HP 5890 Series II GC Manual
HP 5890 Series II GC Manual
HP 5890 Series II GC Manual
Gas Chromatograph
Service Manual
Table of Contents
SVC TOC - 1
Setting the GAIN Calibration Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 3- 23
Entering Specific ZERO and GAIN Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 3- 24
Replacing/Repairing a Flow Manifold Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 3- 25
SVC TOC - 2
ZONE TEMPERATURE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 3
Remove/Replace Inlet, Detector, and Valve Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 4
Heater/Sensor Cable Assemblies
Disconnect/Connect Heater and Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 4
Wiring on Main PCB
Remove/Replace Inlet Zone Heater and Sensor Cartridges . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 9
` Remove/Replace Packed Column Inlet Heater and Sensor Cartridges . . . . . . . . . SVC 6- 9
` Remove/Replace Septum- Purged Packed Column Inlet ................... SVC 6- 11
Heater and Sensor Cartridges
` Remove/Replace Split- Splitless/Split- Only Capillary Inlet . . . . . . . . . . . . . . . . . SVC 6- 13
Heater and Sensor Cartridges
` Remove/Replace PCOC Inlet Heater and Sensor Cartridges . . . . . . . . . . . . . . . . . . . . SVC 6- 16
Remove/Replace Detector Zone Heater and Sensor Cartridges . . . . . . . . . . . . . . . . . . . . SVC 6- 18
` Remove/Replace TCD Heater and Sensor Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 18
` Remove/Replace FID Heater and Sensor Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 20
` Remove/Replace NPD Heater and Sensor Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 24
` Remove/Replace ECD (19233A/19235A VERSIONS) . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 28
Heater and Sensor Cartridges
` Remove/Replace ECD (G1223A/G1224A VERSIONS) . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 31
Heater and Sensor Cartridges
` Remove/Replace FPD Heater and Sensor Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 34
Remove/Replace Valve Box Heater and Sensor Cartridges . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 37
Replacing TCD Delta- T Temperature Sensor Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 39
Remove/Replace PCOC Inlet Cryogenic Cooling (Cryo- Blast) Weldment . . . . . . . . . . . SVC 6- 42
Temperature Sensor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 6- 45
SVC TOC - 3
SECTION 8. KEYBOARD AND DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . .SVC 8- 1
KEYBOARD AND DISPLAY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 8- 1
KEYBOARD AND DISPLAY TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . SVC 8- 2
Replace Display PCB Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 8- 3
SVC TOC - 4
INET PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APX A- 19
BUFFERED INET PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APX A- 20
DICE PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APX A- 21
DICE CONNECTOR PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APX A- 22
ELECTRONIC FLOW SENSOR MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APX A- 24
VALVE PCB CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APX A- 25
SVC TOC - 5
Section 1
INTRODUCTION
HP 5890 SERIES II GAS CHROMATOGRAPH
This section is intended to help the technician isolate problems to a specific component or compo-
nents. The HP 5890 Series II may be found in many different configurations, with varying component
options. This complicates the process of providing detailed troubleshooting procedures for even gener-
al problems. But, by using the general troubleshooting techniques presented here, along with the func-
tional diagrams found at the end of this section, successful results should be achieved.
There are five inlet options and six detector options which may be encountered when servicing an HP
5890 Series II Gas Chromatograph, as well as a wide variety of flow and pressure control components.
All of these common inlet and detector components are represented by the functional diagrams at the
end of this section. When troubleshooting inlets, detectors, and/or the flow/pressure systems, fold out
the page corresponding to the employed detector, while leaving the book open to the page corre-
sponding to the employed inlet. Maintenance procedures for most of the components are given in the
following sections. Procedures are supplied to remove, replace, and/or clean various subassemblies,
based on the current maintenance philosophy, i. e., to allow replacement of the lowest level compo-
nents applicable for a particular item.
Specific part numbers are not given in this portion of the service manual. For all replacement part num-
bers, refer to the IPB portion of this document.
This document is not meant to provide instruction for first time installation of any of the options dis-
cussed. The add- on sheets, which accompany the various options, exist for just this purpose, and
should be referenced when performing a first time installation.
TABLE OF CONTENTS
SVC 1- 1
Electronic Troubleshooting
INTRODUCTION
This section is intended to aid the operator and service engineer in the troubleshooting process, i.e., of
going from symptom to cause. It has been subdivided into four subsections by type of symptom.
Part A covers the most obvious indications of problems. The instrument apparently (generally when
t work at all. (NON- FUNCTIONING INSTRUMENT)
first turned on) doesn’
Part B includes the symptoms that can appear as a visual indication or message on the front of the
keyboard/display module. These messages are a result of the instrument’ s extensive automonitoring
system. (AUTOMONITOR MESSAGES)
Part C discusses the visual information that the operator can instigate and use as part of the trouble-
shooting process. These visual indications are normally not available unless specifically requested by
the operator. (OPERATOR INSTIGATED INDICATIONS)
Part D contains symptoms (other than those that appear on the visual display) that indicate a possible
problem. Typically, these types of symptoms can be associated with a specific functional area of the
instrument. (FUNCTIONAL SYMPTOMS )
In all nonelectrically oriented sections of this manual, the standard Hazardous Voltage Warning strongly
recommends turning off all of the power to the instrument. However, this section, as well as most of
Service Section, requires that some electrical measurements be made on active (energized) circuits.
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
SVC 1- 2
PART A NON- FUNCTIONING INSTRUMENT
A totally non- functioning or DEAD instrument is one that apparently isn’t working at all. It has no visual
indications (i.e., messages) on its front panel and produces no noise or heat.
The most obvious cause for such a problem is that line power is not reaching the instrument or that the
instrument is not turned on. First check that the Line Power Switch is ON. Then verify that the instru-
ment power cord is plugged into a proper receptacle. If neither of these acts restore the instrument to
operation, suspect that there may be a problem with the receptacle or the power being supplied to it.
This type of situation generally requires that a local electrical maintenance person be informed to reme-
dy the problem. However, on the rare occasion that power is being provided, but the instrument is not
working, the problem area must be isolated by tests and measurements on the instrument.
Two bits of information, plus the use of IPB, should enable service- trained personnel to isolate and
then correct the cause of the problem if it is power related. The first important bit of information is about
the fuses that are internal to the instrument. The second bit is the normal sequence of events that oc-
curs as the instrument is energized (Power On Sequence).
Fuse Information
Fuses have been installed at several locations within the instrument for the protection of major power
circuits. They are designed to open as quickly as possible to prevent damage to other components
within the circuit. Occasionally, an opened fuse may have been caused by a short onetime surge; how-
ever, it is far more common that a component within the protected circuit has failed. When an open fuse
is noticed, replace it once. If the replacement blows, suspect a component failure.
Fuses are located on the AC Power Board and on the Main Board. The AC Power Board fuses protect
the two high- power circuits. One fuse, (F1) or two in a split phase circuit (F3 & F4), protects the col-
umn oven heater and fan. Another fuse (F2) or two in a split phase circuit (F1 & F2) protects the main
power transformer. (Refer to Section 8 of the IPB portion of this document for power supply PCB infor-
mation. Refer to Section 9 of the IPB portion of this document for main PCB information.)
The three secondary voltages of the main power transformer are protected with fuses located on the
Main Board. F3 protects the 120 VAC secondary which ultimately provides heater power for all of the
zones. F4 and F5 protect the 40 VAC secondary which ultimately provides all of the DC supply voltages
(+5, +10, +15, - 15, +24, - 24). Fuses protect the 3 VAC secondary that is used for FID ignitor (F1)
and electronic flow sensor voltages (F2).
SVC 1- 3
Power On Sequence
As long as correct Line Voltage is provided to the instrument, the following events should occur when
the instrument’ s Line Power Switch is placed in its ON position. Main Transformer (T1) primary winding
is energized (fused by F2 on AC Board or F1 & F2 if split phase). (Refer to Section 9 of the IPB portion
of this document for main PCB information.)
The three secondary windings (3 VAC, 40 VAC, and 120 VAC) of T1 are energized. All are fused on the
Main Board. These voltages arrive on the main board through connector J10. (Refer to appendix A of
this document for all connector information.)
The 40 VAC is rectified and divided to produce +24 VDC and +15 VDC.
From these DC supplies, the +10 VDC, the +5 VDC, and the Master Oscillator (for clocks) begin to
function.
As these other supplies begin, the (POWER ON PULSE) and the CPU portion of the circuitry begin to
initialize, first themselves, and then through the Data Bus and other portions of the instrument.
One of the initializations that occurs through the Data Bus is in the Triac Control section to produce the
control signal for K3 (zone power relay) on the Main Board and the signal for K1 ( oven contactor) on
the AC Board.
K3 relay allows distribution of the fused 120 VAC secondary from the Main Transformer.
K1 power contactor on the AC Board allows line power distribution to the Oven Fan Motor and to the
Oven Heater Triac circuit. Note that the oven fan will run as long as power is allowed (under software
control) through K1. However, the oven heater is NOT energized until oven heat is requested.
SVC 1- 4
PART B AUTOMONITOR MESSAGES
This section includes the symptoms that can appear as a visual indication or message on the front of
the keyboard/display module. These messages may appear (depending upon their seriousness) either
at the time that the problem occurs or in the instrument’
s Self Test.
Messages resulting from the automonitoring software within the instrument will be one of four classes:
FATAL ERR:
H2 ALARM -
FAULT:
WARN:
The FATAL ERR: message is the most serious. This class of message indicates that the HP 5890 SE-
RIES II is essentially nonfunctional. The instrument will always go to a NOT READY state and even the
keyboard is inoperative.
FATAL ERR: EPP & FLOW Indicates Electronic Pressure Control (EPC) and Electronic Flow Sen-
sor(EFS) modules are installed simultaneously. The instrument must be powered down and one of two
modules must be removed to correct this situation. No damage should occur to the instrument.
FATAL ERR: BAD RAM indicates a problem with RAM chip and its circuitry in the CPU Section of Main
Board. Replace Main Board.
FATAL ERR: BAD ROM indicates a problem with ROM chip and its circuitry in the CPU Section of Main
Board. Replace Main Board.
FATAL ERR: > !25 MS indicates that the 40 Hz task couldn’t complete within !25 milliseconds. Suspect
a problem with the Clock Section of the Main Board; however, the CPU Section could also cause this
indication. Replace Main Board.
FATAL ERR: STACK ERR indicates that stack is beyond legal limits. Suspect a problem in the CPU Sec-
tion of the Main Board. Replace Main Board.
FATAL ERR: RUN CNTL indicates that the Run Control task couldn’ t complete within 25 milliseconds.
Suspect a problem with the Clock Section of the Main Board; however, the CPU Section could also
cause this indication. Replace Main Board.
As can be seen from the FATAL ERR: message listing above, they are generally an indication that a fail-
ure exists either in the Clock or CPU Sections of the Main Board. The Clock Section operation can be
easily checked by measuring the frequencies on its outputs. Once the clocks are verified to be good,
the CPU (Z80) could be checked by substitution.
The H2 ALARM message indicates a failure of the system to hold or reach the electronic pressure set-
point. All electronic pressures and heated zones will be shut off. To recover, the problem must be cor-
rected and the GC power cycled.
SVC 1- 5
H2 ALARM - EPP B indicates electronic pressure problem with
the B systems ability to hold pressure. Possibly a leak, trouble shoot the proportional control valve,
pressure transducer and the inlet in the case of the EPC. Trouble shoot the forward pressure regulator
and gage in the case of the MPC.
The FAULT: message indicates that a major subsystem of the HP 5890 SERIES II is not functioning
properly. Although the operation of the suspected subsystem is suspended until the problem is cor-
rected, the balance of the GC is operational. Note that the instrument can never reach a fully READY
state when a FAULT condition exists.
FAULT: ADC OFFSET indicates a problem with the thermal ADC offset reading. Replace the Main
Board.
FAULT: LINE SENSE indicates a problem either with the actual line voltage or with the sensing circuit.
Measure the line voltage and if the measurement is between +5% and- 10% of the instruments stated
rating then the line voltage is O.K. Determine if the 120 VAC secondary exists and if its fuse (F3) is
open. If both F3 and the 120 VAC secondary are good then their is a failure in the line sense circuit and
the main board should be replaced.
FAULT: OVEN > MAX+20 indicates that the oven senses its temperature has exceeded the current
setpoint value by more than 20 degrees C. This message (as any FAULT message regarding a tem-
perature problem) shuts down all of the temperature systems. The problem could be either in the oven
sensing or in the oven control circuits. List the oven temperature; if the display indicates that the actual
valve is above 800 degrees C, most likely the oven sensor is open (although it could be some compo-
nent in the sensing circuit). If the actual value of the oven temperature seems reasonable, the problem
is likely to be in the oven control circuitry.
FAULT: (ZONE NAME) TEMP RDG where the ZONE NAME could be OVEN, INJA, INJB, DETA,
DETB, or AUX. Any of these messages indicates that the specified zone (or oven) temperature reading
was out of acceptable range. This most often is the result of an inoperative sensor in the named zone.
FAULT: (OUTPUT NAME) TEST where the OUTPUT NAME could be DAC1, DAC2, ATTN1, or
ATTN2. If thermal fault messages also appear, suspect the A/D Converter circuitry. The A/D Converter
section of the Main Board is used to measure DAC and ATTN outputs. However, if only this test mes-
sage appears, the most obvious area to suspect is the D/A Converter portion of the appropriate board.
DAC2 or ATTN2 indicates the D/A section of the Interface Board; whereas the DAC1 or ATTN1 indi-
cates the D/A portion of the Main Board. Other areas that could be at fault include the CPU and A/D
sections of the Main Board, but are less likely. Occasionally, multiple faults messages may exist at the
same time. Only the last message to occur will automatically be displayed on the front panel of the in-
strument. Others will be retained in the instrument’ s memory. By pressing the CLEAR key, the instru-
ment will roll through all of its Not Ready states (which include all FAULTs).
FAULT: EPP RAM TEST indicates the RAM has failed selftest. This requires board replacement.
FAULT: EPP ROM TEST indicates the ROM has failed selftest and should be replaced.
FAULT: INET CPU indicates that the Communications Interface Board is not responding properly. Typi-
cally, this message is caused by a faulty microprocessor (CPU) on the Interface Board.
FAULT: INET CPU RAM indicates that the read/write memory internal to the CPU on the Interface
Board is not functioning as expected. Replace either the Interface Board or its CPU.
SVC 1- 6
FAULT: INET RAM indicates that the RAM chip on the Interface Board is not responding properly. Typi-
cally, the RAM chip on the Interface Board should be replaced.
FAULT: INET ROM indicates that the ROM chip on the Interface Board is not responding properly. Typi-
cally, the ROM chip on the Interface Board should be replaced.
Another good technique to investigate multiple messages, after noting the currently displayed mes-
sage, is to switch the power line switch of the instrument off, and then on. This will force the instrument
to process through its initializing SelfTest. During this testing sequence, indications other than the pre-
viously displayed message may appear to provide more information.
By running the instrument SelfTest ((either at power turn- on or through the Calib and Test (Clear Dot)
Modes)), WARN: messages may appear.
The WARN: message indicates that a condition exists that may need attention. Generally, the instru-
ment remains fully operational, except for the function indicated on the visual display. Pressing any in-
strument function will erase the WARN: message. The following five WARN: messages will only appear
via the SelfTest.
WARN: MEMORY RESET indicates that the instrument memory has been reset to the default setpoints
including flow and oven calibrations. This could have been done by operator keyboard entry (see Sec-
tion 13 of this manual), by RAM replacement, or by removing the battery.
WARN: SIGNAL CHANGED indicates that a detector that was previously assigned to a particular signal
is no longer recognized. The instrument will reconfigure the signal. This may occur as a result of detec-
tor boards having been removed during a repair. If these boards have not been recently removed, sus-
pect a failure and refer to Detector Problems later in this section.
WARN: NO DETECTORS indicates that no detector boards are installed or that they are not recog-
nized as being installed by the processor. If detector boards are physically installed and not recognized,
suspect the boards, the I/O section, or the CPU section of the Main Board.
The WARN: OVEN SHUT OFF message is somewhat of a hybrid between other WARN: messages
and a FAULT: message. Similar to other WARN: messages, the WARN: OVEN SHUT OFF message
occurs most often as a result of inoperative hardware (rather than software). This may be something as
simple as the operator leaving the oven door open. However, different from other WARN: (similar to
FAULT:) messages, the WARN: OVEN SHUT OFF message may occur any time that conditions war-
rant. The operator need not run the SelfTest for this message to be displayed. WARN: OVEN SHUT
OFF indicates that the oven temperature has been shut off because it could not heat as quickly as it
should or because it cooled more slowly than it should. Suspect that the oven flap could be stuck, or
that a large thermal leak from the oven has occurred (make sure that the oven door is shut). Once the
WARN: OVEN SHUT OFF is displayed, the oven temperature will remain off until the message is
cleared. The operator need only to press the
SVC 1- 7
PART C OPERATOR INSTIGATED INDICATIONS
This section discusses the visual information that the operator can instigate and use as part of the trou-
bleshooting process. These visual indications are normally not available unless specifically requested
by the operator.
There are several functions of the CALIB AND TEST (Clear Dot) modes that can be used as a diagnos-
tic tool. Similarly, the TEST CHROMATOGRAM can be extremely useful. Each of these operator insti-
gated functions is specifically designed to aid the overall troubleshooting process and is activated from
the keyboard.
Of the ten functions accessible through the CALIB AND TEST (Clear Dot), five may be thought of as
servicing functions. The other five functions are generally thought of as operational functions. These are
explained in the operation and reference manuals.
To enter any of the CALIB AND TEST (Clear Dot) modes, press: the Clear key, the Decimal key and a
number from 0 through 9. The actual digits 4,5,7,8,9 represent the typical test modes. These are as
follows:
To escape from any of the CALIB AND TEST (Clear Dot) modes press any of the instrument function
keys.
In the Display Memory mode, some keys on the keyboard are redefined:
SVC 1- 8
The Minus key decrements the address.
The ENTER key switches the type of value presentation. The binary display mode can be entered from
the hexadecimal mode by pressing . If already in the binary mode, it will return to the hexadecimal
mode.
The binary mode is very similar to the hexadecimal mode except that the value of the address, and only
that value (one byte), is displayed in the binary code. If the next value (one byte in binary) is desired,
simply increment the address, which is always displayed in hexadecimal. The incrementing and decre-
menting of addresses in the binary mode are done in the same manner as in the hexadecimal mode.
To leave this Display Memory routine, press any of the instrument function keys. This also reestablishes
the normal key definitions.
The next indication is when the unit displays TESTING MEMORY. During this time, the unit tests most
of the processor memory (ROM) circuits. Note that during this time only the NOT READY LED remains
lit.
The third indication is when the unit displays TESTING SIGNAL PATH. During this phase of the selftest,
the unit actually exercises most of the signal handling sections of the Main Board. Note that the analog
sensors (i.e., temperature sensors) are NOT tested at this time; they are tested after the selftest. How-
ever, by linking the A/D through the CPU to the D/A and by looping the D/A output back as an input to
the A/D, most of the Main Board’ s signal handling circuits are checked.
The fourth (and unless an error is found, the final) indication is the PASSED SELFTEST message. This
message verifies that the selftest sequence has been completed. The PASSED SELFTEST display re-
mains until some further action is taken by the operator or some area not tested during the SelfTest is
detected.
By pressing the clear key, the visual display should change to some message about OVEN TEMP. This
action, with its resulting message, verifies that the keyboard is communicating with the CPU.
If a component failure exists in the HPIL circuitry, or if either the Interface Board or HPIL Cable is not
properly installed, a FAILED SELFTEST message will be displayed.
SVC 1- 9
To leave this mode of testing, press any of the instrument function keys.
The test chromatogram, which is permanently stored in the HP 5890 SERIES II, is initiated by pressing
the START key. Each chromatographic cycle consists of three peaks. Each peak is about 1/10 the
height of the previous peak, with the first (tallest) peak having a height value of about 125 mV at = 0
(+1 V analog output); halfheight width of this peak is about 0.13 minutes. Each cycle is about 1.5 min-
utes in length. The chromatogram will continue to cycle until the STOP key is pressed. The test chroma-
togram is useful as a troubleshooting aid in deciding whether a lost or noisy signal observed at a con-
nected integrating or chart recording device is due to a chromatographic problem (lost sample due to
leaks, noise due to a dirty detector, etc.), versus problems either with the integrating/recording device
itself, or in its connecting cables.
If the test chromatogram does not exhibit any problems at the integrating/recording device, a chromato-
graphic problem is likely to exist; if the test chromatogram exhibits noise, or does not appear at all, the
problem is most likely to be hardware related. Check setpoints on both the HP 5890 SERIES II and the
integrating/recording device.
SVC 1- 10
PART D FUNCTIONAL SYMPTOMS
This section contains symptoms (other than those that appear on the visual display) that indicate a pos-
sible problem. Typically, these types of symptoms can be associated with a specific functional area of
the instrument.
Zone doesn’
t heat all other zones O.K.
With an Ohm meter measure the resistance of the cartridge heater (should be about 200- 220 ohms).
With the power removed this can be measured by removing the J9 connector for INJA, INJB, DETA,
and DETB. To measure the AUX zone remove the J14 connector. The pins are labeled on the main
board next to the appropriate J connector. Replace the cartridge heater if it is open or shorted. If the
cartridge heater tests O.K. and sensor test O.K. (see temperature sensor resistance chart), the problem
is in the zone control on the main board and the main board should be replaced. To measure resis-
tance of sensors remove connector P7, sensors are labeled on main PCB.
If Zone will not reach desired temperature or cycles over more then plus or minus 1 degree C then the
insulation around the zone and the insulation of the oven shell should be examined and additional insu-
lation added if necessary. Also refer to the operating manual to verify the zone is being used proper-
ly(i.e., oven at - 50 degrees C, injection port at 100 degrees C). This type of operation will not work.
The Main Board is generally serviced from a replacement aspect, the introduction includes an illustra-
tion of its functional configuration followed by information about its connectors and test points.
Any replacement or space electrical parts that are subject to damage by static electricity will be shipped
in static- protective bags or containers. Be certain to utilize these protective devices when storing items
of this nature.
Generally, since board or module replacement constitutes the majority of electronic repairs, the only
electronic test equipment necessary is a quality Volt Ohm Ampmeter.
The HP 5890 Series II GC contains a minimum of four and a maximum of nine electronic boards. The
four boards always installed are one of the AC Power Boards, the Keyboard and Display Board(usually
done as one module), and the Main Board. The actual AC Power Board located in the rear of the instru-
ment behind the column oven compartment is one of three possible boards based on the voltage and
phase configuration of the line. The Keyboard and Display Board are two boards located on the front of
the Electronics Module. The Keyboard plugs directly into the Display Board. The Main Board is
mounted inside the right side panel of the instrument and occupies most of the space in the Electronics
Module. More importantly, the Main Board contains most of the instrument’ s electronics.
General Description:
The 05890- 60015 PC board is a collection of circuits which allow operation of the 5890 Series II gas
chromatograph. The circuits on the new board include power supplies, CPU, A/D converter, D/A con-
verter, clocks and general control circuits. (Refer to the main PCB diagrams, pages SVC 1 - 12 and
SVC 1 - 13.)
The functions provided by the new PC board are the same as those provided by the original HP 5890A
GC except that components have been added to control an additional heated zone and 2 AC valves.
The new board differs only in its implementation of these functions. The foremost change is the use of
a 68 pin PLCC custom IC which performs the same functions as do 26 TTL IC’ s on the original
05890- 60010 board
SVC 1- 11
Connectors 1 thru 15 are used to connect the Main Board either with the other electronic assemblies
within the instrument or external devices, such as an integrator. (Refer to the main PCB diagrams,
pages SVC 1 - 13 and SVC 1 - 14. Refer to appendix a of this document for information on the main
PCB connectors.)
SVC 1- 12
MAIN PCB FUNCTIONAL ZONES
HEATED
TEST POINTS
VALVES AND CRYO ZONES
DAC A/D
DETECTORS AND
TRIACS
SVC 1- 13
REMOTE
START/STOP
OVEN
FLAP
ZONE
ANALOG ANALOG STEPPER
TEMP
SIGNAL 1 SIGNAL 2 MOTOR,
SENSORS
OUTPUT OUTPUT IGNITOR,
&
VLVA, VLVB
INJECTION
PORT FAN
P4 P5 P6 P7 P8
F1 J1 VALVE PCB
KEYBOARD
5A
AND J1 P1
DISPLAY MAIN PCB 250V
CRYO &
J9 4 HEATED
DETECTOR ZONES
A J2 P2 F3
PCB 5A
250V 5th HEATED
DETECTOR J14 ZONE &
B J2 P3 VALVE 1 & 2
PCB
PRESSURE
CONTROL J1 P13
PCB
P10
COMMUNICATIONS
PCB F2
J12 P12
5A
250V TRANSFORMER
ELECTRONIC
FLOW J1 P11
SENSOR F4, F5 MAIN SWITCH
5A
250V
AC PCB
OVEN TRIAC
OVEN HEATER
SVC 1- 14
Section 2
INLET COMPONENTS
REPLACING INLET COMPONENTS
There are five inlet options available for the HP 5890 Series II Gas Chromatograph; packed column,
packed column with septum purge, split/splitless capillary, split- only capillary, and Programmable Cool
On- Column capillary (PCOC). Maintenance procedures for all the inlets are given in the following
pages. Procedures are supplied to remove, replace, and/or clean various subassemblies, based on the
current maintenance philosophy, i. e., to allow replacement of the lowest level components applicable
for a particular inlet.
Specific part numbers are not given in this section. For all replacement part numbers, refer to Section 5
of the IPB portion of this document (Inlet Components).
All of the inlets are heated using a heater/sensor setup which consists of at least one heater cartridge
and one sensor cartridge. Heating of the inlet zones is not covered in this section. For information on
the zone heater/sensor systems, refer to Section 6 of the service portion of this document (Zone Tem-
perature).
This document is not meant to provide instruction for first time installation of the inlet options discussed.
Add- on sheets exist for just this purpose, and should be referenced when performing a first time instal-
lation.
TABLE OF CONTENTS
SVC 2- 1
PACKED COLUMN INLET
Remove/Replace Packed Column Inlet
1/4- INCH
SCREW
AND
WASHER
SCREWS
SVC 2- 2
11. Remove any insulation from around the top of
the inlet.
12. Use a Pozidriv screwdriver to remove the two
screws securing the inlet and insulation plate to
the instrument. (Depending on the age of the
instrument, the insulation plate may be flat, as
shown at the left, or may be a box, as shown INSULATION
below. PLATE
13. Lift the inlet enough to expose the heated block and heater/sensor wiring.
14. Remove any insulation from around the base of the inlet.
Handle the heater and sensor cartridges with care to prevent breakage. The cartridges
(particularly the smaller sensor cartridge) are fragile.
15. Carefully slide the heater and sensor cartridges out of the heated block portion of the inlet.
Use caution to avoid sharp bends when bending tubing. Sharp bends may crimp the tubing.
16. If the inlet is to be replaced, prepare the replacement inlet by pre- bending its tubing into orien-
tations similar to that of the removed inlet.
17. Slide the heater and sensor cartridges into the heated block of the inlet being installed.
SVC 2- 3
21. Connect the Carrier Gas Inlet, disconnected in step 9.
22. Install the liner and all other hardware (except the column) removed during step 5.
29. Install the left side panel and secure using two screws. WELDMENT
SVC 2- 4
SEPTUM- PURGED PACKED COLUMN INLET
Remove/Replace Septum- Purged Packed Column Inlet
1/4- INCH
SCREW
AND
WASHER
SCREWS
SVC 2- 5
11. Cap the base of the inlet.
TOP INSERT
WELDMENT
Use caution to avoid sharp bends when bending HEATED BLOCK
tubing. Sharp bends may crimp the tubing. STRAP
SCREW
19. If the inlet base weldment is to be replaced,
O- RING
prepare the replacement by pre- bending its
tubing into orientations similar to that of the re-
moved inlet.
21. Slide the heater and sensor cartridges into the BASE WELDMENT
heated block of the inlet being installed.
SVC 2- 6
23. Carefully install the inlet into its inlet opening in the top of the instrument.
24. Replace any insulation that was removed from around the inlet.
25. Install the top cover over the inlet. SLOTS
26. Secure the inlet to the top cover using two screws.
27. Secure the top cover and inlet to the instrument
using two screws.
28. Bend the tubes running from the installed inlet
to the inlet flow control components so that
they lay within the “U”- shaped channels to the
left of the inlets.
44. Install the left side panel and secure using two screws.
SVC 2- 7
SPLIT- ONLY CAPILLARY INLET
Remove/Replace Split- Only Capillary Inlet
4. When the heated zones are cool, turn off all gas
supplies.
1/4- INCH
SCREW
AND
WASHER
SCREWS
SVC 2- 8
9. Disconnect the Carrier Gas Inlet (labelled “C”)
which terminates at a fitting either at the EFS, a
chemical filter, or a mass flow controller
mounted on the flow panel.
SPLIT
VENT
10. Disconnect the Septum Purge Outlet (labelled
“P”) which terminates at the splitless solenoid
valve (“normally closed”fitting) mounted inside
the flow module.
CARRIER
SEPTUM
11. Disconnect the Split Vent Outlet (labelled “S”) PURGE
SHELL WELDMENT
which terminates at a splitless solenoid valve
(normally “open”fitting) mounted inside the
flow module. INSERT
ASSEMBLY
12. Remove any insulation from around the top of
the inlet.
14. Detach and remove the tubing nut from the fit-
ting on the shell weldment.
20. Gently pull the inlet up and out of its instrument LOWER
cavity. INSULATION
SVC 2- 9
Handle the heater and sensor cartridges with care to prevent breakage. The cartridges
(particularly the smaller sensor cartridge) are fragile.
23. Carefully slide the heater and sensor cartridges
out of the heated block portion of the inlet.
HEATER/SENSOR
CABLE ASSEMBLY
LINER
Use caution to avoid sharp bends when
bending tubing. Sharp bends may crimp the
tubing.
SHELL
24. Remove any insulation from the shell weldment. WELDMENT
32. Install the retaining nut on the base of the shell weldment securing the heated block to the shell
weldment.
33. Install any removed insulation around the heated block (within the cavity provided in the shell
weldment).
34. Carefully install the inlet, securing it to the instrument with two Pozidriv screws.
NOTE
To lessen the possibility of pressure leaks, always install a new anealed seal, when the old seal
has been removed.
35. Tighten the retaining nut at the base of the shell weldment.
36. Install the reducing nut, flat washer, and anealed seal onto the base of the retaining nut.
37. Install the lower insulation cover and three pieces of lower insulation, inside the column oven.
38. Tighten the two screws which secure the lower insulation cover inside the column oven.
SVC 2- 10
39. Replace any insulation that was removed from
around the inlet.
SLOTS
40. Bend the tubes running from the new insert
assembly and split vent tube to the inlet flow
control components so that they lay within the
“U”- shaped channels to the left of the inlets.
51. Install the left side panel and secure using two screws.
SVC 2- 11
SPLIT/SPLITLESS CAPILLARY INLET
Remove/Replace Split/Splitless Capillary Inlet
4. When the heated zones are cool, turn off all gas
supplies.
1/4- INCH
SCREW
AND
WASHER
SCREWS
SVC 2- 12
9. Disconnect the Carrier Gas Inlet (labelled “C”)
which terminates at a fitting either at the EFS, a
chemical filter, or a mass flow controller SEPTUM
PURGE
mounted on the flow panel.
14. Detach and remove the tubing nut from the fit-
ting on the shell weldment.
20. Gently pull the inlet up and out of its instrument LOWER
cavity. INSULATION
SVC 2- 13
Handle the heater and sensor cartridges with care to prevent breakage. The cartridges
(particularly the smaller sensor cartridge) are fragile.
23. Carefully slide the heater and sensor cartridges
out of the heated block portion of the inlet.
HEATER/SENSOR
CABLE ASSEMBLY
LINER
Use caution to avoid sharp bends when
bending tubing. Sharp bends may crimp the
tubing.
SHELL
24. Remove any insulation from the shell weldment. WELDMENT
32. Install the retaining nut on the base of the shell weldment securing the heated block to the shell
weldment.
33. Install any removed insulation around the heated block (within the cavity provided in the shell
weldment).
34. Carefully install the inlet, securing it to the instrument with two Pozidriv screws.
NOTE
To lessen the possibility of pressure leaks, always install a new anealed seal, when the old seal
has been removed.
35. Tighten the retaining nut at the base of the shell weldment.
36. Install the reducing nut, flat washer, and anealed seal onto the base of the retaining nut.
37. Install the lower insulation cover and three pieces of lower insulation, inside the column oven.
38. Tighten the two screws which secure the lower insulation cover inside the column oven.
SVC 2- 14
39. Replace any insulation that was removed from
around the inlet.
SLOTS
40. Bend the tubes running from the new insert
assembly and split vent tube to the inlet flow
control components so that they lay within the
“U”- shaped channels to the left of the inlets.
51. Install the left side panel and secure using two screws.
SVC 2- 15
PROGRAMMABLE COOL ON COLUMN INLET (PCOC)
Remove/Replace PCOC Inlet
4. When the heated zones are cool, turn off all gas
supplies.
LEFT SIDE
PANEL
1/4- INCH
SCREW
AND
WASHER
SCREWS
SVC 2- 16
9. Disconnect the Carrier Gas Inlet which termi-
nates either at the Forward Pressure Regulator
(for Manual Pressure Control) or the PCOC Pro-
portional Control Valve (for Electronic Pressure
Control).
AUTO
INJECTION
ASSEMBLY OPTIONAL
MANUAL
INJECTION
ASSEMBLY
SEPTUM DUCKBILL
SEPTUM
INSERT
PCOC INSERT
SPRING
AIR DEFLECTOR
HEATER/SENSOR
CABLE ASSEMBLY
WELDMENT
INSULATION
CAVITY
SLEEVE
SCREW
13. Remove the air deflector using a Pozidriv screwdriver to remove the screw securing the air de-
flector to the inlet weldment.
SVC 2- 17
Handle the heater and sensor cartridges with care to prevent breakage. The cartridges
(particularly the smaller sensor cartridge) are fragile.
14. Carefully slide the heater and sensor cartridges out of the heated block portion of the inlet.
15. Use a Pozidriv screwdriver to remove the two screws securing the inlet to the instrument.
17. If installed, remove the cryo- blast tube from the inlet weldment.
(a) (b)
Use caution to avoid sharp bends when bending tubing. Sharp bends may crimp the tubing.
19. If the inlet is to be replaced, prepare the replacement inlet by pre- bending its tubing into orien-
tations similar to that of the removed inlet.
20. Replace any insulation that was removed from around the inlet.
SVC 2- 18
21. Bend the tubes running from the installed inlet
to the inlet flow control components so that
they lay within the “U”- shaped channels to the
left of the inlets.
SLOTS
22. Install the tubes removed from the employed
flow controller in steps 9 and 10.
Handle the heater and sensor cartridges with care to prevent breakage. The cartridges
(particularly the smaller sensor cartridge) are fragile.
25. Carefully slide the heater and sensor cartridges into the heated block portion of the inlet.
26. Install the air deflector and secure it to the weldment using one screw.
27. Install the injection assembly, septum,PCOC insert spring, and insert (the injection assembly
secures the other items to the inlet weldment).
28. Install the liner and all other hardware (except the column) removed in step 5.
34. Install the left side panel and secure using two screws.
SVC 2- 19
INJECTION PORT COOLING FAN
Remove/Replace Cooling Fan
HAZARDOUS VOLTAGES ARE PRESENT IN THE INSTRUMENT WHEN THE POWER CORD IS
CONNECTED. AVOID A POTENTIALLY DANGEROUS SHOCK HAZARD BY DISCONNECTING
THE POWER CORD BEFORE WORKING ON THE INSTRUMENT.
1. Set the main power line switch to the off position. RED O VISIBLE
2. Disconnect the power cable from its receptacle.
NOTE
If an autosampler is installed, the injection
port cover will not be present. OFF ON
3. Remove the injection port cover by grasping its
back edge and lifting it upward.
LID SHAFT
1/4- INCH
SCREW
AND WASHER
SVC 2- 20
5. Remove the electronics carrier top cover .
SCREWS
6. Remove the right side panel by
removing four screws: two each
along its top and bottom edges.
P7
1 2 OVEN C10
3 4 DETA
5 6 DETB
7 8 INJA C9
9 10 INJB
11 12 AUX
13 14 FAN+
P7 -
Q3
Q6
SVC 2- 21
11. Use the lance release tip of an AMP pin extrac-
EXTRACTION TOOL
tion/lance reset tool (8710- 1542) to remove the STOP
LANCE RESET
appropriate pins from connector P7. (The tool TOOL
features a lance release tip and a lance reset
LANCE
tip. The lance release tip is used to depress RELEASE
the pin locking lance to extract the pin from a TIP
BACK OF CONTACT
HOUSING (TYPICAL)
13. Insert the pins for the replacement fan into their
appropriate locations in the plug, making sure
the locking lance on each pin seats into its hole
through the side of the plug.
RECEPTACLE
BOX (TYPICAL)
14. Gently pull on the wire to ensure that the pin is
locked in the connector.
LOCKING
LANCE
15. Insert connector P7 into its corresponding CAVITY
receptacle on the main PCB. LOCKING
LANCE
16. Install the new fan and fan cover and
secure using two screws.
BACK OF
18. Install the right side panel and secure using HOUSING
four screws.
19. Install the electronics carrier top cover.
20. If removed, install autosampler and associated bracketry.
SVC 2- 22
Section 3
FLOW/PRESSURE CONTROL
COMPONENTS
FLOW/PRESSURE CONTROL COMPONENTS
Flow and pressure control components include pressure regulators, pressure gauges, mass flow con-
trollers, capillary solenoid valves, detector flow manifold blocks, and the Electronic Flow Sensor (EFS)
module. There are many options available for the HP 5890 Series II. Maintenance procedures for the
most common items found in the instrument. Procedures are supplied to remove, replace, and/or
clean various subassemblies, based on the current maintenance philosophy, i. e., to allow replacement
of the lowest level components applicable for a particular assembly.
Specific part numbers are not given in this section. For all replacement part numbers, refer to Sections
3 and 4 of the IPB portion of this document (Detector Flow Manifold Assemblies and Injection Port Flow/
Pressure Control Modules, respectively).
This document is not meant to provide instruction for first time installation of any of the options dis-
cussed. Add- on sheets exist for just this purpose, and should be referenced when performing a first
time installation.
TABLE OF CONTENTS
SVC 3- 1
PCOC EPC/MPC TROUBLESHOOTING
The Programmable Cool On Column (PCOC) injection port is designed to allow the injection syringe to
admit sample directly into the capillary column(320, 200, 100 micron id). This is accomplished by the
use of an insert which serves to align the syringe with the capillary column and make a seal with both
the column and the syringe needle. Maximum sample volumes are smaller compared with other inlets,
typically in the range of 0.5 microlitre to 2.0 microlitre. The ideal volume depends on the column id, the
compatibility of the sample solvent and the stationary phyase, sample concentration, stationary phase
film thickness, and column flow rate. Usually the smaller the sample the better, providing that sensitivity
requirements are met.
The Programmable Cool On Column injection port operates by forward pressure control of the inlet and
the inclusion of a preset foward pressure contolled septum purge vent carries septum bleed out to vent.
A typical example of pressure setting and associated flows would be: 50psi for the carrier with a setting
of 10 to 20psi in the injection port. This will also yeild a 10 to 20 ml/min septum purge vent flow.
Temperature Control
Pressure Control
Repeatability of set point value agter septum change and 5- minute equilibration
1. Manual Pressure Control: 0.1- 0.2psi(0.7- 1.4kPa)
Electronic Pressure Control: 0.050psi(0.35kPa)
SVC 3- 2
Electronic Pressure Control 1 second to 99%
Safety Shutdown (Standard): If the system is unable to reach or maintain pressure set point value after
45 seconds the following 3 things happen. The alarm relay is triggered and the alarm sounds immedi-
ately. Pressure Control Valve shuts off all but a few ml/min of flow (bypass flow still permitted). The
oven and all heated zones are shut down.
This is a Fatal Error. The only way to recover is to power cycle the GC. If the leak has not been fixed,
the same sequence will repeat.
The Column head pressure may be controlled by either of two systems, Manual Presure Control (MPC)
or Electronic Pressure Control (EPC)
The MPC in an uncomplicated system consisting of 1) a manually adjustable forward pressure regulator
which sets the pressure in the inlet and 2) a factory preset forward pressure regulator allowing 10 to 20
ml/min to escape to vent pulling septum bleed with it.
Possible failures could include pluged restrictor in the inlet to the FPR. This would prevent the inlet from
reaching pressure setpoint. The FPR could be stuck open allowing the injection port to go to the same
pressure as the source gas tank. It could be stuck in the closed position preventing the injection point
from reaching the setpoint. Leaks in any of the tubing connections would also prevent the injection port
from reaching or maintaining pressure setpoint. Leaks at the Septum, Column fitting, Septum Purge
Control, Column Head Pressure gage or Purge Vent restrictor could also make injection port pressure
control difficult. These leaks should be checked by capping off the injection port or suspected part to
isolate it rather then using soap solution leak detection fluid.
The EPC uses a digitally controlled proportional control valve and electronic presssure transducer to
perform the same functions as the MPC’ s manual forward pressure control and column head pressure
gage. One additional feature of the EPC is a bypass flow line designed to protect the column with a
small flow (.1 to 3 ml/min) in the event that the proportional control valve or electronics would fail. The
same plugging or leak considerations as the MPC apply with the addition of the possiblity of electronic
failures to either the proportional valve, pressure transducer or electronic control board. These will be
verified by substitution.
1. Configuration is wrong
SVC 3- 3
Not Ready light flickers
(oscillating temperature)
1. Configuration is wrong
2. Inlet temperature equilibration time too short.
Configuration is wrong
1. Possible problem with either EPC pressure transducer or EPC control bd.
SVC 3- 4
Remove/Replace Inlet Flow Control Components
This procedure applies to the packed, purged packed, split/splitless, and split only
inlets. Separate procedures exist for removal/replacement of the PCOC Electronic
Pressure Control (EPC) flow module and the PCOC Manual Pressure Control (MPC)
flow module. A separate procedure also exists for replacement of the split/splitless
capillary inlet solenoid valve.
1. Set the main power line switch to the off position.
4. When the heated zones are cool, turn off all gas
supplies.
SVC 3- 5
9. Remove two nuts securing the flow module to
the mainframe (one next to the pressure gauge,
and one at the lower edge of the module).
15. If the system is leak- free, install the left side panel and secure using two screws.
SVC 3- 6
Remove/Replace Split/Splitless Capillary Inlet Solenoid Valve
4. When the heated zones are cool, turn off all gas
supplies.
ELECTRONICS
CARRIER TOP
COVER
SCREWS
12. Disconnect all plumbing from the solenoid valve. (Label the tubes, noting the valve fittings to
which they connect, to facilitate easy assembly.
SOLENOID
VALVE
13. Loosen the two screws securing the solenoid valve to the flow control mounting bracket
14. Remove the solenoid valve from the flow control bracket.
15. Install the replacement solenoid valve in the same location and orientation as the old one.
16. Secure the solenoid valve to the flow control bracket by tightening two screws.
17. Trace and free the solenoid valve electrical leads along their path to the P8 connector at the
upper right corner of the main PCB.
18. Route the leads for the new solenoid valve along the same path, securing them with plastic wire
ties.
P7
C10
1 2 IGN C9
3 4 VLVA
5 6 VLVB
7 8 FLAP
9 10 FLAP
11 12 FLAP Q3
13 14
P8
Q6
SVC 3- 8
When removing a connector from a receptacle, pull on the connector not on its wires.
Pulling on the wires may cause breakage.
19. Disconnect connector P8 from its associated connector on the main PCB by pulling it straight
out.
BACK OF CONTACT
HOUSING (TYPICAL)
CONTACT
(TYPICAL)
BACK OF
HOUSING
SVC 3- 9
23. Gently pull on the wire to ensure that the pin is locked in the connector.
24. Insert connector P8 into its receptacle by pressing it straight in until it bottoms.
When connecting lines and fittings, ensure that all o- rings are properly installed.
25. Connect the plumbing to the new valve.
28. If the system is leak- free, verify operation of the split/splitless system by operating the solenoid
valve via the keyboard.
SVC 3- 10
Remove/Replace Electronic Pressure Control (EPC) Components
4. When the heated zones are cool, turn off all gas
supplies.
SVC 3- 11 SEPTUM
PURGE
REGULATOR
13. Remove the nut securing the PCOC purge regulator to the EPC flow bracket.
14. Remove the screw securing the EPC flow control bracket to the instrument flow carrier (which
was previously obscured by the proportional control valve).
bracket. EPC
SENSOR
PCB
18. Remove the EPC cable from the EPC sensor
PCB and the connector receptacle on the pro-
portional control valve.
SCREWS
VALVE
TRANSDUCER
BRAZEMENT
SCREWS
SEALER PLATE
O- RING
O- RING FITTING
HOUSING
PROPORTIONAL
CONTROL VALVE
SVC 3- 12
22. Remove the two screws securing the fitting housing to the proportional control. (This will free
the valve transducer brazement from the proportional control valve.)
SCREWS
VALVE
TRANSDUCER
BRAZEMENT
O- RING FITTING
HOUSING
PROPORTIONAL
CONTROL VALVE
23. Remove the four screws securing the inlet bypass clamp to the proportional control valve.
RESTRICTOR
O- RING
O- RING
RESTRICTOR
INLET BYPASS
CLAMP
SCREW
When connecting lines and fittings, ensure that all o- rings are properly installed.
25. Assemble the EPC components in the reverse order of disassembly.
28. If the system is leak- free, install the left side panel and secure using two screws.
SVC 3- 13
Remove/Replace Manual Pressure Control (MPC) Components
4. When the heated zones are cool, turn off all gas
supplies.
SVC 3- 14
8. Remove two nuts securing the flow module to
the mainframe (one next to the pressure gauge,
and one at the lower edge of the module).
SVC 3- 15
Remove/Replace EPC/MPC Pressure Control PCB
SCREWS
ELECTRONICS
CARRIER TOP
COVER
SCREWS
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
SVC 3- 16
6. Disconnect any cables which are connected to the pressure control PCB.
7. Remove the pressure control PCB from the right side of the instrument by grasping it in the
center area along its outer edge and pulling it straight out.
8. Install the pressure control PCB by sliding it into its mounting location on the main PCB.
PRESSURE CONTROL
PCB (TYPICAL)
SVC 3- 17
- - - - - - - - DON’
T CARE
INLET B1 DOWN
INLET B0 UP
INLET A1 DOWN
INLET A0 DOWN CHOICE OF PID CONSTANTS
SVC 3- 18
Replace Electronic Flow Sensor Module
4. When the heated zones are cool, turn off all gas
supplies.
ELECTRONICS
CARRIER TOP
COVER
SCREWS
P11
Locking Tabs
WHEN DISCONNECTING A PLUG, PULL ON THE PLUG NOT ON ITS WIRES. PULLING
ON THE WIRES MAY CAUSE BREAKAGE.
14. Remove the EFS module from the instrument.
16. Secure the EFS module to the instrument using two screws.
18. Restore the gas supply to the instrument module (both channels, “
A”and “B”), and check for
leaks at all installed fittings.
SVC 3- 20
19. If the system is leak- free, replace the cover and panels and restore power to the instrument.
Check that the EFS is operational by displaying the flow rate for each channel (“ A”and “B”) on
the display board and also verify the value with a bubble flow meter. It is suggested that the
flow rate through each channel be different, in order to verify that the plumbing for the two
channels has not been “cross- connected.”
20. If a flow rate value for either channel is displayed which does not correspond to the value ob-
tained using a bubble flow meter, leak- test the entire system. If the system is completely
leak- free, the EFS may require calibration.
SVC 3- 21
Electronic Flow Sensor (EFS) Calibration
Electronic flow sensor (EFS) calibration may be performed any time to ensure displayed flow rate accu-
rately represents real gas flow rate through the sensor. The EFS is factory calibrated for four standard
gases, H2, He, N2, and Ar/CH4, within the flow rate range of 0 to 100 ml/min. This covers the majority
of chromatographic applications.
Two situations where it would be appropriate to perform recalibration would be where a nonstandard
gas is to be used (e.g., something OTHER than H2, He, N2, or Ar/CH4), or if flow rates in excess of 100
ml/min are to be used.
EFS calibration requires setting two values for a given flow channel- first, the ZERO value (defined with
NO flow through the given flow channel) and then the GAIN value (calculated, based upon a measured
flow rate value).
D The instrument must be on for at least one hour for thermal equilibration of the EFS.
D Since gas flow through the channel to be calibrated will be interrupted, detectors should be
turned off (particularly an NPD or TCD! ), and the oven cooled to ambient temperature (to
protect columns).
D The EFS is calibrated to measure volumetric flow at standard temperature and pressure.
Flows measured at ambient temperature with a bubble flow meter will have to be converted
from ambient temperature and pressure to standard temperature and pressure.
Preparation
1. Access the EFS by removing the left side panel; remove two screws along its lower edge, slide
the panel toward the rear of the instrument, and then lift.
CLEAR . 2 ENTER
GAIN A is displayed, followed by two values: the observed flow rate through Channel A, and the current
GAIN calibration value for Channel A.
1. Press ZERO : FLOW A ZERO is displayed, followed by a value (the current ZERO calibration
value for EFS Channel A). Note that Channel A is assumed by default; if channel B is to be cali-
brated instead, press B .
SVC 3- 22
2. DISCONNECT the gas source to the particular flow channel being calibrated. DO NOT trust an
on/off valve, pressure regulator, or mass flow controller to be an effective shutoff device; ANY
gas flowing through the EFS will invalidate the ZERO calibration value. Disconnect the source
at any convenient point (e.g., at the connection of the supply line into the instrument).
3. Locate the EFS module and note its labelling: CHANNEL A/CHANNEL B, IN/OUT. For the chan-
nel being calibrated, locate and disconnect its OUT fitting; use two wrenches in opposition to
prevent twisting the tubes.
4. Install the EFS flow- measuring adapter (Part No. 05890- 80620) into the female OUT fitting to
the EFS module. Connect a bubble flow meter to the adapter.
5 Allow ample time (up to 1/2- hour) for residual gas within connected plumbing to bleed off.
Verify that absolutely NO flow is observed at the connected bubble flow meter.
6. Assuming there is no gas flow through the channel being calibrated, press ENTER at the key-
board. This updates the ZERO calibration value.
1. At the keyboard, press FLOW : GAIN A (or GAIN B) is displayed, followed by two values (the
observed flow rate through the channel, and the current GAIN calibration value for the channel).
2. Connect the gas supply to the channel being calibrated.DO NOT connect the OUT fitting for the
particular channel.
3. Using a suitable flow- measuring device (accurate to better than 1 ml/min) connected at the
OUT fitting for the given channel, adjust flow through the channel so measured flow rate is ap-
proximately in the middle of the range to be used. For example, if the range of flow rates to be
used is between 50 and 150 ml/min, measured flow rate should be adjusted to about 100 ml/
min.
D After obtaining the desired flow rate, press CLEAR . 2 ENTER :to return to set-
ting the GAIN value.
4. Allow ample time for the flow rate to equilibrate (no drift should be observed).
5. Assuming no drift in measured flow rate, note the flow rate value at the connected flow- mea-
suring device. Enter this measured value through the keyboard:
Measured Value
{ (#) } ENTER
SVC 3- 23
6. After a short time, GAIN A (or GAIN B) is again displayed, followed by the observed flow rate
and a new GAIN calibration value based upon the measured flow rate.
NOTE
The displayed flow rate value should now be quite close to the measured flow rate
value. If not, drift may have occurred. If drift occurs, the process should be repeated.
7. This completes EFS calibration. Remove the flow- measuring adapter, connect the channel
OUT fittings (use two wrenches in opposition to avoid twisting tubes), replace the left side pan-
el, and restore the instrument to service.
CLEAR . 2 ENTER
GAIN A (or GAIN B) is displayed, followed by two values (the observed flow rate through the channel
and the current GAIN calibration value for the channel).
NOTE
- { (#) } ENTER
- is necessary to signify entry of a GAIN calibration value, rather than a measured flow rate.
3. Press ZERO : FLOW A ZERO is displayed, followed by a value (the current ZERO calibration
value for EFS Channel A).
{ (#) } ENTER
Note that alternately pressing ZERO or FLOW displays either the ZERO calibration value or
the GAIN calibration value for the given channel (A or B).
SVC 3- 24
Replacing/Repairing a Flow Manifold Block
Each detector requires a flow manifold block for gas control. There are various types of blocks, de-
pending upon the particular detector, and upon whether or not capillary makeup gas is also to be
supplied to the detector.
4. When the heated zones are cool, turn off all gas
supplies.
SVC 3- 25
12. With a Pozidriv screwdriver, remove the mounting screw from the rear of the block. (The block
must be removed from the rear of the instrument.)
FRONT CLAMPING
PLATE
FID/FPD IGNITION
VALVE
PLUG VALVE
COMPRESSION
SPRING
NEEDLE VALVE
ASSEMBLY
ON/OFF VALVE
AUXILIARY
INLET FITTING
FID/FPD IGNITION
MICRO SWITCH
WELDMENT
FLOW MANIFOLD
BLOCK (TYPICAL)
RESTRICTOR
13. Install the new block on the flow panel from the rear of the instrument. The block fits on the
panel over two standoffs, in only one direction.
14. Replace the mounting screw on the block and tighten it firmly.
15. Connect the plumbing on the rear of the block. The fittings are labelled on the block. In addi-
tion:
D On an FID/NPD, replace the hydrogen and air tubes. The hydrogen tube (painted red) con-
nects to the lower fitting. The gas tube retainer fits properly only when the hydrogen and
air tubes are installed correctly.
D On an FID or FPD block, connect the ignitor leads. (The leads may be reversed without
consequence.)
SVC 3- 26
16. Restore the gases supplied to the system and leak check all installed fittings.
17. If the system is leak- free, reinstall panels and covers and restore power.
SVC 3- 27
Section 4
DETECTORS
REPLACING DETECTOR COMPONENTS
There are five detector options available for the HP 5890 Series II Gas Chromatograph; Thermal
Conductivity (TCD), Flame Ionization (FID), Nitrogen- Phosphorus (NPD), Electron Capture (ECD), and
Flame Photometric (FPD). Maintenance procedures for all the detectors are given in the following
pages. Procedures are supplied to remove, replace, and/or clean various subassemblies, based on the
current maintenance philosophy, i. e., to allow replacement of the lowest level components applicable
for a particular detector.
Specific part numbers are not given in this section. For all replacement part numbers, refer to Section 2
of the IPB portion of this document (Detector Options).
All of the detectors are heated using a heater/sensor setup which consists of at least one heater car-
tridge and one sensor cartridge. Heating of the detector zones is not covered in this section. For infor-
mation on the zone heater/sensor systems, refer to Section 6 of the service portion of this document
(Zone Temperature).
This document is not meant to provide instruction for first time installation of the detector options dis-
cussed. Add- on sheets exist for just this purpose, and should be referenced when performing a first
time installation.
TABLE OF CONTENTS
SVC 4- 1
Remove/Replace NPD Active Element Power Control . . . . . . . . . . . . . . . . SVC 4- 38
Remove/Replace NPD Detector Weldment . . . . . . . . . . . . . . . . . . . . . . . . . SVC 4- 41
SVC 4- 2
Detector Troubleshooting
Problem Probable Cause Corrective Action
1. No signal output to exter- a. Improper keyboard or ex- 1. Refer to operation and ref-
nal data handling device ternal device operation, or erence manuals as well as
(i.e., integrator, etc.). improper cabling. the manuals for the exter-
nal device.
2. Strange chromatograph a. Faulty detector PCB. 1. Replace detector PCB.
output. Test chromato- 2. If problem persists, install
gram is ok. original detector PCB and
refer to probable cause b.
b. Faulty main PCB. 1. Replace main PCB.
SVC 4- 3
THERMAL CONDUCTIVITY DETECTOR (TCD)
The main portion of the TCD detector is a heated block into which a heater cartridge and two sensor
cartridges are installed. In addition to the standard heater and sensor cartridges, a second sensor car-
tridge (referred to as the delta- t cartridge) is employed which is connected to the TCD detector PCB. If
the detector requires replacement, the entire assembly is replaced as a unit.
4. When the heated zones are cool, turn off all gas
OFF ON
supplies.
TOP COVER
SOLENOID
VALVE
SCREW
6. If the detector is not going to be replaced with a
new detector, cap the detector base. DETECTOR
COVER
7. Lift the hinged top cover at its front edge,
exposing the detector area.
8. Remove the TCD detector cover by removing
two screws: one from each side of the detector
cover.
9. If the detector is not going to be replaced with a
new detector, cap the TCD vent port on the top
SVC 4- 4
VENT
of the detector. (This will not be required on a PORT
series connected TCD.)
ELECTRONICS
CARRIER TOP
COVER
16. Trace the reference gas inlet tubes attached to the base of the detector to their connections at
the TCD solenoid valve. Observe the location on the solenoid valve where each tube is con-
nected.
SVC 4- 5
Top View (Two TCD Detectors Installed) COM
N.C.
N.O.
N.O.
COM
N.C.
FRONT OF INSTRUMENT
Use caution when removing and installing the plastic M8 tubing nuts. Excessive force
can damage them.
17. Disconnect the tubes from the solenoid valve by loosening the plastic fittings securing them.
(The fittings should only be finger- tight. If more force is required to loosen them, use a small
pair of pliers to free the fittings.) Note the solenoid valve fitting where each tube is attached.
(Corresponding tubes on the new detector must be connected to the same fittings.)
18. If a new detector is being installed, prepare the replacement detector block by pre- bending its
tubes until they are oriented similarly to those on the detector just removed.
19. If a new detector is being installed, ensure that the base and vent port of the new detector are
capped to prevent contamination.
20. Install the heater, temperature sensor, and delta- t sensor cartridges into the heated block.
21. Carefully install the detector, securing it to the instrument with two screws.
TO FLOW
BLOCK
SVC 4- 6
23. Connect the TCD filament and “delta- T”tem-
FILAMENT GAS
perature sensor leads at the connector block LEADS TYPE
on the detector PCB, making sure the filament DELTA- T
leads are connected properly per the illustration SENSOR a N2, Ar
at the right. LEADS He, H2 '
When installing insulation, use care not to plug the vent port. If flow is interrupted
while the TCD is on, it will shorten its life dramatically.
27. Taking care not to block the vent port, install insulation around the detector block.
28. Install the electronics carrier top cover.
Use caution not to crimp the filament and delta- t sensor leads when installing the
TCD detector cover.
29. Install the TCD detector cover and secure using
two screws.
SVC 4- 7
Remove/Replace TCD Solenoid Switching Valve
4. When the heated zones are cool, turn off all gas
OFF ON
supplies.
TO DETECTOR
SOLENOID VALVE
TO FLOW
BLOCK
SCREWS
6. Remove the electronics carrier top cover
(above the signal cable plugs and receptacles
to expose the top edge of the
TCD detector PCB).
7. Remove the right side panel by
removing four screws: two each SCREWS
along its top and bottom edges.
RIGHT SIDE
8. Locate the solenoid valve to ELECTRONICS PANEL
be replaced. CARRIER TOP
COVER
SVC 4- 8
9. Trace the electrical leads from the solenoid
valve to the “
J24”connector on the TCD detec-
tor PCB (lower right edge).
N.O.
N.O.
COM
N.C.
FRONT OF INSTRUMENT
SVC 4- 9
17. Install the new solenoid valve body on the mounting bracket in the same location and position
as the old one.
18. Secure the solenoid valve bracket to the instrument using two screws.
Ensure that all gas supplies are on and all connections are made before applying
power to the instrument. If flow is interrupted while the TCD is on, damage to the
detector will occur.
23. Restore power to the HP 5890 Series II.
24. Verify operation of the TCD solenoid switching valve by turning on the detector via the keyboard
and listening for the solenoid valve to cycle from one state to the other at a steady rate.
25. Run a TCD Test Sample Chromatogram (refer to HP 5890 Series II Reference Manual) to ensure
that the system is operating properly. (If reversed peaks are experienced, the most likely cause
is reversed gas tubes connected to the TCD solenoid valve.)
SVC 4- 10
FLAME IONIZATION DETECTOR (FID)
Remove/Replace FID Ignitor
DETECTOR PCB
INTERCONNECT
COLLECTOR
NUT
IGNITOR
COLLECTOR
SPANNER NUT
COLLECTOR
MOUNT
THERMAL CLAMPS
STRAP
6. Use a wrench to remove the ignitor from the FID ignitor castle.
7. Ensuring that the washer is in place, (between the ignitor castle and the threads of the ignitor)
install the new ignitor; tightening it to a snug fit.
8. Connect the ignitor wire lead connector to the mating connection on the ignitor wire (which
runs to the FID flow manifold).
9. Restore all gas supplies.
10. Restore power to the HP 5890 Series II.
SVC 4- 11
Remove/Replace FID Diode Bridge Assembly
SCREWS
SCREWS
SVC 4- 12
9. Disconnect the ignitor wire lead connector at
MATING CONNECTOR TO
the mating connection of the diode bridge as- DIODE BRIDGE ASSEMBLY
sembly lead (adjacent to the ignitor).
GROUND
CABLE
IGNITOR
LEAD
SWITCH
LEAD
DIODE
BRIDGE
ASSEMBLY
14. Install the replacement diode bridge assembly into the instrument.
15. Connect the diode bridge assembly to its connector at the FID flow manifold.
16. Connect the diode bridge assembly spade lug ground cable to the instrument by placing it be-
neath and tightening the screw that secures it..
17. Thread the ignitor wire lead along its path from the diode bridge assembly to the detector igni-
tor connector.
18. Connect the ignitor wire lead connector to the mating connection of the diode bridge assembly
lead (adjacent to the ignitor).
19. Install the rear panel and secure using four screws.
20. Install the left side panel and secure using two screws.
21. Restore power to the instrument.
SVC 4- 13
Remove/Replace FID Collector Body/Collector Assembly
The FID collector body may be replaced as a piece part, or the entire collector assembly may be re-
placed as a unit. Refer to section 2 of the IPB portion of this document for part number information
applicable to the FID detector.
4. When the heated zones are cool, turn off all gas
OFF ON
supplies.
SVC 4- 14
c. Remove the knurled connector nut from the
collector housing.
COLLECTOR BODY
LOWER COLLECTOR
INSULATOR
COLLECTOR SPANNER NUT
SCREW
l. Install the collector nut over the ignitor castle and spring washer and onto the collector
housing hand- tight.
SCREWS
ELECTRONICS
CARRIER TOP
COVER RIGHT SIDE PANEL
SVC 4- 15
c. Disconnect the ignitor wire lead connector at the mating connection adjacent to the ig-
nitor.
d. Loosen the screws securing the clamps holding the detector PCB interconnect in place.
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
e. Remove the FID detector PCB by sliding it
out of the main PCB (at the right side of the COLLECTOR IGNITOR
instrument). Removal of the PCB will with- ASSEMBLY
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes.
h. Install the FID detector PCB by sliding it
into its mounting location on the main PCB CLAMPS
(at the right side of the instrument). Instal-
lation of the PCB will insert the interconnect
into the thermal strap. Use caution to avoid
damaging the spring at the end of the inter-
connect.
SVC 4- 16
k. Secure the collector mount to the thermal strap using three screws.
l. Connect the ignitor wire lead connector at the mating connection adjacent to the ignitor.
n. Install the right side panel and secure using four screws.
SVC 4- 17
Remove/Replace FID Jet
SCREWS
ELECTRONICS
CARRIER TOP
COVER
SCREWS
CLAMPS
SVC 4- 18
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
9. Remove the FID detector PCB by sliding it out of the main PCB (at the right side of the instru-
ment). Removal of the PCB will withdraw the interconnect from the thermal strap. Use caution
to avoid damaging the spring at the end of the interconnect.
10. Remove the three screws securing the collector
mount to the thermal strap.
COLLECTOR IGNITOR
11. Remove the collector mount and collector as- ASSEMBLY
sembly as a unit.
THERMAL
STRAP
14. Use an inert gas to blow out the detector weld- JET
ment, cleansing it of any debris.
SVC 4- 19
DO NOT OVER- TIGHTEN THE JET! OVER- TIGHTENING MAY PERMANENTLY
DEFORM AND DAMAGE THE JET, THE DETECTOR BASE OR BOTH.
17. Install the replacement jet finger- tight. (Use two fingers on the nut driver to obtain this tight-
ness).
18. Tighten the jet 1/8- turn past finger- tight using the nut driver.
19. At the bottom of the detector, inside the column oven, install the column and any associated
hardware removed in step 12.
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
20. Install the FID detector PCB by sliding it into its CLAMPS
mounting location on the main PCB (at the right
side of the instrument). Installation of the PCB
will insert the interconnect into the thermal
strap. Use caution to avoid damaging the
spring at the end of the interconnect.
23. Secure the collector mount to the thermal strap using three screws.
24. Connect the ignitor wire lead connector at the mating connection adjacent to the ignitor.
25. Restore all gas supplies to the instrument and check for leaks at all installed fittings.
26. If the system is leak free, install the right side panel and secure using four screws.
27. Install the electronics carrier top cover.
28. Restore power to the HP 5890 Series II.
SVC 4- 20
Remove/Replace FID Detector Weldment
4. When the heated zones are cool, turn off all gas
supplies. OFF ON
TOP COVER
NOTE PRESS
HERE TO
If an autosampler is installed, the injection FREE
port cover will not be present. COVER
SVC 4- 21
10. At the lower right edge of the cover, press from right- to- left until the right side hinge releases.
11. With the lower right side of the cover pushed in, lift the right side of the cover and slide it to the
right to remove the top cover and lid shaft as a unit.
12. If an autosampler is installed on the instrument,
it will be necessary to remove it and its mount-
ing bracket to allow removal of the left side cov-
er as follows:
SVC 4- 22
18. Loosen the screws securing the clamps holding DETECTOR PCB
INTERCONNECT
the interconnect in place. COLLECTOR
NUT
IGNITOR
COLLECTOR
SPANNER
NUT
COLLECTOR
MOUNT
THERMAL CLAMPS
STRAP
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
19. Remove the FID detector PCB by sliding it out of the main PCB (at the right side of the instru-
ment). Removal of the PCB will withdraw the interconnect from the thermal strap. Use caution
to avoid damaging the spring at the end of the interconnect.
20. Remove the three screws securing the collector mount to the thermal strap.
21. Remove the collector mount and collector assembly as a unit.
22. Use a 1/4- inch nut driver to remove the jet
from the detector weldment.
JET
23. Use a 1 and 1/4- inch socket to remove the
base spanner nut from the detector weldment. BASE SPANNER NUT
24. Remove the thermal strap by removing the five THERMAL STRAP
screws securing it to the instrument.
26. Slide the insulation plate out from over the de- HEATED
BLOCK
tector weldment.
SVC 4- 23
29. Lift the base up enough to expose the heated
block, heater and sensor cartridge wires.
SCREW
30. Carefully slide the two cartridges out of the
block. (The smaller of the two cartridges is the FAN
SHROUD
sensor and must be handled gently in order to
prevent breakage.)
COOLING FLOW
FAN DIRECTION
31. If a PCOC fan is installed, remove the back cov- ARROW
er of the instrument by removing four screws
and sliding the cover off of the rear of the in-
strument.
FLOW
MANIFOLD
TUBE OUTLET
JET
FITTING PLATE
THERMAL STRAP
34. Disconnect the tubes by removing the tube outlet
fitting plate from the manifold block. INSULATION
PLATE
HEATED
BLOCK
When bending tubing, do not make sharp
bends which may crimp the tubing. HEATER
35. Prepare the replacement detector weldment by SENSOR
bending its tubes until they are oriented similar-
ly to those on the weldment just removed.
SVC 4- 24
37. Slide the heater and sensor cartridges into the heated block portion of the replacement detec-
tor weldment.
38. Position the replacement detector weldment in
the detector opening.
FLOW
MANIFOLD
SVC 4- 25
47. Remove the cap from the detector weldment
top opening.
JET
48. Use an inert gas to blow out the detector weld-
ment, cleansing it of any debris.
Do not over- tighten the jet! Over- tightening may permanently deform and damage the jet, the
detector base, or both.
51. Install the replacement jet finger- tight. (Use
two fingers on the 1/4- inch nut driver to obtain
this tightness).
52. Tighten the jet 1/8- turn past finger- tight using the nut driver.
` The following steps require protection against ESD (Electro- Static Discharge). Use a
grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small) connected to a
suitable ground. Failure to heed this caution may result in damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always place them in
static control envelopes or enclosures.
53. Install the FID detector PCB by sliding it into its CLAMPS
mounting location on the main PCB (at the right
side of the instrument). Installation of the PCB
will insert the interconnect into the thermal
strap. Use caution to avoid damaging the
spring at the end of the interconnect.
SVC 4- 26
59. Install the collector mount and collector assem-
bly as a unit.
60. Secure the collector mount to the thermal strap DETECTOR PCB
INTERCONNECT
using three screws. COLLECTOR
NUT
IGNITOR
61. Connect the ignitor wire lead connector at the COLLECTOR
SPANNER
mating connection adjacent to the ignitor. NUT
63. Install the left side panel and secure using two
screws.
THERMAL CLAMPS
64. Install the right side panel and secure STRAP
using four screws.
SVC 4- 27
NITROGEN- PHOSPHORUS DETECTOR (NPD)
Remove/Replace NPD Active Element Power Transformer (Toroid)
SCREWS
RIGHT SIDE
PANEL
ELECTRONICS COVER
CARRIER TOP
COVER SCREWS
SVC 4- 28
` When disconnecting a plug, pull on the
plug not on its wires. Pulling on the wires
TO NPD TRANSFORMER
may cause breakage. TOP PART OF CONNECTOR
` The following steps require protection TO NPD BEAD
against ESD (Electro- Static Discharge). POWER
Use a grounded wrist strap (part no. CONTROL
BOTTOM PART
9300- 0969 - large, or 9300- 0970 - OF
small) connected to a suitable ground. CONNECTOR
Failure to heed this caution may result in
damage to the instrument.
9. Disconnect the NPD bead power cable from the LOCKING TAB
10. Use the side edge of an AMP pin extraction/ 1 LOCKING TAB
lance tool (8710- 1542) to remove the interlock- 5 NOTE
ing side covers from the plug. (The plug is ASSEMBLED
1 CONNECTORS
made up of two connectors; one is for the to-
roid bead power, the other is for the active con-
trol element.)
TOOL
EXTRACTION
STOP
LANCE RESET
TOOL
LANCE
RELEASE
TIP
DETECTOR COVER
COLLECTOR
INTERCONNECT
CLAMP SCREW
SVC 4- 29
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
12. Remove the detector PCB from the right side of the instrument by grasping it in the center area
along its outer edge and pulling it straight out. (This will draw the interconnect out of the detec-
tor.)
13. Use a 1.5- mm hex wrench to loosen the two
set screws which secure the collector inside the
SPACER
collector assembly.
TOROID WIRE
SOLDERED AT THIS
POINT
COLLECTOR
SET SCREW
COLLECTOR BODY
SCREWS
COLLECTOR
ASSEMBLY
TOROID
SPACER
ASSEMBLY
SCREW
SVC 4- 30
17. Remove the collector assembly and the toroid
spacer assembly from the detector cover, as a
unit.
Do not handle the collector with bare hands. Use needle- nose pliers when handling
the collector to avoid contaminating it with finger oils and/or other contaminants.
NPD COLLECTOR ASSEMBLY
28. Use needle- node pliers to install the collector
into the collector assembly, from the bottom. COLLECTOR
BODY
29. Align the collector to the collector assembly NPD COLLAR
in accordance with the illustration below.
NOTE POSITION
30. When properly aligned, secure the collector OF COLLECTOR
inside the collector assembly by tightening two
set screws.
SVC 4- 31
32. Guide the new bead power cable through the slot on the edge of the electronics carrier and
down through the rectangular opening in the carrier top marked Detector A or B, depending on
which position is being used.
33. Orient the new plug in the same position as the one removed.
34. Install the interlocking side covers on the bead power and active element power control cables.
TO NPD TRANSFORMER
TOP PART OF CONNECTOR
TO NPD BEAD
POWER
CONTROL
BOTTOM PART OF
CONNECTOR
LOCKING TAB
1 LOCKING TAB
5 NOTE
ASSEMBLED
1 CONNECTORS
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
35. Install the NPD detector PCB by aligning the PCB with the guide slots. Press the board into its
connector on the circuit board.
NPD power control plugs installed in the wrong position will permanently damage the
NPD detector PCB.
36. Insert the bead power cable and active element power control cable plug into its connector re-
ceptacle on the NPD detector PCB.
37. Tighten the interconnect clamp screws on the thermal strap.
38. Install the right side panel and secure using four screws.
39. Install the electronics carrier top cover.
40. Restore all gas supplies.
41. Restore power to the instrument.
SVC 4- 32
Remove/Replace NPD Collector
COVER
SPACER
TOROID WIRE
SOLDERED AT THIS
POINT
COLLECTOR
SET SCREW
7. Use a 1.5- mm hex wrench to loosen the two
set screws which secure the collector inside the
collector assembly.
Do not handle the collector with bare hands. SET SCREW COLLECTOR
Use needle- nose pliers when handling the COLLECTOR ASSEMBLY
collector to avoid contaminating it with finger SET SCREW
COLLECTOR
oils and/or other contaminants.
SVC 4- 33
8. Use needle- nose pliers, inserted through the opening in the top of the detector cover, to re-
move the collector by forcing it down from inside the top of the collector assembly.
9. Use needle- node pliers to install the connector
into the collector assembly, from the bottom.
NPD COLLECTOR ASSEMBLY
10. Align the collector to the collector assembly COLLECTOR
in accordance with the illustration below. BODY
NPD COLLAR
11. When properly aligned, secure the collector
inside the collector assembly by tightening two NOTE POSITION
OF COLLECTOR
set screws.
SVC 4- 34
Remove/Replace NPD Jet
SCREWS
ELECTRONICS
CARRIER TOP
COVER
SCREWS
SVC 4- 35
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
8. Remove the NPD detector PCB by sliding it out of the main PCB (at the right side of the instru-
ment). Removal of the PCB will withdraw the interconnect from the thermal strap. Use caution
to avoid damaging the spring at the end of the interconnect.
9. At the bottom of the detector being serviced,
inside the column oven, remove the column
and hardware associated with the detector(s) COVER
(liner, column/liner nuts, ferrules, makeup gas
adapter,etc.).
COLLECTOR DETECTOR
COVER
SVC 4- 36
Do not over- tighten the jet! Over- tightening may permanently deform and damage
the jet, the detector base or both.
16. Install the replacement jet finger- tight. (Use two fingers on the nut driver to obtain this tight-
ness).
17. Tighten the jet 1/8- turn past finger- tight using the nut driver.
18. At the bottom of the detector, inside the column oven, install the column and any associated
hardware removed in step 12.
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
19. Install the NPD detector PCB by sliding it into Clamps
its mounting location on the main PCB (at the
right side of the instrument). Installation of the
PCB will insert the interconnect into the thermal
strap. Use caution to avoid damaging the
spring at the end of the interconnect.
SVC 4- 37
Remove/Replace NPD Active Element Power Control
SCREWS
RIGHT SIDE
PANEL
ELECTRONICS
CARRIER TOP
COVER SCREWS
` When disconnecting a plug, pull on the plug not on its wires. pulling on the wires
may cause breakage.
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result
TO NPD in
TRANSFORMER
TOP PART OF CONNECTOR
damage to the instrument.
TO NPD BEAD
5. Disconnect the NPD bead power cable from the POWER
detector PCB by pulling it straight off. CONTROL
BOTTOM PART
6. Use the side edge of an AMP pin extraction/ OF
CONNECTOR
lance tool (8710- 1542) to remove the interlock-
ing side covers from the plug. (The plug is
TOOL
made up of two connectors; one is for the to-
STOP LOCKING TAB
EXTRACTION
roid bead
LANCEpower,
RESETthe other is for the active con-
trol element.)
TOOL 5
LANCE
RELEASE
TIP 1 LOCKING TAB
5 NOTE
ASSEMBLED
1 CONNECTORS
LANCE DASH NUMBER
RESET TIP MARKED HERE
SVC 4- 38
7. Remove the control knob from the potentiome-
NPD DETECTOR
ter assembly by pulling it straight off. A PANEL
` NPD power control plugs installed in the wrong position will permanently
damage the NPD detector PCB.
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
14. Install the interlocking side covers on the two connectors which make up the connector to be
installed in the NPD detector PCB.
TO NPD TRANSFORMER
15. Insert the plug into its connector on the NPD TOP PART OF CONNECTOR
detector PCB.
TO NPD BEAD
POWER
16. Remove the 1/2- inch nut from the new poten- CONTROL
tiometer assembly. BOTTOM PART
OF
CONNECTOR
17. Install the new potentiometer assembly on the
panel from the rear.
LOCKING TAB
18. Install the mounting nut and tighten it firmly.
5
19. Turn the potentiometer shaft fully counterclock-
wise. 1 LOCKING TAB
5 NOTE
ASSEMBLED
20. Slide the dial indicator onto the power control
1 CONNECTORS
shaft.
21. While holding the potentiometer shaft fully counter clockwise with a screwdriver, adjust the dial
indicator to read “000”.
SVC 4- 39
22. While still holding the potentiometer shaft fully counterclockwise with a screwdriver, use a
1.0- mm hex wrench to tighten the two hex screws around the outside of the brass collar.
23. Mount the control knob by pushing it on to the control shaft.
24. Install the right side panel and secure using four screws.
25. Install the electronics carrier top cover.
26. Restore power to the instrument.
SVC 4- 40
Remove/Replace NPD Detector Weldment
TOP COVER
NOTE
PRESS
If an autosampler is installed, the injection HERE TO
FREE
port cover will not be present. COVER
6. Remove the injection port cover by grasping its
back edge and lifting it upward.
SVC 4- 41
10. At the lower right edge of the cover, press from right- to- left until the right side hinge releases.
11. With the lower right side of the cover pushed in, lift the right side of the cover and slide it to the
right to remove the top cover and lid shaft as a unit.
12. If an autosampler is installed on the instrument, it will be necessary to remove it and its mount-
ing bracket to allow removal of the left side cover as follows:
a. Remove the autosampler tray from its
mounting bracket by first simultaneous-
ly lifting and turning the two tray locks
which hold it in position, then sliding
the tray away from the instrument.
INTERCONNECT
CLAMP SCREW
SVC 4- 42
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
20. Disconnect the NPD bead power cable from the detector PCB by pulling it straight off.
21. Remove the NPD detector PCB by sliding it out of the main PCB (at the right side of the instru-
ment). Removal of the PCB will withdraw the interconnect from the thermal strap. Use caution
to avoid damaging the spring at the end of the interconnect.
22. Use a spanner wrench (part no. 19301- 00150) to remove the base spanner nut from the detec-
tor weldment.
23. Remove the thermal strap by removing the five screws securing it to the instrument.
24. Remove the two screws securing the detector
weldment to the instrument.
25. Slide the insulation plate out from over the de-
tector weldment.
SVC 4- 43
30. If a PCOC fan is installed, remove the back cov-
er of the instrument by removing four screws
and sliding the cover off of the rear of the in- SCREW
strument.
FAN
31. If installed, remove the PCOC fan cover to allow SHROUD
removal of the tubing attached to the detector
weldment. COOLING FLOW
FAN DIRECTION
32. Trace the hydrogen and air inlet tubes, at- ARROW
tached
to the detector weldment, to their appropriate
connection at the flow manifold block (exposed
left side of the instrument). (The specific desti-
nations of the two tubes depends upon the
function of each tube, and upon whether the
detector base is located in the “A”or “B”detec-
tor position.)
FLOW
MANIFOLD
TUBE OUTLET
FITTING PLATE
JET
When bending tubes, do not make sharp
bends which may crimp the tubing. BASE SPANNER NUT
34. Prepare the replacement detector weldment by
bending its tubes until they are oriented similar- THERMAL STRAP
ly to those on the weldment just removed.
INSULATION
35. Position the replacement detector over the PLATE
opening where it is to be installed.
HEATED
36. Slide the heater and sensor cartridges into the BLOCK
heated block portion of the replacement detec-
tor weldment. HEATER
SENSOR
37. Position the replacement detector weldment in
the detector opening.
SVC 4- 44
38. Install the insulation around the detector weld-
ment.
COOLING FLOW
44. Install the thermal strap and secure it to the in- FAN DIRECTION
strument using five screws. ARROW
DETECTOR COVER
COLLECTOR
INTERCONNECT
CLAMP SCREW
SVC 4- 45
CONNECTING THE HYDROGEN INLET TUBE AT THE WRONG LOCATION ON THE
FLOW MANIFOLD BLOCK WILL RESULT IN LEAKAGE, CREATING A FIRE AND
EXPLOSION HAZARD.
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
NOTE
Do not over- tighten the jet! Over- tightening may permanently deform and damage
the jet, the detector base, or both.
50. Install the replacement jet finger- tight. (Use two fingers on the 1/4- inch nut driver to obtain
this tightness).
51. Tighten the jet 1/8- turn past finger- tight using the nut driver.
SVC 4- 46
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
52. Install the NPD detector PCB by sliding it into CLAMPS
its mounting location on the main PCB (at the
right side of the instrument). Installation of the
PCB will insert the interconnect into the thermal
strap. Use caution to avoid damaging the
spring at the end of the interconnect.
61. Install the right side panel and secure using four screws.
62. Install the electronics carrier top cover.
63. Install the hinged top cover and secure using a screw and washer.
64. Connect the ground strap to the hinged top cover using a screw.
65. Restore all gas supplies.
66. Restore power to the instrument.
SVC 4- 47
ELECTRON CAPTURE DETECTOR (ECD)
The ECD consists of two parts: the detector cell, and a heated block. UNDER NO CONDITION IS THE
ECD CELL TO BE DISASSEMBLED. It will simply be exchanged for a new one. This does not require
the detector heated block to be removed from the mainframe. There are two types of ECD detectors
which may be installed in an HP 5890 Series II. The older version (shown below on the left) is referred
to as the 19233A/19235A variety. The newer version (shown to the right of the 19233A/19235A version)
is referred to as the G1223A/G1224A variety. Instructions for disassembly and maintenance are given
for both versions of the ECD detector.
SVC 4- 48
ELECTRON CAPTURE DETECTOR (ECD) (19233A/19235A VERSIONS)
4. When the heated zones are cool, turn off all gas OFF ON
supplies.
TOP COVER
SVC 4- 49
10. Remove the screw securing the ground strap to
the hinged top cover
11. With the lower right side of the cover pushed in, lift the right side of the cover and slide it to the
right to remove the top cover and lid shaft as a unit.
12. Remove the electronics carrier top cover by grasping it at the rear and lifting upwards until its
catch releases, then pulling it towards the rear of the instrument.
13. Remove the right side panel by removing four screws: two each along its upper and lower
edges.
SCREWS
RIGHT SIDE
PANEL
ELECTRONICS
CARRIER TOP
COVER
SCREWS
17. Disconnect the cell collector lead from the PCB CELL COLLECTOR
interconnect. LEAD
PCB INTERCONNECT
CLAMPS
THERMAL
` The following steps require protection against ESD STRAP
(Electro- Static Discharge). Use a grounded wrist
strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution
may result in damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
19. Remove the detector PCB from the right side of the instrument by grasping it in the center area
along its outer edge and pulling it straight out. (This will draw the interconnect out of the detec-
tor clamps on the thermal strap.
20. Remove the five screws securing the thermal strap and shield to the instrument.
SVC 4- 50
21. Remove the shield from the thermal strap by
carefully working it over the collector lead and
exhaust vent tube. (Depending on the detec-
tor’
s location, it may be necessary to bend the
shield to remove and install it. Avoid excessive
bending as this will fatigue the metal shield,
shortening its life.)
NOTE
Perform steps 27 through 32 only if it is
HEATED BLOCK
desired to remove the ECD heated block.
Otherwise, proceed to step 33.
27. If required, remove the two Pozidriv screws se-
curing the heated block to the instrument.
SVC 4- 51
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
39. Install the detector PCB at the right side of the instrument. (This will feed the interconnect in to
the detector clamps on the thermal strap.)
40. Tighten the screws securing the clamps which hold the interconnect in place.
41. Connect the cell collector lead to the PCB interconnect.
42. Position the detector cover over the detector.
43. Secure the detector cover to the thermal strap with three screws.
44. Remove the cap from the base of the detector (inside the column oven).
45. Install any hardware removed in step 5 of this procedure (liner, column/liner nuts, ferrules,
makeup gas adapter,etc.).
46. Disconnect any tubing attached to the detector exhaust vent tube.
47. Plug the detector exhaust vent tubing.
48. Restore supply pressure, and check for leakage at the column and makeup gas adapter fit-
tings.
49. If no leaks exist, shut off the supply pressure.
50. Remove the plug from the detector exhaust vent.
51. Install the right side panel and secure using four screws.
52. Install the electronics carrier top cover.
53. Install the hinged top cover and secure using a screw and washer.
54. Connect the ground strap to the hinged top cover using a screw.
55. Restore power to the instrument.
SVC 4- 52
ELECTRON CAPTURE DETECTOR (G1223A/G1224A VERSIONS)
4. When the heated zones are cool, turn off all gas OFF ON
supplies.
TOP COVER
SVC 4- 53
10. Remove the screw securing the ground strap to
the hinged top cover
11. With the lower right side of the cover pushed in, lift the right side of the cover and slide it to the
right to remove the top cover and lid shaft as a unit.
12. Using a Pozidriv screwdriver, remove the screw
securing the detector top cover to the thermal
strap.
17. Slide the locking tab on the ECD cover back, ECD COVER
freeing the cover from the anode shaft of the
ANODE
cell weldment.
CELL WELDMENT
18. Carefully slide the ECD cover over the anode
shaft and anode, and remove it from the detec-
tor.
NOTE
PLATED
LOWER
Perform steps 23 through 31 only if it is BODY
desired to remove the ECD heated block.
Otherwise, proceed to step 32.
23. If required, remove the two Pozidriv screws se-
curing the heated block to the instrument.
BOTTOM
INSULATION
24. Lift the heated block out of its mounting posi- LOWER HEATED BLOCK
tion. BOTTOM INSULATION
SVC 4- 54
25. Carefully slide the two cartridges (heater/sen-
sor) out of the block. The sensor enters the
block from the top. The heater enters from be-
low. The smaller of the two cartridges is the
sensor and must be handled gently in order to
prevent breakage.
26. Remove any insulation from around the base of the removed weldment and inside the lower
heated block.
27. Remove the lower heated block.
28. Install the removed insulation in the lower heated block.
29. Slide heater and sensor cartridges into the new block.
30. Install the lower heated block in its mounting position.
31. Secure the lower heated block to the instrument using two screws.
32. Install any removed insulation in the lower heated block.
33. Place the new weldment in the lower heated block.
34. Install the upper heated block on the weldment.
35. Secure the upper heated block and detector weldment to the lower heated block using two
screws.
36. Remove the cap from the base of the detector (inside the column oven).
37. Carefully slide the ECD cover over the anode shaft and anode, and install it on the detector.
38. Slide the locking tab on the ECD cover forward, capturing the cover over the anode shaft of the
cell weldment.
39. Tighten the locking screw on the ECD cover
40. Connect the cell collector lead from the cell anode to the PCB interconnect.
41. Position the detector cover over the detector.
42. Secure the detector cover to the instrument with a screw.
43. Install any hardware removed in step 5 of this procedure (liner, column/liner nuts, ferrules,
makeup gas adapter,etc.).
44. Plug the detector purge and exhaust vent tubing.
45. Restore supply pressure, and check for leakage at the column and makeup gas adapter fit-
tings.
46. If no leaks exist, shut off the supply pressure.
47. Remove the plug from the detector purge and exhaust vent tubes.
48. Connect the purge and exhaust vent tubes to the applicable tubes disconnected in step 14.
49. Install the right side panel and secure using four screws.
50. Install the electronics carrier top cover.
51. Install the hinged top cover and secure using a screw and washer.
52. Connect the ground strap to the hinged top cover using a screw.
53. Restore power to the instrument.
SVC 4- 55
Clean Anode (ECD Cell Weldment) (G1223A/G1224A Versions)
1. Set the main power line switch to the off position. RED O VISIBLE
ANODE
11. Carefully slide the ECD cover over the anode
shaft and anode, and remove it from the detec- CELL WELDMENT
tor.
SVC 4- 56
12. Loosen the anode retaining nut on the cell
weldment.
19. Insert the anode into the nut and ferrule until it
bottoms.
21. Carefully slide the ECD cover over the anode shaft and anode, and install it on the detector.
22. Slide the locking tab on the ECD cover forward, capturing the cover over the anode shaft of the
cell weldment.
23. Tighten the locking screw on the ECD cover
24. Connect the cell collector lead from the cell anode to the PCB interconnect.
25. Position the detector cover over the detector.
26. Secure the detector cover to the instrument with a screw.
27. Restore power to the instrument.
SVC 4- 57
FLAME PHOTOMETRIC DETECTOR (FPD)
Clean/Replace Photomultiplier Tube (PMT)
SVC 4- 58
6. Remove the spring securing the PMT assembly to its support bracket.
7. Cut the cable- tie securing the resistor network cable assembly to the PMT assembly tube
body.
8. Holding the tube body, unscrew the end cap (counter- clockwise) until the threads disengage.
9. Grasp the resistor network cable assembly and pull it (along with the end cap and PMT) out of
the tube body.
PMT ASSEMBLY
TUBE BODY
PHOTO-
MULTIPLIER
(CHIMNEY AND BRACKETRY TUBE (PMT)
REMOVED FOR CLARITY) O- RING
END CAP
RESISTOR NETWORK
CABLE ASSEMBLY
10. If the PMT is not to be replaced, clean the window of the tube with a lint- free lens tissue and
proceed to step 15 . (If necessary clean the window with a solution of soft soap and warm wa-
ter. Rinse with distilled water.)
Replace the PMT if there is any evidence of chips, scratches or cracks in its window
surface area. A damaged tube must be replaced before continuing to operate the
instrument.
11. If the PMT is to be replaced, carefully remove the PMT from the socket associated with the re-
sistor network cable assembly, in the end cap.
13. Carefully remove the new PMT from its packing case and insert the base of the tube into the
socket of the resistor network cable assembly ). Be very careful when inserting the tube in order
to prevent damage to its contacts (observe keying).
SVC 4- 59
Ensure that no fingerprints, dust, grease, etc. are present on the PMT window facing
the detector module.
14. Remove the plastic light seal cap covering the window of the PMT.
15. Carefully insert the PMT into the tube body and engage the threads of the end cap. Seat the
end cap (hand tight).
16. Slide the PMT tube assembly onto the detector assembly.
17. Secure the resistor network cable assembly to the PMT assembly using a cable- tie.
18. Secure the PMT assembly to its support bracket using the extension spring.
19. Install the FPD cover on the instrument and secure using a thumbscrew.
SVC 4- 60
Clean/Replace FPD Filter
SVC 4- 61
8. Remove the extension spring holding the PMT assembly to the support bracket.
9. Remove the PMT assembly by pulling it toward the rear of the instrument.
11. If the filter is not going to be replaced, wipe it clean using a lint- free lens tissue. Be careful not
to scratch the surface of the filter. (If necessary clean the filter with a solution of soft soap and
warm water. Rinse with distilled water.)
SULPHUR FILTER
PMT ASSEMBLY
12. Replace the filter if there is any evidence of chips, scratches or cracks in its surface area.
13. Install the cleaned/new filter in the flange adapter. (If the filter is silvered on one side, the sil-
vered side must face toward the flame. If the filter has a indicator arrow on its edge (>) the ar-
row must point towards the PMT.)
14. Slide the PMT tube assembly onto the detector assembly.
15. Secure the PMT assembly to its support bracket using the extension spring.
16. Install the FPD cover on the instrument and secure using a thumbscrew.
SVC 4- 62
Remove/Replace FPD Diode Bridge Assembly
6. If an autosampler is installed on the instrument, it will be necessary to remove it and its mount-
ing bracket to allow removal of the left side cover as follows:
a. Remove the autosampler tray from its mounting bracket by first simultaneously lifting
and turning the two tray locks which hold it in position, then sliding the tray away from
the instrument.
b. Lift the autosampler tray from its mounting bracket and set it aside.
c. Remove the autosampler bracket by removing the 6 screws securing it to the instru-
ment.
SVC 4- 63
7. Remove the two screws securing the left
side panel along its bottom edge.
SCREWS
SCREWS
11. Lift the hinged top cover at its front edge, EXHAUST TUBE
exposing the detector area. CHIMNEY
SVC 4- 64
16. Trace the lead, freeing it along its path, to the diode bridge assembly.
17. Disconnect the diode bridge assembly spade lug ground cable from the instrument by loosen-
ing the screw that secures it..
18. Disconnect the diode bridge assembly from its connector at the FPD flow manifold.
GROUND
CABLE
IGNITOR
LEAD
SWITCH
LEAD
DIODE
BRIDGE
ASSEMBLY
20. Install the replacement diode bridge assembly into the instrument.
21. Connect the diode bridge assembly to its connector at the FID flow manifold.
22. Connect the diode bridge assembly spade lug ground cable to the instrument by placing it
beneath and tightening the screw that secures it..
23. Thread the ignitor wire lead along its path from the diode bridge assembly to the detector igni-
tor connector.
24. Connect the ignitor wire lead connector to the glo- plug on the detector weldment and secure
using a screw.
25. Install the chimney assembly over the detector weldment and secure using two screws.
26. Install the exhaust tube on the detector weldment (through the opening in the top of the chim-
ney) and tighten using a 9/16- inch wrench.
28. Install the FPD cover on the instrument and secure using a thumbscrew.
29. Install the rear panel and secure using four screws.
30. Install the left side panel and secure using two screws.
SVC 4- 65
Clean/Replace FPD Heat Shield Windows
SVC 4- 66
8. Remove the extension spring holding the PMT assembly to the support bracket.
9. Remove the PMT assembly by pulling it toward the rear of the instrument.
SULPHUR FILTER
PMT ASSEMBLY
Use care during disassembly of the detector block assembly in order to prevent
possible damage to the quartz windows.
11. Remove the o- ring from the flange adapter.
12. Remove the four screws securing the flange ring and flange adapter to the stainless steel cou-
pling. (This will free the second heat shield window and two o- rings. Use care to top the com-
ponents from dropping out of the flange adapter. )
13. Tip the exposed end of the flange adapter down, to prevent loss of the second heat shield win-
dow and associated o- rings, and remove it, the heat shield window, o- rings, and the flange
ring, from the detector.
14. Remove the four screws and associated lock washers securing the stainless steel coupling,
clamp, heat shield disk, first heat shield window, and heat shield gasket to the detector weld-
ment.
15. Tip the exposed end of the stainless steel coupling down, to prevent loss of the heat shield
disk, first heat shield window, and heat shield gasket, and remove it, the heat shield disk, first
heat shield window, and heat shield gasket, from the detector weldment.
SVC 4- 67
WELDMENT
STAINLESS STEEL
COUPLING
O- RING (0905- 1104)
SECOND HEAT
SHIELD WINDOW
O- RING (0905- 0955)
FLANGE ADAPTOR
FLANGE RING
SCREW
O- RING (0905- 1103)
SCREW
NOTE
Due to the composition of the first heat shield gasket, it may be difficult to remove the
first heat shield window from the detector weldment. If difficulties are encountered, it
may be necessary to use a sharp implement to pry the first heat shield window out of
the detector weldment. This may cause chipping or breakage of the window, in which
case it must be replaced. Also, if chipping or breakage occurs, use an inert gas to
blow any fragments out of the detector weldment, and clean the weldment with an
approved solvent.
16. If the heat shield windows are not going to be replaced, wipe them clean using a lint- free lens
tissue. Be careful not to scratch the surface of the windows. (If necessary clean the windows
with a solution of soft soap and warm water. Rinse with distilled water.)
NOTE
During assembly of the detector, always use new seals (o- rings, gaskets) and
discard the old ones.
17. Assemble the heat shield gasket (new), first heat shield window, heat shield disk, stainless steel
coupling and clamp to the detector weldment and secure using four screws and four lock
washers. (Tighten screws evenly to ensure a gas- and light- tight seal.)
18. Assemble the second heat shield window, associated o- rings (new), flange adapter, and
flange ring to the stainless steel coupling and secure using four screws. (Tighten screws evenly
to ensure a gas- and light- tight seal.)
19. Install the o- ring for the sulphur filter in the flange adapter.
SVC 4- 68
21. Slide the PMT tube assembly onto the detector assembly.
22. Secure the PMT assembly to its support bracket using the extension spring.
23. Install the FPD cover on the instrument and secure using a thumbscrew.
SVC 4- 69
Replace FPD Jet Assembly and First Heat Shield Window
DETECTOR
TOP COVER
SVC 4- 70
11. Release the extension spring securing the PMT assembly to its support bracket.
12. Remove the photomultiplier tube (PMT) assembly and sulphur filter from the detector assembly
and set it aside.
SULPHUR FILTER
PMT ASSEMBLY
13. Remove the drip tube from the exhaust tube at the top of the detector.
CLAMP
SECURING
SCREWS
SVC 4- 71
JET WELDMENT
17. Use a 9/16 inch wrench to loosen the nut hold- O- RING
ing the weldment exit tube to the jet assembly.
It will be necessary to hold the jet assembly VESPEL FERRULE
with a 1/2- inch wrench to prevent rotation.
BRASS NUT
18. Pull the heater and sensor from the detector
weldment assembly.
WELDMENT
STAINLESS STEEL
COUPLING
O- RING (0905- 1104)
SECOND HEAT
SHIELD WINDOW
O- RING (0905- 0955)
FLANGE ADAPTOR
FLANGE RING
SCREW
O- RING (0905- 1103)
SCREW
21. Remove the flange adapter and flange ring by removing the four screws securing them to the
stainless steel coupling.
22. Remove the second heat shield window and two associated o- rings from the stainless steel
coupling.
23. Remove the stainless steel coupling and heat shield disk from the detector weldment by remov-
ing four screws and lock washers.
SVC 4- 72
24. Remove the jet weldment from the base of the weldment. (The jet weldment is not threaded; it
is pressed in.)
NOTE
NOTE
Due to the composition of the first heat shield gasket, it may be difficult to remove the
first heat shield window from the detector weldment. If difficulties are encountered, it
may be necessary to use a sharp implement to pry the first heat shield window out of
the detector weldment. This may cause chipping or breakage of the window, in which
case it must be replaced. Also, if chipping or breakage occurs, use an inert gas to
blow any fragments out of the detector weldment, and clean the weldment with an
approved solvent.
26. Remove the heat shield gasket from the detector weldment.
31. Trace the tubing from the FPD jet to the con-
nection points at the left side of the instrument.
SVC 4- 73
33. Locate the “U- shaped”slots on the instrument
to the left of the inlet. Bend the tubes from the
new jet to lay within these slots, and any in- SLOTS
stalled clips, and route them to their associated
attachment points on the left side of the instru-
ment.
37. Press the jet weldment into the base of the de-
tector weldment.
NOTE
During assembly of the detector, always use new seals (o- rings, gaskets) and
discard the old ones.
38. Install a new heat shield gasket on the detector weldment.
40. Assemble the heat shield disk, stainless steel coupling and clamp to the detector weldment and
secure using four screws and four lock washers. (Tighten screws evenly to ensure a gas- and
light- tight seal.)
41. Assemble the second heat shield window, associated o- rings (new), flange adapter, and
flange ring to the stainless steel coupling and secure using four screws. (Tighten screws evenly
to ensure a gas- and light- tight seal. Then back off all screws except the top one, to allow
clamping of the weldment to its support bracket.)
42. Install the assembled detector weldment assembly vertically onto the transfer tube weldment,
being careful not to damage the fused silica liner.
43. Install the heater and sensor cartridges into the detector weldment.
SVC 4- 74
44. Secure the weldment exit tube to the jet assembly with by holding the jet weldment with a
1/2- inch wrench, and tightening the nut which secures the weldment with a 9/16- inch
wrench.
45. Install the chimney assembly and secure using two screws.
46. Install the exhaust tube on the detector weldment (through the opening in the top of the chim-
ney) and tighten using a 9/16- inch wrench.
48. Install the o- ring for the sulphur filter in the flange adapter.
50. Slide the PMT tube assembly onto the detector assembly.
51. Secure the PMT assembly to its support bracket using the extension spring.
52. Install the FPD cover on the instrument and secure using a thumbscrew.
SVC 4- 75
Replace Fused Silica Liner
8. Lift the detector top cover to expose the FPD detector weldment.
SVC 4- 76
9. Release the extension spring securing the PMT assembly to its support bracket.
10. Remove the photomultiplier tube (PMT) assembly and sulphur filter from the detector assembly
and set it aside.
SULPHUR FILTER
PMT ASSEMBLY
11. Remove the drip tube from the exhaust tube at the top of the detector.
SVC 4- 77
19. Remove the nut and ferrule (Vespel) from the transfer tube weldment.
20. Remove the lower heater block from the transfer tube by lifting it vertically.
O- RING
GIGABORE
LINER/
FERRULE
BASE
WELDMENT
O-ring
y
3 to 6 mm
b
21. Unscrew the transfer tube weldment from the detector base weldment.
22. Lift the transfer tube weldment (containing the fused silica liner and ferrule) vertically off of the
base weldment.
23. Remove the fused silica liner and ferrule (Vespel) by pulling them out of the bottom of the trans-
fer tube weldment.
24. Install a new liner and ferrule by feeding the liner through the o- ring at the top of the transfer
tube, being careful not to damage the o- ring. The silica liner should extend above the top of
the transfer tube approximately 6- 7mm
NOTE
The fused silica liner and ferrule (Vespel) are combined as Part No. 19256- 80690.
25. Carefully install the fused silica liner, ferrule and transfer tube onto the detector base weldment,
ensuring that the exposed end of the fused silica liner remains 3 to 6- mm above the top of the
transfer tube weldment.
26. Install the heated block onto the transfer tube weldment.
SVC 4- 78
27. Install the brass nut and associated ferrule on the transfer tube weldment.
28. Inside the column oven, connect the column to the detector base weldment.
29. Install the assembled detector weldment assembly vertically onto the transfer tube weldment,
being careful not to damage the fused silica liner.
30. Install the heater and sensor cartridges into the detector weldment.
31. Secure the weldment exit tube to the jet assembly with by holding the jet weldment with a
1/2- inch wrench, and tightening the nut which secures the weldment with a 9/16- inch
wrench.
32. Install the chimney assembly and secure using two screws.
33. Install the exhaust tube on the detector weldment (through the opening in the top of the chim-
ney) and tighten using a 9/16- inch wrench.
36. Slide the PMT tube assembly onto the detector assembly.
37. Secure the PMT assembly to its support bracket using the extension spring.
38. Install the FPD cover on the instrument and secure using a thumbscrew.
SVC 4- 79
Replace Detector Base Weldment
8. Lift the detector top cover to expose the FPD detector weldment.
9. Release the extension spring securing the PMT assembly to its support bracket.
SVC 4- 80
10. Remove the photomultiplier tube (PMT) assembly and sulphur filter from the detector assembly
and set it aside.
SULPHUR FILTER
PMT ASSEMBLY
11. Remove the drip tube from the exhaust tube at the top of the detector.
SVC 4- 81
19. Remove the nut and ferrule (Vespel) from the transfer tube weldment.
20. Remove the lower heater block from the transfer tube by lifting it vertically.
O- RING
GIGABORE
LINER/
FERRULE
BASE
WELDMENT
O-ring
y
3 to 6 mm
b
21. Unscrew the transfer tube weldment from the detector base weldment.
22. Lift the transfer tube weldment (containing the fused silica liner and ferrule) vertically off of the
base weldment.
23. Remove the fused silica liner and ferrule (Vespel) by pulling them out of the bottom of the trans-
fer tube weldment.
24. Remove the two screws securing the detector base weldment to the instrument.
SVC 4- 82
26. If a PCOC fan is installed, remove the back cov-
er of the instrument by removing four screws SCREW
and sliding the cover off of the rear of the in-
strument. FAN
SHROUD
33. Install the new detector base weldment and secure using two screws.
NOTE
It is advisable to install a new fused silica liner while the detector is this state of
disassembly. The following step is only applicable when installing a new liner.
34. Install a new liner and ferrule by feeding the liner through the o- ring at the top of the transfer
tube, being careful not to damage the o- ring. The silica liner should extend above the top of
the transfer tube approximately 6- 7mm
SVC 4- 83
35. Carefully install the fused silica liner, ferrule and transfer tube onto the detector base weldment,
ensuring that the exposed end of the fused silica liner remains 3 to 6- mm above the top of the
transfer tube weldment.
36. Install the heated block onto the transfer tube weldment.
37. Install the brass nut and associated ferrule on the transfer tube weldment.
38. Inside the column oven, connect the column to the detector base weldment.
39. Install the assembled detector weldment assembly vertically onto the transfer tube weldment,
being careful not to damage the fused silica liner.
40. Install the heater and sensor cartridges into the detector weldment.
41. Secure the weldment exit tube to the jet assembly with by holding the jet weldment with a
1/2- inch wrench, and tightening the nut which secures the weldment with a 9/16- inch
wrench.
42. Install the chimney assembly and secure using two screws.
43. Install the exhaust tube on the detector weldment (through the opening in the top of the chim-
ney) and tighten using a 9/16- inch wrench.
46. Slide the PMT tube assembly onto the detector assembly.
47. Secure the PMT assembly to its support bracket using the extension spring.
48. Install the FPD cover on the instrument and secure using a thumbscrew.
SVC 4- 84
Adjust High Voltage
After the replacement of a photomultiplier tube it may be necessary to adjust the output of the high volt-
age supply to the Photo Multiplier Tube (PMT) in order to attain the optimum sensitivity. After installing
the PMT, the FPD check- out/performance verification must be performed. Results are compared with
those of the original PMT. Assuming gas flow rates are correct, and the system leak- free, the PMT
high voltage should be altered only if there is a significant change in sensitivity. The high voltage is
originally set at the factory for optimum sensitivity; signal/noise ratio (0.90 =/- 0.06 Vdc), correspond-
ing to - 850 V dc =/- 50 V dc at the PMT. The PMT voltage limits are: 0.72 V dc to 1.05 Vdc corre-
sponding to a PMT voltage of - 670 Vdc to - 990 Vdc.
SCREWS
SCREWS
NOTE
Noise will appear only about 2/3 as large on analog signal paths than on digital, due to
the high band pass filtering of signal on analog channels.
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
3. The FPD detector board is located in the “B”detector board slot. On the board, locate the high
voltage adjustment and the high voltage reference (HV REF) test point (TP7) .
SVC 4- 85
4. Connect a voltmeter between ground (TP1 on
SIGNAL CABLE
the detector PCB or the aluminum oven top)
and the HV reference test point (TP7). HIGH VOLTAGE
ADJUSTMENT
7. Install the right side panel and secure using four screws.
SVC 4- 86
REPLACING A DETECTOR PCB
Remove/Replace Detector PCB
SCREWS
ELECTRONICS
CARRIER TOP
COVER
SCREWS
7. Lift the hinged top cover at its front edge, exposing the detector area. (If an FPD detector is
installed, it will be necessary to remove the FPD cover by removing the thumbscrew securing it
to the hinged top cover.)
SVC 4- 87
8. With the exception of the TCD and FPD detector PCBs, all of the detector PCBs employed in
the HP5890 Series II include an interconnect assembly, which connects in one fashion or anoth-
er to a portion of the actual detector. In order to remove the detector PCB, the components
which retain the interconnects (or other wiring) must be loosened, removed, or disconnected as
applicable for a particular detector:
` TCD:
STRIPPED END
OF TCD
FILAMENT LEAD
` FID: CLAMPS
INTERCONNECT
` NPD:
SVC 4- 88
` 19233A/19235A ECD:
` FPD:
HIGH VOLTAGE
CABLE
SVC 4- 89
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
9. Remove the detector PCB from the right side of the instrument by grasping it in the center area
along its outer edge and pulling it straight out. (If an interconnect is employed, this will draw it
out of the detector.)
10. Install the replacement detector PCB by sliding it into its mounting location on the main PCB.
(If an interconnect is employed, Installation of the PCB will insert the interconnect into the ther-
mal strap. Use caution to avoid damaging the spring at the end of the interconnect.)
11. In order to install the detector PCB, the components which retain the interconnects (or other
wiring) must be tightened, installed, and/or connected as applicable for a particular detector:
` TCD:
` FID: CLAMPS
INTERCONNECT
SVC 4- 90
` NPD:
` 19233A/19235A ECD:
SVC 4- 91
` FPD:
SIGNAL CABLE
a. Connect the signal cable to its connector
on the FPD detector PCB. HIGH VOLTAGE
CABLE
b. Connect the high voltage cable to its con-
nector on the FPD detector PCB.
SVC 4- 92
Section 5
OVEN TEMPERATURE
REPLACING OVEN TEMPERATURE CONTROL COMPONENTS
Oven temperature control components include the oven, the oven fan and motor, the oven flap motor,
and the cryogenic valve (if installed). Removal and installation instructions for all of these components
are found on the following pages. Refer to page 20 of this section for information on troubleshooting
the oven temperature control components. Refer to Section 6 of the IPB for part numbers associated
with the oven temperature control components.
Current maintenance philosophy suggests that the oven shroud assembly be replaced as a unit, rather
then replacing the heater element or sensor element individually. Maintenance procedures have been
included for both entire shroud replacement, as well as individual part replacement, in the event that
the shroud assembly is not available in a timely manner, etc.
Specific part numbers are not given in this section. For all replacement part numbers, refer to Section 6
of the IPB portion of this document (Oven Assembly).
This document is not meant to provide instruction for first time installation of the options discussed.
Add- on sheets exist for just this purpose, and should be referenced when performing a first time instal-
lation.
TABLE OF CONTENTS
SVC 5- 1
Oven Temperature Troubleshooting
Problem Probable Cause Corrective Action
1. Oven does not heat. a. Faulty fuse F4 or F5 on 1. Check both fuses.
“WARN: OVEN SHUTOFF” main PCB. 2. If either fuse is bad, re-
message appears on dis- place. If neither fuse is
play. bad, go to probable cause
b.
b. Oven heater is open. 1. With instrument power off,
check resistance of oven
heater.
2. If it exhibits a dead or near
short, replace the oven
heater element.
3. If heater element is ok, re-
fer to probable cause c.
c. Faulty power supply PCB. 1. Replace power supply
PCB.
2. If problem persists, reinstall
original power supply PCB
and go to probable cause
d. Faulty main PCB PCB. 1. d.
Check both fuses.
2. Using the same sample a. Oven needs calibration. 1. Calibrate oven per proce-
and conditions on this and dure in this section..
other chromatographs, the
retention times of this GC
differ.
3. Oven does not control. a. Faulty main PCB. 1. Replace main PCB.
4. Oven temperature runs a. Oven heater partially 1. Ensure that the oven heat-
away. grounded. er is not coming in contact
with the oven shell or other
nearby components.
2. If problem persists, go to
probable cause b.
b. Faulty main PCB 1. Replace main PCB.
SVC 5- 2
Replace Oven Shroud Assembly
7. Remove the two screws securing the left side panel along its bottom edge.
8. Slide the left side panel towards the rear of the instrument and lift.
SCREWS
RIGHT SIDE
PANEL
ELECTRONICS
CARRIER TOP
COVER
SCREWS
SCREWS
SCREWS
9. Remove the four screws securing the rear cover at its upper rear portion.
10. Slide the rear cover towards the rear of the instrument.
SVC 5- 3
FAN SHROUD
HEATER SENSOR
STANDOFFS SCREWS
Fan Shroud
WHEN DISCONNECTING A PLUG, PULL ON THE PLUG NOT ON ITS WIRES. PULLING
ON THE WIRES MAY CAUSE BREAKAGE.
14. At the rear of the instrument, disconnect the two heater element leads at the AC power supply
PCB.
HEATER ELEMENT
CONNECTION TERMINALS
15. From inside the oven, draw the heater leads through the opening in the rear of the oven.
SVC 5- 4
16. Disconnect connector P7 from its receptacle on
the main PCB by pulling it straight off. (Heated
zones corresponding to sensor lead locations
are labeled to the right of the P7 connector re-
ceptacle on the main PCB.)
TOOL STOP
LANCE
RELEASE
TIP
INSERT TIP
LOCKING HERE
LANCE (BACK OF
CAVITY CAVITY)
BACK OF CONTACT
HOUSING (TYPICAL)
TAPER LOCKING
LANCE
18. From inside the oven, draw the sensor leads RESET LANCE
through the opening in the rear of the oven. TIP
SVC 5- 5
23. Insert connector P7 into its corresponding receptacle on the main PCB.
24. Route the heater leads from the replacement shroud through the opening in the rear of the
oven so that its ends terminate at the connection locations on the power supply PCB.
25. Connect the heater leads to the corresponding blade lugs on the power supply PCB.
26. Install the oven heater/fan shroud in the instrument oven and secure using four screws.
27. Place a screwdriver through a hole in the shroud and gently spin the fan. Listen to determine if
the fan touches anything while turning. If so, open the shroud and make any necessary adjust-
ments.
29. Install any columns and associated hardware removed at the beginning of this procedure.
32. Ensure that the oven operates properly at some selected temperature (e.g.,100_C).
SVC 5- 6
Replace Oven Heater Element
4. When the heated zones are cool, turn off all gas
supplies. OFF ON
SCREWS
SCREWS
SVC 5- 7
FAN SHROUD
HEATER SENSOR
STANDOFFS SCREWS
Fan Shroud
10. Note the position of the sensor so it may be replaced at the same location.
12. Remove the two screws securing the heater to its standoffs.
SVC 5- 8
13. At the rear of the instrument, disconnect the two heater element leads at the AC power supply
PCB.
HEATER ELEMENT
CONNECTION TERMINALS
14. From inside the oven, draw the heater leads through the opening in the rear of the oven.
16. To prepare a new heater, note that it must be matched to a specific line voltage. From Table
4- 1, verify the unstretched length of the replacement heater element, according to the line volt-
age of the instrument. Stretch the wire EVENLY to the indicated length and allow it to contract
back to an approximate 720 mm length.
17. Route the new heater through insulators so that its ends terminate at the connection locations
on the power supply PCB.
19. Secure the two heater standoffs to the shroud with screws.
SVC 5- 9
20. Install the oven temperature sensor and secure by tightening the retaining clamp.
21. Install the oven heater/fan shroud in the instrument oven and secure using four screws.
22. Place a screwdriver through a hole in the shroud and gently spin the fan. Listen to determine if
the fan touches anything while turning. If so, open the shroud and make any necessary adjust-
ments.
23. Install any columns and associated hardware removed at the beginning of this procedure.
26. Ensure that the oven functions properly at a given temperature (e.g., 100_C).
SVC 5- 10
Replace Oven Temperature Sensor
7. Remove the two screws securing the left side panel along its bottom edge.
8. Slide the left side panel towards the rear of the instrument and lift.
SCREWS
RIGHT SIDE
PANEL
ELECTRONICS
CARRIER TOP
COVER
SCREWS
SCREWS
SCREWS
9. Remove the four screws securing the rear cover at its upper rear portion.
10. Slide the rear cover towards the rear of the instrument.
SVC 5- 11
FAN SHROUD
HEATER SENSOR
STANDOFFS SCREWS
Fan Shroud
14. Note the position of the sensor so that the replacement may be installed at the same location.
17. Remove the sensor through the opening in the rear of the oven. Some insulation will come out
with the sensor.
18. Remove any insulation remaining in the sensor guide and save it for later use.
SVC 5- 12
THE TEMPERATURE SENSOR (SMALL CERAMIC BEAD) IS VERY FRAGILE AND
MUST BE HANDLED CAREFULLY.
19. Insert the new sensor through the opening in the rear of the oven.
20. Position the new sensor cartridge at the same location as the original and secure it by tighten-
ing the retainer clamp.
TOOL STOP
LANCE
RELEASE
TIP
INSERT TIP
LOCKING HERE
LANCE (BACK OF
CAVITY CAVITY)
BACK OF CONTACT
HOUSING (TYPICAL)
SVC 5- 13
23. Prepare the pins corresponding to the replace-
ment sensor cartridges by adjusting their lock-
ing lances using the lance reset portion of the
tool. TAPER
LANCE LOCKING
RESET LANCE
24. Insert the pins for the replacement sensor into TIP
their appropriate locations in the plug, making
sure the locking lance on each pin seats into its
hole through the side of the plug.
LOCKING
LANCE
CAVITY
LOCKING
LANCE
CONTACT
(TYPICAL)
BACK OF
HOUSING
27. Install the insulation removed earlier in the sensor guide, around the sensor wire leads.
29. Install any columns and associated hardware removed at the beginning of this procedure.
32 Ensure that the oven operates properly at some selected temperature (e.g.,100_C).
SVC 5- 14
Replace Oven Fan and/or Oven Fan Motor
4. When the heated zones are cool, turn off all gas OFF ON
supplies.
SCREWS
SCREWS
9. Carefully swing the left edge of the shroud towards the front of the instrument.
10. With a hex wrench, loosen the setscrew securing the fan to the motor shaft.
SVC 5- 15
FAN SHROUD
SENSOR
SCREWS
HEATER
STANDOFFS
SET SCREW
13. At the rear of the instrument, trace the fan motor wire harness to its connector receptacle (J28)
on the AC power board.
WHEN DISCONNECTING A PLUG, PULL ON THE PLUG NOT ON ITS WIRES. PULLING
ON THE WIRES MAY CAUSE BREAKAGE.
14. Disconnect connector J28 from its receptacle by pulling it straight up while squeezing its ribbed
sides.
15. Locate and remove the fan motor ground wire by removing the nut securing it to the instrument.
16. Remove the three nuts (and six associated washers) securing the motor to the oven.
SVC 5- 16
MOUNTING NUT
GROUND
WIRE
18. Install the new fan motor and secure using two washers and one nut at each mounting location.
20. Connect the motor wire harness plug to connector receptacle J28 on the AC power board.
21. Connect the motor ground wire to the oven wall and secure using a nut.
22. Install the fan on the motor shaft and position it so its setscrew will seat against the flat portion
of the shaft.
24. Install the oven heater/fan shroud and secure with four screws.
25. Feed a screwdriver through a hole in the shroud and gently spin the fan.
27. If any noise is heard, open the shroud and repeat steps 4 through 7 and 18 through 22, adjust-
ing the position of the fan on the motor shaft.
29. Install any columns and associated hardware removed at the beginning of this procedure.
SVC 5- 17
TURN OFF THE POWER TO THE INSTRUMENT IMMEDIATELY IF THERE IS EVIDENCE
OF THE FAN BLADES CONTACTING ANYTHING DURING OPERATION, AND/OR IF
THERE IS UNDUE VIBRATION. VIBRATION MAY INDICATE BENT FAN BLADES
AND/OR A BENT MOTOR SHAFT.
31, Restore power to the instrument.
32. Check that the oven controls properly at some selected temperature (e.g., 100_C).
SVC 5- 18
Replace Oven Flap Motor
4. When the heated zones are cool, turn off all gas
supplies. OFF ON
8. Remove the right side panel by removing four screws: two each along its upper and lower
edges.
SCREWS
RIGHT SIDE
PANEL
ELECTRONICS
CARRIER TOP
COVER
SCREWS
SCREWS
SCREWS
SVC 5- 19
9. Facing the rear of the instrument, locate the
oven flap motor (mounted on the oven at its
lower right corner). Trace and free its wire
harness to the P8 connector on the main
PCB.
1 2 IGA
3 4 VLVA
5 6 VLVB
7 8 FLAP
9 10 FLAP
11 12 FLAP SCREW COUPLING
WHEN DISCONNECTING A PLUG, PULL ON THE PLUG NOT ON ITS WIRES. PULLING
ON THE WIRES MAY CAUSE BREAKAGE.
11. Remove the air duct located above the upper oven flap by removing two nuts, one each along
its upper and lower edges.
12. Use a Pozidriv screwdriver to remove the two screws securing the flapper bracket to the instru-
ment.
14. Use a hex wrench to loosen the motor shaft setscrew on the flexible coupling closest to the flap
motor.
15. Use a small Pozidriv screwdriver to remove the motor from the bracket.
16. Insert the shaft of the new stepper motor into the flexible coupling on the flapper assembly.
17. Secure the motor to the flapper bracket using two screws.
19. Mount the oven flap assembly on the instrument and secure using two screws.
SVC 5- 20
20. Mount the air duct over the upper oven flap and secure using two screws.
21. After the new motor has been installed, route its wire harness along the same path used by the
old harness and secure it with plastic wire ties.
SCREW M4 x 8 mm
0515- 0910
FLAPPER
BUSHING
05890- 20730
FLAPPER
OVEN FLAP BRACKET
PINS 05890- 00440
1251- 5963
FLEXIBLE COUPLING
1500- 0671
LOCK WASHER
STEPPER MOTOR 2190- 0468 SCREW M3 x 6 mm
05890- 60940 0515- 0055
SVC 5- 21
22. Use the lance release tip of an AMP pin extrac-
EXTRACTION TOOL
tion/lance reset tool (8710- 1542) to remove the STOP
LANCE RESET
appropriate pins (from the old harness) from TOOL
connector P8. (The tool features a lance re- LANCE
lease tip and a lance reset tip. The lance re- RELEASE
lease tip is used to depress the pin locking TIP
CONTACT
(TYPICAL)
BACK OF
RECEPTACLE HOUSING
BOX (TYPICAL)
26. Insert the plug in its receptacle (P8) on the main PCB. (The plug is keyed and can only be in-
serted one way.)
27. Replace the panels removed at the beginning of this procedure.
28. Connect any gas supplies disconnected in step 4 of this procedure.
29, Restore power to the instrument.
` SMALL PARTICLES OF DEBRIS MAY BE BLOWN OUT OF THE OVEN WHEN THE
FLAP IS OPEN. USE PROPER EYE PROTECTION WHEN OBSERVING THE OVEN
FLAPS THROUGH THE BACK PANEL.
` TO PREVENT POSSIBLE BURNS, AVOID COMING IN CONTACT WITH THE HOT
AIR VENTED FROM THE OVEN.
30. Observe the oven flaps through the back panel. The oven flap motor should close the flap as-
sembly completely.
31. Enter an oven temperature setting of 20_C. The oven flap assembly should now open fully.
SVC 5- 22
Replace Cryogenic Valve and/or Nozzle
ELECTRONICS
CARRIER TOP
COVER
6. Remove the right side panel by removing four screws: two each along its upper and lower
edges.
7. Remove the two screws securing the left side panel along its bottom edge.
8. Slide the left side panel towards the rear of the instrument and lift.
SCREWS
RIGHT SIDE
PANEL
SCREWS
SCREWS SCREWS
SCREWS
9. Remove the four screws securing the rear cover to the instrument.
SVC 5- 23
10. Slide the rear cover towards the rear of the instrument.
15. Disconnect connector J9 from the main PCB by pulling it straight out of its receptacle.
16. Remove the valve assembly from the outside wall of the oven by removing three nuts (and as-
sociated washers) from around the edge of its mounting bracket.
SCREW
17. Withdraw the valve assembly from the side of the instrument, being careful not to bend or dam-
age the nozzle assembly.
18. Separate the valve body from its mounting bracket by removing two screws.
a. Remove the nozzle (notice its position with respect to the valve assembly) from the valve
body and discard.
b. Wrap the threads of the new nozzle with Teflon pipe tape being careful not to cover the first
two threads of the nozzle.
SVC 5- 24
c. Mount the cryogenic nozzle on the valve and tighten it firmly with a wrench. (Be sure to
install a CO2 nozzle (if one was present) in the same position as the old one.)
d. Go to step 22.
20. If a PCOC cryogenic nozzle is installed, proceed as follows: INJECTION PORT COVER
1/4- INCH
SCREW
AND
WASHER
AUTO
INJECTION
ASSEMBLY OPTIONAL
MANUAL
INJECTION
ASSEMBLY
SEPTUM DUCKBILL
SEPTUM
INSERT
PCOC INSERT
SPRING
AIR DEFLECTOR
HEATER/SENSOR
CABLE ASSEMBLY
WELDMENT
INSULATION
CAVITY
SLEEVE
SCREW
SVC 5- 25
c. Remove the air deflector using a Pozidriv screwdriver to remove the screw securing the air
deflector to the inlet weldment.
Handle the heater and sensor cartridges with care to prevent breakage. The
cartridges (particularly the smaller sensor cartridge) are fragile.
d. Carefully slide the heater and sensor cartridges out of the heated block portion of the inlet.
e. Use a Pozidriv screwdriver to remove the two screws securing the inlet to the instrument.
g. If installed, remove the cryo- blast tube from the inlet weldment.
Handle the heater and sensor cartridges with care to prevent breakage. The
cartridges (particularly the smaller sensor cartridge) are fragile.
j. Carefully slide the heater and sensor cartridges into the heated block portion of the inlet.
k. Install the air deflector and secure it to the weldment using one screw.
l. Install the injection assembly, septum, PCOC insert spring, and insert (the injection assem-
bly secures the other items to the inlet weldment).
21. Mount the new valve body on the mounting bracket and secure using two screws.
22. Mount the assembly on the oven wall in the same position as the one just removed.
23. Route the wire harness along the same path used by the old harness and secure it with plastic
wire ties.
SVC 5- 26
1
CRYO 1 & 2
2
3
INJ B 3 & 4
4
5
INJ A 5 & 6 J9
6
HEAT-
7 ERS
DET B 7 & 8
8
9
10
DET A 9 & 10 J9
SVC 5- 27
28. Connect the cryogenic fluid supply fittings to the valve.
31. If there is no evidence of leakage, replace the panels removed at the beginning of this proce-
dure.
34. Check that the oven controls properly at some selected subambient temperature (e.g., - 10_C),
and that no cryogenic fluid flows into the oven at a selected temperature above ambient (e.g.,
100_C).
SVC 5- 28
Calibrate Oven Temperature
To maximize the precision of retention time information, particularly if retention times are to be com-
pared to that of other chromatographs, it may be necessary to calibrate the oven temperature control
circuitry using an independent temperature measuring device.
With the factory- set calibration difference value of 0 (zero), the displayed oven temperature is accurate
to within 1% of the actual temperature (which is expressed in _K (Kelvin)).
The HP 5890 Series II provides the means to reset oven temperature monitoring (if necessary) so that
the ACTUAL displayed temperature value accurately represents the correct temperature.
Calibration of the oven temperature control circuitry requires the operator to enter the difference (delta)
value (in _C) between an independently measured temperature and the corresponding displayed oven
temperature. For example, if the actual measured oven temperature is 148.73_C, while the correspond-
ing displayed temperature is 150.00_C, the delta value is - 1.27.
Oven temperature calibration measurements should be made at a temperature in the mid- range of
those temperatures normally attained during operation. Allow ample time (up to 1/2- hour) for thermal
equilibration at the selected temperature. No drift should be observed.
1. Place the temperature sensing probe in the region of the oven which is occupied by the
column(s).
2. Set the oven temperature to the desired level, allowing ample time for thermal equilibration.
CLEAR . 1 ENTER
4. CALIB will be displayed, followed by two values; the observed oven temperature (to 0.01_C),
and the current delta correction value. Record the current delta correction value. (If problems
occur during recalibration, the value may be re- entered.)
5. Assuming no drift has occurred, the new delta correction value may be entered using the nu-
meric keypad, followed by pressing ENTER .
6. CALIB DELTA will be displayed until ENTER is pressed again. Then the oven temperature cali-
bration occurs. Note that after oven calibration, the displayed oven temperature value should
closely match the value of the installed temperature measuring device.
NOTE
` Any delta correction value may be entered within a range of ¦ 10.00_C. If a value
beyond these limits is entered, the message CORRECTION TOO HIGH is
displayed.
` Assuming the battery protecting the HP 5890 Series II memory is functional, the
new delta calibration value remains in effect even if the instrument is switched,
disconnected from its power source, or experiences a power failure.
SVC 5- 29
Section 6
ZONE TEMPERATURE
REPLACING TEMPERATURE CONTROL COMPONENTS
The HP 5890 Series II uses heater cartridges to apply and temperature sensor cartridges to sense heat
at the various heated zones (inlets, detectors, and valve box, if installed). Replacement of a heater/sen-
sor cable assembly (which consists of the heater and sensor cartridges, as well as the wiring connect-
ing them to the main PCB) is accomplished by partial removal of the applicable heated zone compo-
nent. In addition, the heater/sensor cable assembly must be disconnected from the applicable
connectors on the main PCB. Removal of the wiring from the connectors on the main PCB is covered
first, followed by instructions for removal of the heater and sensor cartridges from the heated zone com-
ponents.
If a TCD detector is installed, a delta- t temperature sensor is used in addition to the standard tempera-
ture sensor cartridge. Removal and replacement of the delta- t temperature sensor cartridge is dis-
cussed after the procedures for standard heater/temperature sensor cartridges.
The HP 5890 Series II also uses an optional cryogenic valve to cool the PCOC inlet. While the cryogen-
ic valve is discussed with oven components in Section 5 of the service portion of this document, remov-
al of the PCOC nozzle (which carries the cooling gas from the valve to the inlet) is discussed in this sec-
tion.
Specific part numbers are not given in this section. For replacement part numbers, refer to the section
of the IPB applicable to the heated zone component being addressed (i. e. inlets - Section 5, detec-
tors - Section 2, valve box - Section 7, cryogenic valve - Section 6).
TABLE OF CONTENTS
SVC 6- 1
` Remove/Replace PCOC Inlet Heater and Sensor Cartridges . . . . . . . SVC 6- 16
Remove/Replace Detector Zone Heater and Sensor Cartridges . . . . . . . SVC 6- 18
` Remove/Replace TCD Heater and Sensor Cartridges . . . . . . . . . . . . . SVC 6- 18
TABLE OF CONTENTS (continued)
SVC 6- 2
Heated Zone Troubleshooting
Problem Probable Cause Corrective Action
1. One heated zone tempera- a. Heater partially shorted to 1. Replace heater and sensor.
ture runs away. chassis (grounded).
b. Faulty main PCB. 1. Replace main PCB (refer to
Section 9).
2. One heated zone will not a. Heater partially shorted to 1. Replace heater and sensor.
heat. chassis (grounded).
b. Faulty main PCB. 1. Replace main PCB (refer to
Section 9).
3. None of the heated zones a. Faulty F3 fuse on main 1. Check main PCB fuse F3;
will heat, but the oven is PCB. replace if required.
ok. b. Faulty main PCB. 1. Replace main PCB (refer to
Section 9).
4. None of the heated zones a. Faulty main PCB. 1. Replace main PCB (refer to
will heat, and the oven will Section 9).
not heat.
SVC 6- 3
Remove/Replace Inlet, Detector, and Valve Box Heater/Sensor Cable
Assemblies
Replacement of a heater/sensor cable assembly (which consists of the heater and sensor cartridges, as
well as the wiring connecting them to the main PCB) is accomplished by partial removal of the applica-
ble heated zone component. In addition, the heater/sensor cable assembly must be disconnected from
the applicable connectors on the main PCB. Removal of the wiring from the connectors on the main
PCB is covered first, followed by instructions for removal of the heater and sensor cartridges from the
heated zone components.
SCREWS
SCREWS
This procedure requires precautions against ESD (Electro- Static Discharge). Use a
grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small) connected
to a suitable ground. Failure to heed this caution may result in damage to the
instrument.
SVC 6- 4
6. Remove the electronics carrier top cover by
grasping it at the rear and lifting until its catch
releases, the pulling it toward the rear of the
instrument .
SCREWS
SCREWS
ELECTRONICS
CARRIER TOP
COVER RIGHT SIDE PANEL
8. Trace the leads of the faulty heater and/or sensor cartridge to their terminating connectors at
the upper right corner of the main PCB (located at the right side of the instrument). All temper-
ature sensor leads terminate at connector receptacle P7 on the main PCB (at the upper right
corner of the PCB). All heater cartridge leads terminate at connector receptacle J9 on the main
PCB (at the right side of the PCB).
9. Route the replacement heater or sensor cartridge leads along the same path.
10. Disconnect or cut any plastic cable ties securing the old heater/sensor cable assembly along its
path.
11. Secure the leads of the replacement heater/sensor cable assembly to the instrument with new
plastic cable ties.
P7
1 2 OVEN C10
3 4 DETA
5 6 DETB
7 8 INJA C9
9 10 INJB
11 12 AUX
13 14 FAN+-
P7
Q3
Q6
SVC 6- 5
1
CRYO 1 & 2
2
3
INJ B 3 & 4
4
5
INJ A 5 & 6 J9
6
HEAT-
7 ERS
DET B 7 & 8
8
9
10
DET A 9 & 10 J9
When disconnecting a plug, pull on the plug, not on its wires. Pulling on the wires may
cause breakage.
12. Disconnect connector P10 from its receptacle on the main PCB by pulling the plug straight out
of the receptacle.
13. Remove the high voltage cover from the upper right portion of the main PCB.
14. Disconnect connector J9 from its receptacle by squeezing its ribbed size and pulling the plug
straight out of the receptacle.
from the plug. The following steps detail how PUSH ROD
to remove the pins from the connector. BUTTON
SVC 6- 6
a. Slide the sleeve portion of the tool straight
into the pin to be removed from the con- PIN CONTACT
(REF)
nector until it is fully bottomed.
b. At the same time, allow the plunger to be
pushed back by the pin.
c. Rotate the body of the tool to ensure it is
fully bottomed, and to ensure the pin lock-
ing lance is released. SLEEVE
When disconnecting a plug, pull on the plug not on its wires. Pulling on the wires may
cause breakage.
21. Disconnect connector P7 from its receptacle by pulling it straight off. (Heated zones corre-
sponding to sensor lead locations are labeled to the right of the P7 connector receptacle on the
main PCB.)
P7
1 2 OVEN C10
3 4 DETA
5 6 DETB
7 8 INJA C9
9 10 INJB
11 12 AUX
13 14 FAN+-
P7
Q3
Q6
SVC 6- 7
22. Use the lance release tip of an AMP pin extrac-
EXTRACTION TOOL
tion/lance reset tool (8710- 1542) to remove the STOP
LANCE RESET
appropriate pins from connector P7. (The tool TOOL
features a lance release tip and a lance reset
LANCE
tip. The lance release tip is used to depress RELEASE
the pin locking lance to extract the pin from a TIP
BACK OF CONTACT
HOUSING (TYPICAL)
CONTACT
(TYPICAL)
BACK OF
HOUSING
25. Gently pull on the wire to ensure that the pin is locked in the connector.
26. Insert connector P7 into its corresponding receptacle on the main PCB.
27. After the leads have been exchanged in the appropriate connectors, proceed to the heater/sen-
sor cable assembly removal/replacement procedure applicable to the desired heated zone.
SVC 6- 8
Remove/Replace Inlet Zone Heater and Sensor Cartridges
INSULATION
PLATE
7. Lift the inlet enough to expose the heated block and heater/sensor wiring.
SVC 6- 9
Handle the heater and sensor cartridges with care to prevent breakage. The
cartridges (particularly the smaller sensor cartridge) are fragile.
9. Carefully slide the heater and sensor cartridges out of the heated block portion of the inlet.
10. Slide the replacement heater and sensor cartridges into the heated block of the inlet being in-
stalled.
15. Install the liner and all other hardware removed during step 2.
18. Install the right side panel and secure using two screws.
21. Secure the rear cover to the instrument by installing and tightening four screws.
SVC 6- 10
` Remove/Replace Septum- Purged Packed Column Inlet Heater and Sensor
Cartridges
SVC 6- 11
10. Carefully slide the heater and sensor cartridges
HEATER/SENSOR
out of the heated block portion of the inlet. CABLE ASSEMBLY
19. Install the right side panel and secure using two screws.
22. Secure the rear cover to the instrument by installing and tightening four screws.
SVC 6- 12
` Remove/Replace Split- Splitless/Split- Only Capillary Inlet Heater and Sensor
Cartridges
INSERT
ASSEMBLY
RETAINING
NUT
SVC 6- 13
11. Use a Pozidriv screwdriver to remove the two screws securing the inlet to the instrument.
12. Gently pull the inlet up and out of its instrument cavity.
Handle the heater and sensor cartridges with care to prevent breakage. The
cartridges (particularly the smaller sensor cartridge) are fragile.
15. Carefully slide the heater and sensor cartridges
HEATER/SENSOR
out of the heated block portion of the inlet. CABLE ASSEMBLY
16. Slide the heater and sensor cartridges into the LINER
17. Install the heated block onto the stem of the SHELL
shell weldment. WELDMENT
NOTE
To lessen the possibility of pressure leaks, always install a new anealed seal, when
the old seal has been removed.
21. Tighten the retaining nut at the base of the shell weldment.
22. Install the reducing nut, flat washer, and anealed seal onto the base of the retaining nut.
23. Install the lower insulation cover and three pieces of lower insulation, inside the column oven.
24. Tighten the two screws which secure the lower insulation cover inside the column oven.
26. Install the insert assembly on the shell weldment and secure using a ???- inch wrench.
27. Install the tubing nut (and associated split vent tube) on the shell weldment and secure using a
1/2- inch wrench.
SVC 6- 14
28. Install the liner in the shell weldment.
29. Install a cap or plug on the end of the inlet (inside the column oven).
35. Install the right side panel and secure using two screws.
38. Secure the rear cover to the instrument by installing and tightening four screws.
SVC 6- 15
` Remove/Replace PCOC Inlet Heater and Sensor Cartridges
LID SHAFT
4. Remove the two screws securing the left side
panel along its bottom edge.
AUTO
INJECTION
ASSEMBLY OPTIONAL
MANUAL
INJECTION
ASSEMBLY
SEPTUM DUCKBILL
SEPTUM
INSERT
PCOC INSERT
SPRING
AIR DEFLECTOR
HEATER/SENSOR
CABLE ASSEMBLY
WELDMENT
INSULATION
CAVITY
SLEEVE
SCREW
SVC 6- 16
7. Remove the air deflector using a Pozidriv screwdriver to remove the screw securing the air de-
flector to the inlet weldment.
Handle the heater and sensor cartridges with care to prevent breakage. The
cartridges (particularly the smaller sensor cartridge) are fragile.
8. Carefully slide the heater and sensor cartridges out of the heated block portion of the inlet.
9. Carefully slide the heater and sensor cartridges into the heated block portion of the inlet.
10. Install the air deflector and secure it to the weldment using one screw.
11. Install the injection assembly, septum, PCOC insert spring, and insert (the injection assembly
secures the other items to the inlet weldment).
13. Install the liner and all other hardware removed in step 2.
15. Install the right side panel and secure using two screws.
18. Secure the rear cover to the instrument by installing and tightening four screws.
SVC 6- 17
Remove/Replace Detector Zone Heater and Sensor Cartridges
SOLENOID
VALVE
VENT
PORT
SCREW
DETECTOR
COVER
6. Cap the TCD vent port on the top of the detector. (This is not be required on a series con-
nected TCD.)
7. Remove the preformed thermal insulation from around the detector to expose the two screws
securing the detector to the instrument mainframe.
8. On a series- connected TCD, disconnect the TCD to FID jumper tube from the TCD oven- re-
turn exhaust vent port.
SVC 6- 18
9. Remove the two screws securing the detector to
the instrument and then lift the block up enough to
expose the heater and sensor cartridge wires.
DELTA-T
SENSOR
NOTE
Replacement of the delta- t temperature sensor is covered later in this section.
11. Install the replacement heater and temperature sensor, and the old delta- t temperature sensor
cartridges into the heated block.
12. Carefully install the detector, securing it to the instrument with two screws.
13. Remove the caps from the detector base and the vent port.
When installing insulation, use care not to plug the vent port. If flow is interrupted while the TCD
is on, it will shorten its life dramatically.
14. Taking care not to block the vent port, install insulation around the detector block.
Use caution not to crimp the filament and delta- t sensor leads when installing the TCD detector
cover.
15. Install the TCD detector cover and secure using
two screws.
17. Install the right side panel and secure using two screws.
20. Secure the rear cover to the instrument by installing and tightening four screws.
SVC 6- 19
` Remove/Replace FID Heater and Sensor Cartridges
NOTE
LID SHAFT
1/4- INCH
SCREW
AND WASHER
SVC 6- 20
9. Disconnect the ignitor wire lead connector at DETECTOR PCB
the mating connection adjacent to the ignitor. INTERCONNECT
COLLECTOR
NUT
10. Loosen the screws securing the clamps holding COLLECTOR
IGNITOR
the interconnect in place. SPANNER
NUT
COLLECTOR
MOUNT
THERMAL CLAMPS
STRAP
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When handling PCBs (Printed Circuit Boards), always place them in static
control envelopes.
11. Remove the FID detector PCB by sliding it out of the main PCB (at the right side of the instru-
ment). Removal of the PCB will withdraw the interconnect from the thermal strap. Use caution
to avoid damaging the spring at the end of the interconnect.
12. Remove the three screws securing the collector mount to the thermal strap.
13. Remove the collector mount and collector assembly as a unit.
14. Use a 1 and 1/4- inch socket to remove the
BASE SPANNER NUT
base spanner nut from the detector weldment.
THERMAL STRAP
15. Remove the thermal strap by removing the five
screws securing it to the instrument.
INSULATION
PLATE
16. Remove the two screws securing the detector
weldment to the instrument.
HEATED
BLOCK
17. Slide the insulation plate out from over
the detector weldment. HEATER
SENSOR
18. Cap the detector weldment at its upper open-
ing, using a detector cap, and at its lower open-
ing, inside the column oven.
19. Remove the insulation around the detector weldment to expose the heated block.
20. Lift the base up enough to expose the heated block, heater and temperature sensor cartridge
wires.
SVC 6- 21
Handle the heater and sensor cartridges with care to prevent breakage. The
cartridges (particularly the smaller sensor cartridge) are fragile.
21. Carefully slide the two cartridges out of the block.
22. Slide the replacement heater and sensor cartridges into the heated block portion of the detec-
tor weldment.
25. Position the insulation plate over the installed insulation and align its mounting holes with those
of the detector weldment.
26. Secure the detector weldment and insulation plate to the instrument with two screws.
27. Install the thermal strap and secure it to the instrument using five screws.
28. Install the base spanner nut on the detector weldment and tighten using an open end wrench.
29. Remove the cap from the detector weldment top opening.
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When handling PCBs (Printed Circuit Boards), always place them in static
control envelopes.
31. Install the FID detector PCB by sliding it into its CLAMPS
mounting location on the main PCB (at the right
side of the instrument). Installation of the PCB
will insert the interconnect into the thermal
strap. Use caution to avoid damaging the
spring at the end of the interconnect.
SVC 6- 22
36. Install the column and any other associated hardware removed in step 2 of this procedure.
37. Install the collector mount and collector assem-
bly as a unit. DETECTOR PCB
INTERCONNECT
COLLECTOR
38. Secure the collector mount to the thermal strap NUT
IGNITOR
using three screws. COLLECTOR
SPANNER
NUT
39. Connect the ignitor wire lead connector at the
mating connection adjacent to the ignitor.
COLLECTOR
MOUNT
40. Slide the rear cover on to the instrument.
42. Install the right side panel and secure THERMAL CLAMPS
STRAP
using four screws.
SVC 6- 23
` Remove/Replace NPD Heater and Sensor Cartridges
NOTE
SVC 6- 24
10. Remove the detector top cover, DETECTOR
COLLECTOR
and all attached components, from COVER
the thermal strap and set aside.
INTERCONNECT
CLAMP SCREW
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When handling PCBs (Printed Circuit Boards), always place them in static
control envelopes.
11. Disconnect the NPD bead power cable from the detector PCB by pulling it straight off.
12. Remove the NPD detector PCB by sliding it out of the main PCB (at the right side of the instru-
ment). Removal of the PCB will withdraw the interconnect from the thermal strap. Use caution
to avoid damaging the spring at the end of the interconnect.
13. Use a spanner wrench (part no. 19301- 00150) to remove the base spanner nut from the detec-
tor weldment.
14. Remove the thermal strap by removing the five screws securing it to the instrument.
15. Cap the weldment openings at the top (over the jet aperture) and bottom
(inside the column oven) to prevent damage and/or contamination.
BASE SPANNER NUT
16. Remove the two screws securing the detector
weldment to the instrument. THERMAL STRAP
17. Slide the insulation plate out from over the INSULATION
detector weldment. PLATE
Handle the heater and sensor cartridges with care to prevent breakage. The
cartridges (particularly the smaller sensor cartridge) are fragile.
20. Carefully slide the two cartridges out of the block.
SVC 6- 25
21. Slide the replacement heater and temperature sensor cartridges into the heated block portion
of the detector weldment.
24. Position the insulation plate over the installed insulation and align its mounting holes with those
of the detector weldment.
25. Secure the detector weldment and insulation plate to the instrument with two screws.
26. Install the thermal strap and secure it to the BASE SPANNER NUT
instrument using five screws.
THERMAL STRAP
27. Remove the cap from the detector weldment
top opening. INSULATION
PLATE
28. Ensure that there is no debris in the detector
weldment. HEATED
BLOCK
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When handling PCBs (Printed Circuit Boards), always place them in static
control envelopes.
30. Install the NPD detector PCB by sliding it into Clamps
its mounting location on the main PCB (at the
right side of the instrument). Installation of the
PCB will insert the interconnect into the thermal
strap. Use caution to avoid damaging the
spring at the end of the interconnect.
SVC 6- 26
NOTE
In the next step, avoid touching the lower end of the collector (end nearest the jet).
Fingerprints and/or other contamination may cause baseline drift and noise.
32. Install the detector top cover, and all DETECTOR COVER
attached components, on the thermal strap. COLLECTOR
37. Install the rear panel and secure using four screws.
38. Install the right side panel and secure using four screws. COVER
SVC 6- 27
` Remove/Replace ECD (19233A/19235A VERSIONS) Heater and Sensor
Cartridges
SVC 6- 28
9. Using a Pozidriv screwdriver, remove the three
screws securing the detector cover to the ther-
mal strap.
12. Disconnect the cell collector lead from the PCB CELL COLLECTOR
interconnect. LEAD
PCB INTERCONNECT
CLAMPS
ECD DETECTOR
WELDMENT
HEATED BLOCK
SVC 6- 29
Handle the heater and sensor cartridges with care to prevent breakage. The
cartridges (particularly the smaller sensor cartridge) are fragile.
29. Carefully slide the heater and temperature sensor cartridges out of the block.
30. Slide the replacement heater and temperature sensor cartridges into the heated block.
31. Install the heated block in its mounting position.
32. Secure the heated block to the instrument using two screws.
33. Install the insulation around the detector base.
34. install the thermal strap, working it carefully over the collector lead and exhaust vent tube.
35. Install the shield over the thermal strap. (Depending on the detector’s location, it may be nec-
essary to bend the shield to remove and install it. Avoid excessive bending as this will fatigue
the metal shield, shortening its life.)
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When handling PCBs (Printed Circuit Boards), always place them in static
control envelopes.
36. Install the detector PCB at the right side of the instrument. (This will feed the interconnect in to
the detector clamps on the thermal strap.)
39. Tighten the screws securing the clamps which hold the interconnect in place.
40. Connect the cell collector lead to the PCB interconnect.
41. Position the detector cover over the detector.
42. Secure the detector cover to the thermal strap with three screws.
43. Remove the cap from the base of the detector (inside the column oven).
44. Install any hardware removed in step 2 of this procedure (liner, column/liner nuts, ferrules,
makeup gas adapter,etc.).
45. Install the rear panel and secure using four screws.
46. Install the right side panel and secure using four screws.
47. Install the electronics carrier top cover.
48. Install the hinged top cover and secure using a screw and washer.
49. Connect the ground strap to the hinged top cover using a screw.
50. Restore all gas supplies.
51. Restore power to the instrument.
SVC 6- 30
` Remove/Replace ECD (G1223A/G1224A VERSIONS) Heater and Sensor
Cartridges
SVC 6- 31
9. Using a Pozidriv screwdriver, remove the screw
securing the detector top cover to the thermal
strap.
BOTTOM
INSULATION
LOWER HEATED BLOCK
Handle the heater and sensor cartridges with
BOTTOM INSULATION
care to prevent breakage. The cartridges
(particularly the smaller sensor cartridge) are
fragile.
SVC 6- 32
22. Carefully slide the heater and temperature sensor cartridges out of the block. The sensor en-
ters the block from the top. The heater enters from below.
23. Slide the replacement heater and sensor cartridges into the heated block.
24. Install the lower heated block in its mounting position.
25. Secure the lower heated block to the instrument using two screws.
26. Install any removed insulation in the lower heated block.
27. Place the detector weldment in the lower heated block.
28. Install the upper heated block on the weldment.
29. Secure the upper heated block and detector weldment to the lower heated block using two
screws.
30. Remove the cap from the base of the detector (inside the column oven).
31. Carefully slide the ECD cover over the anode shaft and anode, and install it on the detector.
32. Slide the locking tab on the ECD cover forward, capturing the cover over the anode shaft of the
cell weldment.
33. Tighten the locking screw on the ECD cover
34. Connect the cell collector lead from the cell anode to the PCB interconnect.
35. Position the detector cover over the detector.
36. Secure the detector cover to the instrument with a screw.
37. Install any hardware removed in step 2 of this procedure (liner, column/liner nuts, ferrules,
makeup gas adapter,etc.).
38. Connect the purge and exhaust vent tubes to the applicable tubes disconnected in step 14.
39. Install the rear cover and secure using four screws.
40. Install the right side panel and secure using four screws.
41. Install the electronics carrier top cover.
42. Install the hinged top cover and secure using a screw and washer.
43. Connect the ground strap to the hinged top cover using a screw.
44. Install the injection port cover.
45. Restore all gas supplies.
46. Restore power to the instrument.
SVC 6- 33
` Remove/Replace FPD Heater and Sensor Cartridges
SULPHUR FILTER
PMT ASSEMBLY
8. Remove the drip tube from the exhaust tube at the top of the detector.
SVC 6- 34
9. Remove the exhaust tube from the detector using a 9/16- inch wrench.
HEATER/
SENSOR
OPENINGS
Handle the heater and sensor cartridges with care to prevent breakage. The
cartridges (particularly the smaller sensor cartridge) are fragile.
15. Remove the second heater cartridge from the
lower heater block.
SVC 6- 35
20. Install the chimney assembly and secure using
two screws.
24. Slide the PMT tube assembly onto the detector assembly.
25. Secure the PMT assembly to its support bracket using the extension spring.
26. Install the FPD cover on the instrument and secure using a thumbscrew.
27. Install the rear cover and secure using four screws.
28. Install the right side panel and secure using four screws.
SVC 6- 36
Remove/Replace Valve Box Heater and Sensor Cartridges
2. Remove the two screws securing the valve box top to the valve box bottom.
3. If any micrometering needle valves are installed, remove the nut(s) securing them to their
mounting bracket(s).
4. Remove the two screws securing each installed micrometering needle valve bracket to the
valve box top.
5. Ensure that there is enough slack in the tubing, running from the valve box into the oven, to
allow lifting of the valve box.
6. Use a 1/4- inch wrench to remove the standoffs securing the valve box to the top of the instru-
ment.
8. Pull any securing tape from around the heater and temperature sensor cables.
9. Remove the heater and sensor cartridge(s) from the valve block(s).
10. Install the replacement heater and/or sensor VALVE BOX TOP
cartridges into the valve block(s).
SVC 6- 37
18. Install the electronics carrier top cover.
SVC 6- 38
Replacing TCD Delta- T Temperature Sensor Cartridges
THE TCD MUST BE TURNED OFF BEFORE REPLACING ITS DELTA- T SENSOR
CARTRIDGE.
1. Set the main power line switch to the off position. RED O VISIBLE
4. When the heated zones are cool, turn off all gas
OFF ON
supplies.
SVC 6- 39
10. Remove the electronics carrier top cover
(above the signal cable plugs and receptacles
to expose the top edge of the TCD detector
PCB).
DELTA- T
SENSOR
CONNECTION
LOCATION
ELECTRONICS
CARRIER TOP
COVER
20. Install the heater, temperature sensor, and replacement delta- t sensor cartridges into the
heated block.
21. Carefully install the detector, securing it to the instrument with two screws.
SVC 6- 40
When installing tubing at the solenoid valve,
ensure that all O- rings are positioned
TO DETECTOR
properly.
NOTE
When installing a series- connected TCD,
make sure its oven- return exhaust vent tube
extends into the oven.
22. Connect and tighten tubing from the detector to
the solenoid switching valve, finger- tight. En-
sure that the tubing is installed at their SOLENOID VALVE
proper fittings on the TCD solenoid valve.
23. Connect the TCD filament and “delta- T”tem-
perature sensor leads at the connector block
on the detector PCB, making sure the filament TO FLOW
leads are connected properly per the illustration BLOCK
at the right.
24. Restore supply pressure and check for leakage FILAMENT GAS
LEADS TYPE
at all installed fittings.
DELTA- T
SENSOR a N2, Ar
25. If no leaks exist, turn off the supply gas.
LEADS He, H2 '
26. Remove the caps from the detector base and
the vent port.
When installing insulation, use care not to plug the vent port. If flow is interrupted
while the TCD is on, it will shorten its life dramatically.
27. Taking care not to block the vent port, install insulation around the detector block.
28. Install the electronics carrier top cover.
Use caution not to crimp the filament and delta- t sensor leads when installing the
TCD detector cover.
29. Install the TCD detector cover and secure using
two screws.
30. Install column and any other hardware removed
in step 5 of this procedure.
31. Restore supply pressure.
32. Restore power to the instrument.
33. Run a TCD Test Sample Chromatogram (refer
to HP 5890 Series II Reference Manual) to en- DETECTOR COVER
sure that the system is operating properly. (If
SVC 6- 41
reversed peaks are experienced, the most likely
cause is reversed gas tubes connected to the
TCD solenoid valve.)
4. When the heated zones are cool, turn off all gas
supplies.
LID SHAFT
8. Slide the left side panel towards the
rear of the instrument and lift.
LEFT SIDE
PANEL 1/4- INCH
SCREW
AND
WASHER
SCREWS
SVC 6- 42
11. Cap the base of the inlet, inside the column oven.
12. Remove the auto- injection assembly (or optional manual injection assembly) by rotating it
counter- clockwise). Be careful not to loose the septum, insert, or PCOC insert spring which
are installed under the injection assembly.
AUTO
INJECTION
ASSEMBLY OPTIONAL
MANUAL
INJECTION
ASSEMBLY
SEPTUM DUCKBILL
SEPTUM
INSERT
PCOC INSERT
SPRING
AIR DEFLECTOR
HEATER/SENSOR
CABLE ASSEMBLY
WELDMENT
INSULATION
CAVITY
SLEEVE
SCREW
13. Remove the air deflector using a Pozidriv screwdriver to remove the screw securing the air de-
flector to the inlet weldment.
14. Use a Pozidriv screwdriver to remove the two screws securing the inlet to the instrument.
16. Remove the cryo- blast tube from the inlet weldment.
SVC 6- 43
(a) (b)
23. Install the replacement cryo- blast weldment onto the inlet weldment.
Handle the heater and sensor cartridges with care to prevent breakage. The
cartridges (particularly the smaller sensor cartridge) are fragile.
25. Carefully slide the heater and sensor cartridges into the heated block portion of the inlet.
26. Install the air deflector and secure it to the weldment using one screw.
28. Install the liner and all other hardware (except the column) removed in step 5.
34. Install the left side panel and secure using two screws.
SVC 6- 44
TEMPERATURE SENSOR DATA
281O
250O
R
E
S
I 200O
S
T
A
N
C
E
150O
(O)
100O
0 100 200 300 400 500
TEMPERATURE ( _C)
To figure the approximate resistance of a temperature sensor, use the following equation:
R = 100O + (.35 ¢ t)
SVC 6- 45
Section 7
VALVES
This section is intended to help the technician isolate problems to a specific valve component or com-
ponents. The HP 5890 Series II may be found in many different configurations, with varying component
options. This complicates the process of providing detailed troubleshooting procedures for even gener-
al problems. But, by using the general troubleshooting techniques presented here, successful results
should be achieved.
Specific part numbers are not given in this portion of the service manual. For all replacement part num-
bers, refer to the Section 7 of the IPB portion of this document.
This document is not meant to provide instruction for first time installation of any of the options dis-
cussed. The add- on sheets, which accompany the various options, exist for just this purpose, and
should be referenced when performing a first time installation.
TABLE OF CONTENTS
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 2
VALCO VALVES 18900F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 2
General Purpose Valves (GPVs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 4
Adjustable Restrictors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 5
Gas Sample Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 5
LIQUID SAMPLE VALVES (LSVs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 6
Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 7
Chromatographic Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 7
Loss of Sensitivity or Excessive Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 7
Loss of Peaks in Specific Areas of the Chromatogram. . . . . . . . . . . . . . . . SVC 7- 7
Baseline Upsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 7
Extraneous Peaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 8
Locating Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 8
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 8
Valve Box Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 15
Valve Actuator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 16
Valve Actuation of GC- Controlled Valves . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 17
Valve Configuration Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SVC 7- 18
SVC 7- 1
INTRODUCTION
The valves described in this manual are manufactured by VALCO Instruments Co, Houston, Texas. As
members of the W- series product line, they are known as ”minivalves.”The valve body is made of Nitron-
ic- 60 with 1/16 inch fittings. The W- series valves are also known as the 18900F series. These valves have
better leakage resistance and a longer life expectancy. An installed valve system is an integrated part of the
HP 5890 Series II Gas Chromatograph. Proper instrument operation will prolong the life of the valve system.
Read all the accompanying information and avoid the following operational abuses:
Basically, valves are composed of four assemblies a driver,valve body, rotor, and preload assembly.
Rotor-Type
Ident Letter Mounting Hole
Port 4
Port 5 Port 3
P
Port 6 Port 2
The valve body is made of Nitronic- 60. This is a high chromium, high nickel content stainless steel, that has
excellent chemical resistance, anti galling characteristics, and high tensile strength. External tubing
(plumbing) is connected to the valve body ports by the use of provided ferrules and fittings.
All general purpose valve bodies include mechanical stops in their index lips. The stops are predetermined
to limit rotor rotation (i.e., 90 Degrees, 60 Degrees, and 36 Degrees), so the correct flow path results when
the index pin is close to or against either stop of the index lip.
SVC 7- 2
CCW CW
Stop Stop
OFF ON
Also note the rotor type stamped into the valve body. The letter indicates the rotor installed in the particular
body. The rotors are interchangeable. Polytetrafluorethylene (Teflon) rotors may be used from 0 to 175
degrees C (This low temperature valve may be marked with P). High Temperature (polyimide) rotors may be
used from 100 to 350 degrees C (This high temperature valve may be marked with PT or just T). The rotor
seat of the valve body is a highly polished conical surface. This finish precludes adsorption of most GC
samples. Additionally, the polished surface with a properly seated rotor will prevent leakage around the
rotor and between nonselected ports.
The rotor assembly is an integral molded and machined conical hub, necessary for proper seating. The
sample will contact either Teflon (low temperature) or polyimide (high temperature) as well as the stainless
steel of the valve.
The rotor fits precisely into the body and nests in the conical seat. It is held in place by a preload assembly.
The grooves in the rotor determine the paths between specific ports. The index pin prevents rotation be-
yond either stop of the index lip. Valve ports are connected by the grooves only when the index pin is close
to or against either stop of the index lip. Any intermediate position results in shutoff of flow through the valve.
SVC 7- 3
Feeler Gauge
(0.010 inch)(0.25 mm)
(Customer Supplied) Valve Rotor
Index Pin
Clockwise
Valve Stop
Counterclockwise
Valve Stop
The HP 5890 Series II was designed to accept valves heated in their own compartments because valves
operate best at a constant temperature. It is important to realize that when a valve is inside a gas chromato-
graph oven during a temperature programmed run, the valve temperature can lag behind the programmed
oven temperature by as much as 20 degrees C, depending on the rate employed. The mass of the pro-
grammed valve is responsible for this lag.
SVC 7- 4
4 4
5 3 5 3
6 2 6 2
1 1
OFF ON
Above is illustrated an actual 6 port valve viewed from the actuator side. A functional two dimensional dia-
gram representing the same valve is shown.
4 4
5 3 5 3
6 2 6 2
1 1
Index Pin
Rotor Groves
OFF ON
Adjustable Restrictors
This restrictors are not designed for temperatures greater than 225 degrees C.
SVC 7- 5
LIQUID SAMPLE VALVES (LSVs)
Liquid sampling valves are designed for use with liquefied gases under pressure such as ethane, propane,
butane, LNG, etc. They are not intended for nonvolatile liquids (at room conditions) where a concealed leak
may allow an accumulation or pool of liquid to form that may present a significant fire hazard. All standard
liquid sample valves have 1/16 inch fittings and are classified by the sample size of the installed rotor (0.2mL,
0.5mL, or 1mL capacity). The two types of valves available are standard or low pressure (1000 psig) and
high pressure (5000 psig), in the four port, single purpose liquid sampling valve. Whenever a liquid sample
valve is used, an adjustable restrictor is employed on the sample outlet line to maintain internal sample pres-
sure and thereby keep a compressed gas liquefied.
SVC 7- 6
TROUBLESHOOTING AND MAINTENANCE
Chromatographic Symptoms
Troubleshooting valves and their related plumbing is primarily a matter of systematic checking and verifica-
tion of unimpaired mechanical operation of any moving part. This requires an understanding of how the
valve functions internally and how the plumbing is configured. A plumbing diagram is essential for effective
troubleshooting. The following symptom cause list gives the most commonly encountered problems and
solutions found with valves.
Poor temperature control may require a full check of electronic and thermal components.
Lack of proper conditioning techniques, columns, etc.
Failure or deterioration of other components (i.e., columns, detectors, etc.).
BASELINE UPSETS
Frequently baseline upsets may be seen on chromatograms when valves are switched. These upsets are
normally caused by pressure changes within the system, injections of large volume samples, or by chang-
ing the amount of restriction in the flow path. These upsets will become more of a problem when high sensi-
tivity is required. Addition of a fixed restriction downstream from the valve may help minimize the upset.
When possible, changes in column length may also help reduce the upsets. Fixed restrictors are used im-
mediately before flame detectors to prevent flameout and are used in some instances to prevent pressure
surges from damaging TCD filaments. Needle valves (Nupro) can be used as adjustable restrictors; howev-
er, they are used typically where a matched restriction is desired and not for preventing pressure or flow
surges. Often confused with baseline upsets, an offset is a shift in the baseline that does not return quickly
to the original level. Baseline offsets may be caused by air leaks but more commonly are due to a change in
SVC 7- 7
gas purity or flow rate in the detector. Poor carrier gas or improperly conditioned filters and traps should be
suspected whenever offsets occur.
EXTRANEOUS PEAKS
Air peaks are sometimes seen in a chromatogram when leakage occurs because the valve rotor does not
seal properly. These leaks may not be detectable by using the soap bubble method. The Leak Test proce-
dure is described in Section 3 of this manual. If a leak is suspected but cannot be located with soap
bubbles, a pressure check will determine definitely if a leak exists. Extraneous peaks can occur sometimes
due to improper conditioning of the valve or contamination. If leaks are not apparent, clean or condition the
valve. Obviously other causes, totally unrelated to the valve, may exhibit similar symptoms. Impure (i.e.,
containing water) carrier gas can cause extraneous peaks.
LOCATING LEAKS
Leak checking the plumbing involved in a valve configured system must be done carefully and methodically.
Several methods may be used, and the best choice will depend upon expediency, accessibility, and the
magnitude of the leak. Refer to Initial Supply Pressures and Leak Testing in Section 3 for details.
PRESSURE CHECK
The pressure check method will indicate, but sometimes not isolate, a leak in the flow path. Since this meth-
od does not necessarily isolate the leak, one of the leak check methods may be needed to locate the leak
specifically. Note that each valve in a system has two flow paths, ON and OFF. A leak sometimes occurs in
only one of these two positions. Check both. To do so perform the following:
2. Cap the valve system at its outlet and pressurize to 689 kPa (100 psi). Allow 2 to 5
minutes for pressure to equilibrate. (If a flow sensor exists, it should read zero flow.)
3. Turn the knob on the regulator counterclockwise until it turns freely. The regulator is now
turned off and the gauge is indicating pressure within the valve system.
4. Commonly, the pressure will drop quickly for approximately 30- 60 seconds; then stabilize.
After this initial drop, the gauge should not show more than a 6.89 to 13.78 kPa (1 to 2 psi) drop
during a 10 minute period.
6. If a leak does show up, try to pinpoint the source with a soap bubble technique. Do
not assume the leak must exist only at a valve. Often plumbing connections such as unions or
bulkhead fittings are at fault. See Valve Box Top Assembly Removal in this section if exposing the
valve system is necessary.
7. If the leak cannot be found easily, divide the system in half and repeat the pressure check.
Continue dividing by halves, and pressure check until the leak is isolated.
SVC 7- 8
Sampling Valve System
Introduction
An installed valve system is an integral part of the HP 5890 SERIES II, GAS CHROMATOGRAPH. To
prolong the life of the valve system, avoid the following operational abuses:
D Scoring of valve surfaces with column packing or particulates in liquid or gas sample.
D Contaminating the system with samples (noneluting materials) or poor quality support gases.
Valves
Valves are composed of two basic assemblies: a body and a rotor.
Multipurpose Valve
________________________________________________________________
________________________________________________________________
________________________________________________________________
All general purpose valve bodies include mechanical stops in their index lips. The stops limit rotor rota-
tion (i.e., 60 degrees,90 degrees), so the correct flow path results when the index pin is close to or
against either stop of the index lip.
SVC 7- 9
CAUTION
Any intermediate position of the rotor may result in an interrupted flow path which
could cause damage to the valve or other components in the chromatograph.
The letter of the rotor type stamped into the valve body indicates the rotor installed in the particular
body.
P Polytetrafluorethylene (Teflon rotor) may be used from 0 to 175 degrees C. (This low tempera-
ture valve may be unmarked - no”P”).
PT High Temperature (polyimide rotor) may be used from 100 to 300 degrees C. (This “high tem-
perature”valve may be marked with “PT”, or just “T”).
The rotor seat of the valve body is a highly polished conical surface. This finish precludes adsorption of
most GC samples. Additionally, with a properly seated rotor the polished surface will prevent leakage
around the rotor and between non- selected ports.
The rotor assembly is essentially a one- piece stainless steel part with an integral molded and ma-
chined conical hub and several parts necessary for proper seating. The sample will contact either Te-
flon (low temperature) or polyimide (high temperature) as well as the stainless steel of the valve.
The rotor fits precisely into the body and nests in the conical seat. It is held in place by a preloaded
assembly.
The grooves in the rotor determine the paths between specific ports and run in a transverse fashion
across the rotor. The index pin prevents rotation beyond either stop of the index lip. Valve ports are
connected by the grooves only when the index pin is close to or against either stop of the index lip.
Any intermediate position results in shutoff of flow through the valve and possible valve damage if left in
this position.
CAUTION
The life of any valve is shortened, if not used within its specified temperature range
SVC 7- 10
graph oven during a temperature- programmed run, the valve temperature can lag behind the pro-
grammed oven temperature by as much as 20 degrees depending on the rate employed. The mass of
the programmed valve is responsible for this lag. For this and other reasons, gas chromatograph
oven- mounted valves are not offered on the HP 5890.
An actual 6- port valve viewed from the actuator side is illustrated in Figure 2- 4. A functional two- di-
mensional diagram representing the same valve is shown in Figure 2- 5.
Note that with this type of diagram, not only the external ports are drawn, but rotor grooves are easy to
see. The transverse grooves appear as curved lines. Note the change in the port- to- port connec-
tions by the grooves when the valve rotor is moved from the left stop to the right stop. Also note that
the rotor grooves move, but the ports do not. Figure 2- 6 Illustrates a Simplified Valve Diagram.
Note that the essential valve features are not lost; namely the index pin, stops, ports, and grooves. This
is the type of diagram that will be used throughout this section. The 6- port, and 10- port valves and
the LSVs function in the same basic manner but with different port locations and rotor grooves.
Some other symbols used in the plumbing configuration diagrams are shown in Figure 2- 7.
Adjustable Restrictor
This restrictor is not designed for temperatures greater than 175 degrees C; for this reason this adjust-
able restrictor is NOT compatible with high- temperature valves.
SVC 7- 11
Whenever a liquid sample valve is used, an adjustable restrictor is employed on the sample outlet line
to maintain internal sample pressure and thereby keep a compressed gas liquefied.
_________________________________________________________________________
_________________________________________________________________________
Temperature Range
From To From To
Ambient 150_C
Ambient 175_C
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
Pressure Limit
PSIG PSIG
5000 1000
400
300
_________________________________________________________________________
SVC 7- 12
Troubleshooting and Maintenance
Chromatographic Symptoms
Troubleshooting valves and their related plumbing is primarily a matter of systematic checking and veri-
fication of unimpaired mechanical operation of any moving part. This requires an understanding of how
the valve functions internally and how the plumbing is configured. A plumbing diagram is essential for
effective troubleshooting.
The following “symptom- cause”list gives the most commonly encountered problems found with valves
and their solution.
D Internal leakage necessitates a complete disassembly and inspection of the mating surfaces.
D Poor temperature control may require a full check of electronic and thermal components.
D If the valve rotates, check for proper alignment of the actuator, mechanical binding or slippage
of connecting parts.
Baseline Upsets
Frequently baseline upsets may be seen on chromatograms when valves are switched. These upsets
are normally caused by pressure changes within the system, injections of large volume samples, or by
changing the amount of restriction in the flow path. These upsets will become more of a problem when
high sensitivity is required. Addition of a fixed restriction downstream from the valve may help minimize
the upset. Changes in column length may also help reduce the upsets.
Fixed restrictors are used immediately before flame detectors to prevent flameout and are used in some
instances to prevent pressure surges from damaging TCD filaments. An adjustable restrictor (needle
valve) can also be used where a matched restriction is desired but not for preventing pressure or flow
surges.
SVC 7- 13
Often confused with baseline upsets, an offset is a shift in the baseline that does not return quickly to
the original level. Baseline offsets may be caused by air leaks but more commonly are due to a change
in gas purity or flow rate in the detector. Poor carrier gas or improperly conditioned filters and traps
should be suspected whenever offsets occur.
Extraneous Peaks
Air peaks are sometimes seen in a chromatogram when leakage occurs because the valve rotor does
not seal properly. These leaks may not be detectable by using the soap- bubble method.
If a leak is suspected but cannot be located with soap bubbles, a pressure check will determine defi-
nitely if a leak exists. Extraneous peaks can occur sometimes due to contamination or improper condi-
tioning of the valve. If leaks are not apparent, clean or condition the valve.
Obviously other causes, totally unrelated to the valve, may exhibit similar symptoms. Impure carrier gas
(i.e., containing water) can cause extraneous peaks.
Locating Leaks
Leak- checking the plumbing involved in a valve configured system must be done carefully and me-
thodically. Several methods may be used, and the best choice will depend upon expediency, accessi-
bility, and the magnitude of the leak.
Pressure Check
The pressure check method will indicate, but sometimes not isolate, a leak in the flow path. Since this
method does not necessarily isolate the leak, other leak check methods may be needed to locate the
leak specifically.
Note
Each valve in a system has two flow paths, ON and OFF. A leak sometimes occurs in
only one of these two positions. Check both.
1. Disconnect the detector from the valve system.
2. Cap the valve system at its outlet and pressurize to 689 kPa (100 psi). Allow 2 to 5 minutes for
pressure to equilibrate. If a flow sensor exists, it should read zero flow.
3. Turn the knob on the regulator counterclockwise until it turns freely. The regulator is now
turned off and the gauge is indicating pressure within the valve system.
4. Generally, the pressure will drop quickly for approximately 30- 60 seconds; then stabilize. After
this initial drop, the gauge should not indicate more than a 6.89 to 13.78 kPa (1 to 2 psi) drop
during a 10 minute period
6. If a leak does show up, try to pinpoint the source using a soap bubble meter. Do not assume
that the leak exists only at the valve. Often plumbing connections such as unions or bulkhead
fittings are at fault. See “Valve Box Top Assembly Removal”in this section should it become
necessary to expose the valve system.
7. If the leak cannot be found easily, divide the system in half and repeat the pressure check.
Continue dividing by halves, and pressure check until the leak is isolated.
SVC 7- 14
Valve Box Assembly Removal
1. Place the main power switch in the off position.
3. Allow some time for the oven and heated zones to cool.
4. When the oven has cooled, turn off all gas supplies.
5. Switch the solenoid valve off so the actuator is in its fully extended position (Figure 2- 29).
Place the main power switch in its “OFF”position. Disconnect the line power cord from its re-
ceptacle.
6. Remove the back panel and allow sufficient time for the oven and heated zones to cool; then
turn off supply gases and the air supply to the solenoids at their sources.
7. If variable restrictors are present, remove their mounting hardware in the following order: two
M4 screws, hex nut, and mounting bracket for each restrictor valve.
8. Remove two, valve box top assembly, mounting screws, one located near the left front corner
and one along the right side edge near the middle. Lift the valve box top assembly straight off
the valve box. Be careful not to move the valve rotor index pin from its “at rest”position.
NOTE
10. Secure the valve box top assembly with two M4 mounting screws. Tighten these screws firmly.
Reinstall hardware for variable restrictors if present.
11. Exercise the valve(s) on and off a few times to verify operation.
SVC 7- 15
Valve Actuator Alignment
1. Remove the valve box top assembly. See steps 1 through 3 “Valve Box Top Assembly Remov-
al.”
2. Loosen the actuator link arm lock screw at each actuator (Figure 2- 29) with a 3mm hex key
wrench so that the coupling/shaft assembly is free to rotate. Push the coupling shaft fully into
the actuator.
3. Turn the valve rotor index pin of each valve counterclockwise (CCW) until it is 0.010 inch (0.25
mm) from the counterclockwise (left- hand) valve stop (Figure 2- 31).
4. Set the valve box top assembly on the lower assembly and secure it with the two screws re-
moved in step 1 above. To do this, simply place the valve box top assembly on the two diago-
nally opposite rectangular standoffs in the lower valve box assembly and install the screws.
(The quick release pin should be installed in the 90 degree position for the 6 port valves and in
the 60 degree position for the 10- port valves.)
5. Gently rotate and push the coupling/shaft assembly with a blade- type screwdriver until the slot
on the coupling fully engages the valve rotor index pin . Repeat this procedure for each valve
installed.
6. Make sure that all solenoid valves are turned “off”by the appropriate valve controller. Turn on
the air supply to the solenoid valve(s). The piston rod of each actuator will move all the way out
to the extended (OFF) position. Very firmly tighten the link arm lock screw for each actuator.
CAUTION
Use care in performing the above operation so as not to accidentally turn the valve
rotor away from its preset (step 2) position.
7. Install the hardware for any variable restrictors present.
SVC 7- 16
Valve Actuation of GC- Controlled Valves
(Operation of one or two 120- volt solenoid valves)
Activation of up to two valve solenoids (designated as Purge A or Purge B) may occur in either of two
ways. The operator may switch the valves manually whenever it is desirable via keyboard entry, or
more conveniently, the valves can be switched ON once and OFF once during a run via the HP 5890’ s
timed events table.
NOTE
If the valve is already in the position where a command instructs it to switch, no action
will occur.
The designated channels (A or B) are determined solely by the wiring connections to the valve box.
SVC 7- 17
Valve Configuration Diagrams
Legend
Adjustable Restrictors
Arrows indicate the can be manually set to
direct ion of flow.
adjust its pressure drop
(e.g., to balance flow).
4
5 Loops have a spe- Fixed restrictors
3 cannot be adjusted.
cified volume + 5%
6 2
1
Union
5
6 4 Jumper volume is Fit-
not specified. ting
1 3
2
Column
SVC 7- 18
4 4
5 3 5 3
6 2 6 2
1 1
OFF ON
Column
or
2nd Valve
Carrier
4 4
5 3 5 3
6 2 6 2
1 1
Loop
In
Sample
Out
OFF ON
Gas Sampling Option, Option 201 or 231
Column 2
Column 1
Carrier
4 4
5 3 5 3
6 2 Detector 6 2
1 or Valve 1
Adj. Restr.
OFF ON
SVC 7- 19
4 4
Stream 1 In to GSV
5 3 5 3
Sample In
Vent 6 2 6 2
1 1
Stream 2 In
OFF ON
Column
Carrier 4 4
5 3 5 3
6 2 6 2
Detector
1 1
OFF ON
Precolumn
4 4
1st Carrier Vent
5 3 5 3
6 2 6 2
1 1
2nd Carrier
Column
Detector
OFF ON
SVC 7- 20
Column 1
6 2 6 2
Detector
1 1
Column 2
OFF ON
Column Selection (Unused Column Isolated), Option 206 or 236
Column 1
4 4
Carrier
5 3 5 3
6 2 6 2
Detector
1 1
Column 2
OFF ON
Sequence Reverse, Option 207 or 237
Column 1
4 4
Carrier Detector
5 3 5 3
6 2 6 2
1 1
Column 2
OFF ON
SVC 7- 21
6 6
7 5 7 5
8 4 8 4
9 3 9 3
10 2 10 2
1 1
OFF ON
Column
Detector
or 2nd Valve
Precolumn
1st Carrier 6 6
7 5 7 5
8 4 8 4
Out 9 3 Vent 9 3
Sample 10 2 10 2
In 1 1
Loop
2nd Carrier
OFF ON
Column
Carrier 6 6
7 5 7 5
Detector 8
8 4 or 2nd Valve 4
Out 9 3 9 3
Sample 10 2 10 2
In 1 1
Loop
OFF ON
SVC 7- 22
Out
Sample 2
In
Loop 2
Carrier 6
7 5 6
7 5
8 4 8 4
Out 9 3 9 3
Sample 1 10 2 10 2
In 1 Detector 1
or 2nd Valve
Loop 1
OFF ON
Column 2
Carrier 6 6
7 5 7 5
8 4 8 4
Out 9 3 9 3
Sample 10 2 10 2
In 1 1
Column 1
Loop
OFF ON
Column 2
Carrier 6
7 5 6
7 5
8 4 8 4
Detector
Out 9 3 or 9 3
Sample 10 2 2nd Valve 10 2
In 1 1
Column 1
Loop
OFF ON
Gas Sampling with Sequence Reverse and Backflush of Column 1, Option 405 or 435
SVC 7- 23
Column 2
Carrier 1 6 Vent 6
7 5 7 5
8 4 8 4
Carrier 2 9 3 9 3
10 2 10 2
1 1
Column 1
Detector
or 2nd Valve
OFF ON
Carrier Carrier
S P S P
W C W C
OFF ON
Column 2
Column 1
Carrier
4 4
5 3 5 3
6 2 6 2
Detector
1 1
Loop
In Adj. Restr.
Sample
Out
OFF OFF
Gas Sample and Column Isolation, Option 601
SVC 7- 24
Column 1 Column 2
Carrier 6
7 5 4
8 4 5 3
9 3
Out 6 2
Sample 10 2 Detector
In 1 1
Loop
Adj. Restr.
OFF OFF
SVC 7- 25
Section 8
KEYBOARD AND DISPLAY
KEYBOARD AND DISPLAY REPLACEMENT
The keyboard and display components of the HP 5890 Series II are housed in a single display PCB as-
sembly. Removal, disassembly. and installation instructions for the display PCB assembly are found on
the following pages. Refer to page XX of this section for information on troubleshooting the keyboard
and display components. Refer to Section 9 of the IPB for part numbers associated with the keyboard
and display components.
Current maintenance philosophy suggests that the display PCB assembly be replaced as a unit, rather
then replacing the display PCB, keyboard connector element, etc. individually. Maintenance proce-
dures have been included to allow for the disassembly of the display PCB assembly in the event that
the shroud assembly is not available in a timely manner, etc.
TABLE OF CONTENTS
SVC 8- 1
Keyboard and Display Troubleshooting
Problem Probable Cause Corrective Action
1. No visual indications of any a. Faulty display PCB assem- 1. Replace display PCB as-
kind on display. bly. sembly.
2. If problem persists, remove
replaced display PCB
3. Install original display PCB
assembly.
4. Go to probable cause b.
b. Faulty display PCB ribbon 1. Replace display PCB rib-
cable. bon cable..
2. If problem persists, go to
probable cause c.
c. Faulty main PCB. 1. Replace main PCB.
2. Some portion of the display a. Faulty display PCB assem- 1. Shut off instrument and re-
is blank. (Bad LED, etc.) bly. start.
2. All indicators should light
during start- up self test.
Observe suspect portion of
display.
3. If any indicators are out, re-
place display PCB.
4. If problem persists, remove
replaced display PCB
5. Install original display PCB
assembly.
6. Go to probable cause b.
SVC 8- 2
Replace Display PCB Assembly
SCREWS
RIGHT SIDE
ELECTRONICS PANEL
CARRIER TOP
COVER
SCREWS
This procedure requires precautions against ESD (Electro- Static Discharge). Use a
grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small) connected
to a suitable ground. Failure to heed this caution may result in damage to the
instrument.
5. Free the keyboard connector (J1) from connector receptacle P1 on the main PCB by releasing
the locking tabs (one on either side of the connector receptacle).
When disconnecting a plug, pull on the plug not on its wires. Pulling on the wires may
cause breakage.
6. Remove connector J1 from connector receptacle P1 by carefully pulling it straight out.
SVC 8- 3
NOTE
It may be necessary to remove the detector PCB from the “a”position on the main
PCB in order to access the locking tabs at the top of the display PCB assembly. Refer
to Section 4 of this document for information on the removal of detector PCBs.
7. Reach behind the display PCB assembly and
depress the two locking tabs which secure the
assembly (at the top) to the electronics bezel.
LOCKING
TABS
8. While depressing the locking tabs on the dis-
play PCB assembly, tilt the top of the display
PCB assembly forward (away from the front of
the instrument).
9. Remove the display PCB assembly from the
instrument.
NOTE
The display PCB assembly may be replaced
as a unit, or the individual pieces which make it
up may be ordered. If the entire display PCB
assembly is to be replaced, go to step 15.
10. Remove the four screws securing the display
PCB to the keyboard bezel. ALIGN HERE
DISPLAY PCB
KEYBOARD
KEYBOARD CONNECTOR
CONNECTOR BODY
ELEMENT
KEYBOARD BEZEL
SVC 8- 4
14. Install the display PCB onto the keyboard bezel (making sure that the keyboard connector ele-
ment and keyboard connector body are properly installed) and secure using four screws.
15. Align the locating tabs on the bottom edge of the replacement display PCB assembly with the
locating slots on the bottom of the opening in the electronics bezel.
16. Tilt the top of the display PCB assembly (toward the rear of the instrument) and gently press on
the display board near the top until the locking tabs “click”into place.
17. If removed, install the detector PCB removed from position “
A”on the main PCB.
18. Install connector J1 into connector receptacle P1 on the main PCB. (When connector J1 is
properly seated, the locking tabs on connector receptacle P1 will wrap around the edge of the
connector, locking it in place.)
19. Install the right side panel and secure using four screws.
20. Install the electronics carrier top cover.
21. Restore all gas supplies.
22. Restore power to the instrument.
23. Observe the alphanu- NORMAL“INTEGRITY CHECK”
meric display, as the in- AT POWER-ON
strument performs an
ACTUAL SETPOINT
internal self- diagnostic Test of display elements:
all alphanumeric and LED
integrity check. to en- elements are lit.
OVEN STATUS
sure that the instrument FINAL RUN
TIME
shows the expected INITIAL
RATE
NOT
READY
normal displays. TIME
ACTUAL SETPOINT
5890 Series II memory test
in progress.
OVEN STATUS
FINAL RUN
RATE TIME
INITIAL NOT
TIME READY
ACTUAL SETPOINT
5890A Self-testing in
progress.
LEDs off, except possibly
OVEN STATUS “NOT READY.”
FI- RUN
RATE NAL
INITIAL TIME NOT
TIME READY
ACTUAL SETPOINT
Message indicating normal
termination of diagnostic
tests after power restoration.
STATUS
OVEN
FINAL
User setpoints remain in
RUN force.
RATE TIME
INITIAL NOT LEDs off, except possibly
TIME READY “NOT READY.”
SVC 8- 5
Section 9
MAIN PCB
Specific part numbers are not given in this section. For replacement part numbers, refer to the Section
9 of the IPB (Electronics).
TABLE OF CONTENTS
SVC 9- 1
Replace Main PCB
4. When the heated zones are cool, turn off all gas
supplies. OFF ON
ELECTRONICS
CARRIER TOP
COVER
SCREWS
SCREWS
SVC 9- 2
7. Disconnect any signal cables installed at the connectors on the top of the main PCB.
SIGNAL CABLE
CONNECTORS
` The following steps require protection against ESD (Electro- Static Discharge).
Use a grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small)
connected to a suitable ground. Failure to heed this caution may result in
damage to the instrument.
` When storing or in between handling of PCBs (Printed Circuit Boards), always
place them in static control envelopes or enclosures.
SVC 9- 3
8. Remove detector PCB(s), optional communications interface PCB, and optional EPC (Electronic
Pressure Control) or MPC (Manual Pressure Control) interfcae PCB if installed. (Refer to section
4 of this manual for information on removal and installation of detector PCBs. Refer to section
10 of this manual for information on removal and installation of Communications interface PCBs.
Refer to section 3 of this manual for information on removal and installation of the EPC/MPC
interface PCB.
PRESSURE CONTROL
PCB (TYPICAL)
SVC 9- 4
WHEN DISCONNECTING A PLUG, PULL ON THE PLUG NOT ON ITS WIRES. PULLING
ON THE WIRES MAY CAUSE BREAKAGE.
9. Disconnect connectors (if present) from their respective receptacles (“J1,”“J7,”“J8,”“J10,”and
“
J11”) by carefully pulling them straight out. (For “
J1”and “ J11,”note the locking tab at each
end of the plug: these must be released to free the plug for removal.) (Also, note that “
J10”
plug is released by squeezing its ribbed sides while pulling.)
P4 P5 P6 P8 P7
P9
J14
P2 P10
P3 P13 P12 P11
P1
10. Remove the high voltage cover covering the triac components.
HIGH VOLTAGE
COVER
11. Disconnect connector from receptacle J9 by squeezing its ribbed sides while pulling it straight
out.
SVC 9- 5
12. Verify all interconnecting plugs are now disconnected.
MOUNTING HOLES
MOUNTING HOLES
MOUNTING HOLES
13. Remove seven screws securing the main PCB to the electronics flow carrier.
14. Remove the main PCB from the instrument by carefully tipping it towards the right side of the
instrument, and then lifting it from its support brackets.
15. Position the replacement main PCB so its lower edge is within the support brackets; then slide
the board to its left or right as needed to align it with locater posts and holes for mounting
screws.
16. Secure the board in place with the seven mounting screws. Make sure the longest screw is
installed in the hole marked “MAIN GND”at the top of the board.
17. Install all connectors, detector PCBs, communications interface PCB (if present), EPC/MPC in-
terface PCB (if present), and signal cables.
19. Install the right side panel and secure using four screws.
SVC 9- 6
22. Observe the alphanumeric dis-
play as the instrument performs NORMAL
an internal self- diagnostic inte- “INTEGRITY CHECK”AT POWER-ON
grity- check. ACTUAL SETPOINT
Test of display elements: all
alphanumeric and LED ele-
23. If the self- testing process does STATUS ments are lit.
OVEN
not complete successfully, and/ FINAL
TIME
RUN
RATE
or if a message other than INITIAL
TIME
NOT
READY
“PASSED SELF TEST”eventu-
ally appears, see “Electronic ACTUAL SETPOINT
5890A memory test
Troubleshooting,”for diagnostic in progress.
STATUS
and troubleshooting informa- OVEN
FINAL RUN
tion. INITIAL
RATE TIME
NOT
TIME READY
ACTUAL SETPOINT
5890A Self-testing in progress.
LEDs off, except possibly “NOT
STATUS
READY.”
OVEN
FINAL RUN
RATE TIME
INITIAL NOT
TIME READY
ACTUAL SETPOINT
Message indicating normal
termination of diagnostic
OVEN STATUS tests after power restoration.
FINAL RUN User setpoints remain in
RATE TIME force.
INITIAL NOT
TIME READY
LEDs off, except possibly
“NOT READY.”
SVC 9- 7
Section 10
DATA COMMUNICATIONS
COMMUNICATION INTERFACE COMPONENTS
There are five possible data communication options which may be encountered in instruments found in
the field. The five options are Non- Buffered INET, Buffered INET, RS- 232- C, HPIB/RS- 232- C
(DICE), and analog input. Communications Interface PCBs are optional and may not be installed in all
instruments.
Specific part numbers are not given in this section. For replacement part numbers, refer to the Section
9 of the IPB (Electronics).
This document is not meant to provide instruction for first time installation of any of the options dis-
cussed. The add- on sheets, which accompany the various options, exist for just this purpose, and
should be referenced when performing a first time installation.
TABLE OF CONTENTS
SVC 10- 1
Replace Communications Interface PCB
SCREWS
RIGHT SIDE
ELECTRONICS PANEL
CARRIER TOP
COVER
SCREWS
This procedure requires precautions against ESD (Electro- Static Discharge). Use a
grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small) connected
to a suitable ground. Failure to heed this caution may result in damage to the
instrument.
NOTE
Depending upon the type of communications PCB installed, there may be one or
more connecting cables installed which must be disconnected before PCB removal.
7. If a non- buffered INET PCB, buffered INET PCB, or HPIB/RS- 232- C PCB is installed, discon-
nect the INSTRUMENT NETWORK (INET) IN and OUT cables from their connectors on the
communications PCB.
SVC 10- 2
8. If an HPIB/RS- 232- C communications PCB is installed, free and remove the rear panel PCB
cable from the connector on the communications PCB by releasing the locking tabs (one on
either side of the connector receptacle) and pulling the cable straight out.
9. If an RS- 232- C communications PCB is installed, a different cable is used to connect the PCB
to the RS- 232- C port of the connected device. Remove the 12- pin connector from the com-
munications PCB. (The cable is installed through the opening where the INET cables are usual-
ly connected.)
10. If an analog input communications PCB in installed, remove the cable connected to at the top
of the PCB.
11. Remove the communications PCB by grasping it in the center area along its right edge and
pulling it from its connector on the main PCB.
COMMUNICATIONS INTERFACE
PCB (TYPICAL)
SVC 10- 3
12. Install the replacement PCB by inserting it straight into its connector on the main PCB.
14. Install the right side panel and secure using four screws.
ACTUAL SETPOINT
5890 Series II memory test
in progress.
OVEN STATUS
FINAL RUN
RATE TIME
INITIAL NOT
TIME READY
ACTUAL SETPOINT
5890A Self-testing in
progress.
LEDs off, except possibly
OVEN STATUS “NOT READY.”
FI- RUN
RATE NAL
INITIAL TIME NOT
TIME READY
ACTUAL SETPOINT
Message indicating normal
termination of diagnostic
tests after power restoration.
STATUS
OVEN
FINAL
User setpoints remain in
RUN force.
RATE TIME
INITIAL NOT LEDs off, except possibly
TIME READY “NOT READY.”
SVC 10- 4
Replace Rear Panel Connector PCB and/or Cable for DICE PCB
SCREWS
RIGHT SIDE
ELECTRONICS PANEL
CARRIER TOP
COVER
SCREWS
SVC 10- 5
suitable ground. Failure to heed this caution
may result in damage to the instrument.
9. Slide the rear panel away from the back of the instrument, taking care not to damage the rear
panel connector PCB ribbon cable.
10. If the rear panel connector PCB is to be replaced, remove it from the rear panel.
11. Free and remove the ribbon cable from the rear panel connector PCB by releasing the locking
tabs (one on either side of the connector receptacle) and pulling the cable straight out.
16. Install the ribbon cable into the connector receptacle on the rear panel connector PCB. (When
the connector is properly seated, the locking tabs on the connector receptacle will wrap around
the edge of the connector, locking it in place.)
17. If a new rear panel connector PCB is being installed, secure it to the rear panel using three
screws.
SVC 10- 6
18. Install the rear panel and secure using four screws.
19. If it was necessary to remove the right side panel, install it and secure using four screws.
20. If it was necessary to remove the electronics carrier top cover, install it now.
ACTUAL SETPOINT
5890 Series II memory test
in progress.
OVEN STATUS
FINAL RUN
RATE TIME
INITIAL NOT
TIME READY
ACTUAL SETPOINT
5890A Self-testing in
progress.
LEDs off, except possibly
OVEN STATUS “NOT READY.”
FI- RUN
RATE NAL
INITIAL TIME NOT
TIME READY
ACTUAL SETPOINT
Message indicating normal
termination of diagnostic
tests after power restoration.
STATUS
OVEN
FINAL
User setpoints remain in
RUN force.
RATE TIME
INITIAL NOT LEDs off, except possibly
TIME READY “NOT READY.”
SVC 10- 7
INET CONFIGURATION
(“CALIB AND TEST”function 3)
The CONFIGURE NETWORK function provides four features: verifying the
INET address for the HP 5890A (as determined through automatic loop
configuration), setting the default HP-IL address to be used when the
HP 5890A is connected to some device where addresses must be set
manually (i.e., no automatic loop configuration), switching the INET
function at the HP 5890A between “global”or “local,”and verifying INET
signal definitions. Each feature is discussed separately.
INET Configuration
ACTUAL SETPOINT
C O N F I G U R E N E T W OR K
ACTUAL SETPOINT
G L O B A L A D D R : 1 i 3 1
ACTUAL SETPOINT
L O C A L A D D R : 1 i 3 1
3174
CLEAR . 3 ENTER
SVC 10- 8
“STOP”keys on other devices on the INET loop (e.g., the controller) will
affect HP 5890A operation.
INET “Global”/“Local”
ACTUAL SETPOINT
G L O B A L A D D R : 1 i 3 1
ACTUAL SETPOINT
L O C A L A D D R : 1 i 3 1
1078
Note that “global”mode has two states: if GLOBAL flashes (default mode)
when displayed, the HP 5890A is in “global”mode, but NOT configured
into the INET system. When the HP 5890A is properly configured into the
INET system, GLOBAL is displayed continuously. This feature provides a
convenient diagnostic to determine if system configuration has occurred
(at least as far as the HP 5890A is concerned).
INET/HP-IL Addresses
Figure 13-6 shows displays occurring either in verifying an INET address
set through automatic loop configuration or in entering a specific HP-IL
default address used when the HP 5890A is included in an HP-IL loop
without automatic configuration. The address is maintained in battery-
protected memory along with other instrument setpoints.
SVC 10- 9
INET/HP-IL Addresses
ACTUAL SETPOINT
G L O B A L A D D R : 1 i 3 1
ACTUAL SETPOINT
D E F A U L T A D D R E S S * 2 5
ACTUAL SETPOINT
G L O B A L A D D R : 1 i 2 5
ACTUAL SETPOINT
A D D R E S S L I M I T = 3 1
3175
{ SIG 1 or SIG 2 }
SVC 10- 10
Figure 13-7 shows resulting displays.
INET-HP 5890A
Signal Definition
ACTUAL SETPOINT
G L O B A L A D D R : 1 i 3 1
ACTUAL SETPOINT
S I G 1 O N R A N G E D
ACTUAL SETPOINT
S I G 1 O N F U L L R A N G E
ACTUAL SETPOINT
S I G 2 O F F
3176
SVC 10- 11
HP-IL LOOPBACK TEST
(“CALIB AND TEST”function 7)
The “HPIL LOOPBACK TEST”may be performed any time to verify that
HP 5890A INET communication is performing satisfactorily. Testing
involves setting up the HP 5890A to send an INET message directly to
itself by connecting its INET output to its INET input. The following
procedure is used:
2. Choose either one of the cables and disconnect it at the next device on
the INET loop.
CLEAR . 7 ENTER
Upon pressing ENTER , the test is performed: the HP 5890A both sends
and verifies a diagnostic message to itself through the connected cable.
Each press of ENTER repeats the test. Each test requires about one
second. Figure 13-8 shows displays to be expected.
ACTUAL SETPOINT
H P I L L O O P B A C K T E S T
ACTUAL SETPOINT
P A S S E D S E L F T E S T
ACTUAL SETPOINT
F A I L E D S E L F T E S T
3177
SVC 10- 12
The message “PASSED SELF TEST”indicates INET, at least with respect
to the HP 5890A, is performing satisfactorily. If FAILED SELF-TEST is
displayed, a bad cable may be indicated; install a different INET cable and
repeat the test. If FAILED SELF-TEST is displayed again for a second
cable, electronic problems within the HP 5890A are indicated; see Section
19, “Electronic Troubleshooting,”for more information.
NOTE
The LOOPBACK TEST may be used to check for continuity in an
INET cable; an open cable causes test failure. Verify that the cable
is at fault (rather than the HP 5890A) by testing a second cable.
SVC 10- 13
Section 11
POWER SUPPLY
REPLACING POWER SUPPLY COMPONENTS
Power supply components include the power supply PCB, the power supply transformer, the power
switch, and the power cable. Removal and installation instructions for all of these components are
found on the following pages.
Specific part numbers are not given in this section. For all replacement part numbers, refer to Section 8
of the IPB portion of this document (Oven Assembly).
This document is not meant to provide instruction for first time installation of the different power supply
options discussed. Add- on sheets exist for just this purpose, and should be referenced when per-
forming a first time installation.
TABLE OF CONTENTS
SVC 11- 1
Remove/Replace Power Supply PCB
SCREWS
SCREWS
This procedure requires precautions against ESD (Electro- Static Discharge). Use a
grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small) connected
to a suitable ground. Failure to heed this caution may result in damage to the
instrument.
6. Use a 7- mm nut driver to remove the screw
securing the upper portion of the dual duct as-
sembly to the outer oven shell.
UPPER
7. Use a Pozidriv screwdriver to loosen (but not SCREW
remove, the screw securing the lower portion of
the dual duct assembly to the outer oven shell. DUAL DUCT
ASSEMBLY
8. Tilt the upper portion of the dual duct assembly
out of the rear of the instrument while lifting it
off of the loosened lower screw. LOWER
SCREW
POWER SUPPLY
TRANSFORMER,
AND BASE
SVC 11- 2
When disconnecting a plug, pull on the plug not on its wires. Pulling on the wires may
cause breakage.
9. Disconnect push- on type connectors J1, J2, J3, and J4 (from blade connectors P1, P2, P3,
and P4, respectively) by grasping each one and pulling it straight off of its terminal.
10. Disconnect connectors J26, J27, and J28 from their respective receptacles. (Remove each one
by squeezing its ribbed sides while simultaneously pulling it out of the receptacle.)
11. Use a 7mm nut driver to loosen, but not remove, the mounting nut corresponding to the mount-
ing slot at the left edge of the AC power supply PCB mounting bracket, alongside the power
transformer.
12. Use the nut driver to remove the two mounting nuts at the right edge of the AC power supply
PCB mounting bracket.
NOTE
The AC power supply PCB, and its associated mounting bracket, are removed and
replaced as a unit.
13. Lift the PCB bracket at its right edge while sliding it to the right to remove it from the instrument.
R3
J26
P4
MOUNTING Oven
SLOT
J27 P3
R2 MOUNTING
HOLES
F2 J28 P1 WHT
6A
F1 20A
R1
Blk
P2
120 Vac Single Phase AC Board
14. Install the replacement AC power supply PCB in the reverse manner by sliding the mounting
slot on the left side of the PCB mounting bracket under the loosened mounting screw adjacent
to the transformer.
15. Install the two mounting nuts at the right edge of the AC power supply PCB mounting bracket.
16. Tighten the two mounting nuts and the mounting screw firmly.
17. Install connectors J26, J27, and J28 into their respective receptacles, pushing each straight
down until fully bottomed.
SVC 11- 3
18. Install push- on- type connectors for oven heater leads (J3 and J4). (Either lead may be con-
nected to either terminal.)
19. Connect power cord lead push- on- type connectors J1 (WHITE lead) and J2 (BLACK lead).
20. Install the dual duct assembly on the installed mounting screw.
21. Install the upper mounting nut to secure the dual duct assembly to the outer oven shell.
normal displays.
ACTUAL SETPOINT
Message indicating normal
termination of diagnostic
tests after power restoration.
STATUS
OVEN
FINAL
User setpoints remain in
RUN force.
RATE TIME
INITIAL NOT LEDs off, except possibly
TIME READY “NOT READY.”
SVC 11- 4
Remove/Replace Power Supply Transformer
SCREWS
SCREWS
SCREWS
ELECTRONICS
CARRIER TOP RIGHT SIDE PANEL
COVER
This procedure requires precautions against ESD (Electro- Static Discharge). Use a
grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small) connected
to a suitable ground. Failure to heed this caution may result in damage to the
instrument.
SVC 11- 5
When disconnecting a plug, pull on the plug not on its wires. Pulling on the wires may
cause breakage.
8. Disconnect connector
P10 from its receptacle
on the main PCB by
squeezing its ribbed
sides while pulling the
plug straight out of the
receptacle.
9. Disconnect connectors
J26 and J27 from their
respective receptacles
on the AC power sup-
ply PCB. (Remove
each one by squeezing
its ribbed sides while si-
multaneously pulling it
out of the receptacle.)
CONNECTOR J27
CONNECTOR J26
GROUND STRAP
SCREW, INSULATOR
BUSHING
SVC 11- 6
11. At the right side of the instrument, below the
main PCB, remove the power switch from its
PRESS HERE
slot by prying the plastic locking tabs on each
side of the switch in toward the switch body.
12. Remove the four push- on- type connectors
from the rear of the switch.
13. Remove the three nuts and one screw securing PULL OUT OF
the transformer bracket to the AC power supply INSTRUMENT
base.
14. Slowly lift the transformer and transformer
bracket off of the AC power supply base as a
unit, being careful not to strain the wiring from
connector P10 and the power switch.
SCREW, INSULATOR
BUSHING
AC POWER
SUPPLY BASE
TRANSFORMER
TRANSFORMER BRACKET EXTENSION
CABLE FOR
UPGRADED
SERIES I
15. Free the wiring from connector P10 and the power switch from their associated paths in the
electronics carrier.
16. Remove the transformer and transformer bracket from the rear of the instrument, as a unit.
17. Remove the four screws and four insulator bushing which secure the transformer to the trans-
former bracket.
SVC 11- 7
18. Install the replacement transformer onto the transformer bracket and secure using four screws
and four insulator bushings.
19. Position the transformer and transformer bracket to allow threading of the P10 connector cable
and power switch wiring through their applicable paths in the electronics carrier.
20. Secure the transformer and transformer bracket to the AC power supply base using three nuts
and one screw.
to the instrument.
ACTUAL SETPOINT
5890 Series II memory test
29. Secure the rear cover in progress.
to the instrument by in- OVEN STATUS
SVC 11- 8
Remove/Replace Power Switch
SCREWS
ELECTRONICS
CARRIER TOP
COVER
SCREWS
This procedure requires precautions against ESD (Electro- Static Discharge). Use a
grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small) connected
to a suitable ground. Failure to heed this caution may result in damage to the
instrument.
6. At the right side of the instrument, below the
main PCB, remove the power switch from its
PRESS HERE
slot by prying the plastic locking tabs on each
side of the switch in toward the switch body.
PULL OUT OF
INSTRUMENT
SVC 11- 9
When disconnecting a plug, pull on the plug not on its wires. Pulling on the wires may
cause breakage.
7. Remove the four push- on- type connectors GREY
BLACK
from the rear of the switch.
1A 1 1B
8. Connect wiring to power switch as shown in
illustration.
ACTUAL SETPOINT
Message indicating normal
termination of diagnostic
tests after power restoration.
STATUS
OVEN
FINAL
User setpoints remain in
RUN force.
RATE TIME
INITIAL NOT LEDs off, except possibly
TIME READY “NOT READY.”
SVC 11- 10
Remove/Replace Power Cable
SCREWS
SCREWS
This procedure requires precautions against ESD (Electro- Static Discharge). Use a
grounded wrist strap (part no. 9300- 0969 - large, or 9300- 0970 - small) connected
to a suitable ground. Failure to heed this caution may result in damage to the
instrument.
6. Use a 7- mm nut driver to remove the screw
securing the upper portion of the dual duct as-
sembly to the outer oven shell.
POWER SUPPLY
TRANSFORMER,
AND BASE
SVC 11- 11
When disconnecting a plug, pull on the plug not on its wires. Pulling on the wires may
cause breakage.
9. Disconnect push- on type connectors J1 and J2 (from blade connectors P1 and P2, respective-
ly) by grasping each one and pulling it straight off of its terminal.
10. Use a 7- mm nut driver to remove the nut securing the power cable ground lead to the AC
power supply base.
CONNECTOR P10
CONNECTOR P10
11. Remove the power cable ground lead from the
GROUND
stud on the AC power supply base. CONNECTOR
17. With the strain relief compressed, insert the power cable through the opening in the power sup-
ply base and seat the strain relief in the opening.
18. Install the power cable ground lead on the stud on the AC power supply base and secure with
a locking nut.
19. Connect power cord lead push- on- type connectors J1 (WHITE lead) and J2 (BLACK lead) to
their appropriate connectors on the AC power supply PCB.
20. Install the dual duct assembly on the installed mounting screw.
21. Install the upper mounting nut to secure the dual duct assembly to the outer oven shell.
25. Secure the rear cover to the instrument by installing and tightening four screws.
SVC 11- 12
28. Observe the alphanu- NORMAL“INTEGRITY CHECK”
meric display, as the in- AT POWER-ON
strument performs an
ACTUAL SETPOINT
internal self- diagnostic Test of display elements:
all alphanumeric and LED
integrity check. to en- elements are lit.
OVEN STATUS
sure that the instrument FINAL RUN
TIME
shows the expected INITIAL
RATE
NOT
READY
normal displays. TIME
ACTUAL SETPOINT
5890 Series II memory test
in progress.
OVEN STATUS
FINAL RUN
RATE TIME
INITIAL NOT
TIME READY
ACTUAL SETPOINT
5890A Self-testing in
progress.
LEDs off, except possibly
OVEN STATUS “NOT READY.”
FI- RUN
RATE NAL
INITIAL TIME NOT
TIME READY
ACTUAL SETPOINT
Message indicating normal
termination of diagnostic
tests after power restoration.
STATUS
OVEN
FINAL
User setpoints remain in
RUN force.
RATE TIME
INITIAL NOT LEDs off, except possibly
TIME READY “NOT READY.”
SVC 11- 13
Appendix A
PCB CONNECTOR INFORMATION
This appendix contains all of the connector mnemonics used throughout the HP 5890 Series II. It is
intended to help the technician isolate problems to a specific component or components. The HP 5890
Series II may be found in many different configurations, with varying component options. This compli-
cates the process of providing detailed troubleshooting procedures for even general problems. But, by
using the general troubleshooting techniques presented in Section 1, along with the pinouts given here,
successful results should be achieved.
TABLE OF CONTENTS
APPX A- 1
EPC PROPORTIONAL CONTROL VALVE . . . . . . . . . . . . . . APPX A- 16
APPX A- 2
AC POWER PCB CONNECTORS
120VAC BOARD
P26.1 GND
P26.2 OVEN CONTROL (to pulse transformer and oven triac gate)
P26.3 K1 OVEN CONTACTOR CONTROL
P26.1 GND
P26.2 OVEN CONTROL (to pulse transformer and oven triac gate)
P26.3 K1 OVEN CONTACTOR CONTROL
APPX A- 3
J27.1 MAIN POWER SWITCH PHASE 1
J27.2 NC
J27.3 MAIN POWER SWITCH NEUTRAL
P26.1 GND
P26.2 OVEN CONTROL (to pulse transformer and oven triac gate)
P26.3 K1 OVEN CONTACTOR CONTROL
APPX A- 4
MAIN PCB CONNECTORS
P1 KEYBOARD CONNECTOR
P1.1 GND
P1.2 - 24V
P1.3 - 15V
P1.4 GND
P1.5 614.4KHz
P1.6 GND
P1.7 *BA4
P1.8 GND
P1.9 38.4KHz
P1.10 *38.4KHz
P1.11 *POP
P1.12 +15V
P1.13 +5V
P1.14 +5V
P1.15 +24V
P1.16 *EXT_IN1
P1.17 *EXT_OUT9
P1.18 *EXT_OUT10
P1.19 BD0
P1.20 BD1
P1.21 BD2
P1.22 BD3
P1.23 BD4
P1.24 BD5
P1.25 BD6
P1.26 BD7
APPX A- 5
P2 DETECTOR A PCB CONNECTOR
P2.1 +15V
P2.2 +15V
P2.3 - 15V
P2.4 - 15V
P2.5 *STOPA
P2.6 +10V REF
P2.7 1Q
P2.8 A1 OF U16.2
P2.9 STARTA
P2.10 A2 OF U16.2
P2.11 gnd
P2.12 gnd
P2.13 gnd
P2.14 gnd
P2.15 GND
P2.16 GND
P2.17 153.6KHz
P2.18 307.4KHz
P2.19 +24V
P2.20 2Q
P2.21 +24V
P2.22 4.9152MHz
P2.23 +5V
P2.24 +5V
APPX A- 6
P3 DETECTOR B PCB CONNECTOR
P3.1 +15V
P3.2 +15V
P3.3 - 15V
P3.4 - 15V
P3.5 *STOPB
P3.6 +10V REF
P3.7 3Q
P3.8 A3 OF U 16.2
P3.9 STARTB
P3.10 A4 OF U 16.2
P3.11 gnd
P3.12 gnd
P3.13 gnd
P3.14 gnd
P3.15 GND
P3.16 GND
P3.17 153.6KHz
P3.18 307.2KHz
P3.19 +24V
P3.20 4Q
P3.21 +24V
P3.22 4.9152MHz
P3.23 +5V
P3.24 +5V
APPX A- 7
P5 ANALOG SIGNAL 2 OUTPUT CONNECTOR
P5.1 RECORDER COMMON
P5.2 GND
P5.3 RECORDER2
P5.4 INTEG2
P5.5 GND
P5.6 COMMON
P5.7 COMMON
P5.8 GND
P5.9 INTEG2
P5.10 RECORDER2
P5.11 GND
P5.12 RECORDER COMMON
*Relay contacts are rated at 3 Watts, 0.25 Amp.; 28VDC maximum resistive load only; 1.2 msec bounce.
**Relay contacts are rated at 10 Watts, 0.5 Amp., 200VDC maximum resistive load only; 0.4 msec bounce.
APPX A- 8
P8 OVEN FLAP MOTOR CONNECTOR
P8.1 3VAC IGNITOR
P8.2 3VAC IGNITOR
P8.3 +24V
P8.4 VALVA
P8.5 +24V
P8.6 VALVB
P8.7 F0 phase 0 of oven flap stepper motor
P8.8 F2 phase 2 of oven flap stepper motor
P8.9 +24V for oven flap stepper motor
P8.10 +24V for oven flap stepper motor
P8.11 F1 phase 1 of oven flap stepper motor
P8.12 F3 phase 3 of oven flap stepper motor
APPX A- 9
P11 ELECTRONIC FLOW SENSOR CONNECTOR
P11.1 FLOWA
P11.2 FLOWB
P11.3 +10VREF
P11.4 +10VREF
P11.5 +15V
P11.6 GND
P11.7 - 15V
P11.8 GND
P11.9 ACGND
P11.10 ACGND
P11.11 ACGND
P11.12 ACGND
P11.13 - 24V
P11.14 - 24V
P11.15 3VAC fused F1
P11.16 3VAC fused F1
P11.17 3VAC fused F1
P11.18 3VAC fused F1
P11.19 3VAC fused F1
P11.20 3VAC fused F1
P11.21 3VAC fused F2
P11.22 3VAC fused F2
P11.23 3VAC fused F2
P11.24 3VAC fused F2
P11.25 3VAC fused F2
P11.26 3VAC fused F2
APPX A- 10
P12 EPC/MPC PCB CONNECTOR
P12.1 BD0
P12.2 BD1
P12.3 BD2
P12.4 BD3
P12.5 BD4
P12.6 BD5
P12.7 BD6
P12.8 BD7
P12.9 GND
P12.10 *EXT_IN2
P12.11 *EXT_OUT2
P12.12 *EXT_OUT0
P12.13 *EXT_OUT1
P12.14 *EXT_OUT8
P12.15 +5V
P12.16 +5V
P12.17 9.8304MHz
P12.18 GND
P12.19 GND
P12.20 GND
P12.21 GND
P12.22 GND
P12.23 D240
P12.24 POP
P12.25 +15V
P12.26 - 15V
P12.27 +10VREF
P12.28 COMMON
P12.29 DAC2
P12.30 ATTN2 ( goes thru R5 to RCDR2 of P5 )
APPX A- 11
P13 COMMUNICATIONS PCB CONNECTOR
P13.1 BD0
P13.2 BD1
P13.3 BD2
P13.4 BD3
P13.5 BD4
P13.6 BD5
P13.7 BD6
P13.8 BD7
P13.9 *EXT_OUT3 - - - - - - - - - - - - - - - - - - - | Decode to give
P13.10 A(5) | addresses 3,35,67,99
P13.11 A(6) | for Input or Output
P13.12 *EXT_IN3 - - - - - - - - - - - - - - - - - - - - - |
P13.13 +5V
P13.14 +5V
P13.15 DGND ( for digital circuits)
P13.16 DGND ( for digital circuits)
P13.17 D240 ( 240 Hz square wave)
P13.18 POP ( power- on- pulse)
P13.19 SGND ( for switching or analog circuits)
P13.20 SGND ( for switching or analog circuits)
P13.21 +24V
P13.22 +24V
P13.23 - 24V
P13.24 - 24V
APPX A- 12
DISPLAY PCB
J1.1 GND
J1.2 - 24V
J1.3 - 15V
J1.4 GND
J1.5 614.4KHz
J1.6 GND
J1.7 *BA4
J1.8 GND
J1.9 38.4KHz
J1.10 *38.4KHz
J1.11 *JOJ
J1.12 +15V
J1.13 +5V
J1.14 +5V
J1.15 +24V
J1.16 *EXT_IN1
J1.17 *EXT_OUT9
J1.18 *EXT_OUT10
J1.19 BD0
J1.20 BD1
J1.21 BD2
J1.22 BD3
J1.23 BD4
J1.24 BD5
J1.25 BD6
J1.26 BD7
APPX A- 13
DETECTOR PCBS
J2.1 +15V
J2.2 +15V
J2.3 - 15V
J2.4 - 15V
J2.5 *STOJA
J2.6 +10V REF
J2.7 1Q
J2.8 A1 OF U16.2
J2.9 STARTA
J2.10 A2 OF U16.2
J2.11 gnd
J2.12 gnd
J2.13 gnd
J2.14 gnd
J2.15 GND
J2.16 GND
J2.17 153.6KHz
J2.18 307.4KHz
J2.19 +24V
J2.20 2Q
J2.21 +24V
J2.22 4.9152MHz
J2.23 +5V
J2.24 +5V
APPX A- 14
EPC PCB CONNECTORS
J1.1 BD0
J1.2 BD1
J1.3 BD2
J1.4 BD3
J1.5 BD4
J1.6 BD5
J1.7 BD6
J1.8 BD7
J1.9 *EXT_OUT3 - - - - - - - - - - - - - - - - - - | Decode to give
J1.10 A(5) | addresses 3,35,67,99
J1.11 A(6) | for Input or Output
J1.12 *EXT_IN3 - - - - - - - - - - - - - - - - - - - |
J1.13 +5V
J1.14 +5V
J1.15 DGND ( for digital circuits)
J1.16 DGND ( for digital circuits)
J1.17 D240 ( 240 Hz square wave)
J1.18 POP ( power- on- pulse)
J1.19 SGND ( for switching or analog circuits)
J1.20 SGND ( for switching or analog circuits)
J1.21 +24V
J1.22 +24V
J1.23 - 24V
J1.24 - 24V
APPX A- 15
P3.1 P_SENSB (B pressure sensing)
P3.2 +15VDC
P3.3 +5VDC
P3.4 ACOM
P3.5 P_CNTLB
P3.6 - 15VDC
P3.7 SHEILD
APPX A- 16
MPC PCB
J1.1 BD0
J1.2 BD1
J1.3 BD2
J1.4 BD3
J1.5 BD4
J1.6 BD5
J1.7 BD6
J1.8 BD7
J1.9 *EXT_OUT3 - - - - - - - - - - - - - - - - - - | Decode to give
J1.10 A(5) | addresses 3,35,67,99
J1.11 A(6) | for Input or Output
J1.12 *EXT_IN3 - - - - - - - - - - - - - - - - - - - |
J1.13 +5V
J1.14 +5V
J1.15 DGND ( for digital circuits)
J1.16 DGND ( for digital circuits)
J1.17 D240 ( 240 Hz square wave)
J1.18 POP ( power- on- pulse)
J1.19 SGND ( for switching or analog circuits)
J1.20 SGND ( for switching or analog circuits)
J1.21 +24V
J1.22 +24V
J1.23 - 24VDC
J1.24 - 24VDC
APPX A- 17
RS232C PCB CONNECTORS
J12.1 BD0
J12.2 BD1
J12.3 BD2
J12.4 BD3
J12.5 BD4
J12.6 BD5
J12.7 BD6
J12.8 BD7
J12.9 GND
J12.10 *EXT_IN2
J12.11 *EXT_OUT2
J12.12 *EXT_OUT0
J12.13 *EXT_OUT1
J12.14 *EXT_OUT8
J12.15 +5V
J12.16 +5V
J12.17 9.8304MHz
J12.18 GND
J12.19 GND
J12.20 GND
J12.21 GND
J12.22 GND
J12.23 D240 (240 Hz square wave)
J12.24 POP ( power- on- pulse)
J12.25 +15V
J12.26 - 15V
J12.27 +10VREF
J12.28 COMMON
J12.29 DAC2
J12.30 ATTN2
J13.1 GND
J13.2 RXD (RECEIVE DATA)
J13.3 TXD (TRANSMIT DATA)
J13.4 GND
J13.5 GND
J13.6 GND
J13.7 GND
J13.8 GND
J13.9 GND
J13.10 TXD (TRANSMIT DATA)
J13.11 RXD (RECEIVE DATA)
J13.12 GND
APPX A- 18
INET PCB
J12.1 BD0
J12.2 BD1
J12.3 BD2
J12.4 BD3
J12.5 BD4
J12.6 BD5
J12.7 BD6
J12.8 BD7
J12.9 GND
J12.10 *EXT_IN2
J12.11 *EXT_OUT2
J12.12 *EXT_OUT0
J12.13 *EXT_OUT1
J12.14 *EXT_OUT8
J12.15 +5V
J12.16 +5V
J12.17 9.8304MHz
J12.18 GND
J12.19 GND
J12.20 GND
J12.21 GND
J12.22 GND
J12.23 D240 (240 Hz square wave)
J12.24 POP ( power- on- pulse)
J12.25 +15V
J12.26 - 15V
J12.27 +10VREF
J12.28 COMMON
J12.29 DAC2
J12.30 ATTN2
J13.1 OUT
J13.2 OUT_REF
J13.3 IN_REF
J13.4 IN
APPX A- 19
BUFFERED INET PCB
J12.1 BD0
J12.2 BD1
J12.3 BD2
J12.4 BD3
J12.5 BD4
J12.6 BD5
J12.7 BD6
J12.8 BD7
J12.9 GND
J12.10 *EXT_IN2
J12.11 *EXT_OUT2
J12.12 *EXT_OUT0
J12.13 *EXT_OUT1
J12.14 *EXT_OUT8
J12.15 +5V
J12.16 +5V
J12.17 9.8304MHz
J12.18 GND
J12.19 GND
J12.20 GND
J12.21 GND
J12.22 GND
J12.23 D240 (240 Hz square wave)
J12.24 POP ( power- on- pulse)
J12.25 +15V
J12.26 - 15V
J12.27 +10VREF
J12.28 COMMON
J12.29 DAC2
J12.30 ATTN2
P1.1 OUT
P1.2 OUT_REF
P1.3 IN_REF
P1.4 IN
APPX A- 20
DICE PCB
J12.1 BD0
J12.2 BD1
J12.3 BD2
J12.4 BD3
J12.5 BD4
J12.6 BD5
J12.7 BD6
J12.8 BD7
J12.9 GND
J12.10 *EXT_IN2
J12.11 *EXT_OUT2
J12.12 *EXT_OUT0
J12.13 *EXT_OUT1
J12.14 *EXT_OUT8
J12.15 +5V
J12.16 +5V
J12.17 9.8304MHz
J12.18 GND
J12.19 GND
J12.20 GND
J12.21 GND
J12.22 GND
J12.23 D240 ( 240 Hz square wave)
J12.24 POP ( power- on- pulse)
J12.25 +15V
J12.26 - 15V
J12.27 +10VREF
J12.28 COMMON
J12.29 DAC2
J12.30 ATTN2
P1.1 OUT
P1.2 OUT_REF
P1.3 IN_REF
P1.4 IN
APPX A- 21
J1.13 +5 DCV
J1.14 DIO0
J1.15 DIO1
J1.16 DIO2
J1.17 DIO3
J1.18 DIGITAL GROUND
J1.19 DIO4
J1.20 DIO5
J1.21 DIO6
J1.22 DIO7
J1.23 +5 DCV
J1.24 RX (RECEIVE)
J1.25 TX (TRANSMIT)
J1.26 GROUND
J2.1 DIO1
J2.2 DIO2
J2.3 DIO3
J2.4 DIO4
J2.5 EOI
J2.6 DAV
APPX A- 22
J2.7 NRFD
J2.8 NDAC
J2.9 IFC
J2.10 SRQ
J2.11 ATN
J2.12 SHEILD
J2.13 DIO5
J2.14 DIO6
J2.15 DIO7
J2.16 DIO8
J2.17 REN
J2.18 DCOM- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - |
J2.19 DCOM |
J2.20 DCOM | 18 thru 24 tied
J2.21 DCOM | to digital
J2.22 DCOM | ground
J2.23 DCOM |
J2.24 LOGIC- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - |
J3.1 SHEILD
J3.2 TX (TRANSMIT)
J3.3 RX (RECEIVE)
J3.4 NC
J3.5 NC
J3.6 NC
J3.7 GND
J3.8 NC
J3.9 NC
J3.10 NC
J3.11 NC
J3.12 NC
J3.13 NC
J3.14 NC
J3.15 NC
J3.16 NC
J3.17 NC
J3.18 NC
J3.19 NC
J3.20 NC
J3.21 NC
J3.22 NC
J3.23 NC
J3.24 NC
J3.25 NC
APPX A- 23
ELECTRONIC FLOW SENSOR MODULE
J1.1 FLOWA
J1.2 FLOWB
J1.3 +10VREF
J1.4 +10VREF
J1.5 +15V
J1.6 GND
J1.7 - 15V
J1.8 GND
J1.9 ACGND
J1.10 ACGND
J1.11 ACGND
J1.12 ACGND
J1.13 - 24V
J1.14 - 24V
J1.15 3VAC fused F1
J1.16 3VAC fused F1
J1.17 3VAC fused F1
J1.18 3VAC fused F1
J1.19 3VAC fused F1
J1.20 3VAC fused F1
J1.21 3VAC fused F2
J1.22 3VAC fused F2
J1.23 3VAC fused F2
J1.24 3VAC fused F2
J1.25 3VAC fused F2
J1.26 3VAC fused F2
APPX A- 24
Print @ 115% of this size
APPX A- 25