Replacing the Gas/Liquid Separator, NDIR Filter, Waste Block and Reactor Valve Seals in Sievers InnovOx TOC Analyzers

Transcription

1 6060 Spine Road Boulder, CO USA USA Europe Worldwide Replacing the Gas/Liquid Separator, NDIR Filter, Waste Block and Reactor Valve Seals in Sievers InnovOx TOC Analyzers Introduction Purpose: Scope: To replace the Gas/Liquid Separator, NDIR Filter, Waste Block, and Reactor Valve Seals in Sievers InnovOx TOC Analyzers. The replacement of the Gas/Liquid Separator, NDIR Filter and Reactor Valve Seals applies to all Sievers InnovOx Analyzer configurations. The replacement of the Waste Block applies to the On-Line Analyzer model. Safety: Materials Personnel skilled in the maintenance of electromechanical instruments should perform this procedure. This procedure requires that one have access to the inside of the Analyzer case. To avoid potentially dangerous shock, be sure to power off the Analyzer as described in the procedure. GLS/Filter/Waste Upgrade Kit (1) 3/32 Allen Wrench (in Kit) 9/64 Allen Wrench (in Kit) Adjustable Wrench (1) 5/32 Allen Wrench (1) Phillips Screwdriver (1) Disposable Latex Gloves (1 pair) Eye Protection (1 pair) Procedures A. Removing the Existing Waste Block (On-Line Only). B. Installing the New Waste Block (On-Line Only). C. Removing the Existing Gas/Liquid Separator and NDIR Filter. D. Installing the New Gas/Liquid Separator and NDIR Filter. E. Replacing the Reactor Valve Seals. GE Analytical Instruments, Inc. 2012J Page 1 of 20 DIN Rev. B

2 A. Removing the Existing Waste Block (On-Line Only). 1. If the Analyzer is taking measurements, press the Stop Analysis button. 2. Insert a USB flash memory drive into the port on the Analyzer and back up the current Analyzer settings (Maintenance Advanced System Properties USB Backup). Note: For more information, see the section called Saving System Settings in the Analyzer s Operation and Maintenance Manual. 3. Back up the Data History (Data Export Export). Select the appropriate Export option. Note: You can adjust the data history range value by selecting Range prior to exporting. 4. Back up the Diagnostics (Maintenance Diagnostics Export Diagnostics USB). Note: Make sure the export to the USB memory drive is complete before removing from the USB port. Wait 5 seconds after the export feature has indicated it is finished on the InnovOx display. 5. Remove the USB flash memory drive from the USB port and store it in a safe place. 6. Turn off the Analyzer (Maintenance Shutdown). 7. Turn off power to the Analyzer via the power switch on the side of the Analyzer (pictured). 8. Disconnect the power source. GE Analytical Instruments, Inc. 2012J Page 2 of 20 DIN Rev. B

3 9. Unfasten the latches on the left side of the door. 10. Remove all waste tubes attached to the existing Waste Block. Note: Some units may have 2 waste lines and some may have With a 9/64 Allen screwdriver, unfasten the two screws holding the Waste Block in place. 12. Remove Waste Block and discard. GE Analytical Instruments, Inc. 2012J Page 3 of 20 DIN Rev. B

4 B. Installing the New Waste Block (On-Line Only). 1. Place new Waste Block in opening on back of Analyzer, making sure that O-Ring is securely seated on back of Block. 2. With a 9/64 Allen screwdriver, secure the two screws fastening Waste Block to Analyzer. 3. Reconnect Liquid line (bottom), and connect new Gas line (top). 4. Place other end of Gas line in a secure well-ventilated position away from Analyzer. See specific safety recommendations in Chapter 4: Installation in the Analyzer s Operation and Maintenance manual. GE Analytical Instruments, Inc. 2012J Page 4 of 20 DIN Rev. B

5 C. Removing the Existing Gas/Liquid Separator and NDIR Filter. 1. For the On-Line model, Shutdown and Disconnect procedures were carried out in Section A. Refer to Steps A1-A9. 2. For the Lab model, if the Analyzer is taking measurements, press the Stop Analysis button. 3. Insert a USB flash memory drive into the port on the Analyzer and back up the current Analyzer settings (Maintenance Advanced System Properties USB Backup). Note: For more information, see the section called Saving System Settings in the Analyzer s Operation and Maintenance Manual. 4. Back up the Data History (Data Export Export). Select the appropriate Export option. Note: You can adjust the data history range value by selecting Range prior to exporting. 5. Back up the Diagnostics (Maintenance Diagnostics Export Diagnostics USB). Note: Make sure the export to the USB memory drive is complete before removing from the USB port. Wait 5 seconds after the export feature has indicated it is finished on the InnovOx display. 6. Remove the USB flash memory drive from the USB port and store it in a safe place. 7. Turn off the Analyzer (Maintenance Shutdown). 8. Turn off power to the Analyzer via the power switch on the back. 9. Unplug the power cord from the wall socket. 10. Unplug the power cord from the Analyzer (pictured). GE Analytical Instruments, Inc. 2012J Page 5 of 20 DIN Rev. B

6 11. For the Lab model, unfasten the two thumbscrews located on the back side of the Analyzer. 12. Slide back the fluidics cover. 13. Remove the fluidics cover from the Analyzer. GE Analytical Instruments, Inc. 2012J Page 6 of 20 DIN Rev. B

7 14. Important: Refer to the following diagrams showing the routing of tubes in the a) Lab Model and b) On-Line Model when uninstalling and installing the Gas/Liquid Separator and NDIR Filter. a) Lab Model b) On-Line Model GE Analytical Instruments, Inc. 2012J Page 7 of 20 DIN Rev. B

8 15. For both models, remove all tubes from existing Gas/Liquid Separator. 16. For Lab model, remove T Connection (between clear Carrier Gas tube and black tubing) and discard. 17. Disconnect the blue cylindrical NDIR filter and tubing and discard. GE Analytical Instruments, Inc. 2012J Page 8 of 20 DIN Rev. B

9 18. For both models, remove Y-Fitting from NDIR. 19. For the On-Line model, if the waste line tubing has a Y- Fitting, remove and discard (pictured). 20. For the Lab model, leave waste Y-Fitting in place. 21. For the On-Line model, make sure Sparger tube is routed behind Sparger and Sample-Handling Module, into the Retainer Clips. Note: The Sparger tube is the black ¼ tube connected to the barb at the top of the Sparger at the bottom left of the unit. GE Analytical Instruments, Inc. 2012J Page 9 of 20 DIN Rev. B

10 22. For the On-Line model, attach the tube from the Sample-Handling Pump to bottom-right Waste Port. 23. For the On-Line model, cut new 5 section of tube, and install between Reactor Pump and bottom-left Waste Port. 24. For both models, with a 3/32 Allen wrench, remove screws and bar holding Separator in place. Discard hardware. Important: For Step 25, be sure to wear gloves and eye protection. 25. In a controlled manner, drain Separator of acidic content and rinse out before discarding. GE Analytical Instruments, Inc. 2012J Page 10 of 20 DIN Rev. B

11 26. With a Phillips screwdriver, remove existing NDIR Filter Clamp and discard. D. Installing the New gas/liquid Separator and NDIR Filter. 1. Slide new Gas/Liquid Separator Bracket over existing posts. 2. Place metal sleeves over posts. GE Analytical Instruments, Inc. 2012J Page 11 of 20 DIN Rev. B

12 3. With a Phillips screwdriver, attach a 6-32 x 1/2 screw to left post. 4. Mount Gas/Liquid Separator Securing Bracket onto right post (as shown) with a 6-32 x 1/2 screw, tightening almost all the way, but leaving Securing Bracket loose. 5. Slide Gas/Liquid Separator onto Bracket, without tubes, making sure that two front fittings face forward. GE Analytical Instruments, Inc. 2012J Page 12 of 20 DIN Rev. B

13 6. Hold Securing Bracket against Separator while completely tightening Securing Bracket screw. 7. Connect black Sparger tube to top-right fitting on Separator. 8. Connect black NDIR Outlet tube (from left side of NDIR) to top-left fitting on Separator. GE Analytical Instruments, Inc. 2012J Page 13 of 20 DIN Rev. B

14 9. Connect white Reactor Outlet tube to front-right fitting on Separator. 10. Connect Waste tube to front-left fitting on Separator. 11. For the On-Line model, connect other end of tube to top fitting of Waste Block. 12. For the Lab model, connect other end of tube to bulkhead fitting of Waste Block. 13. Attach black tube to bottle containing de-ionized water. 14. Connect tube to top-middle fitting, and fill Separator with water, until it is filled past the top gray bar of Separator cylinder. GE Analytical Instruments, Inc. 2012J Page 14 of 20 DIN Rev. B

15 15. Connect bottom (shorter) tube of NDIR Filter tube to middle-top fitting on Separator. 16. Connect top (longer) tube of NDIR Filter to NDIR Module. 17. Connect clear Carrier Gas tube to the tee fitting between the NDIR filter and the NDIR. 18. Affix the included Gas/Liquid Separator sticker to the inside of the Analyzer, near the Separator, for reference. GE Analytical Instruments, Inc. 2012J Page 15 of 20 DIN Rev. B

16 E. Replacing the Reactor Valve Seals. 1. Locate the High-Pressure Valve Motors inside the fluidics cover. 2. Remove the connector cables from the plastic clamps. 3. With a 5/32 Allen Wrench, remove the four hex-head screws holding the High-Pressure Valve Motor in place. GE Analytical Instruments, Inc. 2012J Page 16 of 20 DIN Rev. B

17 4. Remove both High-Pressure Valve Motors by pulling them out from the Valve Housing. Important: Use disposable latex gloves when handling the Valve Seal(s). The manufacturer has indicated that the lubricant used to coat the Valve Seal may cause skin and eye irritation. 5. Retrieve the two Valve Seals from the kit. 6. With an adjustable wrench, fasten each Valve Seal to the High-Pressure Valve Motor, onequarter turn past finger-tight. GE Analytical Instruments, Inc. 2012J Page 17 of 20 DIN Rev. B

18 7. Re-install the High-Pressure Valve Motors by inserting it into the Valve Housing. 8. With a 5/32 Allen Wrench, tighten the four hex-head screws to fasten the High-Pressure Valve Motor in place. Note: Before tightening the screws, make sure motor wires are not pinched between the motor and the housing. 9. Insert the connector cables into the plastic clamps. GE Analytical Instruments, Inc. 2012J Page 18 of 20 DIN Rev. B

19 10. For the On-Line model, close the Analyzer door, and fasten the latches on the left side of the door. 11. For the Lab model, replace the fluidics cover on the Analyzer. 12. Secure the fluidics cover by sliding it forward. GE Analytical Instruments, Inc. 2012J Page 19 of 20 DIN Rev. B

20 13. Tighten the two thumbscrews on the back of the Analyzer. 14. For the On-Line model, connect the power source. 15. Turn on power to the Analyzer via the power switch on the side of the Analyzer (pictured). 16. For the Lab model, plug the power cord into the Analyzer (pictured). 17. Plug the other end of the power cord into the wall socket. 18. Turn on power to the Analyzer. 19. For both models, restore system operation, and make sure that the Analyzer is functioning correctly. Note: It will take measurements for the Reactor Valve Seals to seat properly. 20. Recalibrating the Analyzer is recommended due to the new Gas/Liquid Separator design. 21. Dispose of removed materials according to local regulations. GE Analytical Instruments, Inc. 2012J Page 20 of 20 DIN Rev. B