CGV

User's
Manual
GC1000 Mark II
Process Gas Chromatograph
Maintenance and Inspection Manual
IM 11B03A03-04E
IM 11B03A03-04E
2nd Edition
<Toc> <Ind> <Rev> <Introduction> i
◆ Notice
● Regarding This Manual
1. This Manual should be passed on to the end user.
2. Read this manual carefully and fully understand how to operate this product before
you start operation.
3. Yokogawa makes no warranty of any kind with regard to this material, but not limited
to, implied warranties of merchantability for particular purpose.
4. All rights reserved. No part of this manual may be reproduced in any form without
Yokogawa’s written permission.
5. Great effort has been expended to ensure that the descriptions in this manual are
correct. Should you, however, come across a questionable area or note an inconsis-
tency, a telephone call or letter to Yokogawa.co.,ltd. noting the questionable area
would be highly appreciated.
6. The contents of this manual are subject to change without prior notice.
● Regarding Protection, Safety, and Prohibition Against Unauthorized Modifica-

tion.
1. For the protection and safe use of the product and the system controlled by it, be sure
to follow the instructions on safety described in this manual when handling the prod-
uct. In addition, if you handle the product in contradiction to these instructions, our
company does not guarantee safety.
2. The following safety symbol marks are used on the product concerned or in this
Manual :
WARNING
A WARNING sign denotes a hazard. It calls attention to procedure, practice, condition
or the like, which, if not correctly performed or adhered to, could result in injury or
death of personnel.
CAUTION
A CAUTION sign denotes a hazard. It calls attention to a procedure, practice, condi-
tion or the like, which, if not correctly performed or adhered to, could result in damage
to or destruction of part or all of the product.
IMPORTANT:
Indicates that operating the hardware or software in this manner may damage it or
lead to system failure.
NOTE:
Draws attention to information essential for understanding the operation and features.
TIP:
Gives information that complements the present topic.
Media No. IM 11B03A03-04E 2nd Edition : July. 2002 (YK) IM 11B03A03-04E 2nd Edition : July. 1. 2002-00
All Rights Reserved Copyright © 2001, Yokogawa Electric Corporation
<Toc> <Ind> <Rev> <Introduction> ii
See Also:
Gives the reference locations for further information on the topic.
Protective ground terminal:

In order to provide protection against electrical shock in case of a fault. This symbol
indicates that the terminal must be connected to ground prior to operation of equip-
ment.
Function ground terminal:

In order to provide protection against noise. This symbol indicates that the terminal
must be connected to ground prior to operation of equipment.
Alternating current
Indicates the power switch state “ON”.
Indicates the power switch state “Stand - by”.
Indicate the power switch state “OFF”.
3. If protection / safety circuits are to be used for the product or the system controlled by
it, they should be installed outside of the product.
4. When you replace parts or consumables of the product, use those specified by our
company.
5. Do not modify the product.
● Exemption from Responsibility

1. Yokogawa Electric Corporation does not make any warranties regarding the product
except those mentioned in the WARRANTY that is provided separately.
2. Yokogawa Electric Corporation assumes no liability to any party for any loss or dam-
age, direct or indirect, caused by the use or any unpredictable defect of the product.
● Regarding Software and set including Software Supplied by YOKOGAWA

1. Yokogawa makes no other warranties expressed or implied except as provided in its
warranty clause for software supplied Yokogawa.
2. Use this software with one specified computer only.
You must purchase another copy of the software for use with each additional com-
puter.
3. Copying this software for purposes other than backup is strictly prohibited.
4. Store the streamer or floppy disk (original medium) in a secure place.
5. Reverse engineering such as the disassembly of software is strictly prohibited.
6. No portion of the software supplied by Yokogawa may be transferred, exchanged, or
sublet or leased for use by any third party without prior permission by Yokogawa.
IM 11B03A03-04E 1st Edition : Oct.31,2001-00

<Toc> <Ind> <Rev> <Introduction> iii
◆ Warning/Caution Labels
● To ensure safety operation of this equipment, warning/caution labels are at-
tached on the equipment as follows. Check these labels for your safety opera-
tion.
[Left side] [Front] [Right side] [Back]

F0001.EPS
A B
The inside of the enclosure is high temperature after turning off the power.
Don’t touch the inside of the enclosure or the compponents, the protective gas
should be suoolied for more than one hour after turning off the power.
D E
F0002.EPS

<Toc> <Ind> <Rev> <Introduction> iv
◆ Introduction
Thank you for purchasing the GC1000 Mark II process gas chromatograph.
This manual describes the meintenance and inspection of Model GC1000D / GC1000S /
GC1000T / GC1000E / GC1000W / GC1000C (Hereafter, it is abbreviated as GC1000
Mark II) Process Gas Chromatograph.
Please lead the following respective documents before installing and using the GC1000
Mark II system.
● Documents Related to the GC1000 Mark II Process Gas Chromatograph

1. Instruction manuals
The product comes with the following instruction manuals.
■ Instruction manuals that do not depend upon the specifications of the product
(1) Overview (IM 11B03A03-01E)
(2) Basic Operation and Startup (IM 11B03A03-02E)
(3) Maintenance and Inspection Manual (IM 11B03A03-04E)
(4) LCD Panel Operation Manual (IM 11B03A03-05E)
(5) Alarm Message Manual (IM 11B03A03-06E)
and Installation Manual (TI 11B03A03-03E)
■ Instruction manuals that depend upon the specifications of the product

(1) GCMT Gas Chromatograph Maintenance Terminal Software Package Operation
Guide (IM 11B03G03-03E)
(2) Capture It! Manual (IM 11B3G1-02E)
■ Instruction manuals for related products

(1) Model GCCU Computing Unit for a gas chromatograph (IM11B03S03-01E)
(2) GCCU Utility Software Manual (IM11B3S2-02E)
(3) Analyzer Server User's Manual (IM11B5B1-01E)
(4) ASMT Analyzer Server Maintenance Terminal Operation Guide
(IM11B05A03-01E)
(5) GCIU Interface Unit (IM 11B5B2-01E)
and Hub GCHUB Installation Manual (TI 11B5C1-01E)

<Toc> <Ind> <Rev> <Introduction> v
2. Operation Data
Operation data is supplied with the operation manuals in the delivered package and con-
tains the following required to use the gas chromatographs.
● Process conditions and measurement range
● Instrument specifications and operating conditions
● Standard sample for calibration
● Column system and column
● Miscellaneous data
Chromatogram, base line, repeatability, power supply voltage variation, etc.
● Analyzer flow diagram and installation
● Parts composition table
● General connection diagram
● Sampling system diagram (only if supplied by Yokogawa)
● Is the System Ready?

Before reading this manual, the following preparations must have been completed.
● The system must be unpacked and installed in the correct place.
● The piping for the utility gases such as carrier and calibration gases must be com-
pleted, followed by leak checking.
● The wiring for the power supply and others must be completed.
If these have not been completed yet, see the Installation Manual (TI 11B03A03-03E).
After completion, return to this manual and do the following:
● If the system power is on, turn off the power.
● Shut off all the gases at the flow control units.
Please read the following respective cautions (General Precautions, Caution of
using Explosion-Protection Instruments, on Piping Construction, and on Piping
Work) before installing and using the GC1000 system.

<Toc> <Ind> <Rev> <Introduction> vi
● General Precautions
WARNING
(1) In order to analyze gases, process gas chromatographs use a sample of the process
gas and utility gases.
Since these gases are typically combustible, combustion-sustaining, toxic,
odorous, resolvable, polymerizing, or corrosive, refer to the “Safety Informa-
tion” in our approval drawings and others to ensure safety thoroughly before
using these analyzers.
(2) Up to two protection systems, each of which weighs approximately 10 kg, are installed
on top of the GC1000. Therefore, the center of gravity is higher than the center of the
analyzer body.
Take great care when carrying and installing (piping- wiring) the GC1000. The
GC1000 must be carried and installed very carefully (including piping and
wiring) by more than one person (at least four people are recommended).
(3) Since the GC1000 are precision instruments, take care when handling not to
jolt of knock them.
(4) Use the GC1000 within the range of your purchase specifications.
Yokogawa assumes no responsibility for problems resulting from use by the customer
outside the purchase specifications.
If the GC1000 need to be modified or repaired, please contact your nearest Yokogawa
representative. Yokogawa assumes no responsibility for results where the customer or
any third party has attempted to modify or repair these products.
(5) When touching LCD Panel switches
When touching LCD Panel switches, first, discharge Electro Static Charge of the body.
Then, touch the LCD Panel switches. If not, LCD display may be changed by Electro
Static Discharge.
IMPORTANT:
(1) Read the attached instruction manual before operating the GC1000
(2) The instruments must be installed and operated according to the installation manual,
instruction manual, approval drawings, and operation data.
IM 11B03A03-04E 2nd Edition : July. 1. 2002-00

<Toc> <Ind> <Rev> <Introduction> vii
● CAUTIONS OF USING EXPLOSION-PROTECTION INSTRUMENTS
The GC1000 Process Gas Chromatographs are designed to protect against explosion.
When these analyzers are used in a hazardous area, observe the following precautions.
Since the applicable standard differs depending on the specifications of the analyzer to be
used, check the specifications of your analyzer.
(1) Kinds of explosion protection

To assure explosion protection, the GC1000 Process Gas Chromatographs have a pres-
surized and flameproof construction, or type X purging and explosionproof construction
meeting the following standards :
<GC1000D / GC1000S>
• JIS Expd IIB + H2 T1 (programmed-temperature oven 320˚C max., isothermal oven
225˚C max., liquid-sample valve 250˚C max.)
<GC1000W / GC1000C>
CENELEC (ATEX directive) certified : Group II Category 2G
• EEx pd II B +H2 T1 (programmed-temperature oven 320°C max, isothermal oven
225°C max., liquid-sample valve 250°C max.)
• EEx pd II B +H2 T4 (programmed-temperature oven 95°C max, isothermal oven 95°C
max., liquid-sample valve 95°C max.)
<GC1000T / GC1000E>
FM Type X purging and Explosionproof for CLI, DIV1, GPS B, C & D, NEMA3R.
Type Y purging and Type X purging for CLI, DIV1, GPS B, C & D, NEMA3R.
• T1 (programmed-temperature oven 320˚C max., isothermal oven 225˚C max., liquid-
sample valve 250˚C max.)

<Toc> <Ind> <Rev> <Introduction> viii
CSA Type X purging and Explosionproof for CLI, DIV1, GPS B, C & D, TYPE3R.
Type Y purging and Type X purging for CLI, DIV1, GPS B, C & D, TYPE3R.
(2) Precautions for Explosionproof section (The analyzer with optional code
"FM/CSA Type Y purging" does not have the explosionproof section.)
When handling the screws on the cover of the Protection system, note the following to
avoid damaging the screws since they cannot be repaired.
(1) The enclosure is pressurized. Before removing the cover, reduce the internal pres-
sure by loosening the sealing plug for wiring on the enclosure or relevant means.
(2) When removing the cover, prevent any dirt or foreign matter from contaminating the
screw part.
(3) When installing the cover, tighten the screws by hand ; never use tools.
(4) Since the screws are coated with MOLYKOTE, do not lubricate them.
(3) Precautions when using hydrogen gas

When using hydrogen gas as the carrier gas, the FID or FPD combustion gas, to ensure
safety, install the analyzer in a location equipped with a ventilator or where there is suffi-
cient ventilation. Make sure there are no gas leaks from the pipe joints and inspect for
leaks.
(4) Installation site and environment

The analyzer specifications allow it to be used in hazardous areas as defined by Zone1 IIB
+ H2T1, T2, T3, T4 (JIS / CENELEC) or DIV1, GPS B, C & D, T1, T2, T3, T4 (FM / CSA).
However, never install the analyzer in an area where the density of explosive gas persists
for a long time.
(5) Wiring works

Model GC1000D / GC1000S, analyzer obtains explosion proof authorization by the com-
plete set including metal fittings of the attachment.
When performing wiring, always use the attached sealing fittings and flameproof packing
adapter.

<Toc> <Ind> <Rev> <Introduction> ix
(6) Maintenance and inspection
During usual maintenance and inspection, it is not necessary to check the explosion-
protected section.
Before opening the door of the explosion-protected section for maintenance and inspec-
tion, be sure to turn off the power. After completing maintenance and checks, close the
door completely then turn on the power after checking that the specified explosion protec-
tion performance is guaranteed. The parts to be checked are described in the Maintenance
and Inspection Manual (IM 11B03A3 - 04E).
If any of the following damage occurs, contact a Yokogawa sales representative or the
Yokogawa sales division
(1) If the screws securing the Protection System (explosionproof construction) are dam-
aged
(2) If the exterior or light transmission section of the enclosures is damaged
(3) If packings are cracked or conspicuously deformed
(7) Override function (The analyzer with optional code "FM/CSA Type Y purg-
ing" does not have this function.)
WARNING
• When the override function is used, Analyzer becomes an ignition source and the high
temperature and the high voltage part will be exposed.
• Please confirm that in the ambient atmosphere, the concentration of explosive gases
is less than the allowable limit, by using a gas detector.
To return to the normal operation, turn off “the override switch” and then close the door as it
was before turning on power.
In this analyzer, if the pressure of the pressurized / type X purged enclosure system (oven,
electronic section) drops while the power is on, the pressurized explosion protection sec-
tion is activated to stop power supply. Therefore, in case of opening the door of the oven or
of the electronic section inadvertently, for maintenance, while the power is on, the protec-
tion system is activated to cut off the power.
The “override function” intensively releases this function of protection system.
The override switch is installed in section.
(8) Replacing parts

Always use parts specified by Yokogawa when replacing parts, for replacement, refer to the
Maintenance and Inspection Manual (IM 11B03A03 - 04E).
IM 11B03A03-04E 2nd Edition : July. 1,2002-00

<Toc> <Ind> <Rev> <Introduction> x
(9) Operation
WARNING
<CENELEC>
* Only trained persons may use this instrument in a hazardousl location.
* Do not open when energized.
<FM>
For type X purging:
* This equipment contains components that operate at high temperature. The equip-
ment shall be deenergized for 60 minutes to permit those components to cool before
the enclosure is opened unless the area is demonstrated to be nonhazardous at the
time.
* Enclosure shall not be opened unless the area is known to be nonhazardous, or
unless all devices within have been de-energized.
* Power shall not be restored after enclosure has been opened until enclosure has
been purged for 12 minutes. (When the internal pressure is restored, the system
automatically purges over the 12 minutes, then turns on the power again.)
For explosionproof enclosure:
* Seal all conduits within 18 inches
* Open circuit before removing cover.
For type Y purging:
* Enclosure shall not be opened unless the area is known to be non-hazardous, or
unless all devices within have been de-energized. Power shall not be restored after
enclosure has been opened until enclosure has been purged for 12 minutes at speci-
fied pressure indicated by the pressure gauge
labeled “EL.BOX” in the pressure and flow control section.
* Alarm shall be provided and connected to alarm contact output.
(a) The alarm shall generate a visual or audible signal that attracts attention
(b) The alarm shall be located at constantly attended location.
(c) Electrical alarms shall be approved for the location in which they are installed.

<Toc> <Ind> <Rev> <Introduction> xi
<CSA>
For type X purging:
* This equipment contains components that operate at high temperature. The equip-
ment shall be deenergized for 60 minutes to permit those components to cool before
the enclosure is opened unless the area is demonstrated to be nonhazardous at the
time.
unless all devices within the enclosure have been de-energized. Power must not be
restored after enclosure has been opened until enclosure has been purged for 12
minutes at a flow rate of 0.05m3/min.
* Power will automatically be removed when purge pressure falls below 40 mm (1.6 in)
of water column.
For explosionproof enclosure:
* A seal shall be installed within 50 cm of the enclosure.
* Open circuit before removing cover.
For type Y purging:
unless all devices within the enclosure have been de-energized. Power must not be
restored after enclosure has been opened until enclosure has been purged for 12
minutes at a flow rate of 0.05m3/minute min.
* Remove power below 40mm (1.6in) of water column.
Take care not to generate mechanical spark when accessing to the instrument and periph-
eral devices in hazardous locations.
Do not press prick the keyboard of LCD panel (operation and display section) using such
as knives and sticks.
(10) Maintenance and Repair

The instrument modification or parts replacement by other than authorized representative
of Yokogawa Electric Corporation is prohibited and will void the approval of Factory Mutual
Research Corporation and CSA certification and CENELEC certification .

<Toc> <Ind> <Rev> <Introduction> xii
● Precautions Against Electrostatic Problems
The GC1000 system uses numerous IC components. When handling cards with IC
components mounted on them for maintenance or setting changes, take full precau-
tions against electrostatic problems.
These precautions are summarized below.
(a) When storing or carrying cards, enclose them in a conductive bag or antistatic
bag. (Cards as shipped by Yokogawa are enclosed in a conductive bag or
antistatic bag labeled with cautions against electrostatic problems.)
(b) Whenever mounting or demounting cards into or from a product, wear a wrist
strap grounded via a 1 MΩ resistance. Connect the wrist strap to any ground
terminal near the ground wire or to any unpainted part of the grounded frame.
Gard List strap

Sheet
List strap
1M‰
F0003.EPS
Using a wrist strap and conductive sheet Using a Conductive Sheet
(c) When servicing cards on the bench, place them on a conductive sheet
grounded via a 1 MΩ resistance, wearing a wrist strap as in (2) above. Keep
easily-chargeable plastic materials away from the bench.
(d) Never touch components mounted on the cards, the pattern side, connectors,
pin components, etc. with bare hands, unless using a wrist strap and a conduc-
tive sheet.
(e) Wrist straps and conductive sheets are available from Yokogawa Engineering
Service (YSV).
IM 11B03A03-04E
<Int> <Ind> <Rev> Toc-1
GC1000 Mark II Process Gas Chromatograph

Maintenance and Inspection Manual
IM 11B03A03-04E 2nd Edition
CONTENTS
◆ Notice ............................................................................................................ i
◆ Warning/Caution Labels ............................................................................... iii
◆ Introduction.................................................................................................. iv
1. Maintenance and Inspection ..................................................................... 1-1
1.1 Explosion-protection Structure .......................................................................... 1-1
1.2 Stopping the system .......................................................................................... 1-1
1.3 Routine Inspection ............................................................................................ 1-2
1.4 Replacing the Cylinders .................................................................................... 1-2
1.5 Leak Test .......................................................................................................... 1-2
1.6 Checking Chromatograms ................................................................................ 1-2
1.7 Recommended Parts List for Periodical Exchange ............................................ 1-3
2. Procedure for Replacing Parts .................................................................. 2-1
2.1 Precautions for Parts Replacement ................................................................... 2-1
2.2 Parts for Protection System ............................................................................... 2-2
2.2.1 Pressure Switch for Detecting Internal Pressure ............................... 2-3
2.2.2 Fuses ............................................................................................... 2-5
2.2.3 Relays .............................................................................................. 2-6
2.3 Components for Electronic Section ................................................................... 2-9
2.3.1 Replacing the Cards ......................................................................... 2-9
2.3.2 Replacing the LCD Unit .................................................................. 2-13
2.3.3 Replacing the Fuses ....................................................................... 2-14
2.3.4 Replacing the Solenoid Valves ........................................................ 2-15
2.3.5 Replacing the Pressure Switch for Carrier Gas ............................... 2-16
2.4 Components for Pressure/Flow Control Section .............................................. 2-17
2.4.1 Regulator Valve for Carrier Gas ...................................................... 2-17
2.4.2 Replace Valve for Other Gases ....................................................... 2-18
2.4.3 Replace Valve for Purge Air and Air for Solenoid-valve .................... 2-19
2.4.4 Pneumatic Valve for Atmospheric Balance ...................................... 2-21
2.4.5 Pneumatic Valve for High Speed Cooling Down .............................. 2-22
2.4.6 Vortex Tube .................................................................................... 2-23
2.4.7 Hydrogen Limiting Unit ................................................................... 2-24
2.5 Components for Isothermal Oven .................................................................... 2-25
2.5.1 Heater for Isothermal Oven ............................................................. 2-25

<Int> <Ind> <Rev> Toc-2
2.5.2 Temperature Sensor for Isothermal Oven ....................................... 2-27
2.5.3 Thermal Conductivity Detector (TCD) ............................................. 2-28
2.5.4 Flame Ionization Detector (FID) ...................................................... 2-30
2.5.5 Methane-converter ......................................................................... 2-32
2.5.6 Rotary Valve and Valve Sheet ......................................................... 2-33
2.5.7 Liquid-sample Valve (LSV) .............................................................. 2-39
2.5.8 Restrictors ...................................................................................... 2-45
2.5.9 Columns ......................................................................................... 2-46
2.5.10 Flame Arrester ................................................................................ 2-47
2.5.11 Gasket in Isothermal Oven ............................................................. 2-48
2.5.12 Air Turbine for Agitator Fan ............................................................. 2-49
2.5.13 Pneumatic Valve for Atmospheric Balance (Rotary Valve) ............... 2-50
2.6 Components for Programmed-temperature Oven ........................................... 2-52
2.6.1 Heater for Programmed-temperature Oven .................................... 2-52
2.6.2 Replacing Temperature Sensor for Programmed-temperature Oven 2-54
2.6.3 Replacing Columns ........................................................................ 2-55
2.6.4 Replacing Gaskets in Programmed-temperature Oven ................... 2-56
2.6.5 Replacing Air Turbine for Agitator Fan ............................................. 2-57
2.7 Components in Sample Processing System .................................................... 2-59
2.7.1 Replacing Sample Processing System ........................................... 2-59
2.7.2 Replacing the Valve for Balancing Atmospheric Pressure and/or Needle
Valve for Controlling Flowrate ......................................................... 2-61
2.7.3 Replacing the Flowmeter ................................................................ 2-62
2.7.4 Replacing the Pressure Gauge ....................................................... 2-64
2.7.5 Replacing the pneumatic valve for actuating external air supply ...... 2-65
2.7.6 Replacing the Pneumatic Valve for Balancing Atmospheric Pressure or
Stream Switching ............................................................................ 2-67
3. Troubleshooting ........................................................................................ 3-1
3.1 Common Procedure of Troubleshooting ............................................................ 3-1
3.2 Troubleshooting Diagram for Abnormal Analysis Result .................................... 3-2
3.2.1 Abnormal Component Concentration Value ...................................... 3-2
3.2.2 Abnormal Retention Time ................................................................. 3-3
3.2.3 Abnormal Chromatogram ................................................................. 3-4
3.2.4 Column system failure ...................................................................... 3-8
◆ Revision Record ............................................................................................ i

<Toc> <Ind> <1. Maintenance and Inspection > 1-1
1. Maintenance and Inspection
1.1 Explosion-protection Structure

Whenever performing maintenance on the GC1000 process gas chromatograph, first
inspect the system according to the instructions given in Table 1.1 to ensure that explosion-
protection conditions are maintained. If the following problem occurs, contact YOKOGAWA
service center:
(1) Damage around the setscrews on the protection system (explosion-proof structure).
(2) Damage to any enclosure surface or transparent part.
(3) Any crack or excessive deformation to any of the gaskets.
Table 1.1 Maintenance and Inspection
Item Method Criterion Corrective Action
Enclosure Visual Free from damage Contact YOKOGAWA
Transparent part Visual No damage Contact YOKOGAWA
Setscrew Visual and by touch No looseness, dust or rust Retighten and clean,
or contact YOKOGAWA
Gaskets Visual No cracks or excessive deformation Contact YOKOGAWA
Cable inlet Visual and by touch No damage, deterioration or looseness Retighten or replace
Terminal Visual by touch No looseness or dirt on insulators Retighten , parts
change and clean
T0101.EPS
1.2 Stopping the system

Unless in case of emergency, stop the system by Basic Operation and Start up Manual (IM
11B03A03-02E) before turning off the power.

1.3 Routine Inspection

The routine maintenance inspection must be done according to Table 1.2. In the inspection,
confirm that all of the readings are consistent with the values indicated in the operation
data. These readings, if previously entered on the “Operation Condition”, can also be
confirmed on that screen.
Since these inspection items vary depending on the instrument specifications, select the
required items according to the specifications.
Table 1.2 Inspection Items
Recommended
Item Interval
Reading of pressure gauge on carrier gas cylinder 24 hours
Reading of carrier-gas pressure gauge 24 hours
Reading of sample-gas pressure gauge 24 hours
Reading of sample-gas flowmeter 1 to 7 days
Reading of sample-gas bypass flowmeter 1 to 7 days
Reading of purge-air pressure gauge 24 hours
Readings of pressure gauges on the hydrogen gas for combustion and nitrogen gas cylinders 1 to 7 days
Readings of pressure gauges for hydrogen gas for combustion and nitrogen gas 1 to 7 days
Reading of pressure gauge for combustion air 24 hours
Current temperatures of isothermal and programmed-temperature ovens, etc. 1 to 7 days
Calibration coefficient 1 to 7 days
T0102.EPS
1.4 Replacing the Cylinders

After replacing the carrier gas, FID or FPD hydrogen gas for combustion, air, or standard
gas cylinder, always perform a leak test on the couplings around the pressure-reducing
valves on the cylinder. The leak test must be performed two or three times within three
days after replacing a cylinder.
1.5 Leak Test

After replacing or repairing any of the parts for piping or those located inside or outside the
instrument, always check the connections for possible leaks. This checkup procedure is
called a leak test.
During the leak test, keep the pipes pressurized, apply soap water (“Snoop” or an equiva-
lent) to the connections, then check for possible leaks. If a leak was found, retighten the
connection or replace any defective parts. Any leak may cause bad analysis result or
increase of consumption of unilities.
1.6 Checking Chromatograms

After replacing any of the parts of the system, resume operation, record several chromato-
grams, then compare the results with those shown in the Operation Data.

1.7 Recommended Parts List for Periodical Exchange

Following is a list of parts that will be necessary to exchange periodically and their standard
exchange cycle.
The exchange cycle differs depending on the process sample specifications and the
condition of use, so please exchange parts according to the adequate cycle to your
GC1000 Mark II. It is recommended that the actual exchange term will be decided by the
customer’s experience.
Table 1.3 Recommended Parts List for Periodical Exchange
Item Name Part Number Exchange Period Note
Rotary Valve Valve Seat K9034ZA 100-thousand times CSW(Rulon) (K9034DNx2)
K9034FF 0.33µL(Rulon)
K9034ZE 1µL(Rulon) (K9034DSx2)
K9034ZD 2µL(Rulon) (K9034DRx2)
K9034ZC 3µL(Rulon) (K9034DQx2)
K9034ZB Over 10µL(Rulon) (K9034DPx2)
K9034FR CSW(Teflon)
K9402XX 0.33µL(Teflon)
K9034FL 1µL(Teflon)
K9034FK 2µL(Teflon)
K9034FJ 3µL(Teflon)
K9034FH Over 10µL(Teflon)
Valve Gland K9034BA 5-years CSW(SUS316)
K9034BP 0.33 to 3µL(SUS316)
K9034BJ 10µL(SUS316)
K9034BH 25µL(SUS316)
K9034BG 50µL(SUS316)
K9034BB Over 100µL(SUS316)
K9034GX CSW(Hastelloy)
K9034GV 0.33 to 3µL(Hastelloy)
K9034GS 25µL(Hastelloy)
K9034GR 50µL(Hastelloy)
K9034GN Over 100µL(Hastelloy)
Liquid Sampling Valve Seal Element K9402VG 50-thousand times Rulon
K9402VH Teflon
O-ring K9402UN 2-years
Filter Element L9862AG 1-year
Gasket L9862AC 1-year
L9862AD
Stream Switching Valve Diaphragm K9192WL 3-years Viton & Teflon
K9192WV Silicone & Teflon
T0103.EPS

Table 1.4 Recommended Parts List for Periodical Exchange
Exchange
Item Name Part Number Note
Period
Oven Heater K9409GE 5-years Isothermal Oven, 100V Explosion-proof Enclosure: 1
K9409GF Isothermal Oven, 110V Explosion-proof Enclosure: 1
K9409GG Isothermal Oven, 115V Explosion-proof Enclosure: 1
K9409GH Isothermal Oven, 120V Explosion-proof Enclosure: 1
K9409GN Isothermal Oven, 100V Explosion-proof Enclosure: 2
K9409GP Isothermal Oven, 110V Explosion-proof Enclosure: 2
K9409GB Isothermal Oven, 115V Explosion-proof Enclosure: 2
K9409GC Isothermal Oven, 120V Explosion-proof Enclosure: 2
K9409GS Isothermal Oven, 200V
K9409GT Isothermal Oven, 220V
K9409GU Isothermal Oven, 230V
K9409GV Isothermal Oven, 240V
K9409GA 2-years Programmed Temperature Oven, 100V
K9409GB Programmed Temperature Oven, 110V
K9409GC Programmed Temperature Oven, 115V
K9409GD Programmed Temperature Oven, 120V
K9409GE Programmed Temperature Oven, 200V
K9409GF Programmed Temperature Oven, 220V
K9409GG Programmed Temperature Oven, 230V
K9409GH Programmed Temperature Oven, 240V
Turbine K9400FA 5-years
Packing K9407NB 5-years For GC1000S/E/C
K9407NA For GC1000D/T/W
Vortex tube L9872BM 5-years
T0104.EPS

<Toc> <Ind> <2. Procedure for Replacing Parts > 2-1
2. Procedure for Replacing Parts

2.1 Precautions for Parts Replacement
(1) Always observe the instructions in this manual when replacing parts.
(2) When disconnecting pipes, do not allow any oil or moisture to get inside the pipes.
(3) When cleaning the inside of a pipe, do not use any solvent containing non-volatile
impurities, since this will contaminate the inside of the pipe, prevent normal analysis,
and possible necessitate parts replacement to restore the system to normal. When the
pipes need to be cleaned with a solvent, use highly-pure acetone.
(4) After replacing piping parts, always perform the leak test.
This section shows that how to exchange the maintenance parts which is used in the
section below.
(A) Protection system
(B) Electronic section
(C) Pressure and flow sontorol section
(D) Isothermal oven
(E) Programmed-temperature oven (only GC1000D/T/W)
(F) Analyzer base sampling section (GCSM)
Display Explosion proof enclosures
(number depends on
specifications)
(A) Protection system
(B) Electronic section

Terminal section
(D) Isothermal oven

(E) Programmed-temperature
oven
(C) Pressure and
flow control section
(F) Analyzer base

sampling section
F0201.EPS
Figure 2.1
Comfirm the location of the replacement parts which is housed by Figure 2.1.
2.2 Parts for Protection System

Here shows the instruction of following replacing parts in the explosion proof Enclosure.
1. Pressure switch
2. Fuse
3. Relay and Relay board
There are 2 types of the explosion proof enclosure as follws (Figure 2.2) for GC1000 Mark
II. No enclosure mounted for the type of FM/CSA Y-purge.
Status display Status display
(a) 1 piece of the enclosure (b) 2 pieces of the enclosure

F0202.EPS
Figure 2.2

2.2.1 Pressure Switch for Detecting Internal Pressure

This pressure switch detects the internal pressure in the electronic section and isothermal
and programmed-temperature (GC1000D/GC1000T/GC1000W) ovens. Three pressure
switches are installed on the GC1000D/GC1000T/GC1000W and two on the GC1000S/
GC1000E/GC1000C, and all are provided on the protection system equipped with a status
display. These switches are set such that they are turned off at 392±20 Pa.
Pressure switch Pressure switch

GC1000D/T/W GC1000S/E/C
F0203.EPS
Figure 2.3
[1] Stop the system.

[2] Turn off the power.
[3] Confirm that the LEDs which display the status on the protection system are all off.
CAUTION
The isothermal oven is extremely hot immediately after turning off the power. Keep the
protection gas supplied for more than an hour after turning off the power. Keep hands away
from the oven components.
[4] Turn off the protection gas.

[5] Loosen the locknut on the cover for the protection system with the status display, then
remove the cover.
[6] Remove the cover from the pressure switch.
[7] Disconnect the two wires connected to the pressure switch. Each wire is labeled with
a number. Be sure to note the number and corresponding location of each wire before
removal.
[8] Disconnect the three pipes connected to the pressure switch. Each pipe other than
those provided between the switches is labeled with a number. Be sure to note the
number and corresponding location of each pipe before removal. Note that the switch
on the far left has an insertion pin for the stop plug on one side of the secondary stage.
[9] Remove the setscrews from the pressure switch.
[10] Install a new switch in the reverse order of steps [7] to [10].
[11] After checking that the piping and wiring are correct, confirm that there are no leaks in
the piping.
[12] Replace the cover on the protection system. Fully rotate the cover until it stops, rotate
it back so the locknut is positioned in place, then tighten the locknut.

<Replacement Parts>
K9401JG
Cover
Setscrews (two)
Primary stage
Secondary stage
Secondary stage
Wires
Ultrasonic fusion
F0204.EPS
Figure 2.4 Pressure Switch for Detecting Internal Pressure

2.2.2 Fuses
The fuses discussed here are installed in the power line to the protection system. The fuses
are housed in the capsule of the protection system on the far right.
CAUTION
[4] Loosen the locknut on the cover of the protection system on the far right, then remove
the cover.
[5] The fuse holder which contains the fuses is fixed either on the front or on the right side
of the unit, depending on the specifications (see the figure below). Make sure where
the fuse holder is installed.
[6] Hold the fuse holder cap as shown in the following figure, then remove the cap.
[7] Replace the fuse in the fuse holder cap with a new one.
Fuse rating Dimensions : ø5.2 x 20 mm
Rated voltage : 250V AC
Rated current : 0.5 A
Pre-arcing time : Normal/FAST
[8] Confirm that the fuse is securely installed in the cap.
[9] Replace the cap on the fuse holder. Push the cap into the fuse holder until it locks with
a click.
[10] Confirm that the cap is firmly installed on the fuse holder.
<Replacement Parts>
S9557VK
Fuses
F0205.EPS
Figure 2.5

2.2.3 Relays
There are two types of relays as follows, depending on the specifications.
When the protection system with the status display is located on the far right: Refer to (A).
When the protection system with the status display is located second from the far
right:Refer to (B).
(A) When the protection system with the status display is located on the far right, the
relays are all installed in that unit.
(B) When the protection system with the status display is located second from the far
right, the relays are all installed in that unit.
(1) Relay bord

CAUTION
[4] Loosen the locknut on the cover for the protection system on the far right, then remove
the cover.
[5] Remove all the connectors attached to the five locations on the relay board, labeling
them for ease of identification later.
[6] Remove the two screws on the neck of the metal fitting, then dismount the whole
assembly of the relay board and metal fitting from the capsule.
[7] Remove the relay from the socket on the relay board, then replace it with a new one.
Push the relay into the socket until it locks with a click.
[8] Confirm that the relay is firmly installed in the socket.
[9] Replace the whole assembly of the relay board and metal fitting into the capsule.
[10] Attach the connectors to the relay board.
[11] Confirm that the connectors are placed in the correct locations.
[12] Confirm that the metal fitting equipped with the relay board is securely installed in the
capsule.
<Replacement Parts>
K9633AA (GC1000D/T)
K9633AB (GC1000S/E)

Relay board
F0206.EPS
Figure 2.6
(2) Relays
[3] Confirm that the status display LEDs on the protection system are all off.
CAUTION
[4] Loosen the locknut on the cover of the protection system on the far right, then remove
the cover.
[5] Remove the relay from the socket on the metal fitting, then replace it with a new one.
Push the relay into the socket until it locks with a click.
[6] Confirm that the relay is firmly installed in the socket.
<Replacement Parts>
A1740MR (100V)
A1741MR (200V)

Relay
F0207.EPS
Figure 2.7

2.3 Components for Electronic Section

2.3.1 Replacing the Cards
Replacement cards are preadjusted at YOKOGAWA before shipment and should therefore
be installed as received. Observe the following precautions when replacing cards.
[2] Turn OFF the power to the system.
[3] Open the door of electronic section by hexagonal wrench.
CAUTION
• Do not remove or insert cards while the power is ON, because it may cause malfunc-
tions.
• Cards are installed in the pressurized, explosion-proof/type X purged protection
endosure. After replacement, return the unit to its original conditions to maintain the
explosion-proof/type X purging condition.
• Always hold the handle of a card when removing or inserting it.
[4] Disconnect the cables to the card, if any.

[5] Hold the handle of a card and pull it out from the rack.
CAUTION
• Always install a new card in the place of the card being replaced. If the new card is
inserted in the wrong slot, the card may malfunction.
• The name of the card is labeled on both the upper section of the rack and the front
side of the card. Insert the card into the correct slot.
• Never modify a card in an attempt to give it different functions.
[6] Install a new card in the place of the card being replaced.
[7] Close the door of electronic section.
[8] Reconnect the cables, if any.

<Replacement Parts>
1 K9633CB Marshaling board (for JIS, FM X-purge, CSA X-purge, without LSV)
K9633CC Marshaling board (for JIS, FM X-purge, CSA X-purge, with LSV)
K9633DB Marshaling board (for FM Y-purge, CSA Y-purge, GC1000S/E/C, without LSV)
K9633DC Marshaling board (for FM Y-purge, CSA Y-purge, GC1000S/E/C, withLSV)
K9633DE Marshaling board (for FM Y-purge, CSA Y-purge, GC1000D/T/W)
2 K9633EA Communication board (for PC communication)
K9633EB Communication board (for DCS, GCCU communication)
K9633EC Communication board (for AO)
3 K9633GA Temperature IF board (for GC1000D/T/W)
K9633GB Temperature IF board (for GC1000S/E/C, with LSV)
4 K9633JA EV IF board
5 K9633LA Hub TP board(dual channel, with power off signal)
K9633LB Hub TP board(dual channel, without power off signal)
K9633LC Hub TP board(single channel, with power off signal)
K9633LD Hub TP board(singlel channel, without power off signal)
6 K9633PA FPD Amp board
7 K9633QA AO mother board
8 K9633RA AO board (no isolation type)
K9633RB AO board (isolation type)
9 K9633SA AO terminal board
10 K9633TA Pressure monitor board (for CENELEC, without analog input)
K9633TB Pressure monitor board (for JIS, FM X-purge, CSA X-purge, without analog input)
K9633TC Pressure monitor board (for CENELEC, with analog input)
K9633TD Pressure monitor board (for JIS, FM X-purge, CSA X-purge, with analog input)
11 K9633UA AI terminal board
12 K9634BA Back board
13 K9634CA CPU card (for T1, T2)
K9634CB CPU card (for T3)
K9643CC CPU card (for T4)
14 K9634DA TCD card (standard)
15 K9634EA FID card (standard)
K9634EB FID card (FID+methane converter)
16 K9634FA FPD card (standard)
17 K9634GA Anabus card (for dual channel)
K9634GB Anabus card (for single channel)
18 K9634JA Temperature card (for GC1000D/T/W, T1)
K9634JB Temperature card (for GC1000D/T/W, T2)
K9634JC Temperature card (for GC1000D/T/W, T3)
K9634JD Temperature card (for GC1000D/T/W, T4)
K9634JE Temperature card (for GC1000S/E/C, with LSV, or FPD, T2)
K9634JF Temperature card (for GC1000S/E/C, with LSV, or FPD, T3)
K9634JG Temperature card (for GC1000S/E/C, with LSV, or FPD, T4)
19 K9634KA AI card (for voltage input, 1 - 5 V)
K9634KB AI card (for current input, 4 - 20 mA)
Replacement cards located at Figure 2.8 to 2.12.

2 1 5 F0208.EPS
Figure 2.8
4 3
F0209.EPS
Figure 2.9

6 14 15 16 19 17 18 13
12
F0210.EPS
Figure 2.10
7
F0211.EPS
Figure 2.11
10
11
F0212.EPS
Figure 2.12

2.3.2 Replacing the LCD Unit

(1) Shut down the system and turn the power OFF.
(2) Open the door of the electronic section with a wrench.
(3) Remove the five cable connectors attached to the LCD unit.
(4) Loosen the 12 screws around the LCD unit, then remove the LCD unit together with
the mounting bracket.
(5) Loosen the screws at the four corners on the front face of the LCD unit, then remove
the LCD unit itself. Screws, spacers and other associated parts are used again, take
care not to lose them.
(6) Secure the new LCD unit to the mounting bracket with the screws, then mount it onto
the door of the electronic section. Tightly fasten all of the 12 screws to maintain the
explosion-proof condition.
(7) Install the five cable connectors to the position being removed.
(8) Close the door of the electronic section.
<Replacement Parts>
K9633NA
LCD unit
F0213.EPS
Figure 2.13

2.3.3 Replacing the Fuses
Table 2.1
(a) (b) (c)
Parts number A1513EF A1543EF A1542EF S9540VK
Rated voltage 250V AC 250V AC 250V AC 250V AC
Rated current 5A 30A 15A 15A
Pre-arcing time TIME LAG NORMAL NORMAL NORMAL
T0201.EPS
The replacing procedure is as follows.
In case of item (a)

(2) Confirm that the status display LEDs on the protection system are all off.
(3) Remove the six screws on the power unit cover with a wrench, then remove the cover.
(4) Remove the fuse holder cap by rotating it counterclockwise.
(5) Remove the fuse to be replaced from the cap and install a new one.
(6) Install the cap equipped with a fuse in the fuse holder. Press the cap and apply pres-
sure in a clockwise motion to install it.
(7) Confirm that the cap is securely installed in the fuse holder.
(8) Attach the power unit cover. Tightly fasten all of the six screws to maintain the explo-
sion-proof condition.
In case of item (b) or (c)

(2) Confirm that the status display LEDs on the protection system are all off.
(3) Remove the six screws on the power unit cover with a wrench, then remove the cover.
(4) Replace tha fuse. It can be replaced by pulling out.
(5) Attach the power unit cover. Tightly fasten all of the six screws to maintain the explo-
sion-proof condition.
(a)
(b)
(c)
F0214.EPS
Figure 2.14

2.3.4 Replacing the Solenoid Valves

(1) Shut down the system and turn the power off.
(2) Turn off the purge air.
(3) Remove the six screws on the terminal cover (located on the right) with a wrench, then
remove the cover itself. (Take care not to get the cover upside-down.)
(4) Remove the connector at the tip of the cable for the solenoid valve to be replaced from
the terminal.
(5) Label the new solenoid valve with the number, then use marking seal on the valve
removed.
(6) Remove the two screws on the front side of the solenoid valve, then remove the
solenoid valve itself.
(7) Replace the solenoid valve and gasket with new ones.
(8) Fasten the two screws on the front side of the solenoid valve.
(9) Insert the connector at the tip of the cable on the solenoid valve.
(10) Firmly tighten all of the six screws on the terminal cover to maintain the explosion-
proof condition.
<Replacement Parts>
K9409DS
Solenoid valves
Terminal F0215.EPS
Figure 2.15

2.3.5 Replacing the Pressure Switch for Carrier Gas

(2) Turn off the carrier gas.
(3) Remove the six screws on the terminal cover (located on the right) with a wrench, then
remove the cover itself. (Take care not to get the cover upside-down.)
(4) Remove the connector at the tip of the cable for the pressure switch to be replaced
from the marshaling board.
(5) Open the door of the pressure/flow control section.
(6) Remove the pressure switch.
(7) Install a new pressure switch.
(8) Insert the connector at the tip of the cable on the pressure switch.
(9) Firmly tighten all of the six screws on the terminal cover to maintain the explosion-
proof condition.
(10) Close the door of the pressure/flow control section
<Replacement Parts>
K9630LA
Pressure switch for carrier gas

F0216.EPS
Figure 2.16

2.4 Components for Pressure/Flow Control Section

2.4.1 Regulator Valve for Carrier Gas
The regulator valve for the carrier gas, which is installed in the isothermal oven, is used to
control the carrier gas pressure (see Figure 2.17).
[2] Turn off the power supply.
CAUTION
The isothermal oven is extremely hot immediately after turning off the power.
Keep the protection gas supplied for more than an hour after turning off the power. Keep
hands away from the oven components.
[3] Turn off the supplies of the carrier and other gases (FID hydrogen gas for combustion
and FID combustion air) and supply of samples.
[4] Open the door
[5] Remove the couplings connected to the inlet (IN) and outlet (OUT) of the regulator
valve (see Figure 2.17). Label the couplings for ease of identification later.
[6] Remove the stem lock then remove the stem itself.
[7] Remove the mounting locknut then remove regulator valve.
[8] Install a new regulator valve in the reverse order of steps [5] to [7].
[9] Start supplying the carrier and other gases, then perform a leak test around the
couplings.
[10] Set the carrier gas pressure to the value indicated in the operation data. Adjust and
set the pressure by loosening the stem lock then rotating the stem. After completing
the setting, fix the stem with the locknut.
[11] Close the door
<Replacement Parts>
Applicable Temperature Range O-ring
K9409AW below 180°C Viton
K9409AV below 225°C Kalrez
regulation valve for Mounting locknut Stem lock

carrier gas
Stem
pressure regulator section

isothermal oven F0217.EPS
Figure 2.17 Regulator Valve for Carrier Gas

2.4.2 Replace Valve for Other Gases

The regulator valve for other gases, which is installed in the pressure/flow control section,
is used to control the pressures of the FID hydrogen gas (or nitrogen) for combustion and
FID combustion air (see Figure 2.18).
CAUTION
[3] Turn off the supplies of the FID hydrogen (or nitrogen) gas for combustion, FID com-
bustion air, and carrier gas.
[4] Open the door of isothermal oven.
[5] Remove the couplings connected to the inlet (IN) and outlet (OUT) of the regulator
valve (see Figure 2.18). Label the couplings for ease of identification later.
[6] Remove the stem lock then the stem itself.
[7] Remove the mounting locknut then the regulator valve.
[8] Remove the pressure gauge from the regulator valve.
When reinstalling the pressure gauge, always use sealing tape.
[10] Start supplying the FID hydrogen (or nitrogen) gas for combustion, FID combustion
air, and carrier gas, then perform a leak test around the couplings.
[11] Set the pressure of the line where the regulator valve has been replaced to the value
indicated in the operation data.
Adjust and set the pressure by loosening the stem lock then rotating the stem.
After completing the setting, fix the stem with the locknut.
[12] Close the door of isothermal oven.
<Replacement Parts>
K9409AW
Washer Pressure gauge regulator valve

Stem lock
Stem
IN
OUT
Mounting locknut
Mounting plate F0218.EPS
Figure 2.18 Regulator Valve for Gases

2.4.3 Replace Valve for Purge Air and Air for Solenoid-valve
The regulator valve for purge air and air for solenoid valve, which is installed in the pres-
sure/flow control section, is used to control the pressures of the protection gas, solenoid-
valve air and vortex tube air (see Figure 2.19).
CAUTION
[3] Turn off the supply of the protection gas and disconnect all of the tubes connected to
the manifold regulator valve. When disconnecting the tubes, label them for ease of
identifying the connections later (see Figure 2.19).
[4] Remove the coupling on the 1/16” tube connected to the lower part of the manifold
regulator valve.
[5] Remove the two screws on the mounting bracket which fix the manifold regulator
valve.
[6] Remove the two screws on the back of the mounting bracket which fix the manifold
valve to the mounting bracket.
[7] Remove the conversion coupling connected to the lower part of the manifold pres-
sure-reducing valve.
When reinstalling the conversion coupling, always use sealing tape.
[9] Confirm that the pipe connections are correct, then check the piping for leaks.
[10] Set the pressures of the protection gas, solenoid-valve air, as well as the air for the
vortex tube or quick-refrigeration pneumatic valve to the values indicated in the
operation data. Adjust and set the pressure by rotating the knob; the knob locks when
it is pressed in. When adjusting the pressure, pull the knob out if it is locked, then after
completing the setting, press and lock the knob.
<Replacement Parts>
L9850CD 3-valves
L9850CC 4-valves
L9850CD 5-valves
L9850CE 6-valves

Knob
Tube
Bracket
Screw for mounting

bracket
Conversion coupling
1/16” coupling
F0219.EPS
Figure 2.19 Regulator Valve for Air Purge and Air for SolenoidValve

2.4.4 Pneumatic Valve for Atmospheric Balance

See Figure 2.20.
CAUTION
The isothermal oven isextremely hot immediately after turning off the power. Keep the
[3] Turn off the supply of the protection and sample gases, then disconnect the pipe
connected to the pneumatic valve for the atmospheric pressure balancing.
[4] Remove the two screws which fix the mounting bracket.
[5] Remove the two screws on the back side of the mounting bracket which fix the pneu-
matic valve for the atmospheric pressure balancing.
[6] Remove the conversion coupling connected to the inlet (IN) and the outlet (OUT) of
the pneumatic valve for the atmospheric pressure balancing.
[7] Install a new pneumatic valve for the atmospheric pressure balancing in the reverse
order of steps [3] to [6].
When reinstalling the conversion coupling, always use sealing tape.
[8] Confirm that the pipe connections are correct, then perform a leak test.
<Replacement Parts>
K9192WP
Mounting screw (four)
Needle valve for sampling rate control
Pneumatic valve for atomospheric balabce
F0220.EPS
Figure 2.20 Pneumatic Valve for Atmospheric Balance

2.4.5 Pneumatic Valve for High Speed Cooling Down

See Figure 2.21.
CAUTION
[3] Turn off the supply of the protection gas, then disconnect all of the tubes connected to
the pneumatic valve for high speed cooling down.
[4] Remove the two setscrews which fix the pneumatic valve for high speed cooling
down.
[5] Remove the four connectors attached to the pneumatic valve for high speed cooling
down.
[6] Install a new pneumatic valve for high speed cooling down in the reverse order of
steps [3] to [5].
[7] When reinstalling the connectors, always use sealing tape.
Confirm that the pipe connections are correct, then check the piping for leaks.
<Replacement Parts>
L9860AW
Connector
Setscrew
F0221.EPS
Figure 2.21 Pneumatic Valve for High Speed Cooling Down

2.4.6 Vortex Tube

See Figure 2.22.
CAUTION
[3] Turn off the supply of the protection gas, pull out the tube connected to the vortex tube
assembly, then remove the coupling on the pipe.
[4] If a regulator valve is attached to the metal fitting for a vortex tube, then remove both
tubes connected to the regulator valve.
[5] Remove the two setscrews from the metal fitting.
[6] Remove the two setscrews which fix the vortex tube to the metal fitting.
[7] Install a new vortex tube in the reverse order of steps [3] to [6].
[8] Confirm that there are no leaks.
<Replacement Parts>
K9400VZ
Body
Vortex tube
Connector
Bracket
Mounting
bracket
F0222.EPS
Figure 2.22 Vortex tube

2.4.7 Hydrogen Limiting Unit

The hydrogen limiting unit comprises a mass-flow controller, pneumatic valve and regulator
valve. This unit can set a limit on the flow of hydrogen or shut it down. The flow of hydrogen
is regulated to 300ml/min by the mass-flow controller. In addition, if the system cannot
maintain the required pressurized-construction, explosion-proof/type X purging perfor-
mance (if the internal pressure cannot be maintained at the specified level), it delivers a
signal to actuate the pneumatic valve, shutting down the hydrogen gas supply.
CAUTION
[3] Turn off the supplies of the FID hydrogen (or nitrogen) gas for combustion, FID com-
bustion air, and carrier gas, then remove the three couplings on the pipe connected to
the hydrogen limiting unit.
[4] Remove the four setscrews which fix the hydrogen limiting unit.
[5] Install a new hydrogen limiting unit in the reverse order of steps [3] and [4].
[6] Confirm that the pipe connections are correct, then check the piping for leaks.
[7] Set the pressure of the regulator valve at the hydroger limiting unit to 490 kPa .
<Replacement Parts>
K9630MA Hydrogen Limiting Unit
Regulator
Connector
Connector Mounting screw (two) F0223.EPS
Figure 2.23 Hydrogen Limiting Unit

2.5 Components for Isothermal Oven

2.5.1 Heater for Isothermal Oven
The heater for the isothermal oven is a nichrome wire which regulates the temperature of
the Isothermal oven.
CAUTION
[3] Turn off the protection gas supply.

[4] Remove the four screws, then the fan cover.
[5] Remove the temperature sensor from the heater cover, then bend the sensor so the
heater cover can be removed.
[6] Remove the four screws, then the heater cover.
[7] Remove the locknuts which fix the terminals on both sides of the heater, then pull out
the heater through the heater guide.
[8] Hold both ends of the new heater and stretch it to about 500mm long.
Make sure that the heater is extended evenly (see Figure 2.24).
[9] Reinstall the new heater. Confirm that the heater is not sagging.
[10] Reinstall the heater cover, temperature sensor and fan cover in the reverse order of
steps [4] to [6]. When reinstalling the temperature sensor, make sure that it does not
touch the fan or fan cover.
<Replacement Parts>
Supply voltage
K9409GN 100V AC (Isothermal oven temperture over 145°C)
K9409GE 100V AC
K9409GP 110V AC (Isothermal oven temperture over 145°C)
K9409GF 110V AC
K9409GB 115V AC (Isothermal oven temperture over 145°C)
K9409GG 115V AC
K9409GC 120V AC (Isothermal oven temperture over 145°C)
K9409GH 120V AC
K9409GS 200V AC
K9409GT 220V AC
K9409GU 230V AC
K9409GV 240V AC

Setscrew for fan Fan Fan cover Temperature sensor
Plate for
holding
Gasket
Setscrew for Setscrew for

fan cover heater cover
Temperature Nut
sensor Washer
Terminal
Heater
Approx.
500mm
F0224.EPS
Figure 2.24 Heater for Constant-temperature Oven

2.5.2 Temperature Sensor for Isothermal Oven

The temperature sensor for the isothermal oven is a platinum resistance temperature
detector (Pt100 ohm), and it regulates the temperature of the isothermal oven.
CAUTION

[4] Remove the four screws on the fan cover then the fan cover itself.
[6] Remove the four screws on the heater cover, then the heater cover itself.
[7] Remove the locknuts which fix the terminals on the temperature sensor, then the
temperature sensor itself.
[8] Reinstall a new sensor.
<Replacement Parts>
K9400YV For control (Explosion-proof Enclosure: 1)
K9400YW For protected temperature (Explosion-proof Enclosure: 1)
K9400ZY For control (Explosion-proof Enclosure: 2)
K9400ZZ For protected temperature (Explosion-proof Enclosure: 2)
Unit: mm
F0225.EPS
Figure 2.25 Temperature Sensor

2.5.3 Thermal Conductivity Detector (TCD)

There are two types of thermal conductivity detector, low temp. type or high temp. type. The
low temp. type can be used for either normal or corrosion-resistant type. Figure 2.26 shows
the external view of a low temp. type of thermal conductivity detector.
• Replacing the low temp. type of TCD

CAUTION
[3] Turn off the supply of the protection, carrier and sample gases.
[4] Remove the four couplings connected to the TCD. When removing the couplings,
label them for ease of identifying the connections later.
[5] Remove the four wires connected to the TCD.
[6] Remove the two setscrews which fix the TCD.
[7] Install a new TCD.
[8] Reconnect the wires and pipes in the reverse order of steps [4] to [6], then confirm the
wiring and perform a leak test.
• Replacing the high-temp. type of TCD

CAUTION
[4] Remove the four couplings connected to the TCD. When removing the couplings,
[5] Remove the wires connected to the TCD card from the connectors, then bring them
through the bushing hole into the constant-temperature oven.
[6] Remove the two setscrews which fix the TCD.
[7] Install a new TCD.

<Replacement Parts>
Low temp. type K9192QA For normal type (Material: Alminium)
K9192QB For corrosion-resistant type (Material: SUS316)
K9192QJ For high-sensitive type (Material: Alminium)
K9192QL For high-sensitive and corrosion-resistant
type (Material: SUS316)
High temp. type K9192SB (Material: SUS316)
Normal type Corrosion-resistant type
Mounting
screws
F0226.EPS
Figure 2.26 TCD

2.5.4 Flame Ionization Detector (FID)

There are two types of flame ionization detector, low temp. type or high temp. type. Each
type can be used for corrosion-resistant applications. Figure 2.27 shows the external view
of a low temp. type of flame ionization detector.
• Replacing the low temp. type of FID

CAUTION
[3] Turn off the supply of the protection gas, carrier gas, hydrogen (or nitrogen) gas for
combustion, combustion air, and sample gas.
[4] Remove the three couplings connected to the FID. When removing the couplings,
[5] Remove the four wires connected to the FID.
[6] Remove the two setscrews which fix the FID.
[7] Install a new FID.
• Replacing the high-temp. type of FID

CAUTION
[4] Remove the three couplings connected to the FID. When removing the couplings,
[5] Remove the wires connected to the FID card from the connectors.
[6] Remove the two setscrews which fix the FID.
[7] Install a new FID.

<Replacement Parts>
Low temp. type K9194XA For normal type (Material: SUS316)
K9194XB For corrosion-resistant type (Material: Hastelloy C)
High temp. type K9402RA For normal type (Material: SUS316)
K9402RD For corrosion-resistant type (Material: Hastelloy C)
Mounting screws
F0227.EPS
Figure 2.27 FID

2.5.5 Methane-converter
The methane-converter is used in conjunction with the FID to measure low-concentration
carbon monoxide or dioxide. See Figure 2.28.
CAUTION
[4] Remove the two couplings connected to the methane-converter. When removing the
couplings, label them for ease of identifying the connections later.
[5] Remove the two wires connected to the terminals of the methane-converter.
[6] Remove the two setscrews which fix the methane-converter, then the methane-
converter itself.
[7] Install a new methane-converter.
<Replacement Parts>
K9192TG
Screw
In
Heater terminals
Out
Screw
F0228.EPS
Figure 2.28 Methane converter

2.5.6 Rotary Valve and Valve Sheet

The rotary valve, which is located in the isothermal oven, is used as a sampling, column-
switching, or backflush valve. It can be used for either general-purpose or high-temperature
applications.
Table 2.2
Model Suffix code Option code Description
GCRV Rotary valve
Bellows -G Rubber
material -M Metal
O-Ring B Viton
material K Kalrez
Valve material A Gas sampling
B Liquid sampling
C Back flash & column switching
D Gas sample (for GC6)
E Liquid sample (for GC6)
F Back flash & column switching (for GC6)
Sheet material R Rulon
T Teflon
Grand material S SUS316
H Hastelloy C
Sample volume of A side N Not provided
C Switching valve
1 Liquid sample: 0.33 µl
2 Liquid sample: 1 µl
5 Gas sample: 10 µl
8 Gas sample: more than 100 µl
Sample volume of B side N Not provided
C Switching valve
1 Liquid sample: 0.33 µl
8 Gas sample: more than 100 µl
Purge/Suction N Not provided
Yes/No P Purge
E Suction
T0202.EPS

• Replacing the rotary valve
[2] Turn off the supply of the sample.
[3] If the system is equipped with a stream switching valve, set the operation mode to
manual mode, then actuate the stream switching valve for the sample processing
system to be replaced so the valve is left open.
[4] If the sample is liquid, purge the sampling line with the carrier or forced-feed gas after
turning off the supply of the sample.
[5] Close the stream switching valve.
CAUTION
combustion if an FID is used, and combustion air.
[8] Remove the coupling connected to the rotary valve. When removing the couplings,
label them for ease of identifying the connections later. The rotary valve is either a
single-sleeve or double-sleeve valve, depending on the specifications.
Each type comprises four to six pipes extending from the sleeve.
[9] Remove the two screws which are not painted with red enamel to disassemble the
rotary valve. Do not touch the two screws which are painted red.
[10] Install a new rotary valve, bending the pipe as shown in Figure 2.29, using a pipe of
approximately 10mm diameter to support it to avoid excessive force on the neck of the
pipe being bent. The cap nut at the tip of the pipe is stamped with a number. Engage
the cap nut with the counterpart referring to the number previously labeled or the
diagram of the column system in the operation data.
[11] Perform a leak test on the piping.
1.6 mm dia. tube
10 mm dia. pipe
Rotary valve mounting screw

Do not loosen the
screws coated with
red enamel
Sampling valve Column switching valve Backflush valve F0229.EPS
Figure 2.29 Rotary Valve

• Replacing the gland
See Figure 2.30.
CAUTION
[8] Remove the coupling connected to the rotary valve. When removing the coupling,
label them for ease of identifying the connections later. A rotary valve is either a single-
sleeve or double-sleeve valve, depending on the specifications. Each type comprises
four to six pipes extending from the sleeve.
[9] Remove the two screws which are not painted with red enamel to disassemble the
rotary valve. Do not touch the two screws which are painted red.
[10] Remove the two screws on the gland, then the gland itself.
[11] Install a new gland.
[12] Reinstall the rotary valve in the reverse order of steps [8] and [9], then reconnect the
pipes.
<Replacement Parts>
K9034BP for liquid samples (sample volume: 3µl or less), material: SUS316
K9034BJ for gas samples (sample volume: 10µl), material: SUS316
K9034BH for gas samples (sample volume: 25µl), material: SUS316
K9034BG for gas samples (sample volume: 50µl), material: SUS316
K9034BB for gas samples (sample volume: 100µl or more), material: SUS316
K9034BA for switching valve, material: SUS316
K9034AW for plug
K9034GV for liquid samples (sample volume: 3µl or less), material: Hastelloy C
K9034GS for gas samples (sample volume: 25µl), material: Hastelloy C
K9034GR for gas samples (sample volume: 50µl), material: Hastelloy C
K9034GN for gas samples (sample volume: 100µl or more), material: Hastelloy C
K9034GX for switching valve, material: Hastelloy C
No marking (carved seal) is done on the gland for the replacement. If the marking is
needed, contact YOKOGAWA.

• Replacing the valve sheet for rotary valve
See Figure 2.30 and 2.31.
[5] Close the streame switching valve.
CAUTION
[8] Loosen the nut manually and remove the pipe.
[9] Remove the gasket, gland assembly, and the valve sheet, in this order. Do not remove
the washer and coil spring (see Figure 2.15).
[10] As shown in Figure 2.16, the valve sheet and gland assembly have a specific orienta-
tion; install these components in the correct orientation.
[11] Reassemble the components in the reverse order of steps [5] to [6] and firmly tighten
the nut manually. Do not allow oil or grease to adhere to the sheet.
<Replacement Parts>
K9034FF sample volume: 0.33µl, material: Rulon
K9034DS * sample volume: 1µl, material: Rulon
K9034DR * sample volume: 2µl, material: Rulon
K9034DQ * sample volume: 3µl, material: Rulon
K9034DP * sample volume: 10µl or more, material: Rulon
K9034DN * for switching valve, material: Rulon
K9034DM for plug
J9201HY sample volume: 0.33µl, material: Teflon
K9034FL sample volume: 1µl, material: Teflon
K9034FK sample volume: 2µl, material: Teflon
K9034FJ sample volume: 3µl, material: Teflon
K9034FH sample volume: 10µl or more, material: Teflon
K9034FR for switching valve, material: Teflon
* When ordering * items, the following P/N should be specified.
K9409ZE (2 pcs. of K9034DS)
K9409ZD (2 pcs. of K9034DR)
K9409ZC (2 pcs. of K9034DQ)
K9409ZB (2 pcs. of K9034DP)
K9409ZA (2 pcs. of K9034DN)

Remove two screws not coated with
red enamel (for valve replacement only.
Do not remove these when replacing
only valve seat.)Do not loosen the
screws coated with red enamel.
Coiled spring
(doesn’t need removal)
Do not loose these
screws.
Valve seat
Gasket
Washer
(doesn’t need
removal)
Gland AS
Tube for piping
Nut
F0230.EPS
Figure 2.30 Rotary valve

(a) Valve seat for sampling valve
For gas application
Groove for positioning

gland assembly
Pin
Groove for positioning Valve seat for

the valve seat gas application
Rotor part
For liquid application
Valve seat for

Rotor part liquid application
(b) Valve seat for column switching or backflush valve
Top mark
Bearing Top mark
Pin
Valve seat
Rotor part
F0231.EPS
Figure 2.31 Valve Sheet

2.5.7 Liquid-sample Valve (LSV)

The liquid-sample valve is used as a sampling valve for liquid samples. See Figure 2.32.
Table 2.3
Model Suffix code Option code Description
GCLV Liquid sampling valve
Sample -1 0.1 µl
volume -2 0.25 µl
-3 0.5 µl
-4 1 µl
-5 2 µl
-6 3 µl
Wetted material S SUS316
H Hastelloy C
Insert material M SUS316
G Glass (straight)
C Glass (cup)
J Glass (with neck)
Sealing material R Rulon
T Teflon
Column connection A 1/8"
B 1/16"
C Capillary
D Mega-bore
Split/Leakage back flash N None
1 1/8"
2 1/16"
T0203.EPS

• Replacing the seal unit
CAUTION
[8] Remove the four couplings connected to the locations extending from the isothermal
oven. When removing the couplings, label them for ease of identifying the connections
later.
[9] Remove the locknuts on the LSV using the special tool, then remove the cylinder of
the LSV.
[10] Remove the seal unit. If it is difficult to remove the seal unit, first remove the four
screws on the locknut-clump fitting, then the fitting itself.
[11] Install a new seal unit, then reinstall the cylinder assembly in the reverse order of step
[9].
[12] Reconnect the pipes in the reverse order of step [8].

• Replacing the heater or temperature sensor
CAUTION
[3] Pull out the terminal block and remove the wires (two for the heater and four for the
temperature sensor) connected to the component to be replaced.
[4] Remove the heater cover.
[5] Remove the heat insulator.
[6] Remove the setscrews on the component to be replaced, then the component itself.
[7] Install a new component and fix it with the setscrews.
[8] Reinstall the bracket, frame and cover in the reverse order of steps [3] to [5], then
reconnect the wires.

• Replacing the LSV itself
CAUTION
[8] Pull out the terminal block and remove the wires (two for the heater and four for the
temperature sensor) connected to the component to be replaced.
[9] Remove the heater cover.
[10] Remove the heat insulator.
[11] In the isothermal oven, the bracket is attached to the LSV with two screws and to the
inner wall of the oven with four screws. Remove these screws (six in all) then the
bracket itself.
[12] Remove the six couplings connected to the LSV. When removing the couplings, label
them for ease of identifying the connections later.
[13] Remove the four screws which fix the LSV from outside the constant-temperature
oven, then the LSV itself.
[14] Install a new LSV.
[15] Reinstall the bracket, heat insulator, and cover in the reverse order of steps [9] to [12],
then reconnect the pipes.
[16] Reconnect the pipes in the reverse order of step [8] and [12]. Confirm the wiring and
perform a leak test on the piping.

<Replacement Parts>
1 K9402WA Stem (sample volume: 0.1µl, material: SUS316)
K9402WB Stem (sample volume: 0.25µl, material: SUS316)
K9402WC Stem (sample volume: 0.5µl, material: SUS316)
K9402WD Stem (sample volume: 1µl, material: SUS316)
K9402WE Stem (sample volume: 2µl, material: SUS316)
K9402WF Stem (sample volume: 3µl, material: SUS316)
K9402WG Stem (sample volume: 0.1µl, material: Hastelloy C)
K9402WH Stem (sample volume: 0.25µl, material: Hastelloy C)
K9402WJ Stem (sample volume: 0.5µl, material: Hastelloy C)
K9402WK Stem (sample volume: 1µl, material: Hastelloy C)
K9402WL Stem (sample volume: 2µl, material: Hastelloy C)
K9402WM Stem (sample volume: 3µl, material: Hastelloy C)
2 K9402VG Seal element (Rulon)
K9402VH Seal element (Teflon)
3 K9402VA Insert (SUS16)
K9402VB Insert (Glass, straight)
K9402VC Insert (Glass, with cup)
K9402VD Insert (Glass, with neck)
4 K9402QA Temperature Sensor (PT100Ω, setting temp.: 145°C or less)
K9402QB Temperature Sensor (PT100Ω, setting temp.: 145°C or more)
5 K9402QG Heater (for 100V)
K9402QH Heater (for 110V)
K9402QJ Heater (for 115V or 120V)
K9402QK Heater (for 200V)
K9402QL Heater (for 220V)
K9402QM Heater (for 230V or 240V)
6 K9402UG Sample Tube (SUS316)
K9402UH Sample Tube (Hastelloy C)
7 K9402UN O-Ring (Kalrez)
8 K9400XU Connector (for Mega-bore column or capilary column)
K9400XX Connector (for 1/8”)
K9400XY Connector (for 1/16”)

Seal element Bracket Seal element
Cylinder Screw
Flange
1 2
7
6
4 5
F0232.EPS
Figure 2.32 LSV Liquid Sampling Valve

2.5.8 Restrictors
A restrictor can be used for either low-temperature or high-temperature applications. The
O-ring material for the restrictor differs depending on whether the temperature of the
isothermal oven is above or below 145°C.
CAUTION
combustion, combustion air, and sample.
[4] Remove the two couplings connected to the restrictor. When removing the couplings,
[5] Hold the restrictor both from inside the isothermal oven and from the pressure control-
ler using a tool, and remove the locknuts on the pressure controller, then the restrictor
itself.
[6] Install a new restrictor in the reverse order of step [5].
[7] Reconnect the pipes in the reverse order of step [4], then perform a leak test.
<Replacement Parts>
K9409CA For low-temperature applications
K9409CB For high-temperature applications
IN
OUT
Pipe
IN
Restrictor
F0233.EPS
Figure 2.33 Restrictor

2.5.9 Columns
Columns are classified into packed, mega-bore, and capillary columns.
[5] Close the channel switchover valve.
CAUTION
[8] Remove the two locknuts on both sides of the column, then the column. When remov-
ing the coupling, label them for ease of identifying the connections later.
[9] Install a new column. When installing a mega-bore or capillary column to the rotary
valve, make sure that the column is inserted into pipe on the valve to a depth of
approximately 20mm. When installing the column to an LSV, thread it through a
splitter and insert it into the LSV to a depth of approximately 5mm. Refer to Figure
2.34.
Cut the edge by glass cutter.

Graphite ferrule
Nut
Maga-bore column
Capillary column
<Without splitter> <With splitter>

Prod to the end
10 to 15mm
20 to 25mm
Glass insert with neck Streight insert

F0234.EPS
Figure 2.34

2.5.10 Flame Arrester

CAUTION
combustion, combustion air, and sample.
[4] Remove all of the couplings (two to eight) connected to the flame arrester. When
removing the couplings, label them for ease of identifying the connections later.
[5] Remove the flame arrester. If the flame arrester is threaded through the wall of the
isothermal oven, pull it out.
[6] Install a new flame arrester in the reverse order of steps [4] and [5].
<Replacement Parts>
K9194TA
F0235.EPS
Figure 2.35

2.5.11 Gasket in Isothermal Oven

CAUTION

[4] The gasket lines the edges of the inner walls of the isothermal oven. Separate the
gasket from the edges and gently pull it away from the oven walls.
[5] Line a new gasket along the edges of the inner walls, gently pressing its grooves to fit
over the edges.
[6] After replacement, confirm that the gasket fits over the edges properly.
<Replacement Parts>
K9407NB
Gasket for isotermal oven
F0236.EPS
Figure 2.36

2.5.12 Air Turbine for Agitator Fan

CAUTION
[3] Turn off the supply of the protection gas.

[4] Remove the four setscrews on the fan cover, then the fan cover itself.
[5] Remove the temperature sensor from the heater cover and bend the sensor so the
[6] Remove the four screws on the heater cover then the heater cover itself.
[7] Remove the two screws on the fan, then the fan itself.
[8] Remove the nine screws on the gasket and gasket-holding plate, then the gasket and
gasket-holding plate.
[9] Remove the three screws on the air turbine for the agitator fan.
[10] Install a new air turbine for the agitator fan.
[11] Reinstall the gasket, gasket-holding plate, fan, heater cover, temperature sensor and
fan cover in the reverse order of steps [4] to [8]. When reinstalling the temperature
sensor, make sure that it does not touch the fan or fan cover.
<Replacement Parts>
K9400FA Turbine
K9400FU Gasket
Screws of mounting the air turbine for agitator fan
F0237.EPS
Figure 2.37 Turbine for agitator fan

2.5.13 Pneumatic Valve for Atmospheric Balance (Rotary Valve)

A rotary valve for high-temperature applications is used for the pneumatic valve for balanc-
ing the atmospheric pressure, which is located in the isothermal oven.
• Replacing the pneumatic valve for equalizing atmospheric pressure (rotary

valve)
CAUTION
[4] Remove the couplings connected to the pneumatic valve for balancing the atmo-
spheric pressure (rotary valve). When removing the couplings, label them for ease of
identifying the connection later. The valve comprises two pipes extending from the
sleeve.
[5] Remove the two screws which are not painted with red enamel, then the rotary valve.
Do not touch the two screws which are painted red.
[6] Install a new rotary valve, using a pipe of approximately ø10mm diameter to support it
to avoid excessive force on the neck of the pipe being bent. The cap nut at the tip of
the pipe is stamped with a number. Engage the cap nut with the counterpart referring
to the number previously labeled or the diagram of the column system in the operation
data.
• Replacing the gland

See Figure 2.30.
CAUTION
combustion if an FID is used, combustion air, and sample.

[4] Remove the couplings connected to the pneumatic valve for balancing the atmo-
spheric pressure (rotary valve). When removing the couplings, label them for ease of
identifying the connections later.
[5] Remove the two screws which are not painted with red enamel then the rotary valve
itself. Do not touch the two screws which are painted red.
[6] Remove the two screws on the gland, then the gland itself.
[7] Install a new gland.
[8] Reinstall the pneumatic valve for balancing the atmospheric pressure (rotary valve) in
the reverse order of steps [4] and [5], then reconnect the pipes.
• Replacing the valve sheet for pneumatic valve for balancing atmospheric pres-
sure (rotary valve)
CAUTION
combustion if an FID is used, and combustion air, and sample.
[4] Loosen the nut manually and remove the pipe.
[5] Remove the gasket, gland assembly, and valve sheet, in this order. Do not remove the
washer and coil spring (see Figure 2.30).
[6] The valve sheet and gland assembly have a specific orientation. Install these compo-
nents with the correct orientation.
[7] Reassemble the components in the reverse order of steps [4] and [5] and firmly
tighten the nut manually.
Do not allow oil or grease to adhere to the sheet.

2.6 Components for Programmed-temperature Oven

2.6.1 Heater for Programmed-temperature Oven
The heater for the programmed-temperature oven is a nichrome wire which regulates the
temperature of the programmed-temperature oven (see Figure 2.38).
[2] Turn off the power
CAUTION
The programmed-temperature oven is extremely hot immediately after turning off the
power.

[4] Remove the four screws, then the fan cover.
[6] Remove the four screws, then the heater cover.
[7] Remove the locknuts which fix the terminals on both sides of the heater, then pull out
the heater through the heater guide.
[8] Hold both ends of the new heater and stretch it to approximately 500 mm long. Make
sure that the heater is extended evenly.
[9] Reinstall the new heater. Confirm that the heater is not sagging.
<Replacement Parts>
Supply voltage
K9409GA 100V AC
K9409GB 100V AC
K9409GC 110V AC
K9409GD 115V AC
K9409GE 120V AC
K9409GF 220V AC
K9409GG 230V AC
K9409GH 240V AC

Setscrew for
fan cover
Fan cover
Setscrew for
fan cover
Fan
Heater cover
Temperature sensor
Setscrew for heater cover
F0238.EPS
Figure 2.38 Turbine in Programmed-temperature Oven

2.6.2 Replacing Temperature Sensor for Programmed-temperature

Oven
The temperature sensor for the programmed-temperature oven is a platinum resistance
temperature detector (Pt100 ohm) used to control the temperature of the oven.
CAUTION
power.

[4] Remove the four screws on the fan cover then the fan cover itself.
[6] Remove the four screws on the heater cover, then the heater cover itself.
[7] Remove the locknuts which fix the terminals on the temperature sensor, then the
temperature sensor itself.
[8] Reinstall a new sensor.
<Replacement Parts>
J9208NZ
Unit: mm
Oven
F0239.EPS
Figure 2.39

2.6.3 Replacing Columns

Columns are classified into packed, mega-bore, and capillary columns.
CAUTION
power.
[8] Remove the two locknuts on both sides of the column, then the column.
When removing the couplings, label them for ease of identifying the connections later.
[9] Install a new column. When installing a mega-bore or capillary column, bring it from
the constant-temperature oven through the pipe to the programmed-temperature oven
so it can be fitted with the connecting pipe. When installing the column to the rotary
valve, make sure that the column is inserted into pipe on the valve to a depth of
approximately 20 mm. When installing the column to an LSV, thread it through a
splitter and insert it into the LSV to a depth of approximately 5 mm.

2.6.4 Replacing Gaskets in Programmed-temperature Oven

CAUTION
power.

[4] Remove the door of the programmed-temperature oven.
[5] Remove the four screws from inside the programmed-temperature oven then the
gasket and gasket-holding plate.
[6] Line a new gasket.
[7] Reinstall the gasket-holding plate. Make sure that the gasket fits over the edges of the
door properly with no broken part on the gasket.
<Replacement Parts>
K9400LJ
Gasket Screw Gasket-holding plate
F0240.EPS
Figure 2.40 Gasket in Programmed-temperature Oven

2.6.5 Replacing Air Turbine for Agitator Fan

CAUTION
power.
[3] Turn off the supply of the protection gas.

[4] Remove the four setscrews on the fan cover, then the fan cover itself.
[5] Remove the temperature sensor from the heater cover and bend the sensor so the
[6] Remove the four screws on the heater cover then the heater cover itself.
[7] Remove the two screws on the fan, then the fan itself.
[8] Remove the nine screws on the gasket and gasket-holding plate, then the gasket and
gasket-holding plate.
[9] Remove the three screws on the air turbine for the agitator fan.
[10] Install a new air turbine for the agitator fan.
[11] Reinstall the gasket, gasket-holding plate, fan, heater cover, temperature sensor and
fan cover in the reverse order of steps [4] to [8]. When reinstalling the temperature
sensor, make sure that it does not touch the fan or fan cover.
<Replacement Parts>
K9400FA Turbine
K9400FU Gasket

Setscrew on Air Turbine for Agitator Fan
F0241.EPS
Figure 2.41 Air Turbine for Agitator Fun

2.7 Components in Sample Processing System

2.7.1 Replacing Sample Processing System
The sample processing system is a train of a filter, regulator valve for samples, stop valve,
stream switching valve and needle valve.
However, depending the specifications, some systems may not comprise all of these
components. To replace any of these components, follow the steps below.
manual mode, then actuate the stream switching valve on the channel for the sample
processing system to be replaced so the valve is left open.
CAUTION
[7] Remove the two pipes connected to the needle valve shown on the far left in Figure
2.42.
[8] Remove the locknut on the outside of the analyzer unit.
[9] Remove the sample processing system from the analyzer.
[10] Remove the component to be replaced and install a new component.
[11] Reassemble the sample processing system in the reverse order of steps [7] to [9].
When installing a replacement component, always use sealing tape.
[12] Confirm that there are no leaks in the piping.
<Replacement Parts>
L9853AR Needle valve
K9192WA Stream switching valve (Diaphragm: Viton)
K9192WB Stream switching valve (Diaphragm: Silicone)
L9850AQ Regulator valve for samples (Diaphragm: Viton)
L9850AL Regulator valve for samples (Diaphragm: Silicone)
L9862AB Filter
Stream switching valve Regulator valve for samples

Filter
Needle valve Cap nut

Locknut
F0242.EPS
Figure 2.42 Example of Sample Processing System (May Contain a Stop Valve Depending on the System)

• Replacing the filter element
CAUTION
[7] Remove the cap nut (see Figure 2.43).

[8] Replace the filter element with a new one. Reattach the gaskets in place. If any of the
gaskets shows deterioration or deformation, also replace it with a new one.
[9] Firmly tighten the cap nut.
<Replacement Parts>
L9862AG Filter element
L9862AC Gasket 1
L9862AD Gasket 2
Bushing
Gasket 1
Nut
Filter element
Gasket 2
Filter unit
F0243.EPS
Figure 2.43

2.7.2 Replacing the Valve for Balancing Atmospheric Pressure and/or

Needle Valve for Controlling Flowrate
See Figure 2.44 for the replacement procedure.
CAUTION
[4] Remove the pipes connected to the valve for balancing the atmospheric pressure and
needle valve for controlling the flowrate.
[5] Remove the four setscrews which fix the fitting.
[6]-1 When replacing the valve for balancing the atmospheric pressure, remove the nut on
the rear of the fitting.
[6]-2 When replacing the needle valve for controlling the flowrate, remove the two set-
screws on the front of the fitting.
[7] After replacing the valve(s), reassemble the sample processing system in the reverse
order of steps [4] to [6].
[8] After confirming that the piping is correct, check that there are no leaks.
<Replacement Parts>
L9853AA Needle valve
K9192WP Valve for balancing atomospheric pressure (Diaphragm: Viton)
K9192WQ Valve for balancing atomospheric pressure (Diaphragm: Silicone)
Setscrews (four)
Needle valve for controlling sample flowrate
Valve for balancing atmospheric pressure
F0244.EPS
Figure 2.44 Valve for Balancing Atmospheric Pressure and Needle Valve for Controlling Flowrate

2.7.3 Replacing the Flowmeter

CAUTION
[7] Remove the four pipes connected to the flowmeter.

[8] Remove the two locknuts on the base.
[9] Replace the flowmeter in the reverse order of steps [7] and [8].
<Replacement Parts>
K9193GA for gas samples (Gasket: Viton)
K9193GB for liquid samples (Gasket: Teflon)
K9193GU for gas samples (Gasket: Viton)
Taper tube
Setscrews (two)
Gaskets
Base Connector
Nut 2
Nut 1
Sample Bypass
flowrate flowrate F0245.EPS
Figure 2.45 Taper Tubes

When replacing only the taper tube, follow the procedure below (see Figure 2.45).
CAUTION
[7] Remove the lower pipe connected to the flowmeter assembly.

[8] Securely hold the connector and loosen nut 1 and nut 2.
[9] Gently move the connector downward and remove the taper tube. Replace the gasket
if any damage is found.
[10] Install a new taper tube in the reverse order of steps [7] to [9].
<Replacement Parts>
L9866AK Taper tube
L9866AP Taper tube
L9866AR Taper tube
L9866AS Taper tube
K9193GQ Gasket
K9193GR Gasket

2.7.4 Replacing the Pressure Gauge

CAUTION
[7] Remove the pipe connected to the elbow on the rear of the pressure gauge.
[8] Remove the two setscrews on the fitting.
[9] Remove the two nuts and two washers that fix the pressure gauge to the fitting.
[10] Remove the elbow connected to the pressure gauge.
[11] Install a new pressure gauge in the reverse order of steps [7] to [10]. When attach-
ing the elbow, always apply sealing tape to the connection with the pressure gauge.
<Replacement Parts>
L9867AG 0 to 0.2 MPa
L9867AJ 0 to 0.6 MPa
Bracket
Setscrews (two)
Pressure gauge
Washers (two)
Nuts (two)
Elbow
F0246.EPS
Figure 2.46 Pressure Gauge

2.7.5 Replacing the pneumatic valve for actuating external air supply
CAUTION
[3] Turn off the supply of the protection gas, then remove the tubes connected to ports IN,
OUT1, OUT2 and OPE of the pneumatic valve. When removing the tubes, label them
for ease of identifying the connections later (see Figure 2.48).
[4] Remove the two setscrews.
[5] Install a new pneumatic valve for actuating the external air supply in the reverse order
of steps [3] and [4].
[6] After confirming that the piping is correct, check that there are no leaks.
[7] After completing the piping, follow the steps below.
(1) After fully opening each of the needle valves, rotate it back two turns to lock it.
(2) Supply air, then make sure that air comes out from point [a] but not from point [b].
(3) Actuate valve SV11, then make sure that air comes out from [b] but not from [a].
(4) Repeat steps (2) and (3), then confirm that the delay in the start and stop of air
feed at [a] and [b] with respect to the action of SV11 is no more than 0.5 seconds.
(5) If the stop of air feed at [b] does not take place within 0.5 seconds as the result of
step 4, open the EHX1 needle valve by 1/4 turn and reexamine the delay. If the
reexamination still shows the same result, repeat this step.
(6) If the stop of air feed at [b] does not take place within 0.5 seconds as the result of
step (4), open the EHX2 needle valve by 1/4 turn and reexamine the delay. If the
reexamination still shows the same result, repeat this step.
<Replacement Parts>
K9193NX
K9193NY
K9193NZ

OPE.
Needle valve
EXH2
OUT2
IN
EXH1
OUT1
Setscrew (two)
F0247.EPS
Figure 2.47 Pneumatic Valve for Actuating External Air Supply
If the valve is K9193NX: If the valve is K9193NY: If the valve is K9193NZ:

SV11 PV11 SV11
OUT IN OUT IN OUT IN
EXH EXH EXH
OUT2 IN OUT2 IN OUT2 IN
OUT1 Air Air Air
OUT1 OUT1
[a] [b] [a]

PV12 PV11 PV12
[b] F0248.EPS
PV11
Figure 2.48

2.7.6 Replacing the Pneumatic Valve for Balancing Atmospheric

Pressure or Stream Switching
[1] Remove the four screws on the upper section of the stream switching valve (see
Figure 2.49) or the valve for balancing the atmospheric pressure (see Figure 2.50)
then the upper section of the valve itself.
[2] Replace the diaphragm sheet with a new one and reassemble the valve. Install the
new diaphragm with the same orientation as the old one to avoid inserting it inside out.
Exercise care to avoid losing the adjusting pin and spring at the lower section of the
valve.
11 Number Part Name Part Number Quantity

7
1 BASE K9192WD 1
3 2 BODY K9192WE 1
5
3 CAP K9192WF 1
2
4 PISTON K9192WG 1
6 4 5 O-RING K9192QU 1
air in 6 O-RING K9817FK 1

9
7 SPRING K9192WH 1
8
8 SPRING K9035AW 1
10
9 PIN K9192WK 1
10 DIAPHRAGM K9192WL 1
1 11 SCREW Y9335JU 4
F0249.EPS
Figure 2.49 Stream Switching Valve
air in
Number Part Name Part Number Quantity
1 BASE K9192WD 1
12
11 2 BODY K9192WR 1
3 3 CAP K9192WS 1
6 4 PISTON K9192WT 1
2
8 5 DIAPHRAGM K9192WL 1
6 O-RING L9817FP 1
4
9 7 SPRING K9192WU 4
7
8 PIN K9035AK 1
10 5 9 SPRING K9035AW 1
10 O-RING L9817MY 1
1 11 SCREW Y9335JW 4
F0250.EPS
Figure 2.50 Valve for Balancing Atmospheric Pressure

Blank Page
<Toc> <Ind> <3. Troubleshooting > 3-1
3. Troubleshooting
3.1 Common Procedure of Troubleshooting

Common procedure of troubleshooting os shown as followings.
Abnormality occurs
Checking of alarm
Checking of analysis result
Checking of chromatogram
Checking of parameters
Checking of utility
Checking of sampling system
Checking of process condition
Checking with standard sample
Checking of parts
F0301.EPS
Figure 3.1 Common Procedure of Troubleshooting

3.2 Troubleshooting Diagram for Abnormal Analysis

Result
3.2.1 Abnormal Component Concentration Value
Troubleshooting diagram for abnormal component concentration value is shown as follow-
ings.
Abnormal component
concentration value
No
Chromatogram Check setting values
is abnormal
Yes No
Setting values Check the condition
are abnormal of process sample
Yes
Check setting values Change settings to

of sequence correct value
Setting are No
Change settings to
correct correct value
Yes
Abnormal chromatogram
Refer to "3.2.3 Anbormal Chromatogram".
F0302.EPS
Figure 3.2 Troubleshooting Diagram for Abnormal Component Concentration Value

3.2.2 Abnormal Retention Time

Troubleshooting diagram for abnormal retention time is shown as followings.
Abnormal retention time
No Set carrier gas pressure to

Carrier gas pressure
is as specified the specified value
Yes
No Oven temperature
Oven temperature Refer to the oven temperature control failure
is as specified control failure
Yes
Carrier gas No
flow through detector vent Leakage and cloggung in Refer to the leakage and clogging
is as specified piping inside the GC1000 in piping inside the GC1000
Yes
Disconnect vent line pipng

outdside GC1000
No Clogging in vent line piping

Retention time is
still abnormal outside the GC1000
Yes
No
Chromatogram is Change setting
abnormal values of gate timing
Yes
Refer to "3.2.3 Anbormal Chromatogram". F0303.EPS
Figure 3.3 Troubleshooting Diagram for Abnormal Retention Time

3.2.3 Abnormal Chromatogram

It is available to use three types of detector such as TCD, FID and FPD. Troubleshooting
diagram for abnormal chromatogram is different according to the shown as followings.

(1)In Case of TCD
Troubleshooting diagram for abnormal chromatogram is shown as followings.
Status of No DET CURRENT No

Turn on detector
detector is ON ERROR is occured
Yes Yes
Bridge balance No
of detector is good Replace detector
Yes
Wiring for No
detector is good Replace wiring for detector
Yes
Replace detector board
Current value No
Adjust current with volume
is as specified in operation
data on detector board
Yes No
Current can be adjusted
Yes
End
Baseline of No Refer to the column system failure or

Column system failure or
detector is abnormal sampling system failure sampling system failure
Yes
Temperature No Wait for stabilization of

of oven is stable oven temperature
Yes
No
External piping is clean Use clean piping
Yes
Bridge No
balance of detector is Repalce detector
good
Yes
Insulation No
resistance of detector is
good
Yes
No
Wiring for detector is Replace wiring for detector
good
Yes
F0304.EPS
Figure 3.4 Troubleshooting Diagram for Abnormal Chromatogram (TCD)

(2)In Case of FID
Status of No No
DET FLAME OUT Turn detector
detector is ON
is occured
Yes Yes
Flow rate No
Adjust flow rate of
of combustion gas is as
specified combustion gas
Yes
Voltage value No
for ignition at DET board is Replace detector board
as specified
Yes
Voltage No
value for ignition at DET is Replace wiring for detector
as specified
Yes
Replace detector
Flow rate No
of combustion gas is as Adjust flow rate of
Yes
High voltage No
value for signal at DET card is Replace detector card
as specified
Yes
High voltage No
value for signal at DET is Replace wiring for detector
as specified
Yes
Baseline No Refer to the column system failure or
of detector ia abnormal Column system failure or
sampling system failure
sampling system failure
Yes
No Wait for stabilization of
Temperature of oven is
stable oven temperature
Yes
No
Combustion air is clean Use clean combustion air
Yes
No
External pipng is clean Ude clean piping
Yes
Instalation No
resistance of detector is Replace detector
good
Yes
No
Wiring for detector is Replace wiring for detector
good
Yes
F0305.EPS
Figure 3.5 Troubleshooting Diagram for Abnormal Chromatogram (TID)

(3)In Case of FPD
Status of No No
DET FLAME OUT TUrn on detector
detector is ON is occured
Yes Yes
Flow rate No
Yes
Voltage value No
for ignition at DET board is Repalce detector board
as specified
Yes
Voltage value No
for ignition at DET is as Replace wiring for detector
specified
Yes
Replace detector
Flow rate No
Yes
Increase combustion air pressure
to twice value as specified
Level No Refer to the "Basic operation manual"

Re-turn on detector with
of flame signal increase
correct procedure
Yes
Decrease combustion air
pressure to as specified value
High voltage No
Replace high voltage
value for amp. board is as
specified power supply
Yes
Voltage value No
for amp. board at DET board is Replace detector board
as specified
Yes
Voltage value No Replace wiring for

for amp. board at amp. board is
as specified amp. board
Yes
Baseline No
Column system failure or Refer to the column system failure
of detector is abnormal
sampling system failure or sampling system failure
Yes
No Wait for stabilization of
Temperature of oven is
stable oven temperature
Yes
No
Use clean combustion air
Combustion gas is clean
Yes
No
External piping is clean Use clean piping
Yes
Replace detector card, amp.
board or photo-multiplier
F0306.EPS
Figure 3.6 Troubleshooting Diagram for Abnormal Chromatogram (FPD)

3.2.4 Column system failure

Contact YOKOGAWA for column system failure.

<Int> <Toc> i
◆ Revision Record
● Manual No. : IM 11B03A03-04E
● Title : GC1000 Mark II Process Gas Chromatograph Maintenance and Inspection Manual
Oct. 2001/1st Edition

Newly published
July
. 2002/2nd Edition
Introduction modified below;

Added “(5) When touching LCD Panel switches” to “WARNING”;
Corrected a part of “CENELEC (ATEX directive) certification”;
Corrected a part of “Installation site and environment”;
Added “Explanation for type Y purging” to “WARNING of explosionproof enclosure” of FM
and CSA certification;

Blank Page

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User's

● Regarding Protection, Safety, and Prohibition Against Unauthorized Modifica-

Protective ground terminal:

Function ground terminal:

Indicates the power switch state “Stand - by”.

Indicate the power switch state “OFF”.

● Exemption from Responsibility

● Regarding Software and set including Software Supplied by YOKOGAWA

IM 11B03A03-04E 1st Edition : Oct.31,2001-00

[Left side] [Front] [Right side] [Back]

IM 11B03A03-04E 1st Edition : Oct.31,2001-00

● Documents Related to the GC1000 Mark II Process Gas Chromatograph

■ Instruction manuals that depend upon the specifications of the product

■ Instruction manuals for related products

IM 11B03A03-04E 1st Edition : Oct.31,2001-00

● Is the System Ready?

IM 11B03A03-04E 1st Edition : Oct.31,2001-00

IM 11B03A03-04E 2nd Edition : July. 1. 2002-00

(1) Kinds of explosion protection

IM 11B03A03-04E 2nd Edition : July. 1. 2002-00

(3) Precautions when using hydrogen gas

(4) Installation site and environment

(5) Wiring works

IM 11B03A03-04E 2nd Edition : July. 1. 2002-00

(8) Replacing parts

IM 11B03A03-04E 2nd Edition : July. 1,2002-00

IM 11B03A03-04E 2nd Edition : July. 1. 2002-00

(10) Maintenance and Repair

IM 11B03A03-04E 2nd Edition : July. 1. 2002-00

Gard List strap

Using a wrist strap and conductive sheet Using a Conductive Sheet

GC1000 Mark II Process Gas Chromatograph

IM 11B03A03-04E 2nd Edition

IM 11B03A03-04E 2nd Edition : July. 1. 2002-00

IM 11B03A03-04E 1st Edition : Oct.31,2001-00

1. Maintenance and Inspection

1.1 Explosion-protection Structure

1.2 Stopping the system

IM 11B03A03-04E 1st Edition : Oct.31,2001-00

1.3 Routine Inspection

1.4 Replacing the Cylinders

1.5 Leak Test

1.6 Checking Chromatograms

IM 11B03A03-04E 1st Edition : Oct.31,2001-00

1.7 Recommended Parts List for Periodical Exchange

IM 11B03A03-04E 1st Edition : Oct.31,2001-00

IM 11B03A03-04E 1st Edition : Oct.31,2001-00

2. Procedure for Replacing Parts

(A) Protection system

(B) Electronic section

(D) Isothermal oven

(F) Analyzer base

2.2 Parts for Protection System

Status display Status display

(a) 1 piece of the enclosure (b) 2 pieces of the enclosure

IM 11B03A03-04E 1st Edition : Oct.31,2001-00

2.2.1 Pressure Switch for Detecting Internal Pressure

Pressure switch Pressure switch

[1] Stop the system.

[4] Turn off the protection gas.

IM 11B03A03-04E 1st Edition : Oct.31,2001-00

Figure 2.4 Pressure Switch for Detecting Internal Pressure

IM 11B03A03-04E 1st Edition : Oct.31,2001-00