Fid Cell Access; Replacing The Breather; Replacing The Thermocouple Assembly; Replacing The Polarizer - ABB PGC5000 Series Service Instructions Manual

PGC5000
PGC5000 Series Service Instructions

7.2.1 FID cell access

1. If power is applied to the analyzer, turn it off.
2. Turn off oven air to the Isothermal Oven and allow all temperature zones to cool.
3. Turn off carrier and other utility gases, as applicable.
4. Open the isothermal oven door.

7.2.2 Replacing the breather

1. Loosen the breather set screw using a 0.050-inch Allen wrench, then extract the adapter fitting from the detector.
2. Using a 9/16-inch open-end wrench and a 1/2-inch backup wrench, disconnect 1/4-inch vent connection from breather.
3. Remove the breather with adapter fitting from the analyzer oven.
4. Remove adapter fitting from breather using 3/4-inch and 1/2-inch open-end wrenches.
5. Using a 3/4-inch open-end wrench and a 1/2-inch backup wrench, remove the 1/4-inch male connector from the existing
breather.
6. Remove existing PTFE tape from the nipple of the adapter fitting and apply new tape.
7. Remove the existing PTFE tape from the male connector and apply new tape.
8. Install the detector outlet adapter into the breather and finger tighten. Finish tightening using 3/4-inch and 1/2-inch open-
end wrenches.
9. Install the 1/4-inch male connector into the breather using 3/4-inch and 1/2-inch open-end wrenches.
10. Connect the 1/4-inch detector vent tubing to the breather. Finger tighten, then tighten with a 9/16-inch open-end wrench
and a 1/2-inch backup wrench.
11. Ensure the detector vent o-ring is in place in the adapter fitting.
12. Finish installing the breather by inserting the cylindrical end of the adapter fitting completely into the detector outlet and
tightening the set screw with a 0.050-inch hex key wrench. Note the set screw will fit into the groove of the adapter fitting
when it is installed correctly.
13. Reconnect the red coaxial cable to the top of the detector.
14. Close and secure the isothermal oven door.

7.2.3 Replacing the thermocouple assembly

1. Locate the thermocouple assembly as identified by the two red and black wires.
2. If applicable, remove any cable ties and free the wiring to expose the wire splices.
3. Cut and remove the heat shrink and glass tape from the red and black wires to expose the soldered connections.
4. Using a 40 watt soldering iron, disconnect the wiring splice.
5. Using a 3/8-inch open-end wrench, carefully remove the thermocouple. Note its location for reassembly.
6. Carefully insert the replacement thermocouple into the detector body and finger-tighten, taking care not to damage it.
Finish tightening using a 3/8-inch open-end wrench.
7. Roll each end of the red and black wires of the new thermocouple assembly between your forefinger and thumb, causing
the wire ends to be tightly spiral wrapped.
8. Using the 40 watt soldering iron and approved high temperature solder, "tin" the wire ends.
9. Spread or expand the end of approved heat shrink to allow easy installation over the solder connection.
10. Install the heat shrink over each of the wires and slide it as far as possible from the connection. This will prevent
premature shrinking of it when the connection is soldered.
11. Overlap the "tinned" ends of the red wire from the analyzer electronics and red element assembly wire, then solder the
wires together using approved high temperature solder and the 40 watt soldering iron.
12. Repeat step 11 for the black wire.
13. Apply a short wrap of glass tape over each connection.
14. Slide the heat shrink over the soldered connection and shrink it with a heat gun.
15. Reconnect the red coaxial cable to the top of the detector.
16. Close and secure the isothermal oven door.

7.2.4 Replacing the polarizer

1. Locate the polarizer as identified by the element with the single green wire.
2. If applicable, remove any cable ties and free the wiring to expose the wire splice.
3. Cut and remove the heat shrink and glass tape from the green wire to expose the soldered connection.
4. Using a 40 watt soldering iron, disconnect the wire splice.
5. Using a 3/8-inch open-end wrench, carefully remove the polarizer assembly.
6. Carefully insert the replacement polarizer into the detector body and finger tighten, taking care not to damage it. Finish
tightening using a 3/8-inch open-end wrench.
SI/PGC5000-EN, Rev B
7 Subassembly repair
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