected in
Gradient Cool2.
(TA_CF_COOL12) step Cooling 2
Check the sample
This warning message is
conditioning system.
normal in the first cycle!
Click on Press to Reset or
If the cloud point is detected
activate the reset line.
again in step Cooling 2
during subsequent cycles,
the cooling rate
(GradientCool2) is too high.
Possibly, the product
contains gas bubbles or dirt
particles.
Timeout cooling 2 ! The system did not switch to Check the product-
the process step Cooling 3 dependent parameters
(TA_TO_COOL2)
within the time defined in "CoolTime2" (too short) and
the parameter "CoolTime2". "GradientCool2" (too low).
Switching takes place either After a product change, also
when the cloud point is check the "_lastFreezPoint"
reached and the parameter
("SwitchOffFreezDer"), or at "SwitchOffFreezDer".
a temperature difference of
Check
X°C
(X = "SwitchPointCool23") - Peltier elements
before the last freezing point - the corresponting controls
is reached. - and PT 100
Click on Press to Reset or
activate reset line.
Timeout cooling 3 ! The system did not switch to Check the product-
the process step Freezing dependent parameters
(TA_TO_COOL3)
Point Detection within the "CoolTime3" (too short) and
time defined in the "GradientCool3" (too low).
parameter "CoolTime3". After a product change, also
Switching takes place when check the "_lastFreezPoint"
the cloud point is reached and the parameter
("SwitchOffFreezDer"). "SwitchOffFreezDer".
Check
- Peltier elements
- the corresponting controls
- and PT 100
Click on Press to Reset or
activate reset line.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Troubleshooting 53

Error Message / (TAG) Cause / Result Troubleshooting

No Flow through Test Cell in In the process step Check the product
step flushing/heating ! Flushing/Heating, a check is temperature, the parameter
carried out whether product "Flowcheck", and the
(TA_NF_CELL)
is flowing into the cell. For temperature of the
this purpose, the system intermediate stage (as,
checks whether the before the valve is opened,
temperature in the the cell is heated at least to
measuring cell rises above the temperature of the
the parameter "Flowcheck". intermediate stage) !
If the temperature is not
Check the sample
reached, this indicates that
conditioning system and the
there is no product flow into
valves.
the cell.
Click on Press to Reset or
activate reset line.
Prestage Temperature not In the process step Check the parameters
reached in Time ! Flushing/Heating or Freezing "HeatingRamp" (too low)
Point Detection, the and "FlushingTime1" (too
(TA_TO_PRESTAGE)
measuring cell did not reach short).
the target temperature
Check
within the time defined in
"FlushingTime1". - Peltier elements
- the corresponting controls
Possible defects:
Peltier element of the - and PT 100
measuring cell, controls, or Click on Press to Reset or
PT 100 activate reset line.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

54 Troubleshooting

Error Message / (TAG) Cause / Result Troubleshooting

Timeout Freezing Point The freezing point could not Check the parameter values!
Detection ! be detected within the time
2 + 3. The values can be set
"Timeout Freez".
(TA_TO_FREEZ) to zero. If the problem is
The freezing point is solved but the freezing point
detected when the is slightly too low, the value
normalized detector signal "FreezPointDet" should be
reaches the value of the raised in small steps. (e.g.
cloud point plus the product- 0.05).
specific parameter
Check the sample
"FreezPointDet". Before, the
conditioning system.
value must once fall below
the offset ("CloudPointDet") Click on Press to Reset or
to the cloud point. During activate reset line.
Freezing Point Detection,
the cell is heated slowly with
the gradient
"CoolGradient3".
Possible causes:
1. "CoolGradient3" is too
small in relation to the time
„TimeOutFreez“
2. "CloudPointDet" too high
(value never falls below)
3. "FreezPointDet" too high
(detector value cannot be
reached within the defined
time)
4. False detection of the
cloud point caused by dirt
particles or gas bubbles
Prestage too cold for this While switching from Check the parameter values!
Process / Product ! Cooling 3 to Freezing Point
The parameter "CntrPre-
Detection, the temperature
(TA_T_PRESTAGE) StageW" should be adjusted
difference to the
(min. 10°C above the
intermediate stage is less
expected freezing point).
than 5°C. In this case, the
measuring cell cannot be Click on Press to Reset or
heated in a defined manner. activate reset line.
The intermediate stage is
too cold for the product.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Troubleshooting 55

Errors from System Monitors

Note: These errors are displayed in the History Table and in the main window. Since
the error messages can be configured, depending on language, the error TAGs
are relevant.

Error Message / (TAG) Cause / Result Troubleshooting

Heat Exchanger of peltier Water temperature in the Check temperature of

elements too warm ! heat exchanger is too high. cooling water.
(TA_TH_HEATEXCHANGER) (Parameter: Click on Press to Reset or
WaterTempHigh) activate the reset line.
Heat Exchanger of peltier Water temperature in the Check temperature of
elements too cold ! heat exchanger is too low. cooling water.
(TA_TL_HEATEXCHANGER) (Parameter: Click on Press to Reset or
WaterTempLow) activate the reset line.
Measuring Temperature out The product temperature Check the product
of Range ! does not lie within the temperature, and also the
permitted range respective temperatures of
(TA_TL_MEAS_OUT)
(parameters: intermediate stage and heat
"ProductTempMin", exchanger (cooling water) !
"ProductTempHigh")
Check the tempering in the
or -85°C to 55°C, if no sample conditioning system.
product is selected
Click on Press to Reset or
activate the reset line.
Phototransistor out of The photo transistor input Check the LED and the
Range ! receives an implausible photo transistor.
value while the LED is
(TA_PH_TRANSISTOR) Click on Press to Reset or
switched on.
activate the reset line.
Photo transistor or LED
faulty, or open circuit, or
error in IO board.
OverTemperature Board ! The IO board is too warm! Check ambient conditions
(surrounding temperature)!
(TA_TH_BOARD)

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

56 Troubleshooting

Error Message / (TAG) Cause / Result Troubleshooting

Temperature fuse at heat The temperature fuse at the Check the cooling system.
exchanger broken ! heat exchanger or at the
Check the parameter
intermediate stage is
(TA_LOCKOUT) "WaterTempHigh", as this
broken, or the thermostat
should trigger the error
switch of the heat
"Prestage too warm !" or
exchanger was actuated, or
"Heat Exchanger of Peltier
the temperature of the
Elements too warm !",
measuring cell is too high.
before the temperature
The cable connection to the fuses melt.
temperature fuse is
After solving the problem,
interrupted, or the
replace the faulty
temperature fuse is faulty.
temperature fuse, if
The temperature of 76°C required, and restart the
was exceeded for a short analyzer.
period at the heat
exchanger or the
intermediate stage. (Before
this temperature is reached,
the analyzer should normally
have been deactivated by
other errors.)
There is probably a problem
at the cooling system
(coolant flow has stopped or
is too low).
Prestage too cold ! Temperature of the Check the temperature of
intermediate stage lies the intermediate stage, the
(TA_TL_PRESTAGE)
below -60°C. (As this sensor and its calibration,
temperature is not reached and the parameter "CntrPre-
during normal operation, it StageW".
indicates an error of the
Click on Press to Reset or
PT-100 / calibration.)
activate the reset line.
Overpressure in contaiment The pressure in the product Check the entire line system
pressure switch 1 ! inlet of the measuring cell for possible clogging,
has risen above 0.3 bar. particularly Slop and Vent.
(TA_OVERPRESS_1)
Check the pressure reducer
of the product and the flow
rate.
Click on Press to Reset or
activate the reset line.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Troubleshooting 57

Error Message / (TAG) Cause / Result Troubleshooting

Overpressure in contaiment The pressure in the product Check the entire line system
pressure switch 2 / inlet of the measuring cell for possible clogging,
Lockout ! has risen above 0.5 bar. particularly Slop and Vent.
(TA_OVERPRESS_2) Check the pressure reducer
of the product and the flow
rate.
Make sure that you have
removed the cause of the
overpressure. Then, set the
digital output Product
Enable manually, and click
on Press to Reset or
activate the reset line.

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

58 Troubleshooting

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Program Parameters 59

9 Program Parameters

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

60 Program Parameters

9.1 List of Parameters

The following table contains a list of parameters which control the flow of the analysis
cycle.

Note: Generally, changes in these parameters will not become active immediately,
but only at the start of the next analysis cycle.
A small number of parameters will only become active after a program restart.
These parameters are marked with "#N" (New start) in the table.

For every parameter, the recommended value or range is indicated. The following
abbreviations are used:

B binary value 1 or 0 (Yes/No, active/not active, true/false)

N integer without unit
T temperature in the configured unit °C or °F
DT temperature difference in the configured unit °C or °F
% percent
U factor in reference to 1 (1 corresponds to 100%)
s seconds
h hours
DTps temperature difference in the configured unit °C or °F per second
- no recommendation

Note: Temperature values can be output in Celsius or Fahrenheit. This is configured

by the manufacturer during installation and first startup. It is not possible to
make alterations during program run, or to configure other measuring units. In
the following table, all temperature values are given in °C.

Parameter Value/Range Meaning

Product-dependent Parameters:
CloudinessController 30 .. 60 s Periodic time (repeat time) for rebalancing
the detector during cooling stage 2
(Cooling2) (only transmission, not in first
cycle).
CloudPointDet 0.08 U Offset for the detected cloud point of the
normalized detector signal, must be
underrun before detection of freezing point.

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Program Parameters 61

Parameter Value/Range Meaning

CntrPre-StageW -15 .. -35 T Target temperature of the intermediate
stage, depending on the expected freezing
point
CoolTime1 600 s Maximum time for cooling stage 1
(Cooling1)
CoolTime2 1200 s Maximum time for cooling stage 2
(Cooling2)
CoolTime3 600 s Maximum time for cooling stage 3
(Cooling3)
DeadTime 60 .. 300 s Duration of the program step DeadTime
DetectionDelay 0.0 s Time in seconds for how long the detection
value must be reached in order to signal a
true detection (eliminates the effect of gas
bubbles etc.)
FreezPointDet 0.05 U The freezing point is detected when the
normalized detector signal reaches the value
of the cloud point (normalized detector
signal) plus the product-specific parameter
"FreezPointDet".
FlushingTime1 60 .. 240 s Maximum time for adapting the product
temperature to the temperature of the
intermediate stage in the state
Flushing/Heating, and for reheating the cell
to the temperature of the intermediate stage
in the step Freezing Point Detection
FlushingTime2 60 .. 240 s Duration of the program step Flushing
GradientCool1 0,10 .. 0.25 DTps Cooling rate for program step Cooling1
GradientCool2 0,05 .. 0.15 DTps Cooling rate for program step Cooling2
GradientCool3 0,05 .. 0.1 DTps Cooling rate for program step Cooling3
HeatingRamp 0.7 DTps Heating rate for the program step
Flushing/Heating, and for heating the
measuring cell to the temperature of the
intermediate stage after Freezing Point
Detection
LED_Level 1N controls the luminosity of the LED in three
steps (0 - 2)
Offset 0.0 T Offset value for freezing point
PolDetection 1U Limit value for polarization detection of the
cloud point
PolFreezDetection 1,1 Limit value for polarization detection of the
freezing point

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

62 Program Parameters

Parameter Value/Range Meaning

ProdTempHigh 15 .. 40 T Maximum product temperature in program
step Sample Check
ProdTempLow -10 .. +10 T Minimum product temperature in program
step Sample Check
ProdTempMin -80 T Minimum product temperature in all process
steps
StabilizingTime 3s Time parameter for program step Sample
Check
SwitchOffFreezDer -1,3 Threshold value for Cloud Point detection in
program step Cooling 3 (1st derivative)
SwitchPointCool23 3 DT Temperature difference to last Freezing
Point, triggers switching from Cooling2 to
Cooling3
WCellStart 10 .. 30 T Cell temperature which must be reached
before start in step Flushing Heating
General Parameters:
DetectorDarkPol 0.2 U Limit value for detector test in polarization
method (dark current test, value of the
detector signal – direct, not normalized –
which must be underrun in process step
ALIGNMENT, with deactivated LED)
DetectorDarkTest 0.6 U Limit value for detector test in transmission
method (dark current test, value of the
detector signal – normalized – which must
be underrun in process step ALIGNMENT,
with deactivated LED)
DetectorTest 0.8 U Parameter for detector test in transmission
detection (minimum value of normalized
detector signal in process step ALIGNMENT,
with activated LED)
DiffTempCellCooler 1 DT Parameter to check function of Peltier
elements in program step Cooling 1.
Triggers next step if value is exceeded.
Fahrenheit 0B 0 = all temperatures in the display and the
configuration files (*.conf) are given in
degrees Celsius
1 = all temperatures in the display and the
configuration files (*.conf) are given in
degrees Fahrenheit

PACS Software for FRP-4 Version 1.0.1., 23.08.2004

Program Parameters 63

Parameter Value/Range Meaning

FlowCheck -10 .. +10 T Indirect check if product is flowing through
the cell. If value is not reached within
"StartHeatTime" during Flushing Heating,
alarm is triggered
ModbusActive (#N) - 1 = active, 0 = not active
(as ordered) If ModbusActive=1, the Modbus interface
(DDE-Client MB_DDE.exe = option) is
started at program start-up. While the
program is running, the digital inputs are
read via Modbus instead of via the physical
interface.
(Changes in this parameter will only become
active after restarting the program.)
ReadyTime 5 .. 60 s Time interval during which the digital output
Ready remains set after a measuring cycle
StartHeatTime 10 .. 45 s Waiting time in program step Flushing
Heating before heating is started (see also
Flow Check)
StartUpDelay (#N) 5s Waiting time before PACS communicates
with the I/O board.
(Changes in this parameter will only become
active after restarting the program.)
TmaxInlet 50 T Maximum product inlet temperature
TimeOutFreez 600 s Maximum time for the process step Freezing
Point Detection
TimeOutPrestage 900 s Maximum time for reaching the temperature
"CntrPre-StageW" of the intermediate stage
(Pre-Stage)
ValidationCycleBreak 1 0 = Validation cycle starts after a complete
process cycle
1 = Validation cycle starts immediately,
current analysis is aborted
ValidationOutDelay 20 .. 60 s Delay time for validation output valve
(option)
ValidationCycleNo 3N Number of validation cycles
WaterTempHigh 40 .. 50 T Maximum temperature for heat exchanger
WaterTempLow -30 .. 0 T Minimum temperature for heat exchanger

Version 1.0.1., 23.08.2004 PACS Software for FRP-4

64 Program Parameters

Parameter Value/Range Meaning

Further values which are set by PACS:
These parameters begin with an underscore and should not be changed.
_abnormalTermination - Detects whether program ended normally or
was interrupted by power cut or other cause
_autoStart - Process starts immediately after program
start
_historylen - Maximum number of days for which entries
are displayed in History Table, LogBook, and
Alarm Table.
_lastarchivetime - Internal time, when History Table, Log Book,
and Alarm Table were last archived
_lastFreezPoint - Last measured Freezing Point
_lastCloudPointTime - Internal time, when last Cloud Point was
measured
_online - After exiting the program, this internal
variable contains information on the most
recently selected stream

PACS Software for FRP-4 Version 1.0.1., 23.08.2004