Troubleshooting, Repairing and Replacing D/3^® I/O

The existing 16000 Series I/O has been in service for many years and has proven to be very reliable.  However over time the I/O may start to degrade somewhat due to several factors, including environmental issues.  Therefore the issue naturally arises as to how to maintain the I/O if you use the GATEWAY 16000 to migrate to a new Control System.

PCT can repair and/or replace all types of D/3^® I/O modules and associated equipment. We can help you maintain your I/O and restore it to like new condition at a fraction of the cost of replacement and provide many more years of service.

Below are some Frequently Asked Questions about maintaining D/3^® I/O.
  The first section is General Questions
  The second section features Specific I/O Problems

General I/O Questions

Specific I/O Problems

Answers to Frequently Asked Questions

If I use the GATEWAY 16000 to migrate my 16000 I/O to a new system, who will support the I/O?
PCT can repair and/or replace all types of D/3^® I/O modules and associated equipment.
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Is there a warranty on your repairs?
Yes. PCT's module repair service includes two week turnaround and is warranted for ninety days from the time the equipment is put into service, or for one year from the delivery date, whichever occurs first.
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What is the turn around on repairs?
For non-expedited repairs typical turn around time is two weeks or less after receipt of the item to be repaired.  If you are in a rush we can turn around a repair in three days or less for an expediting fee of 20% (on most items).  We also have an advanced exchange program for items we have on the shelf in which case we can ship the day we receive the order.
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Specifically what parts does PCT have available for replacement?
A detailed list can be found on the D/3 DCS^® Hardware Price List. This price list includes both I/O and other system components.
In addition there are I/O kits listed on D/3 DCS^® Hardware Kits Price List.
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Does PCT manufacture any of the parts?
Parts on D/3 DCS^® Hardware Price List that begin with PCT are manufactured by PCT.  All other parts are new or refurbished original equipment.
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How can I be sure of the quality of repairs and used parts?
All used parts supplied by PCT are refurbished and covered by our warranty.  When PCT repairs or refurbishes an item we replace the failed component(s) and the item is tested for a minimum of 24 hours.  Parts refurbished or repaired by PCT have a less than 1% failure rate during the warranty period.
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Does PCT have guaranteed response maintenance contracts?
Process Computer Technology has the capability to provide on-site maintenance and repair services for both your D/3 ^® I/0 and the complete D/3 DCS^®. Several levels of assistance are available, from basic phone support to 24 hour 7 day on-site.  Service contracts are custom written to the customer's specifications.

I am tired of getting called out at 2 in the morning to fix bad analog points.  Does PCT have a fix for this situation?
Sticking or bad contacts on the Analog Input Relay Termination Panels is a common problem.  One bad relay on a 16 point board can cause all points to give erroneous readings.  PCT manufactures operationally compatible solid state relay modules as a replacement for the mechanical reed relays on the termination panel.  Solid-state relays have a longer life expectancy but when they do fail they tend to fail open, affecting only one point.
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Why do the analog input reed relays fail so often?
The reed relays in the analog intput cards are mechanical relays and are therefore subject to mechanical failure.  The typical service life of the reed relays in this application is five to seven years.  The solid-state relays used by PCT are not subject to mechanical failure.  Barring unexpected problems such as shorts or lightning strikes the solid-state relays should not need to be replaced for the life of the system.  In order to eliminate unpleasant surprises in the middle of the night PCT recommends replacing the reed relays with solid-state relays after five years of service.
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My analog output cards are starting to fail and when they do all 8 points go out.  Does PCT have a solution?
Failures on the Multiple Analog Output Termination Panel requires 8 outputs be taken out of service to replace the termination panel in order to repair the one failing output.  This occurs because the termination panel has active components for each output.  PCT has developed an 8 or 16 analog output direct replacement kit whose termination panel has no active components, virtually eliminating one failure affecting any other outputs.
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When I work on my PCM I style I/O termination panels I seem to have intermittent failures.  I suspect a short.  Can you help me?
Yes, this is another common problem. The PCM I style I/O termination panels has intermittent failures when the termination panel door is opened to gain access to the field wiring terminations.  PCT can provide replacement wiring harnesses to eliminate bad connections which cause this problem.
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I am having problems with the 16000 Series I/O Multiplexer backplane.   What can PCT do for me?
PCT manufactures replacement units which are fully compatible.
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My power supplies are starting to get noisy causing me all sorts of problems.  Will replacement power supplies be available?
Power supplies become noisy and unreliable over time.  PCT offers a full line of replacement power supplies for the D/3^® including MUX and Excitation power supplies as well as PCM I, PCM II & III Micro Power supplies.  For details and a review of new features such as front panel adjustments see the PCT Power Supplies page (Acrobat format).  And if you decide to keep your old power supply PCT manufactures a power supply tester which enables you to adjust power supplies under load conditions on the bench.
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