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Model 83i GC Instruction Manual Hg Non-Inertial Dilution Probe Part Number 105190-00 1Aug2012

© 2007 Thermo Fisher Scientific Inc. All rights reserved. Specifications, terms and pricing are subject to change. Not all products are available in all countries. Please consult your local sales representative for details. Thermo Fisher Scientific Air Quality Instruments 27 Forge Parkway Franklin, MA 02038 1-508-520-0430 www.thermo.com/aqi

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WEEE Compliance

This product is required to comply with the European Union’s Waste Electrical & Electronic Equipment (WEEE) Directive 2002/96/EC. It is marked with the following symbol:

Thermo Fisher Scientific has contracted with one or more recycling/disposal companies in each EU Member State, and this product should be disposed of or recycled through them. Further information on Thermo Fisher Scientific’s compliance with these Directives, the recyclers in your country, and information on Thermo Fisher Scientific products which may assist the detection of substances subject to the RoHS Directive are available at: www.thermo.com/WEEERoHS.

Thermo Fisher Scientific Model 83i GC Instruction Manual i

About This Manual

This manual provides information about installing, maintaining, and servicing the Model 83i GC Hg Non-Inertial Dilution Probe. It also contains important alerts to ensure safe operation and prevent equipment damage. The manual is organized into the following chapters and appendixes to provide direct access to specific operation and service information.

● Chapter 1 “Introduction” provides a detailed description of the construction and flow logic of the probe.

● Chapter 2 “Installation” describes how to mount the probe, and connect the umbilical in preparation for operation.

● Chapter 3 “Operation” describes the settings, utilities, and other guidelines necessary to operate the probe properly.

● Chapter 4 “Preventive Maintenance and Servicing” provides the recommended replacement parts and schedule to maintain proper operation. It also includes contact information for product support for product information.

● Appendix A “Warranty” is a copy of the warranty statement.

Review the following information carefully before using the Model 83i GC Hg Non-Inertial Dilution Probe. This manual provides specific information on how to operate the probe, however if the probe is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

This manual contains important information to alert you to potential safety hazards and risks of equipment damage. Refer to the following types of alerts you may see in this manual.

Safety

Safety and Equipment Damage Alerts

About This Manual

ii Model 83i GC Instruction Manual Thermo Fisher Scientific

Safety and Equipment Damage Alert Descriptions

Alert Description

DANGER A hazard is present that could result in death or serious personal injury if the warning is ignored. ▲

WARNING A hazard or an unsafe practice could result in serious personal injury if the warning is ignored. ▲

CAUTION A hazard or unsafe practice could result in minor to moderate personal injury if the warning is ignored. ▲

Equipment Damage A hazard or unsafe practice could result in property damage if the warning is ignored. ▲

Safety and Equipment Damage Alerts in this Manual

Alert Description

WARNING If the equipment is operated in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. ▲

The service procedures in this manual are restricted to qualified service personnel only. ▲

Equipment Damage When cleaning a silica-coated part, rinse with a solvent that will dissolve probable surface contaminants (that is, use a nonpolar solvent to remove hydrocarbon contaminants, or a more polar solvent to remove more active contaminants). Avoid using cleaners containing abrasives as they can scratch the layer. Mild sonication may assist in contaminant removal, but do not oversonicate as this could damage the layer. Do not use basic solutions with pH>8. Do not steam clean as this could also damage the layer. ▲

The following symbol and description identify the WEEE marking used on the instrument and in the associated documentation.

Symbol Description

Marking of electrical and electronic equipment which applies to electrical and electronic equipment falling under the Directive 2002/96/EC (WEEE) and the equipment that has been put on the market after 13 August 2005. ▲

WEEE Symbol

About This Manual

Thermo Fisher Scientific Model 83i GC Instruction Manual iii

Service is available from exclusive distributors worldwide. Contact one of the phone numbers below for product support and technical information or visit us on the web at www.thermoscientific.com/aqi.

1-866-282-0430 Toll Free

1-508-520-0430 International

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Available 24-hours a day and seven-days a week, the online library provides quick access to information regardless of time zone or office hours.

To register for an account or log in, please visit www.thermoscientific.com/aqilibrary.

Where to Get Help

Thermo Fisher Scientific Model 83i GC Instruction Manual v

Contents Introduction........................................................................................................ 1-1

Description ......................................................................................... 1-1 Flow Schematic ................................................................................... 1-4

Installation ......................................................................................................... 2-1 Checking the Parts for Installation ...................................................... 2-1 Installing the Universal Flange to Stack............................................... 2-3 Mounting the Probe to Universal Flange............................................. 2-4 Attaching the Umbilical to Probe Chassis............................................ 2-7 Connecting the Umbilical Plumbing................................................... 2-9 Connecting the Umbilical Wiring..................................................... 2-16 Preparing the Enclosure for Operation .............................................. 2-19

Operation ............................................................................................................ 3-1 Dilution Eductor Air Supply............................................................... 3-1 Dilution Vacuum Pressure .................................................................. 3-1 Dilution Ratio..................................................................................... 3-2 Bypass Eductor Air Supply .................................................................. 3-2 Filter-Stinger Blow Back Air Supply.................................................... 3-2 Calibration - Zero Gas Supply ............................................................ 3-3 Total and Elemental Mercury Sample Lines ........................................ 3-3 Filter Block Temperature .................................................................... 3-3 Converter Temperature....................................................................... 3-3

Preventive Maintenance and Servicing....................................................... 4-1 Safety Precautions ............................................................................... 4-3 Replacement Parts List ........................................................................ 4-4 Replacement Tubing List .................................................................... 4-5 Removing the Probe Enclosure Cover ................................................. 4-6 Detaching the Umbilical from the Probe Chassis ................................ 4-7 Removing the Probe from the Sample Port ....................................... 4-14 Removing the Universal Flange from the Stack ................................. 4-16 Replacing Factory Supplied Tubing .................................................. 4-19 Removing the Filter Block-Support Plate Assembly from Probe Chassis .......................................................................................................... 4-23 Removing the Filter Block Assembly from the Support Plate ............ 4-29 Removing the Filter Block Assembly from Probe Chassis .................. 4-31 Dismantling the Filter Block Assembly ............................................. 4-34 Servicing the Filter Housing Assembly .............................................. 4-37

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Contents

vi Model 83i GC Instruction Manual Thermo Fisher Scientific

Servicing the Dilution Eductor Assembly .......................................... 4-41 Servicing the Bypass Eductor Assembly ............................................. 4-45 Servicing the Sample Flow Orifice Assembly ..................................... 4-48 Servicing the Filter Heater Assembly ................................................. 4-50 Servicing the Dilution Eductor-Sample Flow Orifice Plumbing Assembly .......................................................................................................... 4-53 Servicing the Filter Blow Back-Sample Pressure Manifold Assembly . 4-55 Servicing the Calibration Supply-Stinger Blow Back Manifold Assembly .......................................................................................................... 4-56 Servicing the Diluted Sample Return Plumbing Assembly ................ 4-57 Servicing the Bypass Eductor Return Tubing .................................... 4-59 Removing the Sample Stinger Assembly from Probe Support Assembly .......................................................................................................... 4-59 Servicing the Sample Stinger Assembly.............................................. 4-64 Removing the Probe Support Assembly from the Chassis.................. 4-70 Servicing the Probe Support Assembly .............................................. 4-72 Removing the Gas Conditioning Tray Assembly from the Probe Chassis .......................................................................................................... 4-74 Dismantling the Gas Conditioning Tray Assembly ........................... 4-78 Servicing the Scrubber Assembly ....................................................... 4-80 Servicing the Converter Assembly ..................................................... 4-82 Removing the Electro-Pneumatic Tray Assembly from the Probe Chassis .......................................................................................................... 4-84 Dismantling the Electro-Pneumatic Tray Assembly .......................... 4-88 Servicing the Accumulator Tank Assembly........................................ 4-90 Servicing the Solenoid Valve Plate Assembly ..................................... 4-91 Servicing the Terminal Block Assembly............................................. 4-94 Servicing the Solenoid Valves Control Lines Wiring Assembly.......... 4-96 Servicing the Solenoid Valves Common Lines Wiring Assembly ....... 4-97 Servicing the Solenoid Valves Ground Lines Wiring Assembly.......... 4-97 Service Locations............................................................................... 4-98

Warranty.............................................................................................................A-1

Appendix A

Thermo Fisher Scientific Model 83i GC Instruction Manual vii

Figures Figure 1–1. Model 83i GC Probe Flow Schematic ............................................. 1-4 Figure 2–1. Parts for Installation ........................................................................ 2-2 Figure 2–2. Sample Port with Universal Mounting Flange................................ 2-4 Figure 2–3. Model 83i GC Cover Removal ......................................................... 2-5 Figure 2–4. Model 83i GC Slid into the Sample Port......................................... 2-6 Figure 2–5. Model 83i GC Fastened to Universal Mounting Flange ................. 2-7 Figure 2–6. Model 83i GC with Gas Conditioning Tray Removed ..................... 2-8 Figure 2–7. Model 83i GC with Umbilical Secured ........................................... 2-9 Figure 2–8. Model 83i GC Plumbing Lines....................................................... 2-10 Figure 2–9. Electro-Pneumatic Tray Plumbing Connections ............................ 2-11 Figure 2–10. Umbilical Plumbing Grommet Positions...................................... 2-12 Figure 2–11. Dilution Air and Vacuum Plumbing Connections ........................ 2-13 Figure 2–12. Eductor Air Plumbing Connections.............................................. 2-14 Figure 2–13. Probe System Plumbing Diagram................................................ 2-15 Figure 2–14. Cal/Zero Gas and Blow Back Air Connections Viewed from Right Side Access Window ......................................................................................... 2-16 Figure 2–15. Probe with Electro-Pneumatic Tray Assembly Slid Out.............. 2-17 Figure 2–16. Umbilical Wiring Terminal Connections ..................................... 2-18 Figure 3–1. Mercury CEMS System Plumbing Diagram .................................... 3-4 Figure 4–1. Undoing the Probe Enclosure Cover Latches .................................. 4-6 Figure 4–2. Removing the Probe Enclosure Cover ............................................. 4-6 Figure 4–3. Probe with the Cover Removed....................................................... 4-7 Figure 4–4. Gas Conditioning Tray Assembly Top View.................................... 4-8 Figure 4–5. Probe with Gas Conditioning Tray Slid Out .................................... 4-9 Figure 4–6. Dilution Air and Vacuum Plumbing Connections ............................ 4-9 Figure 4–7. Bypass Eductor Air Plumbing Connections ................................... 4-10 Figure 4–8. Electro-Pneumatic Tray Assembly Top View ................................ 4-10 Figure 4–9. Cal/Zero Gas, Blow Back Air and Accumulator Tank Supply Connections Viewed from Right Side Access Window..................................... 4-11 Figure 4–10. Electro-Pneumatic Tray Assembly with Accumulator Tank Removed ............................................................................................................................ 4-11 Figure 4–11. Umbilical Wiring Terminal Connections ..................................... 4-12 Figure 4–12. Umbilical Strain Relief Fitting Close-up View ............................ 4-13 Figure 4–13. Probe with Umbilical Removed ................................................... 4-13 Figure 4–14. Unfastening Probe from Universal Mounting Flange ................. 4-15 Figure 4–15. Pulling the Probe out of the Sample Port.................................... 4-15

Figures

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Figure 4–16. Probe Removed from the Sample Port ........................................4-16 Figure 4–17. Universal Mounting Flange Attached to the Sample Port after Probe Removal ....................................................................................................4-17 Figure 4–18. Universal Mounting Flange Detachment from the Sample Port after Probe Removal ....................................................................................................4-17 Figure 4–19. Universal Mounting Flange Removed .........................................4-18 Figure 4–20. Orifice-Converter and Orifice-Scrubber Tubing Replacement ....4-20 Figure 4–21. Heated Dilution Eductor Air and Heated Bypass Eductor Air Tubing Replacement .......................................................................................................4-21 Figure 4–22. Calibration/Zero Gas Supply Tubing Replacement .....................4-21 Figure 4–23. Bypass Eductor Air Supply Tubing Replacement ........................4-22 Figure 4–24. Filter and Stinger Blow Back Air Tubing Replacement...............4-22 Figure 4–25. Hg Spike Gas and Cal/Zero Gas Tubing Replacement................4-23 Figure 4–26. Filter Blow Back Air Plumbing Disconnection .............................4-24 Figure 4–27. Bypass Eductor Air, Hg Spike Gas, Cal/Zero Gas, Stinger Blow Back Air, Orifice-Converter Diluted Sample, and Orifice-Scrubber Diluted Sample Plumbing Disconnection .....................................................................................4-25 Figure 4–28. Dilution Air and Vacuum Plumbing Disconnection .....................4-26 Figure 4–29. Diluted Sample Return, Bypass Return, and Sample Inlet Plumbing Disconnection .....................................................................................................4-26 Figure 4–30. Gas Conditioning Tray Slid Out to Front of Probe Chassis..........4-27 Figure 4–31. Filter Thermocouple-Heater Wiring Terminations ......................4-27 Figure 4–32. Filter Support Plate Mounting Nut Removal ...............................4-28 Figure 4–33. Probe with Filter Block-Support Plate Assembly Removed from Chassis ................................................................................................................4-29 Figure 4–34. Filter Block-Mounting Plate Assembly Removed from Probe Chassis ................................................................................................................4-30 Figure 4–35. Detaching the Filter Block Assembly from the Mounting Plate .4-30 Figure 4–36. Filter Block Assembly Removed from Mounting Plate Assembly4-31 Figure 4–37. Removing the Filter Block Assembly from Probe Chassis...........4-33 Figure 4–38. Filter Block Assembly Dismantled...............................................4-35 Figure 4–39. Filter Housing Assembly Removed..............................................4-37 Figure 4–40. Filter Cap Removal Handle Attached ..........................................4-38 Figure 4–41. Filter Housing Assembly Dismantled ..........................................4-38 Figure 4–42. Dilution Eductor Assembly Removed ..........................................4-41 Figure 4–43. Dilution Eductor Assembly Dismantled.......................................4-42 Figure 4–44. Bypass Eductor Assembly Removed............................................4-46 Figure 4–45. Bypass Eductor Assembly Dismantled ........................................4-46 Figure 4–46. Sample Flow Orifice Assembly Removed....................................4-48 Figure 4–47. Sample Flow Orifice Assembly Dismantled ................................4-49 Figure 4–48. Filter Heater Assembly Removed ................................................4-50

Figures

Thermo Fisher Scientific Model 83i GC Instruction Manual ix

Figure 4–49. Filter Heater Assembly Dismantled ............................................ 4-51 Figure 4–50. Dilution Eductor-Sample Flow Orifice Plumbing Assembly Removed ............................................................................................................................ 4-53 Figure 4–51. Dilution Eductor-Sample Flow Orifice Plumbing Assembly Dismantled.......................................................................................................... 4-54 Figure 4–52. Filter Blow Back-Sample Pressure Manifold Assembly Removed ............................................................................................................................ 4-55 Figure 4–53. Filter Blow Back-Sample Pressure Manifold Assembly Dismantled.. ............................................................................................................................ 4-55 Figure 4–54. Calibration Supply-Stinger Blow Back Manifold Assembly Removed ............................................................................................................. 4-56 Figure 4–55. Calibration Supply-Stinger Blow Back Manifold Assembly Dismantled.......................................................................................................... 4-57 Figure 4–56. Diluted Sample Return Plumbing Assembly Removed ............... 4-58 Figure 4–57. Diluted Sample Return Plumbing Assembly Dismantled ........... 4-58 Figure 4–58. Bypass Eductor Return Tubing Dismantled................................. 4-59 Figure 4–59. Probe with Filter Block-Mounting Plate Assembly Removed from Chassis................................................................................................................ 4-60 Figure 4–60. Gas Conditioning Tray Slid Out ................................................... 4-60 Figure 4–61. Stinger Coil Heater Wiring Terminations ................................... 4-61 Figure 4–62. Stinger Coil Heater Wiring Disconnection and Removal ........... 4-61 Figure 4–63. Sample Stinger Assembly Detachment ...................................... 4-62 Figure 4–64. Sample Stinger Assembly Flange Dislodgement........................ 4-63 Figure 4–65. Sample Stinger Assembly Removal ............................................ 4-63 Figure 4–66. Sample Stinger Assembly Removed ........................................... 4-64 Figure 4–67. Sample Stinger Assembly Dismantling ...................................... 4-65 Figure 4–68. Sample Stinger Coil Heater Removed ........................................ 4-66 Figure 4–69. Probe Barrel Assembly Removed ................................................ 4-67 Figure 4–70. Stinger Tube Removed ................................................................ 4-68 Figure 4–71. Shroud Assembly Removed......................................................... 4-68 Figure 4–72. Shroud Assembly Dismantled ..................................................... 4-69 Figure 4–73. Probe Out of Sample Port with Filter Block-Mounting Plate and Sample Stinger Assemblies Removed from Chassis......................................... 4-70 Figure 4–74. Probe Support Assembly 1/4-20 Stand-offs and Retainer Nuts Removal .............................................................................................................. 4-71 Figure 4–75. Probe Support Assembly Removal .............................................. 4-71 Figure 4–76. Probe Support Assembly Removed ............................................. 4-72 Figure 4–77. Probe Support Assembly Dismantled ......................................... 4-73 Figure 4–78. Probe with Gas Conditioning Tray Slid Out and Sample Tubing Disconnected ...................................................................................................... 4-75

Figures

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Figure 4–79. Converter Wiring Removal from Feed-thru Grommet Holder Plate ... .............................................................................................................................4-76 Figure 4–80. Converter Thermocouple and Heater Wiring Terminations........4-76 Figure 4–81. Gas Conditioning Tray Ground Wire Disconnection ...................4-77 Figure 4–82. Probe with Gas Conditioning Tray Removed...............................4-77 Figure 4–83. Gas Conditioning Tray Removed .................................................4-78 Figure 4–84. Gas Conditioning Tray Dismantled..............................................4-79 Figure 4–85. Scrubber Assembly Removed ......................................................4-80 Figure 4–86. Scrubber Assembly Dismantled ..................................................4-80 Figure 4–87. Scrubber Column Assembly Removed.........................................4-81 Figure 4–88. Converter Assembly Removed.....................................................4-82 Figure 4–89. Converter Assembly Dismantled .................................................4-82 Figure 4–90. Converter Core Assembly Removed ............................................4-83 Figure 4–91. Blow Back Air and Calibration gas/Zero Air Inlet Tube Fitting Disconnection .....................................................................................................4-85 Figure 4–92. Calibration Gas/Zero Air and Hg Spike Outlet Tube Fitting Disconnection .....................................................................................................4-85 Figure 4–93. Filter and Stinger Blow Back Air Outlet Tube Fitting isconnection .............................................................................................................................4-86 Figure 4–94. Probe with Electro-pneumatic Tray Assembly Sid Out ...............4-87 Figure 4–95. Probe with Electro-pneumatic Tray Assembly Removed ............4-88 Figure 4–96. Electro-pneumatic Tray Assembly Removed...............................4-89 Figure 4–97. Electro-pneumatic Tray Assembly Dismantled ...........................4-89 Figure 4–98. Accumulator Tank Assembly Removed .......................................4-91 Figure 4–99. Solenoid Valve Plate Assembly Removed...................................4-92 Figure 4–100. Solenoid Valve Plate Assembly Operation-Leak Test Arrangement .............................................................................................................................4-92 Figure 4–101. Solenoid Valve Plate Assembly Dismantled .............................4-93 Figure 4–102. Terminal Block Assembly Removed ..........................................4-95 Figure 4–103. Terminal Block Assembly Dismantling......................................4-95 Figure 4–104. Solenoid Valves Control Lines Wiring Assembly ......................4-96 Figure 4–105. Solenoid Valves Common Lines Wiring Assembly ...................4-97 Figure 4–106. Solenoid Valves Ground Lines Wiring Assembly ......................4-98

Thermo Fisher Scientific Model 83i GC Instruction Manual xi

Tables Table 2–1. Installation Parts List.........................................................................2-3 Table 4–1. Model 83i GC Replacement Parts .....................................................4-4 Table 4–2. Model 83i GC Replacement Tubing ..................................................4-5 Table 4–3. Type K Thermoelectric Voltage in mV............................................ 4-52

Figures

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Thermo Fisher Scientific Model 83i GC Instruction Manual 1-1

Chapter 1 Introduction

The Model 83i GC Mercury (Hg) Non-Inertial Dilution Probe is configured as one component of Thermo Fisher Scientific’s integrated Mercury Continuous Emission Monitoring System (CEMS). Thermo Fisher Scientific’s Mercury Freedom System™ is comprised of the following:

● Hg Analyzer (Model 80i)

● Hg Calibrator (Model 81i)

● Hg Probe Controller (Model 82i)

● Hg Non-Inertial Dilution Probe (Model 83i GC)

● Peripheral components, for example, zero air supply, umbilical, instrument rack, etc.

The Model 83i GC with built-in diluting probe has been designed specifically to monitor gaseous Hg emissions from coal-fired power plants.

This chapter provides the following sections:

● “Description” on page 1-1

● “Flow Schematic” on page 1-4

The high temperature, dilution-based Model 83i GC Hg Non-Inertial Dilution Probe is compact, light weight, and modular in design for ease of both serviceability and manufacturability. The Model 83i GC consists of the following four functional sections:

● Heated Probe Barrel Assembly

● Heated Filter Probe Assembly

● Gas Conditioning Tray Assembly

● Electro-Pneumatic Tray Assembly

The heated filter probe, gas conditioning tray, and electro-pneumatic tray are housed in an enclosure assembly consisting of a stainless steel chassis that is shielded by a one-piece, epoxy-painted aluminum cover. In order to prevent sample condensation, all key elements (particulate filter block

Description

Introduction Description

1-2 Model 83i GC Instruction Manual Thermo Fisher Scientific

assembly, dilution eductor assembly, bypass eductor assembly, and sample flow orifice assembly) are heated and controlled to temperatures as high as 260 °C (500 °F). The sample stinger tube is also heated to a temperature exceeding 500 °F in order to prevent sample condensation and mercury adsorption prior to entering the filter block assembly.

The standard heated probe barrel assembly consists of a 6-foot long by 1/2-inch OD Hastelloy C sample stinger tube that is encased by a 1-inch OD, schedule 40, 316SS welded pipe/flange assembly. A 5-foot long, 240 VAC/600 W coiled, cable heater envelops the 1/2-inch OD sample stinger tube within the annular space formed inside the 1-inch OD pipe housing. The sample inlet temperature is maximized by operating the heater with continuous full power, which prevents sample condensation and minimizes mercury adsorption on to the stinger tube. The tip of the sample stinger, which contacts the stack or process gas, is shielded by a Hastelloy C shroud assembly in order to minimize the entry of sample particulates and mist into the system. The heated probe barrel assembly is supported by 1-foot long, 1 1/2-inch OD, schedule 40, 316SS welded pipe/flange assembly attached to the enclosure chassis. The probe barrel assembly is fully retractable without removing the probe enclosure as it attaches and seals to the probe support assembly flange from inside the enclosure chassis.

The heated filter probe assembly, which is easy to service and modular in design, consists of the following primary, components:

● Heated Filter Block Assembly

● Dilution Eductor Assembly

● Bypass Eductor Assembly

● Sample Flow Orifice Assembly

● Filter Heater Assembly

The silica coated, 316SS, filter block assembly is the backbone for all the other modular components and houses a 2 3/8-inch long x 1 1/4-inch OD, 0.5 micron, sintered, silica coated, 316SS filter element. The filter block is directly heated by two 1/4-inch OD, 240 V, 375 W, cartridge heaters. Temperature is monitored and controlled via a 1/8-inch OD type K thermocouple that is embedded in the center of the block. The filter block also provides all the necessary flow pathways to the modular sample and calibration gas components.

The filter heater assembly, which holds the cartridge heaters and thermocouple, mounts on and plugs into the right side of the filter block. Thus, all heat is transferred directly to the filter block. The remaining modular components are heated via thermal conduction from the corresponding filter block surfaces where they are mounted.

Introduction Description


The bypass eductor assembly mounts on the bottom side of the filter block, and houses an eductor that pulls sample through the sample stinger from the stack or process on the front end in a bypass configuration. The dilution eductor assembly mounts on the left side of the filter block, and holds the eductor and critical glass orifice that draws sample through the filter and then dilutes it. The sample flow orifice assembly mounts on the top side of the filter block, and contains the two equal-sized, tubular flow orifices, which regulate the diluted sample flow to the elemental and total mercury channels to the analyzer.

Modular plumbing assemblies that connect to the filter block are the calibration supply/stinger blow back manifold, filter blow back/sample pressure manifold and diluted sample tubing.

Sample-wetted components in the modular assemblies are silica coated in order to prevent mercury adsorption. The modular assemblies can be easily removed for service on either the subcomponent level or for replacement of the entire assembly, whichever is appropriate.

Gas conditioning tray components are mounted on a pullout tray located directly below the filter block assembly. Standard components located on this tray are the high temperature thermal converter and scrubber column assembly. These components condition the diluted sample, respectively, for transport and delivery to the total and elemental mercury channels of the Model 80i Hg Analyzer. The converter reduces any oxidized mercury back to its elemental state yielding the total mercury measurement as the end result. The scrubber column strips any oxidized mercury in providing sample for the elemental mercury measurement. Oxidized mercury is determined by the difference between the total and elemental mercury measurements. An optional, high temperature oxidizer that is employed for performing oxidized mercury calibrations mounts directly above the scrubber column assembly.

All electro-pneumatic components are mounted on a pullout tray located below the gas conditioning tray assembly at the bottom of the enclosure chassis. The components mounted on this tray are the terminal block assembly, solenoid valve plate assembly, and blow back air accumulator tank. The terminal block serves as the interface between the end user umbilical connections and the probe components. The accumulator tank is employed for a serial back purging (blow back) of the sintered metal particulate filter element and sample stinger in order to maintain cleanliness. The solenoid valve plate assembly comprises valves for filter blow back, stinger blow back, zero/span calibration gas, and zero/span Hg spike gas.

Introduction Flow Schematic


A special 4-inch adapted, universal mounting flange has been supplied for installation onto the stack or duct sample port. Four 5/8-11 studs on the flange are employed not only to secure the probe to the sample port, but also to hang and support it during mounting, which facilitates installation.

Referring to Figure 1–1 below, clean dry pressurized (~80 psig) air feeds two electronic pressure regulators in the Model 82i Probe Controller, which adjust and maintain output pressure to the Model 83i GC bypass eductor and blow back pneumatics. Pressurized (~65 psig) Hg-free zero air feeds a third electronic regulator in the Model 82i, which adjusts and maintains dilution air pressure to the Model 83i GC probe dilution eductor. Also contained within the Model 82i are three electronic pressure transducers associated with the individual regulators, as well as an electronic vacuum transducer monitoring the dilution eductor vacuum in the Model 83i GC.

The Model 82i provides both 220 and 110 AC voltage to the Model 83i GC probe. 220 VAC powers the probe’s stinger heater and filter block assembly heaters. 110 VAC powers the total mercury converter as well as four (4) probe solenoid valves for calibration/zero gas, stinger blow back, filter blow back, and Hg spike. The Model 82i also receives two (2) 4-20 mA signals from the probe critical orifice pressure transducer.

Figure 1–1. Model 83i GC Probe Flow Schematic

Flow Schematic



During normal operation, the bypass eductor draws in sample from the stack or process through the sample stinger upstream of the filter block at a flow rate from 2 to 5 SLPM in order to minimize sample response time as well as condition the sample stinger tube. The bulk of the bypass flow is not filtered and returns to the stack or process through a 1/4–inch port located on the probe barrel support assembly flange.

Approximately 250 cc/min of the bypass flow is first drawn through the 0.5 micron, silica coated, sintered 316SS filter element and then through a glass orifice by the dilution eductor, where it is diluted nominally at a 30:1 ratio by the dilution air supply. The dilution eductor is operated such that critical vacuum is developed across the glass orifice. The critical vacuum pressure attained is typically 16 to 20 inches Hg at which the sample flow through the orifice remains constant. The diluted sample is then driven by the dilution air supply through a 15 micron, silica coated, 316SS in-line filter, which serves to protect the sample flow orifices downstream. At this point, the diluted sample flow rate is approximately 10 SLPM.

The bulk of the diluted sample stream is then returned to the stack or process through another 1/4-inch port located on the probe barrel support assembly flange. A small portion of the diluted sample stream is pulled in parallel through each channel of the flow orifice assembly, and then through the converter and scrubber, respectively, to the total and elemental analyzer channels by the system vacuum pump located at the analyzer rack. The flow rates through each channel are approximately equal and typically 250 cc/min. In some cases, where umbilical lines are excessively long the flow orifices size may be increased to improve response time. The absolute pressure downstream of the sample flow orifices is typically 50 to 100 millimeters Hg, which significantly reduces the system response time.

Probe cleanliness is maintained by a periodic, two-stage, automated blow back system. The two-stage process consists of a sequential filter element blow back followed by a sample stinger blow back. The stinger blow back stage is subdivided into two repetitive cycles equal in duration. A typical schedule consists of a 30-second blow back for each stage on an hourly basis. The schedule can be programmed as necessary depending upon the application. An accumulator vessel is located upstream of the filter and stinger blow back supply solenoid valves in order to provide a high pressure spike at the onset of each blow back.

Two calibration valves are also provided to in order to perform regular system calibrations. The calibration/zero solenoid valve is normally employed to perform routine system calibrations. During normal system calibration, span or zero gas is injected in excess upstream of the filter element in order to flood the filter block housing. The bypass eductor is shut down during calibration and the excess calibration gas is vented back to the stack or process bi-directionally through the sample stinger and



bypass return port. A portion of the calibration gas is drawn through the filter element, diluted, conditioned, and transported to each channel of the analyzer in the same manner as done for normal sample monitoring. As with the blow back, calibration can be done automatically, depending on the application requirements.

The mercury spike/zero calibration works in the same fashion as the normal system calibration/zero and is provided for future consideration if and when specific end user requirements have been defined. It can still be employed for an additional calibration gas supply if necessary.


Chapter 2 Installation

The installation procedure of the Model 83i GC Hg Non-Inertial Dilution Probe involves several steps:

● “Checking the Parts for Installation” on page 2-1

● “Installing the Universal Flange to Stack” on page 2-3

● “Mounting the Probe to Universal Flange” on page 2-4

● “Attaching the Umbilical to Probe Chassis” on page 2-7

● “Connecting the Umbilical Plumbing” on page 2-9

● “Connecting the Umbilical Wiring” on page 2-16

● “Preparing the Enclosure for Operation” on page 2-19

The various parts that are required for installation of the Model 83i GC Hg Non-Inertial Dilution Probe have been included and are shown in Figure 2–1. Referring to Table 2–1, verify that all the necessary parts have been received and are not damaged.

Checking the Parts for

Installation

Installation Checking the Parts for Installation


Figure 2–1. Parts for Installation

Installation Installing the Universal Flange to Stack


Table 2–1. Installation Parts List

Item Description Part Number Quantity

1 Gasket ,Universal Mounting Flange 104141-00 1

2 Bolt, SS, 5/8-11 x 2-inch 104144-00 8

3 Lock Washer, SS, 5/8-inch 6583.018 8

4 Nut, SS, 5/8-11 6428.007 4

5 Assembly, Cal/Zero Supply Line Reducer 104795-00 1

6 Fitting, SS, Reducing Union, 3/8 x 1/4 4473 1

7 Universal Mounting Flange, 4-inch 104649-00 1

8 Gasket, Probe Support 104468-00 1

9 Strain Relief, 3-inch CGB 25505026 1

10 Handle, Heated Filter (Not required for installation. Used for servicing filter.)

00500072 1

11 Tubing, Teflon PFA, 1/4 OD x 12-inch long 4206 1

12 Tubing, Teflon PFA, 1/4 OD x 22-inch long 4206 1

Use the following procedure to mount the universal flange to the stack.

Note The stack sample port must be installed on the stack prior to the universal flange installation. Consult factory for further details. For more information, see “Service Locations” on page 4-98. ▲

1. Align the universal mounting flange gasket thru holes (see Figure 2–2) to stack sample port thru holes, such that the mounting studs form a square as viewed straight on.

2. Fasten the universal mounting flange (see Figure 2–2) to stack sample port with 5/8-inch bolts and washers in eight places.

Installing the Universal Flange

to Stack

Installation Mounting the Probe to Universal Flange


Figure 2–2. Sample Port with Universal Mounting Flange

Use the following procedure to mount the probe to the universal flange.

1. Undo the four latches that secure the one-piece probe cover to the back side of the probe chassis.

2. Remove the probe cover (see Figure 2–3) from the probe chassis by gripping the lip in back of the cover, and then pulling up, out, and down in a circular-like fashion.

Mounting the Probe to Universal Flange

Gasket

Universal Mounting Flange

Sample Port

Bolt, SS

Lock Washer, SS



Figure 2–3. Model 83i GC Cover Removal

3. Place the probe support gasket (see Figure 2–4) onto the universal mounting flange studs.

4. Using appropriate equipment and manpower hoist the probe up and slide it in the sample port and then onto the universal mounting flange studs through the holes on the probe support flange (see Figure 2–4).

Note The studs on the universal mounting flange support the probe during fastening. ▲

Cover Lip



Figure 2–4. Model 83i GC Slid into the Sample Port

5. Fasten the probe (see Figure 2–5) to universal mounting flange with 5/8 nuts and lock washers (see Table 2–1) in four places from inside the probe chassis.

Note The nuts can be fastened to the universal mounting flange by inserting a 5/8-inch ratchet through the access holes on the filter block mounting plate or by using a crescent wrench from behind the plate. ▲

Sample Port

Stud

Probe Support Gasket

Installation Attaching the Umbilical to Probe Chassis


Figure 2–5. Model 83i GC Fastened to Universal Mounting Flange

Use the following procedure to secure the umbilical to the probe chassis.

1. Loosen the socket head set screws that secure the gas conditioning tray to the slide rails.

2. Disconnect the orifice-converter and orifice-scrubber tubing from the sample flow orifice assembly.

3. Slide the gas conditioning tray out of the probe chassis without disconnecting any wiring and set it aside with appropriate support (see Figure 2–6).

Attaching the Umbilical to

Probe Chassis

Nuts & Washers (4) Access Holes (4)

Installation Attaching the Umbilical to Probe Chassis


Figure 2–6. Model 83i GC with Gas Conditioning Tray Removed

4. Install the 3-inch strain relief (see Table 2–1) through the hole on the chassis bottom and secure it from inside the chassis using the lock nut provided with it.

5. Slide the umbilical through the strain relief and tighten the strain relief accordingly (see Figure 2–7).

Strain Relief, 3-inch

Orifice-Converter Tube Connection

Orifice-Scrubber Tube Connection

Installation Connecting the Umbilical Plumbing


Figure 2–7. Model 83i GC with Umbilical Secured

6. Support the umbilical externally to relieve stress on the chassis.

Use the following procedure to plumb the umbilical to the probe. Note line #4 is a spare.

1. Cut back the umbilical bypass eductor air supply line accordingly and connect the straight tube reducer union and 22-inch length of Teflon tubing provided (see Table 2–1 and Figure 2–8).

Connecting the Umbilical Plumbing

Umbilical



Figure 2–8. Model 83i GC Plumbing Lines

2. Cut back the cal/zero gas supply line accordingly and connect the elbow tube reducer union assembly and 12-inch length of Teflon tubing provided (see Table 2–1 and Figure 2–8).

3. Connect the cal/zero and blow back supply lines accordingly on the electro-pneumatic tray assembly (see Figure 2–9).

Note The accumulator tank may be disconnected from the right hand side access window and removed if so desired. ▲

Fitting, Reducer Union

Bypass Eductor Air SupplyLine #5

Teflon Tubing 22”

Cal/Zero Gas Supply Line #3

Cal/Zero Line Reducing Assembly

Teflon Tubing 12”



Figure 2–9. Electro-Pneumatic Tray Plumbing Connections

4. Slide the elemental mercury, total mercury, bypass eductor, dilution air, and vacuum lines up through the slotted feed-thru plate, as designated in Figure 2–10.

Blow Back Air Supply Line #8

Cal/Zero Gas Supply Line #3

Accumulator Tank Disconnect Fittings



Figure 2–10. Umbilical Plumbing Grommet Positions

5. Cut back excess tubing and connect the dilution air (line #7) and dilution vacuum (line #6) to the filter block, as shown in Figure 2–11.

Bypass Eductor Air Line #5

Dilution Air Line #7

Dilution Vacuum Line #6

Elemental Mercury Line #2

Total MercuryLine #1



Figure 2–11. Dilution Air and Vacuum Plumbing Connections

6. Cut back excess tubing and connect the bypass eductor air (line #5) to the filter block, as shown in Figure 2–12.

Dilution AirLine #7

Dilution VacuumLine #6



Figure 2–12. Eductor Air Plumbing Connections

7. Slide the gas conditioning tray back into the probe chassis.

8. Secure the tray to the slide rails with the socket head set screws.

9. Cut back excess tubing and connect the elemental mercury (line #2) and total mercury (line #1), respectively, to the converter and scrubber outlets on the gas conditioning tray (see Figure 2–10).

10. Verify connections, as shown in the installed probe system plumbing diagram Figure 2–13.

Bypass Eductor Air Line #5



Figure 2–13. Probe System Plumbing Diagram

Installation Connecting the Umbilical Wiring


Use the following procedure to wire the umbilical to the probe.

1. Disconnect the cal/zero gas and blow back air supply lines from the electro-pneumatic tray solenoid valves via the right side access window (see Figure 2–14).

Figure 2–14. Cal/Zero Gas and Blow Back Air Connections Viewed from Right Side Access Window

2. Loosen the socket head set screws that secure the electro-pneumatic tray to the slide rails.

3. Slide the electro-pneumatic tray out to the edge of the probe chassis (see Figure 2–15).

Connecting the Umbilical Wiring

Blow Back Air Supply Cal/Zero Gas Supply



Figure 2–15. Probe with Electro-Pneumatic Tray Assembly Slid Out

4. Locate the probe terminal block assembly on the bottom left of the electro-pneumatic tray assembly.

5. Cut back any excess length of the umbilical wires leaving an ample service loop for pulling the tray out for service without disconnecting wires.

6. Terminate the umbilical wires as shown in Figure 2–16.

Terminal Block Assembly



Figure 2–16. Umbilical Wiring Terminal Connections

Installation Preparing the Enclosure for Operation


7. Slide the electro-pneumatic tray back into the probe chassis.


9. Reconnect the cal/zero gas and blow back air supply lines.

Use the following procedure to ready the enclosure for operation.

1. Put the probe cover back onto the probe chassis in a reverse fashion as it was removed.

2. Secure the four latches on the probe cover back to the probe chassis.

Preparing the Enclosure for

Operation


Chapter 3 Operation

This chapter describes the settings for operating the Model 83i GC Hg Non-Inertial Dilution Probe. Refer to the Model 80i Hg Analyzer, Model 81i Hg Calibrator, and Model 82i Hg Probe Controller manuals along with the Mercury CEMS system plumbing diagram, shown in Figure 3–1 as necessary. For details, see the following topics:

● “Dilution Eductor Air Supply” on page 3-1

● “Dilution Vacuum Pressure” on page 3-1

● “Dilution Ratio” on page 3-2

● “Bypass Eductor Air Supply” on page 3-2

● “Filter-Stinger Blow Back Air Supply” on page 3-2

● “Calibration - Zero Gas Supply” on page 3-3

● “Total and Elemental Mercury Sample Lines” on page 3-3

● “Filter Block Temperature” on page 3-3

● “Converter Temperature” on page 3-3

The dilution eductor requires approximately a 10 LPM supply of zero air (line #7) at its inlet in order to attain the proper dilution ratio and critical dilution vacuum pressure. The dilution air pressure regulator, located in the Model 82i Probe Controller, is set to approximately 30 psig and is controlled by the Model 80i Hg Analyzer. In most applications, there will be a significant pressure loss in the dilution air pressure during transport through the umbilical line. At least 1 psig pressure loss per 100-feet of umbilical should be expected for a 1/4-inch OD supply line. As an example, for a 500-foot long umbilical, the dilution air pressure could be set to 35 psig at the analyzer rack as a starting point. The pressure could then be fine tuned for the optimal balance of dilution ratio and dilution vacuum pressure.

The dilution vacuum pressure (line #6) interfaces with a transducer located in the Model 82i Probe Controller that is monitored by the Model 80i Hg Analyzer. The probe vacuum port is located upstream of the critical glass

Dilution Eductor Air Supply

Dilution Vacuum Pressure

Operation Dilution Ratio


orifice prior to dilution. The dilution vacuum pressure must be maintained critical to ensure proper system operation for two reasons. First, above the critical vacuum point sample flow through the orifice remains constant enabling more precise control of the dilution ratio. The other reason is that the sample flow through the orifice becomes sonic, which helps to maintain cleanliness of the orifice. The minimum vacuum design specification is 16 inches Hg. Since the minimum vacuum required for establishing critical flow is approximately 15 inches Hg, stable system operation can still be maintained below the design specification. However, the vacuum pressure is typically maintained between 16 and 19 inches Hg.

The standard, nominal dilution ratio of the Model 83i GC probe is 30:1 as determined by the dilution air flow rate and glass orifice size. The dilution ratio can be fine tuned by adjusting the dilution air supply pressure up or down, respectively, to increase or decrease the ratio as long as critical dilution vacuum is maintained. From a practical operational viewpoint, the exact dilution ratio is not important as any deviation from the target is calibrated out as a system bias.

The bypass eductor requires approximately a minimum15 LPM, 10 psig air supply (line #5) at its inlet in order to pull sample bypass flow upstream of the filter. The bypass eductor air pressure regulator, located in the Model 82i Probe Controller, is set and controlled by the Model 80i Hg Analyzer. In most applications, there will be a significant pressure loss in the bypass eductor air pressure during transport through the umbilical line. As with the dilution eductor air pressure, approximately 1 psig pressure loss per 100 feet of umbilical should be allowed.

The minimum recommended filter-stinger blow back air supply pressure (line #8) is 50 psig. The filter-stinger blow back air pressure regulator, located in the Model 82i Probe Controller, is set and controlled by the Model 80i Hg Analyzer. Since there is an isolated blow back accumulator vessel located in the probe that provides a pulsed blow back, line pressure losses are not as significant an issue as with the other air supplies. The pulsed blow back consists of sequentially filling the accumulator, and then opening the appropriate filter or stinger blow back solenoid valve at the probe. The initial surge of air from the local accumulator performs the bulk of the cleaning. Typically the two-stage process consists of a sequential filter element blow back followed by a sample stinger blow back. The stinger blow back stage is subdivided into two repetitive cycles equal in duration. A typical schedule consists of 30-second blow back for each stage on an hourly basis. The schedule frequency and duration can be programmed at the Model 80i as necessary depending upon the application.

Dilution Ratio

Bypass Eductor Air Supply

Filter-Stinger Blow Back Air

Supply

Operation Calibration - Zero Gas Supply


The calibration-zero gas supply (line #3) delivers either span or zero gas to the probe for system calibration. The span gas supply is typically 10 micrograms Hg per cubic meter delivered approximately at a flow rate of 8 LPM from the Model 81i Hg Calibrator. The concentration can be programmed if necessary by the Model 80i Hg Analyzer. The supply is injected upstream of the filter where only a small portion required for dilution is filtered and the bulk is vented to near atmospheric pressure stack.

The total mercury (line #1) and elemental mercury (line #2) diluted sample flows to the analyzer are controlled by equally sized flow orifices located in the flow orifice assembly mounted on the top of the filter block. The standard orifice size produces a critical flow of approximately 250 cc/min as the pressure downstream of the orifice generated by the system vacuum pump at the analyzer rack is 50 to 100 mmHg absolute (26 to 28 inches Hg vacuum). Operating the umbilical sample lines under high vacuum substantially reduces the system response time since the sample velocity is greatly increased as compared to atmospheric conditions.

The filter block temperature is typically set to 220 °C, although it can be set as high as 250 °C, depending upon the application. During SCR (selective catalytic reactor) operation, the operating temperatures may have to be increased due to the presence of ammonia and potential for ammonia salt formation. The control temperature can be programmed at the Model 80i Hg Analyzer.

The converter is typically controlled to approximately 760 °C to reduce any oxidized mercury back to the elemental state for analysis. The control temperature can be programmed at the Model 80i Hg Analyzer.

Calibration - Zero Gas Supply

Total and Elemental Mercury Sample

Lines

Filter Block Temperature

Converter Temperature

Operation Converter Temperature


Figure 3–1. Mercury CEMS System Plumbing Diagram


Chapter 4 Preventive Maintenance and Servicing

This chapter includes the replacement parts and tubing lists as well as detailed dismantling and servicing procedures for the Model 83i GC Hg Non-Inertial Dilution Probe in order to ensure proper operation. All plumbing type replacements should be followed-up with a leak test. For details, see the following:

● “Safety Precautions” on page 4-3

● “Replacement Parts List” on page 4-4

● “Replacement Tubing List” on page 4-5

● “Removing the Probe Enclosure Cover” on page 4-6

● “Detaching the Umbilical from the Probe Chassis” on page 4-7

● “Removing the Probe from the Sample Port” on page 4-14

● “Removing the Universal Flange from the Stack” on page 4-16

● “Replacing Factory Supplied Tubing” on page 4-19

● “Removing the Filter Block-Support Plate Assembly from Probe Chassis” on page 4-23

● “Removing the Filter Block Assembly from the Support Plate” on page 4-29

● “Removing the Filter Block Assembly from Probe Chassis” on page 4-31

● “Dismantling the Filter Block Assembly” on page 4-34

● “Servicing the Filter Housing Assembly” on page 4-37

● “Servicing the Dilution Eductor Assembly” on page 4-41

● “Servicing the Bypass Eductor Assembly” on page 4-45

● “Servicing the Sample Flow Orifice Assembly” on page 4-48

● “Servicing the Filter Heater Assembly” on page 4-50

Preventive Maintenance and Servicing Converter Temperature


● “Servicing the Dilution Eductor-Sample Flow Orifice Plumbing Assembly” on page 4-53

● “Servicing the Filter Blow Back-Sample Pressure Manifold Assembly” on page 4-55

● “Servicing the Calibration Supply-Stinger Blow Back Manifold Assembly” on page 4-56

● “Servicing the Diluted Sample Return Plumbing Assembly” on page 4-57

● “Servicing the Bypass Eductor Return Tubing” on page 4-59

● “Removing the Sample Stinger Assembly from Probe Support Assembly” on page 4-59

● “Servicing the Sample Stinger Assembly” on page 4-64

● “Removing the Probe Support Assembly from the Chassis” on page 4-70

● “Servicing the Probe Support Assembly” on page 4-72

● “Removing the Gas Conditioning Tray Assembly from the Probe Chassis” on page 4-74

● “Dismantling the Gas Conditioning Tray Assembly” on page 4-78

● “Servicing the Scrubber Assembly” on page 4-80

● “Servicing the Converter Assembly” on page 4-82

● “Removing the Electro-Pneumatic Tray Assembly from the Probe Chassis” on page 4-84

● “Dismantling the Electro-Pneumatic Tray Assembly” on page 4-88

● “Servicing the Accumulator Tank Assembly” on page 4-90

● “Servicing the Solenoid Valve Plate Assembly” on page 4-91

● “Servicing the Terminal Block Assembly” on page 4-94

● “Servicing the Solenoid Valves Control Lines Wiring Assembly” on page 4-96

● “Servicing the Solenoid Valves Common Lines Wiring Assembly” on page 4-97

● “Servicing the Solenoid Valves Ground Lines Wiring Assembly” on page 4-97

● “Service Locations” on page 4-98

Preventive Maintenance and Servicing Safety Precautions


Read the safety precautions before beginning any procedures in this chapter.

WARNING The service procedures in this manual are restricted to qualified service representatives. ▲

If the equipment is operated in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. ▲

Equipment Damage When cleaning a silica-coated part, rinse with a solvent that will dissolve probable surface contaminants (that is, use a nonpolar solvent to remove hydrocarbon contaminants, or a more polar solvent to remove more active contaminants). Avoid using cleaners containing abrasives as they can scratch the layer. Mild sonication may assist in contaminant removal, but do not oversonicate as this could damage the layer. Do not use basic solutions with pH>8. Do not steam clean as this could also damage the layer. ▲

Safety Precautions

Preventive Maintenance and Servicing Replacement Parts List


Table 4–1 lists the replacement parts for the Model 83i GC.

Note The recommended replacement interval is site specific; therefore, these are only guidelines. ▲

Table 4–1. Model 83i GC Replacement Parts

Part Number Description Quantity Replacement Interval

103990-00 Teflon Seal 2 3–6 months

104263-00 Filter Element, CR Coated 1 Annual

4090.007 Anti-seize Compound 1 As needed

100634-00 Graphite Ferrule, 1/2” 2 When servicing stinger or as needed

104296-00 Eductor Body, Vespel, 10 LPM 1 As needed

104902-00 Eductor Jet, SS, CR Coated, 10 LPM 1 As needed

26004058 Orifice, Quartz, 360 CC/Min 1 3–6 months

104733-00 O-Ring, Z1031-006 1 3–6 months

104733-01 O-Ring, Z1031-014 1 3–6 months

104733-02 O-Ring, Z1031-106 4 3–6 months

104733-03 O-Ring, Z1031-109 1 3–6 months

104733-05 O-Ring, Z1031-224 1 3–6 months

104302-07 Orifice, SS, CR Coated, #7 2 As needed

104342-00 Heater, Firerod, 240 V,375 W 2 Annual

104343-00 Thermocouple, 1/8” 1 Annual

104497-00 Eductor Assembly 1 As needed

101074-00 Filter, SS, CR Coated, 15 Micron 1 Annual

2136.240 Filter, SS, 15 Micron 1 Annual

105422-00 Fitting Assembly, Coated Elbow with PTFE Ferrule

2 As needed

104500-00 Core Assembly, Mercury Converter 1 3–6 months

102728-00 Heater, Converter, 120 V, 250 W 1 Annual

104747-00 Thermocouple, Converter 1 Annual

104445-00 Scrubber Column 1 3–6 months

2136.335 Solenoid Valve, 115 V 1 As needed

Replacement Parts List

Preventive Maintenance and Servicing Replacement Tubing List


Part Number Description Quantity Replacement Interval

104341-00 Heater Coil, 5 FT, 240 V, 600 W 1 Annual

104650-00 Shroud Assembly, Hastelloy C-276 1 As needed

104432-00 Graphite Ferrule, 1/4” 2 3–6 months

104468-00 Gasket, 2”, Probe Support-Enclosure 1 Annual

104140-00 Gasket, Graphite, 2” 1 Annual

104141-00 Gasket, Graphite, 4” 1 Annual

101694-05 O-Ring, Viton, -222 1 3–6 months

Table 4–2 lists the replacement tubing parts for the Model 83i GC.

Depending on the conditions of the stack or duct annual or more/less frequent, replacement of factory tubing should be performed. An ideal time would be shut-down.

Table 4–2. Model 83i GC Replacement Tubing

Number Description Tubing Length

Nut Fittings

1 Orifice to Converter 17” (1) 1/4” Teflon (1) 1/4” S.S.

2 Orifice to Scrubber 16” (2) 1/4” S.S.

3 Hg Spike Valve to Spike Port 34” (2) 1/4” S.S.

4 Cal/Zero Valve to Calibration Port 32” (2) 1/4” S.S.

5 Filter BB Valve to Filter Port 22” (2) 1/4” S.S.

6 Stinger BB Valve to Stinger Port 32” (2) 1/4” S.S.

7 Sample Transducer to Filter BB Manifold

12” (2) 1/4” S.S.

8 Air Heater Tube to Dilution Eductor 5” (2) 1/4” S.S.

9 Air Heater Tube to Bypass Eductor 2 1/8” (2) 1/4” S.S.

10 Cal/Zero Gas Supply Tubing 12” (2) 1/4” S.S.

11 Bypass Eductor Air Supply Tubing 22” (2) 1/4” S.S.

Replacement Tubing List

Preventive Maintenance and Servicing Removing the Probe Enclosure Cover


Use the following procedure to remove the probe enclosure cover.

1. Undo the four latches that secure the one-piece probe cover to the back side of the probe chassis (see Figure 4–1).

Figure 4–1. Undoing the Probe Enclosure Cover Latches

2. Begin removing the probe cover (see Figure 4–2) from the probe chassis by gripping the lip in back of the cover, and then pulling up, out, and down in a circular-like fashion.

Figure 4–2. Removing the Probe Enclosure Cover

Removing the Probe Enclosure

Cover

Closed Latch

Open Latch

Cover Lip

Preventive Maintenance and Servicing Detaching the Umbilical from the Probe Chassis


3. Slide the probe cover away from and off of the probe chassis along its sides (see Figure 4–3).

Note The probe cover insulation friction fits the left and right sides of the probe chassis. ▲

Figure 4–3. Probe with the Cover Removed

4. Service the probe as necessary per the applicable section(s) of this chapter.

5. Reinstall the probe cover using this procedure in reverse order.

Use the following procedure to detach the umbilical from the probe chassis.

1. Turn off all electrical and gas supplies to the probe.

2. Remove the probe enclosure cover as previously described in “Removing the Probe Enclosure Cover”.

3. Loosen the socket head set screws that secure the gas conditioning tray to the slide rails (see Figure 4–4).

Detaching the Umbilical from

the Probe Chassis



4. Disconnect the elemental mercury (line #1) and total mercury (line #2), respectively, from the converter and scrubber outlets on the gas conditioning tray.

Figure 4–4. Gas Conditioning Tray Assembly Top View

5. Slide the gas conditioning tray out to the edge of the probe chassis without disconnecting any wiring or plumbing (see Figure 4–5).

Note Alternately, the gas conditioning tray can be pulled out of the probe chassis and set aside with appropriate support. In this case, disconnect the orifice-converter and orifice-scrubber diluted sample plumbing on top of the filter block. ▲

Elemental Mercury Line Total Mercury Line



Figure 4–5. Probe with Gas Conditioning Tray Slid Out

6. Disconnect the dilution air (line #7) and vacuum (line #6) from the filter block (see Figure 4–6).

Figure 4–6. Dilution Air and Vacuum Plumbing Connections

7. Disconnect the bypass eductor air (line #5) from the filter block (see Figure 4–7).

Dilution Air

Vacuum



Figure 4–7. Bypass Eductor Air Plumbing Connections

8. Pull the elemental mercury, total mercury, bypass eductor, dilution air, and vacuum lines out of the retainer slot on the feed-thru holder plate (see Figure 4–8).

Figure 4–8. Electro-Pneumatic Tray Assembly Top View

Bypass Eductor Air Supply

Umbilical Tube Retainer Slot



9. Disconnect the cal/zero and blow back air supply lines from the electro-pneumatic tray solenoid valves via the right side access window (see Figure 4–9).

Note Alternately, the accumulator tank may be removed prior to disconnecting the cal/zero and blow back air supply lines (see Figure 4–10). ▲

Figure 4–9. Cal/Zero Gas, Blow Back Air and Accumulator Tank Supply Connections Viewed from Right Side Access Window

Figure 4–10. Electro-Pneumatic Tray Assembly with Accumulator Tank Removed

Blow Back Air Supply Cal/Zero Gas Supply

Cal/Zero Gas Supply

Blow Back Air

Tank Connectors

Accumulator Tank



10. Disconnect all umbilical wires from the terminal strip on the left side of the electro-pneumatic tray assembly (see Figure 4–11).

Figure 4–11. Umbilical Wiring Terminal Connections



11. Loosen the 3-inch strain relief umbilical nut located externally below the probe enclosure (see Figure 4–12).

Figure 4–12. Umbilical Strain Relief Fitting Close-up View

Note The strain relief lock washer inside the probe enclosure may have to be retained to prevent slippage while loosening the umbilical nut. ▲

12. Pull the umbilical out through the strain relief.

13. Slide the gas conditioning tray back into the probe chassis (see Figure 4–13).

Figure 4–13. Probe with Umbilical Removed

Umbilical Strain Relief Nut

Preventive Maintenance and Servicing Removing the Probe from the Sample Port



15. Remove and/or dismantle, and service the Model 83i GC probe as necessary per the “Removing the Probe from the Sample Port” or other applicable section in this chapter.

16. Attach the umbilical back to the probe chassis using this procedure in reverse order after completing probe service.

Use the following procedure to remove the entire probe from the sample port.


2. Detach the umbilical if necessary depending upon the type of service provided as previously described in “Detaching the Umbilical from the Probe Chassis”.

3. Remove the 5/8 nuts and lock washers securing the probe to universal mounting flange in four places from inside the probe chassis (see Figure 4–14).

Note The nuts can be unfastened from the universal mounting flange by inserting a 5/8-inch ratchet through the access holes on the filter block mounting plate or by using a crescent wrench from behind the plate. ▲

Removing the Probe from the

Sample Port

Preventive Maintenance and Servicing Removing the Probe from the Sample Port


Figure 4–14. Unfastening Probe from Universal Mounting Flange

4. Using appropriate support equipment and manpower pull the probe off of the universal mounting flange studs and out of the sample port (see Figure 4–15).

Note The studs on the universal mounting flange support the probe during unfastening. ▲

Figure 4–15. Pulling the Probe out of the Sample Port

Access Hole

5/8” Lock Washer5/8” Nut

Preventive Maintenance and Servicing Removing the Universal Flange from the Stack


5. Provide proper probe support whether keeping it at sample port level or lowering it onto its bottom.

6. Dismantle and service the Model 83i GC probe as necessary per the applicable sections in this chapter (see Figure 4–16).

Figure 4–16. Probe Removed from the Sample Port

7. Reinstall the Model 83i GC probe to the sample port using this procedure in reverse order.

Use the following procedure to remove the universal mounting flange from the sample port.

1. Remove the probe as previously described in “Removing the Probe from the Sample Port” (see Figure 4–17).

Removing the Universal Flange

from the Stack



Figure 4–17. Universal Mounting Flange Attached to the Sample Port after Probe Removal

2. Remove the probe support gasket from the universal mounting flange (see Figure 4–18).

Figure 4–18. Universal Mounting Flange Detachment from the Sample Port after Probe Removal

5/8-11 x 2” SS Bolt

Universal MountingFlange

Probe Support Gasket

5/8” SS Lock Washer

Universal Mounting Flange Gasket



3. Remove the 5/8-inch bolts and lock washers securing the universal mounting flange to the stack sample port in eight places from the rear of the sample port flange.

Note Hold onto the universal mounting flange accordingly during bolt removal as it is the only support provided. ▲

4. Remove the universal flange and gasket from the sample port.

5. Inspect and clean the 2-inch probe support gasket, replacing it as necessary.

Note Replace the probe support gasket annually if not required sooner. ▲

6. Inspect and clean the 4-inch universal mounting flange gasket, replacing it as necessary.

Note Replace the universal mounting flange gasket annually if not required sooner. ▲

7. Clean the universal mounting flange accordingly in preparation for inspection.

Figure 4–19. Universal Mounting Flange Removed

Preventive Maintenance and Servicing Replacing Factory Supplied Tubing


8. Check the structural integrity of the universal mounting flange, repairing or replacing it as necessary.

Note It is critical to thoroughly check the structural integrity of the welded 5/8-inch mounting studs as they solely support the probe to the sample port. If corrosion becomes excessive, especially on the stack side of the flange, replacement may also be warranted. ▲

9. Check the workability of the 5/8-inch male and 5/8-inch female threads on the universal mounting flange, reforming the threads or replacing the flange as necessary.

10. Apply anti-seize compound to the 5/8-inch mounting studs accordingly before reassembly.

11. Check the thread workability of the 5/8-inch hex head sample port mounting bolts, replacing them as necessary.

12. Apply anti-seize compound to the 5/8-inch hex head bolts accordingly before reassembly.

13. Check the condition of the 5/8-inch sample port mounting bolt lock washers, replacing them as necessary.

14. Reattach the universal mounting flange to the sample port using this procedure in reverse order.

Use the following procedure to replace factory supplied tubing if necessary.

Refer to Table 4–2 for the replacement tubing and tube nut-ferrule parts list for the Model 83i GC.

Note Depending on the conditions of the stack or duct, annual or more/less frequent replacement of factory tubing should be performed. An ideal time would be shut-down. ▲

1. Turn off all electrical and gas supplies to the probe, except the power to the heaters, if replacing the tubing with the probe installed.

Replacing Factory Supplied

Tubing



2. Remove the cover as previously described in “Removing the Probe Enclosure Cover” or remove the probe as previously described in “Removing the Probe from the Sample Port”.

3. Disconnect and replace the orifice-converter (Item 1) and orifice-scrubber (Item 2) tubing and nuts-ferrules (see Figure 4–20).

Figure 4–20. Orifice-Converter and Orifice-Scrubber Tubing Replacement


5. Slide the gas conditioning tray out of the probe chassis without disconnecting any wiring and set it aside with appropriate support (see Figure 4–5).

6. Disconnect and replace the heated dilution eductor air (Item 8) and heated bypass eductor air (Item 9) tubing with nuts-ferrules (see Figure 4–21).

Orifice-Converter Tubing

Orifice-Scrubber Tubing



Figure 4–21. Heated Dilution Eductor Air and Heated Bypass Eductor Air Tubing Replacement

7. Disconnect and replace the calibration/zero gas supply (Item 10) tubing with nuts-ferrules (see Figure 4–22).

Figure 4–22. Calibration/Zero Gas Supply Tubing Replacement

Calibration/Zero Gas Support Tubing

Heated Bypass Eductor Air Tubing

(Bypass Eductor Supply Fitting Not Shown For Clarity)

Heated Dilution Eductor Air Tubing



8. Disconnect and replace the bypass eductor air supply tubing (Item 11) with nuts-ferrules (see Figure 4–23).

Figure 4–23. Bypass Eductor Air Supply Tubing Replacement

9. Disconnect and replace the filter blow back air (Item 5) and stinger blow back air tubing (Item 6) with nuts-ferrules (see Figure 4–24).

Figure 4–24. Filter and Stinger Blow Back Air Tubing Replacement

Bypass Eductor Air Supply Tubing

Stinger Blow Back Air Tubing

Filter Blow Back Air Tubing

Preventive Maintenance and Servicing Removing the Filter Block-Support Plate Assembly from Probe Chassis


10. Disconnect and replace the Hg spike gas (Item 3), and cal/zero gas (Item 4) tubing with nuts-ferrules (see Figure 4–25).

Figure 4–25. Hg Spike Gas and Cal/Zero Gas Tubing Replacement

11. Reassemble the probe using this procedure in reverse order.

Use the following procedure to remove the filter block-mounting support assembly for service.

1. Turn off all electrical and gas supplies to the probe, except the power to the stinger heater.

2. Turn off the analyzer sample pump at the rack.


4. Disconnect the filter blow back air manifold plumbing in back of the filter block (see Figure 4–26).

Removing the Filter Block-Support Plate

Assembly from Probe Chassis

Hg Spike Gas Tubing

Cal/Zero Gas Tubing



Figure 4–26. Filter Blow Back Air Plumbing Disconnection

5. Disconnect the bypass eductor air (line #5) underneath the filter block (see Figure 4–27).

Filter Blow Back Air



Figure 4–27. Bypass Eductor Air, Hg Spike Gas, Cal/Zero Gas, Stinger Blow Back Air, Orifice-Converter Diluted Sample, and Orifice-Scrubber Diluted Sample Plumbing Disconnection

6. Disconnect the Hg spike gas, cal/zero gas, and stinger blow back air plumbing in front of the filter block (see Figure 4–27).

7. Disconnect the orifice-converter and orifice-scrubber diluted sample plumbing on top of the filter block (see Figure 4–27).

8. Disconnect the dilution air (line #7) and vacuum plumbing (line #6) in back of the filter block (see Figure 4–28).

Note Remove the elbow tube fitting when disconnecting the dilution air to enable easy access to the sample inlet plumbing connection. ▲

Orifice-Converter Diluted Sample

Orifice-Scrubber Diluted Sample

Stinger Blow Back Air Hg Spike Gas

Cal/Zero Gas Bypass Eductor Air



Figure 4–28. Dilution Air and Vacuum Plumbing Disconnection

9. Disconnect the diluted sample return and bypass return plumbing on the probe support assembly (see Figure 4–29).

Figure 4–29. Diluted Sample Return, Bypass Return, and Sample Inlet Plumbing Disconnection

10. Disconnect the sample inlet plumbing in back of the filter block (see Figure 4-30).


12. Slide the gas conditioning tray out to the front of the probe chassis without disconnecting any wiring (see Figure 4–30).

Dilution AirVacuum

Diluted Sample Return

Bypass Return



Figure 4–30. Gas Conditioning Tray Slid Out to Front of Probe Chassis

13. Pull the filter thermocouple and filter heater probe wiring out of the electro-pneumatic tray assembly and slotted, feed-thru grommet holder plate (see Figure 4–30).

14. Detach the factory wired filter thermocouple and filter heater probe wiring terminations from the probe terminal strip located on the bottom left of the electro-pneumatic tray assembly (see Figure 4–31).

Figure 4–31. Filter Thermocouple-Heater Wiring Terminations

Filter Thermocouple and Heater Wiring

Set Screws (4)



15. Place the filter thermocouple and filter heater probe wiring into the filter block section.



18. Remove the three 1/4-20 nuts that secure the filter support plate to the probe support assembly (see Figure 4–32).

Figure 4–32. Filter Support Plate Mounting Nut Removal

19. Slide the filter block-mounting support assembly out of the probe enclosure and set aside accordingly for service (see Figure 4–33).

Mounting Nut

Preventive Maintenance and Servicing Removing the Filter Block Assembly from the Support Plate


Figure 4–33. Probe with Filter Block-Support Plate Assembly Removed from Chassis

20. Cap off the sample stinger tube protruding from the sample port (see Figure 4–33).


Note Steps 20 to 21 can be skipped if the probe is kept out of service for only a short period of time. ▲

22. Dismantle the filter block-mounting plate assembly per “Removing the Filter Block Assembly from the Support Plate” and “Dismantling the Filter Block Assembly” as necessary for providing the applicable service.

23. Reinstall the filter block-mounting plate assembly using this procedure in reverse order after completing service.

Use the following procedure to remove the filter block assembly from the mounting support assembly.

1. Remove the filter block-mounting plate assembly as previously described in “Removing the Filter Block-Support Plate Assembly from Probe Chassis” (see Figure 4–34).

Removing the Filter Block Assembly from

the Support Plate

Stinger Tube Cap

Preventive Maintenance and Servicing Removing the Filter Block Assembly from the Support Plate


Figure 4–34. Filter Block-Mounting Plate Assembly Removed from Probe Chassis

2. Remove the front and back 1/4-20 nuts on the removable support rod and stand-off that holds the filter block assembly to the support plate (see Figure 4–35).

Figure 4–35. Detaching the Filter Block Assembly from the Mounting Plate

1/4-20 Nut

Removable Stand-off

Removable Support Rod

1-Piece Support Rods

Preventive Maintenance and Servicing Removing the Filter Block Assembly from Probe Chassis


3. Take off the removable support rod and stand-off.

4. Remove the 1/4-20 nuts that secure the filter block assembly to the two 1-piece support rods on the support plate.

5. Pull the filter block assembly off the support rods (see Figure 4–36).

Figure 4–36. Filter Block Assembly Removed from Mounting Plate Assembly

6. Refer to “Dismantling the Filter Block Assembly” as necessary for providing the appropriate service.

7. Reattach the filter block assembly to the support plate assembly using this procedure in reverse order after completing service.

Use the following procedure to remove the filter block assembly from the probe chassis for service.

1. Turn off all electrical and gas supplies to the probe, except the power to the stinger heater.


Removing the Filter Block Assembly

from Probe Chassis




4. Disconnect the filter blow back manifold plumbing in back of the filter block (see Figure 4–26).

5. Disconnect the bypass eductor air (line #5) underneath the filter block (see Figure 4–27).

6. Disconnect the Hg spike, cal/zero, and stinger blow back plumbing in front of the filter block (see Figure 4–27).

7. Disconnect the orifice-converter and orifice-scrubber diluted sample plumbing on top of the filter block (see Figure 4–27).

8. Disconnect the dilution air (line #7) and vacuum plumbing (line #6) in back of the filter block (see Figure 4–28).

Note Remove the elbow tube fitting when disconnecting the dilution air to enable easy access to the sample inlet plumbing connection. ▲

9. Disconnect the diluted sample return and bypass return plumbing on the probe support assembly (see Figure 4–29).

10. Disconnect the sample inlet plumbing in back of the filter block (see Figure 4-30).



13. Pull the filter thermocouple and filter heater probe wiring out of the electro-pneumatic tray assembly and feed-thru grommet holder plate, placing it up in the filter block section (see Figure 4–30).

14. Detach the factory wired filter thermocouple and filter heater probe wiring terminations from the probe terminal strip located on the bottom left of the electro-pneumatic tray assembly (see Figure 4–31).



15. Place the filter thermocouple and filter heater probe wiring into the filter block section.



18. Remove the front and back 1/4-20 nuts on the removable support rod and stand-off that holds the filter block assembly to the support plate (see Figure 4–37).

Figure 4–37. Removing the Filter Block Assembly from Probe Chassis

19. Take off the removable support rod and stand-off (see Figure 4–37)

20. Remove the 1/4-20 nuts that secure the filter block assembly to the two 1-piece support rods on the support plate (see Figure 4–37).

21. Pull the filter block assembly off the support rods and out of the probe enclosure (see Figure 4–37).

Removable Stand-off

Removable Support Rod

Filter Block Assembly

1/4-20 Nut(s)

Preventive Maintenance and Servicing Dismantling the Filter Block Assembly


22. Cap off the sample stinger tube protruding from the sample port (see Figure 4–33).


Note Steps 22 to 23 can be skipped if the probe is kept out of service for only a short period of time. ▲

24. Refer to “Dismantling the Filter Block Assembly” as necessary in order to provide the applicable service.

25. Reinstall the filter block assembly using this procedure in reverse order after completing service.

Use the following procedure to dismantle the filter block assembly into the various component subassemblies.

1. Remove the filter block assembly as previously described in “Removing the Filter Block Assembly from Probe Chassis” or “Removing the Filter Block Assembly from the Support Plate” (see Figure 4–36).

2. Remove the diluted sample return plumbing assembly by breaking the tube connection at the rear of the sample flow orifice assembly (see Figure 4–38).

Dismantling the Filter Block

Assembly



Figure 4–38. Filter Block Assembly Dismantled

3. Remove the bypass eductor return plumbing assembly by breaking the tube connection at the rear of the bypass eductor assembly.

4. Remove the filter blow back/sample pressure manifold assembly by breaking the tube connection at the rear of the filter housing.

5. Remove the calibration supply/stinger blow back manifold assembly by breaking the tube connection at the front of the filter housing.



6. Remove the dilution eductor-sample flow orifice plumbing assembly by breaking the tube connections at the dilution eductor and the sample flow orifice assemblies.

7. Remove the Teflon heated dilution eductor air tubing by breaking the tube connections at the stainless steel heater tube outlet and dilution eductor inlet.

8. Detach the sample flow orifice assembly from the top of the filter housing by removing the four 8-32 x 3/8-inch long socket head cap screws.

9. Detach the filter heater mounting plate assembly from the right side of the filter housing by removing the four 8-32 x 5/8-inch long socket head cap screws and pulling it out.

Note Hold the mounting studs between the plate and filter housing in place accordingly in order to prevent them from backing out while removing the socket head cap screws. ▲

10. Detach the bypass eductor assembly from the bottom of the filter housing by removing the four 8-32 x 1/2-inch long socket head cap screws.

11. Remove the #106 o-ring from the sealing gland on the bypass eductor adaptor plate.

12. Detach the dilution eductor assembly from the left side of the filter housing by removing the four 8-32 x 3/8-inch long socket head cap screws.

13. Remove the #106 o-ring from the sealing gland on the dilution eductor sample port plate.

14. Service the various component subassemblies as necessary per the applicable heading in this chapter.

15. Put the filter block assembly back together using this procedure in reverse fashion.

Preventive Maintenance and Servicing Servicing the Filter Housing Assembly


Note The #106 o-rings and Teflon tubing removed during this procedure should be thoroughly inspected for integrity, and then cleaned and/or replaced accordingly before reassembling the unit. ▲

Use the following procedure to dismantle and completely service the various components of the filter housing assembly.

1. Remove the filter housing assembly from the filter block assembly as previously described in “Dismantling the Filter Block Assembly” (see Figure 4–39).

Figure 4–39. Filter Housing Assembly Removed

2. Attach the filter cap removal handle (see Table 2–1, Item 10) to the assembly using the two 10-32 x 1-inch long socket head cap screws provided (see Figure 4–40).

Servicing the Filter Housing

Assembly



Figure 4–40. Filter Cap Removal Handle Attached

3. Remove the four 1/4-20 x 3/4-inch long socket head cap screws holding the filter cap to the assembly (see Figure 4–41).

Figure 4–41. Filter Housing Assembly Dismantled



4. Pull the filter cap off using the filter cap removal handle.

5. Remove the filter retainer with using a 1/4-inch Allen wrench.

6. Remove the #224 face seal o-ring from the filter cap.

7. Dismantle the filter element from the Teflon seals.

8. Remove the sample inlet and calibration/blow back supply fittings from the filter housing.

9. Remove the four 8-32 x 1/4-inch long standoffs for the filter heater mounting plate assembly.

10. Inspect, and clean or replace the dilution air heater tube as necessary.

Note The dilution air heater tube must be cut off if replaced as the tube nuts and ferrules are permanently affixed in place during assembly. ▲

11. Inspect and clean all sample wetted surfaces on the filter housing, filter cap, and filter retainer accordingly.

Note It is critical that to make certain all sealing surfaces are clean. ▲

12. Check the workability of all 8-32, 10-32, and 1/4-20 female threads on the filter housing and filter cap, re-tapping them as necessary.

13. Check the workability of threads on the 8-32 standoffs, and 10-32 and 1/4-20 socket head cap screws, replacing them as necessary.

14. Apply anti-seize compound (see Table 4–1) to the threads on the 8-32 standoffs, and 10-32 and 1/4-20 socket head cap screws before reassembly.

15. Check the workability of threads on the filter retainer, reforming or replacing it as necessary.

16. Apply anti-seize compound (see Table 4–1) to the threads on the filter retainer before reassembly.



17. Remove Teflon tape from the sample inlet and calibration/blow back supply fittings taken off the filter housing.

18. Inspect, clean, and check the workability of threads on the sample inlet and calibration/blow back supply fittings, replacing them as necessary.

19. Apply new Teflon tape to the NPT threads on the sample inlet and calibration/blow back supply fittings.

20. Check the workability of female NPT threads on the filter housing for the sample inlet and calibration/blow back supply fittings, re-tapping them as necessary.

21. Inspect and ultrasonically clean the sintered metal filter element, replacing it as necessary.

Note Replace the filter element annually if not required sooner. ▲

22. Inspect and clean the two Teflon seals for the filter element, replacing them as necessary.

Note Replace the Teflon seals quarterly if not required sooner. ▲

23. Inspect and clean the #224 filter cap face seal o-ring, replacing it as necessary.

Note Replace the o-ring quarterly if not required sooner. More frequent replacement may be required the more often the filter housing is disassembled due to the occurrence of compression setting at the elevated operating temperature. ▲

24. Put the filter housing assembly back together using this procedure in reverse fashion.

Note Tighten the 1/4-20 socket head cap screws in an “X” pattern when fastening the filter cap back to the housing in order to distribute the load uniformly and prevent damage to the o-ring. ▲

Preventive Maintenance and Servicing Servicing the Dilution Eductor Assembly


Use the following procedure to dismantle and completely service the dilution eductor assembly.

1. Remove the dilution eductor assembly from the filter block assembly as previously described “Dismantling the Filter Block Assembly” (see Figure 4–42).

Figure 4–42. Dilution Eductor Assembly Removed

2. Unscrew the four 6-32 x 1-inch long Philips head pan screws holding the top plate, springs, and washers to the side plates (see Figure 4–43).

Servicing the Dilution Eductor

Assembly



Figure 4–43. Dilution Eductor Assembly Dismantled

3. Remove the top plate and associated hardware.

4. Unscrew the two 6-32 x 1/2-inch long Philips head flat screws located on the side plate holding the eductor body block and orifice holder block in place.



5. Remove the eductor body block and orifice holder block.

6. Unscrew the two 6-32 x 1-1/2-inch long Philips head pan screws to remove each side plate from the sample port plate.

7. Check the workability of threads on the 6-32 Philips head pan screws, replacing them as necessary.

8. Apply anti-seize compound to the threads on the 6-32 Philips head pan screws before reassembly.

9. Remove the #106 face seal o-ring from the sample port plate.

10. Inspect and clean the sample port plate as necessary.


11. Inspect and clean the #106 sample port plate face seal o-ring, replacing it as necessary.

Note Replace the o-ring quarterly if not required sooner. More frequent replacement may be required the more often it is disassembled due to the occurrence of compression setting at the elevated operating temperature. ▲

12. Check the workability of the 6-32 female threads on the sample port plate, reforming them or replacing it as necessary.

13. Check the workability of the 6-32 female threads on the side plate, re-tapping them as necessary.

14. Remove and disassemble the stainless steel vacuum line fittings from the orifice holder block.

15. Remove Teflon tape from the vacuum line fitting NPT threads.

16. Inspect, clean, and check the workability of all threads on the vacuum line fittings, replacing them as necessary.

17. Apply Teflon tape to the NPT threads on the vacuum line fittings.



18. Unscrew and remove the orifice plug holder from the orifice holder block.

19. Remove the glass orifice using appropriate tweezers accordingly.

Note If difficult, an alternative method is to push the glass orifice out from the opposite side using a 1/16-inch maximum diameter pin or pick. ▲

20. Remove, inspect and clean the #006 orifice, #106 orifice body, and #014 orifice plug holder o-rings seals, replacing them as necessary.

Note Replace the o-rings quarterly if not required sooner. More frequent replacement may be required the more it is disassembled due to the occurrence of compression setting at the elevated operating temperature. ▲

21. Inspect, clean or replace the glass orifice as necessary.

Note Glass orifice replacement requirements vary depending upon the application. Replace the orifice quarterly if not required sooner. If in doubt, replace the orifice immediately to ensure proper operation. ▲

22. Inspect and clean the orifice block holder and orifice plug holder accordingly.


23. Check the workability of all mating threads on the orifice holder block and orifice plug holder, reforming threads or replacing parts as necessary.

24. Unscrew, remove and disassemble the stainless steel eductor jet-fittings located on the supply side of the eductor body block.

25. Unscrew and remove the stainless steel fitting located on the exhaust side of the eductor body block.

26. Remove Teflon tape from the eductor body fitting NPT threads.

Preventive Maintenance and Servicing Servicing the Bypass Eductor Assembly


27. Inspect, clean, and check the workability of all threads on the eductor body fittings, replacing them as necessary.

28. Remove, inspect and clean the #109 eductor jet o-ring seals, replacing it as necessary.

Note Replace the o-ring quarterly if not required sooner. More frequent replacement may be required the more it is disassembled due to the occurrence of compression setting at the elevated operating temperature. ▲

29. Inspect and ultrasonically clean the eductor body block and eductor jet, replacing parts as necessary.


30. Check the workability of all mating threads on the eductor body block and eductor jet, reforming threads or replacing parts as necessary.

31. Apply Teflon tape to the NPT threads on applicable eductor fittings.

32. Put the dilution eductor assembly back together using this procedure in reverse fashion.

33. Note Tighten the 6-32 Philips head pan screws in an “X” pattern when fastening the eductor top plate back to the side plate in order to distribute the load uniformly and prevent damage to the o-rings. Compress the springs evenly, but not fully for proper sealing. Do not over tighten the eductor exhaust fittings to avoid damaging the Vespel eductor body. ▲

Use the following procedure to dismantle and completely service the bypass eductor assembly.

1. Remove the bypass eductor assembly from the filter block assembly as previously described in “Dismantling the Filter Block Assembly” (see Figure 4–44).

Servicing the Bypass Eductor

Assembly



Figure 4–44. Bypass Eductor Assembly Removed

2. Disconnect the tube nuts and remove the Teflon heated bypass eductor air tubing (see Figure 4–45).

Figure 4–45. Bypass Eductor Assembly Dismantled

#8-32 x 2” SHCS

Housing Block

1/4” Union

Eductor Spacer Block

1/4” Heated Air Tubing

1/4” Union Elblow

1/4” Air Heater Tube

Adaptor Plate



3. Unscrew the two 8-32 x 2-inch long socket head cap screws and remove the housing block from the adaptor plate.

4. Detach the bypass eductor using a 1/2-inch open end wrench.

Note Do not attempt to remove the eductor by holding onto its body as doing so could break the welded connection to the fitting. ▲

5. Remove the spacer block freed after detaching the eductor.

6. Disconnect and remove the two 1/4-inch union connector and two 1/4 inch union elbow tube fittings from the assembly.

7. Remove Teflon tape from the eductor body fitting NPT threads.

8. Check the workability of all mating NPT threads on the eductor body fitting and adaptor plate, reforming threads or replacing parts as necessary.

9. Inspect and ultrasonically clean the bypass eductor assembly, replacing it as necessary.

10. Check the cleanliness and thread-ability of the bypass eductor, ultrasonically cleaning or replacing it as necessary.

Note The bypass eductor replacement requirements vary depending upon both the application and clean-ability for reuse. It is critical to clean the eductor internals thoroughly for it to operate properly. The eductor can be disassembled further for subcomponent cleaning if necessary. Make certain that debris is thoroughly flushed from the eductor if and after cleaning is attempted. Replace the eductor on an as needed basis. If in doubt, replace the orifice immediately to ensure proper operation. ▲

11. Inspect and ultrasonically clean the adaptor plate and bypass eductor air heater tube, replacing parts as necessary.

Note It is critical that to make certain that the o-ring seal gland on the adaptor plate is clean. The bypass eductor air heater tube must be cut off to be replaced as the tube nuts and ferrules are permanently affixed in place during assembly. ▲

Preventive Maintenance and Servicing Servicing the Sample Flow Orifice Assembly


12. Check the cleanliness and thread-ability of the eductor assembly tube fittings, cleaning or replacing them as necessary.

13. Check the workability of the 8-32 female threads on the adaptor plate, reforming them or replacing it as necessary.

14. Check the workability of threads on the 8-32 socket head cap screws, replacing them as necessary.

15. Apply anti-seize compound to the threads on the 8-32 socket head cap screws before reassembly.

16. Apply Teflon tape to the eductor body fitting NPT threads.

17. Put the bypass eductor assembly back together using this procedure in reverse fashion.

Use the following procedure to dismantle and completely service the sample flow orifice assembly.

1. Remove the sample flow orifice assembly from the filter block assembly as previously described in “Dismantling the Filter Block Assembly” (see Figure 4–46).

Figure 4–46. Sample Flow Orifice Assembly Removed

Servicing the Sample Flow

Orifice Assembly

Preventive Maintenance and Servicing Servicing the Sample Flow Orifice Assembly


2. Unscrew the two 8-32 x 7/8-inch long socket head cap screws and remove the block top from the block bottom (see Figure 4–47).

Figure 4–47. Sample Flow Orifice Assembly Dismantled

3. Unscrew all tube nut connections, breaking the sample flow orifice assembly down into separate parts.

4. Disconnect the male branch tee from the female branch tees at the NPT connection.

5. Remove Teflon tape from the male branch tee fitting NPT threads.

6. Check the workability of the mating NPT threads on the male and female branch tees, reforming threads or replacing parts as necessary.

7. Check the cleanliness and thread-ability of the stainless steel flow orifices, ultrasonically cleaning or replacing them as necessary.

Note The orifice replacement requirements vary depending upon both the application and clean-ability for reuse. Replace the orifices on either an as needed or quarterly basis. Make certain that debris is thoroughly flushed from the filter if and after cleaning is attempted. If in doubt, replace the orifice immediately to ensure proper operation. ▲

1/4” Union Elbow

1/4” Union

1/4” Male Branch Tee

#8-32 x 1/8” SHCSBlock Top

1/4” Port Connector

1/4” Female Branch Tee

Stainless Steel Flow Orifice

Block Bottom

Preventive Maintenance and Servicing Servicing the Filter Heater Assembly


8. Check the cleanliness and thread-ability of the sample flow orifice assembly tube fittings-tubing sections, cleaning or replacing them as necessary.

9. Check the workability of the 8-32 female threads on the block bottom plate, reforming them or replacing it as necessary.



12. Apply Teflon tape to the male branch tee fitting NPT threads.

13. Put the sample flow orifice assembly back together using this procedure in reverse fashion.

Use the following procedure to dismantle and completely service the filter heater assembly.

1. Remove the filter heater assembly from the filter block assembly as previously described in “Dismantling the Filter Block Assembly” (see Figure 4–48).

Figure 4–48. Filter Heater Assembly Removed

Servicing the Filter Heater Assembly



2. Unscrew the two 6-32 x 5/16-inch long socket head cap screws holding each rod heater to heater mounting plate (see Figure 4–49).

Figure 4–49. Filter Heater Assembly Dismantled

3. Remove the rod heaters from the heater mounting plate.

4. Unscrew the two 6-32 x 5/16-inch long socket head cap screws holding the Type K thermocouple to heater mounting plate.

5. Remove the thermocouple from the heater mounting plate.

6. Check the workability of the 6-32 female threads on the heater mounting plate, reforming them or replacing it as necessary.



9. Check for proper resistance of the rod heaters, replacing them as necessary.

Note The heater element resistance is nominally 140 ohms. ▲

#6-32 x 5/16” SHCSThermocouple

Mounting Plate

Rod Heater



10. Check for proper milli-volt output of the Type K thermocouple at a known temperature, replacing it as necessary.

Note Refer to Table 4–3 for the correct milli-volt readings. ▲

Table 4–3. Type K Thermoelectric Voltage in mV

T(°C) +0 +1 +2 +3 +4 +5 +6 +7 +8 +9

0 0.000 0.039 0.079 0.119 0.158 0.198 0.238 0.277 0.317 0.357

10 0.397 0.437 0.477 0.517 0.557 0.597 0.637 0.677 0.718 0.758

20 0.798 0.838 0.879 0.919 0.960 1.000 1.041 1.081 1.122 1.163

30 1.203 1.244 1.285 1.326 1.366 1.407 1.448 1.489 1.530 1.571

40 1.612 1.653 1.694 1.735 1.776 1.817 1.858 1.899 1.941 1.982

50 2.023 2.064 2.106 2.147 2.188 2.230 2.271 2.312 2.354 2.395

60 2.436 2.478 2.519 2.561 2.602 2.644 2.685 2.727 2.768 2.810

70 2.851 2.893 2.934 2.976 3.017 3.059 3.100 3.142 3.184 3.225

80 3.267 3.308 3.350 3.391 3.433 3.474 3.516 3.557 3.599 3.640

90 3.682 3.723 3.765 3.806 3.848 3.889 3.931 3.972 4.013 4.055

100 4.096 4.138 4.179 4.220 4.262 4.303 4.344 4.385 4.427 4.468

110 4.509 4.550 4.591 4.633 4.674 4.715 4.756 4.797 4.838 4.879

120 4.920 4.961 5.002 5.043 5.084 5.124 5.165 5.206 5.247 5.288

130 5.328 5.369 5.410 5.450 5.491 5.532 5.572 5.613 5.653 5.694

140 5.735 5.775 5.815 5.856 5.896 5.937 5.977 6.017 6.058 6.098

150 6.138 6.179 6.219 6.259 6.299 6.339 6.380 6.420 6.460 6.500

160 6.540 6.580 6.620 6.660 6.701 6.741 6.781 6.821 6.861 6.901

170 6.941 6.981 7.021 7.060 7.100 7.140 7.180 7.220 7.260 7.300

180 7.340 7.380 7.420 7.460 7.500 7.540 7.579 7.619 7.659 7.699

190 7.739 7.779 7.819 7.859 7.899 7.939 7.979 8.019 8.059 8.099

200 8.138 8.178 8.218 8.258 8.298 8.338 8.378 8.418 8.458 8.499

210 8.539 8.579 8.619 8.659 8.699 8.739 8.779 8.819 8.860 8.900

220 8.940 8.980 9.020 9.061 9.101 9.141 9.181 9.222 9.262 9.302

230 9.343 9.383 9.423 9.464 9.504 9.545 9.585 9.626 9.666 9.707

240 9.747 9.788 9.828 9.869 9.909 9.950 9.991 10.031 10.072 10.113

250 10.153 10.194 10.235 10.276 10.316 10.357 10.398 10.439 10.480 10.520

260 10.561 10.602 10.643 10.684 10.725 10.766 10.807 10.848 10.889 10.930

270 10.971 11.012 11.053 11.094 11.135 11.176 11.217 11.259 11.300 11.341

Preventive Maintenance and Servicing Servicing the Dilution Eductor-Sample Flow Orifice Plumbing Assembly


11. Apply anti-seize compound to the heater rod and thermocouple elements before reassembly.

12. Put the filter heater assembly back together using this procedure in reverse fashion.

Use the following procedure to dismantle and service the dilution eductor-sample flow orifice plumbing assembly.

1. Remove the dilution eductor-sample flow orifice plumbing assembly from the filter block assembly as previously described in “Dismantling the Filter Block Assembly” (see Figure 4–50).

Figure 4–50. Dilution Eductor-Sample Flow Orifice Plumbing Assembly Removed

2. Unscrew all tube nut connections, breaking the plumbing assembly down into separate parts (see Figure 4–51).

Servicing the Dilution Eductor-

Sample Flow Orifice Plumbing Assembly

Preventive Maintenance and Servicing Servicing the Dilution Eductor-Sample Flow Orifice Plumbing Assembly


Figure 4–51. Dilution Eductor-Sample Flow Orifice Plumbing Assembly Dismantled

3. Check the cleanliness and thread-ability of the plumbing assembly tube fittings-tubing sections, cleaning or replacing them as necessary.

4. Check the cleanliness and thread-ability of the 15 micron silica-coated, stainless steel, in-line filter, ultrasonically cleaning or replacing it as necessary.

Note The filter replacement requirements vary depending upon both the application and clean-ability for reuse. Replace the filter on either an as needed or annually basis. Make certain that debris is thoroughly flushed from the filter if and after cleaning is attempted. If in doubt, replace the filter immediately to ensure proper operation. ▲

5. Put the dilution eductor-sample flow orifice plumbing assembly back together using this procedure in reverse fashion.

15 Micron Filter

1/4” Tube Section

1/4” Tube Section


1/4” Union Elbow

Preventive Maintenance and Servicing Servicing the Filter Blow Back-Sample Pressure Manifold Assembly


Use the following procedure to dismantle and service the filter blow back-sample pressure manifold assembly.

1. Remove the filter blow back-sample pressure manifold assembly from the filter block assembly as previously described in “Dismantling the Filter Block Assembly” (see Figure 4–52).

Figure 4–52. Filter Blow Back-Sample Pressure Manifold Assembly Removed


Figure 4–53. Filter Blow Back-Sample Pressure Manifold Assembly Dismantled

Servicing the Filter Blow Back-Sample Pressure Manifold

Assembly

1/4” Union Elbow

1/4” Union Tee 1/4” Port Connector

15 Micron Filter

Preventive Maintenance and Servicing Servicing the Calibration Supply-Stinger Blow Back Manifold Assembly



4. Check the cleanliness and thread-ability of the 15 micron stainless steel, in-line filter, ultrasonically cleaning or replacing it as necessary.

Note The filter replacement requirements vary depending upon both the application and clean-ability for reuse. Replace the filter on either an as needed or annually basis. Make certain that debris is thoroughly flushed from the filter if and after cleaning is attempted. If in doubt, replace the filter immediately to ensure proper operation. ▲

5. Put the filter blow back-sample pressure manifold assembly back together using this procedure in reverse fashion.

Use the following procedure to dismantle and service the calibration supply-stinger blow back manifold assembly.

1. Remove the calibration supply-stinger blow back manifold assembly from the filter block assembly as previously described in “Dismantling the Filter Block Assembly” (see Figure 4–54).

Figure 4–54. Calibration Supply-Stinger Blow Back Manifold Assembly Removed


Servicing the Calibration Supply-Stinger Blow Back Manifold Assembly

Preventive Maintenance and Servicing Servicing the Diluted Sample Return Plumbing Assembly


Figure 4–55. Calibration Supply-Stinger Blow Back Manifold Assembly Dismantled


4. Put the calibration supply-stinger blow back manifold assembly back together using this procedure in reverse fashion.

Use the following procedure to dismantle and service the diluted sample return plumbing assembly.

1. Remove the diluted sample return plumbing assembly from the filter block assembly as previously described in “Dismantling the Filter Block Assembly” (see Figure 4–56).

Servicing the Diluted Sample

Return Plumbing Assembly

1/4” Union Elbow


1/4” Union Cross

Preventive Maintenance and Servicing Servicing the Diluted Sample Return Plumbing Assembly


Figure 4–56. Diluted Sample Return Plumbing Assembly Removed


Figure 4–57. Diluted Sample Return Plumbing Assembly Dismantled


1/4” Tube Section

1/4” Elbow Union

1/4” Tube Section

Preventive Maintenance and Servicing Servicing the Bypass Eductor Return Tubing


4. Put the diluted sample return plumbing assembly back together using this procedure in reverse fashion.

Use the following procedure to dismantle and service the filter heater assembly.

1. Remove the bypass eductor return tubing from the filter block assembly as previously described in “Dismantling the Filter Block Assembly” (see Figure 4–58).

Figure 4–58. Bypass Eductor Return Tubing Dismantled

2. Check the cleanliness and thread workability of the tubing section, cleaning or replacing it as necessary.

3. Put the bypass eductor return tubing back together using this procedure in reverse fashion.

Use the following procedure to remove the sample stinger assembly from the probe support assembly.

1. Remove the probe as previously described in “Removing the Probe from the Sample Port”, if necessary or proceed directly to step 2.

2. Remove the filter block-mounting plate assembly as previously described in “Removing the Filter Block-Support Plate Assembly from Probe Chassis” (see Figure 4–59).

Servicing the Bypass Eductor

Return Tubing

Removing the Sample Stinger

Assembly from Probe Support Assembly

Preventive Maintenance and Servicing Removing the Sample Stinger Assembly from Probe Support Assembly


Figure 4–59. Probe with Filter Block-Mounting Plate Assembly Removed from Chassis



Figure 4–60. Gas Conditioning Tray Slid Out

Set Screw



5. Detach the factory stinger coil heater wiring terminations from the probe terminal strip located on the bottom left of the electro-pneumatic tray assembly (see Figure 4–61).

Figure 4–61. Stinger Coil Heater Wiring Terminations

6. Pull the stinger coil heater wiring out of the electro-pneumatic tray assembly and slotted, feed-thru grommet holder plate (see Figure 4–62).

Figure 4–62. Stinger Coil Heater Wiring Disconnection and Removal

Stinger Coil Heater Wiring





9. Detach the sample stinger assembly from the probe support assembly by removing the four 1/4-20 x 1/2-inch long socket head cap screws (see Figure 4–63).

Figure 4–63. Sample Stinger Assembly Detachment

10. Uniformly screw in the two 1/4-20 x 3/4-inch long socket head cap as necessary to dislodge and separate the sample stinger flange from the probe support assembly (see Figure 4–64).

1/4-20 x 1/2” SHCS



Figure 4–64. Sample Stinger Assembly Flange Dislodgement

11. Pull the entire sample stinger assembly out of the probe support assembly and probe chassis (see Figure 4–65).

Figure 4–65. Sample Stinger Assembly Removal

1/4-20 x 3/4” SHCS

#222 O-ring

Sample Stinger Assembly

Preventive Maintenance and Servicing Servicing the Sample Stinger Assembly


12. Service the sample stinger assembly as necessary.

13. Replace and properly seat the #222 Viton o-ring seal as necessary.

14. Reinstall the sample stinger assembly back into the probe support assembly and probe chassis using this procedure in reverse fashion.

Use the following procedure to dismantle and service the sample stinger assembly.

1. Remove the sample stinger assembly as previously described in “Removing the Sample Stinger Assembly from Probe Support Assembly” (see Figure 4–66).

Figure 4–66. Sample Stinger Assembly Removed

2. Remove the 1/2-inch cap fitting from the stinger tube.

3. Slide the 1/2-inch tube nut and graphite ferrule off the stinger tube.

Servicing the Sample Stinger

Assembly

1/2” Cap Fitting

1/2” Tube Nut & Graphite Ferrule



4. Pull the heater coil off the sample stinger and out of the probe barrel from the flange side (see Figure 4–67).

5. Unscrew the 1/2-inch tube nut at the sample stinger tip and remove the shroud assembly (see Figure 4–67).

Figure 4–67. Sample Stinger Assembly Dismantling

Note Spin the heater coil in a clockwise manner while pulling it out to relieve coil tension and facilitate its removal. ▲

6. Unscrew the 1/2-inch tube nut that seals the sample stinger to the probe barrel assembly.

7. Pull the sample stinger tube out of the probe barrel from the seal fitting side as the shroud assembly tube nut is permanently affixed.

8. Check the condition of the 1/2 tube nut, cleaning or replacing it as necessary.

9. Install new 1/2-inch graphite ferrule during reassembly.

1/2” Tube Nuts

1/2” Graphite Ferrule

Heater Coil

Probe Barrel

Shroud Housing

Sample Stinger Tube



Note Although the graphite ferrule could be reused to some extent, it is highly recommended to replace it whenever disassembled due to the criticality of the seal in isolating the stack gas from the probe internals. ▲

10. Check the condition and electrical resistance of the heater coil, replacing it as necessary (see Figure 4–68).

Note The heater element resistance is nominally 100 ohms. Replace the heater coil annually or on as needed basis. ▲

Figure 4–68. Sample Stinger Coil Heater Removed

11. Check the cleanliness and structural integrity of the probe barrel, cleaning or replacing it as necessary (see Figure 4–69).

Note It is critical to thoroughly check the structural integrity of the probe barrel including all welded joints, corrosion level, o-ring gland, and stinger seal fitting, as it solely isolates the stack gases from the heater coil and probe internals. ▲



Figure 4–69. Probe Barrel Assembly Removed

12. Check the workability of the 1/4-20 female and 1/2-inch tube fitting threads on the probe barrel, reforming or replacing parts as necessary

13. Apply anti-seize compound to the probe barrel assembly threads as necessary before reassembly.

14. Check the thread workability of the 1/4-20 socket head cap screws, replacing parts and applying anti-seize compound as necessary before reassembly.

15. Replace and properly seat the #222 Viton o-ring seal as necessary.

16. Check the cleanliness and structural integrity of the stinger tube and ferrules, cleaning or replacing it as necessary (see Figure 4–70).

Note These parts typically have good longevity being constructed of Hastelloy C276 and can be replaced on an as needed basis only. ▲

1/2” Tube Fitting

#222 O-ring

1/4-20 x 3/4 “ SHCS

Welded

Welded on Each Side



Figure 4–70. Stinger Tube Removed

17. Unscrew the two #8-32 x 1/8-inch long set screws holding the shroud cover to the shroud body and disassemble the parts (see Figure 4–71).

Figure 4–71. Shroud Assembly Removed

18. Check the cleanliness and structural integrity of the shroud cover, body, and set screws, cleaning or replacing parts as necessary (see Figure 4–72).

#8-32 x 1/8” Set Screw

1/2” Tube Nut

1/2” Graphite Ferrule

1/2” Stinger Tube



Figure 4–72. Shroud Assembly Dismantled

Note These parts typically have good longevity being constructed of Hastelloy C276 and can be replaced on an as needed basis only. ▲

19. Check the thread workability of the 8-32 female threads on the shroud cover and mating 8-32 set screws, reforming them or replacing parts as necessary.

20. Check the thread workability of the 1/2 tube threads on the shroud body, reforming them or replacing it as necessary.

21. Apply anti-seize compound to the shroud assembly body threads as necessary before reassembly.

22. Put the shroud assembly back together using this procedure in reverse fashion.

Note Bottom out the shroud body in the shroud cover and then back off approximately 3/8-inch before locking the set screws in place. ▲

23. Put the sample stinger assembly back together using this procedure in reverse fashion.

Shroud Body

Shroud Cover

Set Screw

Preventive Maintenance and Servicing Removing the Probe Support Assembly from the Chassis


Note Position the stinger tube such that it extends out the same length from the probe barrel flange as prior to dismantling, and then secure the tube fitting seal. ▲

Use the following procedure to remove the probe support assembly from the probe chassis.

1. Remove the sample stinger assembly as previously described in “Removing the Sample Stinger Assembly from Probe Support Assembly” (see Figure 4–73).

Figure 4–73. Probe Out of Sample Port with Filter Block-Mounting Plate and Sample Stinger Assemblies Removed from Chassis

2. Unscrew and remove the three 1/4-20 filter block-support plate assembly male-female stand-offs (see Figure 4–74).

Removing the Probe Support Assembly from

the Chassis

Preventive Maintenance and Servicing Removing the Probe Support Assembly from the Chassis


Figure 4–74. Probe Support Assembly 1/4-20 Stand-offs and Retainer Nuts Removal

3. Unscrew and remove the three 1/4-20 nuts holding the probe support assembly to the back side of the chassis.

4. Pull out the probe support assembly from the chassis (see Figure 4–75).

Figure 4–75. Probe Support Assembly Removal

1/4-20 Nut

1/4-20 stand-off

Probe Support Assembly

Probe Gasket

Preventive Maintenance and Servicing Servicing the Probe Support Assembly


5. Remove the probe gasket off the mounting studs.

6. Check the condition of the gasket, replacing it as necessary.

7. Service the probe support assembly as necessary.

8. Reinstall the probe support assembly into the chassis using this procedure in reverse order.

Use the following procedure to dismantle and service the probe support assembly.

1. Remove the probe support assembly as previously described in “Removing the Probe Support Assembly from the Chassis” (see Figure 4–76).

Figure 4–76. Probe Support Assembly Removed

2. Unscrew and remove the two 1/4-inch diluted sample and bypass return tube fittings from the probe support flange (see Figure 4–77).

Servicing the Probe Support

Assembly

Preventive Maintenance and Servicing Servicing the Probe Support Assembly


Figure 4–77. Probe Support Assembly Dismantled

3. Remove the tube nuts and graphite ferrules from the diluted sample and bypass return tube fittings.

4. Remove Teflon tape from the diluted sample and bypass return tube fittings.

5. Inspect, clean, and check the workability of threads on the diluted sample and bypass return tube fittings, replacing them as necessary.

6. Apply new Teflon tape to the NPT threads on the diluted sample and bypass return tube fittings.

7. Check the condition of the 1/4-inch graphite ferrules, replacing them necessary.

Note The graphite ferrule replacement is application dependent. Replace the graphite ferrules on either an as needed basis or every 3 to 6 months. If in doubt, replace the graphite ferrules immediately as the seals are critical in isolating the return stack gas sample from the probe internals. ▲

1/4” FNPT

1/4” Tube Fitting 1/4” Graphite Ferrule

1/4” Tube Nut

1/4-20 Female

1/4-20 Mounting Stud

Weld on Each Side

Preventive Maintenance and Servicing Removing the Gas Conditioning Tray Assembly from the Probe Chassis


8. Check the cleanliness and structural integrity of the probe support, cleaning or replacing it as necessary.

Note It is critical to thoroughly check the structural integrity of the probe support including all mounting studs, welded joints, corrosion level, and o-ring sealing surface. ▲

9. Check the workability of the three 1/4-20 mounting stud and two 1/4-inch female pipe threads on the probe support flange, reforming or replacing it as necessary

10. Apply anti-seize compound to the 1/4-20 mounting stud threads as necessary before reassembly.

11. Check the thread workability of the 1/4-20 socket head cap screws, replacing parts and applying anti-seize compound as necessary before reassembly.

12. Put the probe support assembly back together using this procedure in reverse order.

Use the following procedure to remove the gas conditioning tray assembly from the probe chassis.



3. Put probe into continuous stinger blow back mode.

4. Turn off the dilution eductor air supply.

5. Turn off the bypass eductor air supply.

6. Turn off the electrical heater power to the converter assembly.


Removing the GasConditioning Tray

Assembly from theProbe Chassis



8. Slide the gas conditioning tray out to the edge of the probe chassis accordingly to allow access to the terminal block assembly on the electro-pneumatic tray assembly below it (see Figure 4–78).

Figure 4–78. Probe with Gas Conditioning Tray Slid Out and Sample Tubing Disconnected

9. Disconnect the sample inlet and sample outlet tubing from the scrubber assembly.

10. Disconnect the sample inlet and sample outlet tubing from the converter assembly.

11. Pull the converter thermocouple and converter heater wiring out of the electro-pneumatic tray assembly and feed-thru grommet holder plate placing it on top of the gas conditioning tray (see Figure 4–79).



Figure 4–79. Converter Wiring Removal from Feed-thru Grommet Holder Plate

12. Detach the factory wired converter thermocouple and converter heater wiring terminations from the terminal block assembly (see Figure 4–80).

Figure 4–80. Converter Thermocouple and Heater Wiring Terminations

Note Proceed with caution as electrical power to other probe components is still available. Depending on safety requirements, turn off all probe power off while performing this operation if necessary. ▲

Converter Wiring



13. Remove the 8-32 kep nut retaining the ground wire to the tray.

14. Take the ground wire off the mounting stud (see Figure 4–81).

Figure 4–81. Gas Conditioning Tray Ground Wire Disconnection

15. Slide the gas conditioning tray completely out of the probe chassis (see Figure 4–82).

Figure 4–82. Probe with Gas Conditioning Tray Removed

Ground Wire Mounting Stud

Preventive Maintenance and Servicing Dismantling the Gas Conditioning Tray Assembly


16. Dismantle and/or service the gas conditioning tray assembly as necessary.

17. Reinstall the gas conditioning tray assembly into the chassis using this procedure in reverse fashion.

Use the following procedure to dismantle the gas conditioning tray assembly into the various component assemblies.

1. Remove the gas conditioning tray as previously described in “Removing the Gas Conditioning Tray Assembly from the Probe Chassis” (see Figure 4–83).

Figure 4–83. Gas Conditioning Tray Removed

2. Remove the four 8-32 kep nuts holding the scrubber assembly to the gas conditioning tray (see Figure 4–84).

Dismantling the Gas Conditioning

Tray Assembly

Preventive Maintenance and Servicing Dismantling the Gas Conditioning Tray Assembly


Figure 4–84. Gas Conditioning Tray Dismantled

3. Take the scrubber assembly off the mounting studs.

4. Remove the four 8-32 kep nuts holding the converter assembly to the gas conditioning tray.

5. Take the converter assembly off the mounting studs.

6. Service the scrubber assembly as described in “Servicing the Scrubber Assembly”.

7. Service the converter assembly as described in “Servicing the Converter Assembly”.

8. Put the gas conditioning try assembly back together using this procedure in reverse order.

Scrubber AssemblyTray

Converter Assembly

Preventive Maintenance and Servicing Servicing the Scrubber Assembly


Use the following procedure to dismantle and completely service the scrubber assembly.

1. Remove the scrubber assembly as previously described in “Dismantling the Gas Conditioning Tray Assembly” (see Figure 4–85).

Figure 4–85. Scrubber Assembly Removed

2. Unscrew and remove the elbow union tube fitting assemblies from the inlet and outlet of the scrubber assembly (see Figure 4–86).

Figure 4–86. Scrubber Assembly Dismantled

Servicing the Scrubber Assembly

Scrubber Column Assembly

Scrubber Holder Bottom

Scrubber Holder Top

Preventive Maintenance and Servicing Servicing the Scrubber Assembly


3. Unscrew the four 6-32 x 5/8-inch long socket head cap screws and remove the scrubber holder top from the scrubber holder bottom.

4. Replace the scrubber column assembly (see Figure 4–87).

Note The scrubber column assembly should be replaced every 3 to 6 months depending upon the application. ▲

Figure 4–87. Scrubber Column Assembly Removed

5. Disassemble the elbow unions into separate fittings.

6. Check the cleanliness and thread work-ability of the elbow union assembly tube fittings, cleaning or replacing them as necessary.

7. Check the workability of the 6-32 female threads on the scrubber holder bottom, reforming them or replacing it as necessary.



10. Put the scrubber assembly back together using this procedure in reverse fashion.

Preventive Maintenance and Servicing Servicing the Converter Assembly


Use the following procedure to dismantle and completely service the converter assembly.

1. Remove the converter assembly as previously described in “Dismantling the Gas Conditioning Tray Assembly” (see Figure 4–88).

Figure 4–88. Converter Assembly Removed

2. Unscrew and remove the elbow reducer union tube fitting assemblies from the inlet and outlet of the converter assembly (see Figure 4–89).

Figure 4–89. Converter Assembly Dismantled

Servicing the Converter Assembly

Scrubber Assembly

Converter Core Assembly

Insulation Cloth Heater

Preventive Maintenance and Servicing Servicing the Converter Assembly


3. Slide the converter core assembly out of the heater.

4. Slide out the thermocouple out of the heater.

5. Unscrew the six Philips head screws and remove the converter assembly cover.

6. Remove the top insulating cloth off the heater.

7. Remove the heater from the enclosure.

8. Replace the Teflon ferrules in the elbow reducer union tube fitting assemblies.

Note The Teflon ferrules should be replaced every 3 to 6 months whenever the converter core assembly is replaced or on an as needed basis depending upon the application. ▲

9. Check and replace the elbow reducer union tube fitting assemblies as necessary.

10. Replace the converter core assembly as necessary (see Figure 4–90).

Note The converter core assembly should be replaced every 3 to 6 months depending upon the application. ▲

Figure 4–90. Converter Core Assembly Removed

Preventive Maintenance and Servicing Removing the Electro-Pneumatic Tray Assembly from the Probe Chassis


11. Check the condition and electrical resistance of the heater, replacing it as necessary.

Note The heater element resistance is nominally 55 ohms. Replace the heater annually or on an as needed basis. ▲

12. Check the condition and milli-volt output of the Type K thermocouple at a known temperature, replacing it as necessary.

Note Refer to Table 4–3 for the correct milli-volt readings. Replace the thermocouple annually or on an as needed basis. ▲

13. Check the workability of the 6-32 female threads on the converter enclosure body, reforming them or replacing it as necessary.

14. Check the workability of threads on the 6-32 Philips head screws, replacing them as necessary.

15. Apply anti-seize compound to the threads on the 6-32 Philips head screws before reassembly.

16. Check condition of remaining parts, replacing them as necessary.

17. Put the converter assembly back together using this procedure in reverse fashion.

Use the following procedure to remove the electro-pneumatic tray assembly from the probe chassis.

1. Turn off the analyzer sample pump.



4. Detach the blow back air and calibration gas/zero air inlet tube fitting connections from the solenoid valve plate assembly, accessing them

Removing theElectro-Pneumatic

Tray Assemblyfrom the Probe

Chassis



from the right hand side window of the probe chassis (see Figure 4–91).

Figure 4–91. Blow Back Air and Calibration gas/Zero Air Inlet Tube Fitting Disconnection

5. Detach the calibration gas/zero air, and Hg spike outlet tube fitting connections from the solenoid valve plate assembly, accessing them from the left hand side window and front side of the probe chassis (see Figure 4–92).

Figure 4–92. Calibration Gas/Zero Air and Hg Spike Outlet Tube Fitting Disconnection

6. Detach the filter blow back air and stinger blow back air outlet tube fitting connections from the solenoid valve plate assembly, accessing them from the front side of the probe chassis (see Figure 4–93).

Blow Back Air Inlet Cal Gas/Zero Air Inlet

Hg Spike Outlet

Cal Gas/Zero Air Outlet



Figure 4–93. Filter and Stinger Blow Back Air Outlet Tube Fitting Disconnection


8. Slide the gas conditioning tray back into place.

9. Tighten the socket head set screws to secure the gas conditioning tray to the slide rails.

10. Loosen the socket head set screws that secure the electro-pneumatic tray assembly to the slide rails, accessing them from both the left and right hand side windows of the probe chassis (see Figure 4-90 and Figure 4-91).

11. Slide the electro-pneumatic tray assembly out of the probe chassis accordingly to allow access to the terminal block assembly (see Figure 4–94).

Stinger Blow Back Air Outlet Fitting

Filter Blow Back Air Outlet Fitting



Figure 4–94. Probe with Electro-pneumatic Tray Assembly Sid Out

12. Disconnect all umbilical wires from the terminal block assembly (see Figure 4–11).

13. Disconnect the chassis ground wire from the terminal block assembly (see Figure 4–11).

14. Slide the electro-pneumatic tray assembly completely out of the probe chassis (see Figure 4–95).


Preventive Maintenance and Servicing Dismantling the Electro-Pneumatic Tray Assembly


Figure 4–95. Probe with Electro-pneumatic Tray Assembly Removed

15. Dismantle and/or service the electro-pneumatic tray assembly as necessary.

16. Reinstall the electro-pneumatic tray assembly back into the chassis using this procedure in reverse fashion.

Use the following procedure to dismantle the electro-pneumatic tray assembly into the various component assemblies.

1. Remove the electro-pneumatic tray assembly as previously described in “Removing the Electro-Pneumatic Tray Assembly from the Probe Chassis” (see Figure 4–96).

Dismantling the Electro-Pneumatic

Tray Assembly

Preventive Maintenance and Servicing Dismantling the Electro-Pneumatic Tray Assembly


Figure 4–96. Electro-pneumatic Tray Assembly Removed

2. Detach the two tube fitting connections holding the accumulator tank to the solenoid valve plate assembly (see Figure 4–97).

Figure 4–97. Electro-pneumatic Tray Assembly Dismantled

Common Lines Wiring Assembly Control Lines Wiring Assembly

Ground Lines WiringAssembly

#8-32 Kep Nut

Solenoid Valve Plate Assembly


Accumulator Tank Assembly

Preventive Maintenance and Servicing Servicing the Accumulator Tank Assembly


3. Remove the accumulator tank assembly from the solenoid valve plate assembly.

4. Disconnect all solenoid valve wires from the terminal block assembly (see Figure 4–11).

5. Disconnect the solenoid valve control lines wiring assembly from the solenoid valves.

6. Disconnect the solenoid valve common lines wiring assembly from the solenoid valves.

7. Disconnect the solenoid valve ground lines wiring assembly from the solenoid valves.

8. Remove the three 8-32 kep nuts holding the solenoid valve plate assembly to the electro-pneumatic tray.

9. Take the solenoid valve plate assembly off the mounting studs.

10. Remove the two 8-32 kep nuts holding the terminal block assembly to the electro-pneumatic tray.

11. Take the terminal block assembly off the mounting studs.

12. Service the individual component assemblies as necessary.

13. Put the electro-pneumatic tray assembly back together using this procedure in reverse order.

Use the following procedure to service the accumulator tank assembly.

1. Remove the accumulator tank assembly from the electro-pneumatic tray assembly as previously described in “Dismantling the Electro-Pneumatic Tray Assembly” (see Figure 4–98).

Servicing the Accumulator

Tank Assembly

Preventive Maintenance and Servicing Servicing the Solenoid Valve Plate Assembly


Figure 4–98. Accumulator Tank Assembly Removed

2. Check the cleanliness and structural integrity of the accumulator tank, cleaning or replacing it as necessary.

Note The structural integrity check should include all welded joints, tube stub fitting seal connections, and corrosion level if any. ▲

3. Cap one of the two tube fitting connections.

4. Pressurize the other tube fitting connection with 50 to 60 psig air.

5. Snoop the tube fitting connections and weld joints for leaks.

6. Repair or replace the accumulator tank as necessary.

7. Repeat steps 3 to 6 until the accumulator tank is leak-free.

8. Put the accumulator tank assembly back together using this procedure in reverse order.

Use the following procedure to service the solenoid valve plate assembly.

1. Remove the solenoid valve plate assembly from the electro-pneumatic tray assembly as previously described in “Dismantling the Electro-Pneumatic Tray Assembly” (see Figure 4–99).

Servicing the Solenoid Valve Plate Assembly

Weld Joints

1/4” Tube Fitting Connections



Figure 4–99. Solenoid Valve Plate Assembly Removed

2. Manifold all inlet tube fitting connections with 1/4-inch OD flexible tubing to a common regulated 50 to 60 psig air supply (see Figure 4–100).

Figure 4–100. Solenoid Valve Plate Assembly Operation-Leak Test Arrangement

3. Connect individual flexible tubing legs to each outlet fitting.

Note The tubing legs need to be long enough to submerge in small container of water for bubble tightness checking. ▲



4. Pressurize the inlet tube fitting manifold 50 to 60 psig.

5. Submerge and hold the tubing legs, one at a time, into small container of water, noting any valve where bubbling was observed.

6. Push the mechanical override buttons, one at a time and check the outlet tubing legs for air flow activation, noting any valve where flow was not observed (see Figure 4–101).

7. Repeat step 5 for each valve, one at a time, with 120 VAC electrical power applied to the valve.

8. Repeat step 6 for each valve, one at a time, with 120 VAC electrical power applied to the valve.

9. Replace any solenoid valve where bubbling was observed or flow was not activated in steps 5 to 8 (see Figure 4–101).

Figure 4–101. Solenoid Valve Plate Assembly Dismantled

10. Repeat steps 5 to 9 for any valve replaced.

11. Remove the 120 VAC power.

Solenoid Valve Override Button

Preventive Maintenance and Servicing Servicing the Terminal Block Assembly


12. Disconnect the flexible tubing legs from the outlet fittings.

13. Cap all outlet tube fittings connections.

14. Snoop the inlet fitting connections and joints for leaks.

15. Push the mechanical override buttons, one at a time, and snoop the outlet fitting connections and seals for leaks.

16. Replace any tube fitting or seal found leaking in step 14 or 15.

17. Repeat steps 14 to 16 for any tube fitting or seal replaced.

18. Disconnect the air supply to the inlet tube fitting manifold.

19. Remove the inlet tube fitting manifold.

20. Uncap all outlet tube fittings connections.

21. Put the solenoid valve plate assembly back into the electro-pneumatic tray assembly in reverse fashion as its removal.

Use the following procedure to service the terminal block assembly.

1. Remove the terminal block assembly from the electro-pneumatic tray assembly as previously described in “Dismantling the Electro-Pneumatic Tray Assembly” (see Figure 4–102).

Servicing the Terminal Block

Assembly

Preventive Maintenance and Servicing Servicing the Terminal Block Assembly


Figure 4–102. Terminal Block Assembly Removed

2. Loosen the center screw on the end ground terminal blocks (see Figure 4–103).

Figure 4–103. Terminal Block Assembly Dismantling

3. Perform electrical continuity check on each terminal block, replacing them as necessary.

Ground Terminal Block (unclipped)

Thermocouple Terminal (unclipped)

Line-Common Terminal Block Thermocouple Terminal Block

Line-Common Terminal Block (unclipped)

Preventive Maintenance and Servicing Servicing the Solenoid Valves Control Lines Wiring Assembly


4. Inspect physical condition of each terminal block, removing them from the mounting rail if necessary, replacing them as necessary.

5. Inspect for good electrical contact between the ground terminals and mounting rail, repairing or replacing them as necessary.

6. Put the terminal block assembly back together using this procedure in reverse fashion.

7. Perform electrical continuity check between the ground terminals and mounting rails.

8. Put the terminal block assembly back into the electro-pneumatic tray assembly in reverse fashion as its removal.

Use the following procedure to service the solenoid valve control lines wiring assembly.

1. Remove the solenoid valve control lines wiring assembly from the electro-pneumatic tray assembly as previously described in “Dismantling the Electro-Pneumatic Tray Assembly” (see Figure 4–104).

Figure 4–104. Solenoid Valves Control Lines Wiring Assembly

2. Perform electrical continuity check on each wire, repairing or replacing the assembly as necessary.

3. Inspect physical condition and integrity of the wires and lug connections, repairing or replacing the assembly as necessary.

4. Put the solenoid valves control lines wiring assembly back into the electro-pneumatic tray assembly in reverse fashion as its removal.

Servicing the Solenoid Valves

Control Lines Wiring Assembly

Preventive Maintenance and Servicing Servicing the Solenoid Valves Common Lines Wiring Assembly


Use the following procedure to service the solenoid valve common lines wiring assembly.

1. Remove the solenoid valve common lines wiring assembly from the electro-pneumatic tray assembly as previously described “Dismantling the Electro-Pneumatic Tray Assembly” (see Figure 4–105).

Figure 4–105. Solenoid Valves Common Lines Wiring Assembly

2. Perform electrical continuity check between each wire segment, replacing the assembly as necessary.

3. Inspect physical condition and integrity of the wires and lug connections, replacing the assembly as necessary.

4. Put the solenoid valve common lines wiring assembly back into the electro-pneumatic tray assembly in reverse fashion as its removal.

Use the following procedure to service the solenoid valve ground lines wiring assembly.

1. Dismantle the solenoid valve ground lines wiring assembly from the electro-pneumatic tray assembly as previously described “Dismantling the Electro-Pneumatic Tray Assembly” (see Figure 4–106).


Common Lines Wiring Assembly


Ground Lines Wiring Assembly

Preventive Maintenance and Servicing Service Locations


Figure 4–106. Solenoid Valves Ground Lines Wiring Assembly

2. Perform electrical continuity check on each wire leg, replacing the assembly as necessary.

3. Inspect physical condition and integrity of the wires and lug connections, replacing the assembly as necessary.

4. Inspect for good electrical ground contact surface on the ring lugs, repairing or replacing the assembly as necessary.

5. Put the solenoid valve ground lines wiring assembly back into the electro-pneumatic tray assembly in reverse fashion as its removal.

Service is available from exclusive distributors worldwide. Contact one of the phone numbers below for product support and technical information or visit us on the web at www.thermo.com/aqi.

1-866-282-0430 Toll Free

1-508-520-0430 International

Service Locations

Thermo Fisher Scientific Model 83i GC Instruction Manual A-1

Appendix A Warranty

Seller warrants that the Products will operate or perform substantially in conformance with Seller's published specifications and be free from defects in material and workmanship, when subjected to normal, proper and intended usage by properly trained personnel, for the period of time set forth in the product documentation, published specifications or package inserts. If a period of time is not specified in Seller’s product documentation, published specifications or package inserts, the warranty period shall be one (1) year from the date of shipment to Buyer for equipment and ninety (90) days for all other products (the "Warranty Period"). Seller agrees during the Warranty Period, to repair or replace, at Seller's option, defective Products so as to cause the same to operate in substantial conformance with said published specifications; provided that (a) Buyer shall promptly notify Seller in writing upon the discovery of any defect, which notice shall include the product model and serial number (if applicable) and details of the warranty claim; (b) after Seller’s review, Seller will provide Buyer with service data and/or a Return Material Authorization (“RMA”), which may include biohazard decontamination procedures and other product-specific handling instructions; and (c) then, if applicable, Buyer may return the defective Products to Seller with all costs prepaid by Buyer. Replacement parts may be new or refurbished, at the election of Seller. All replaced parts shall become the property of Seller. Shipment to Buyer of repaired or replacement Products shall be made in accordance with the Delivery provisions of the Seller’s Terms and Conditions of Sale. Consumables, including but not limited to lamps, fuses, batteries, bulbs and other such expendable items, are expressly excluded from the warranty under this warranty.

Notwithstanding the foregoing, Products supplied by Seller that are obtained by Seller from an original manufacturer or third party supplier are not warranted by Seller, but Seller agrees to assign to Buyer any warranty rights in such Product that Seller may have from the original manufacturer or third party supplier, to the extent such assignment is allowed by such original manufacturer or third party supplier.

In no event shall Seller have any obligation to make repairs, replacements or corrections required, in whole or in part, as the result of (i) normal wear and tear, (ii) accident, disaster or event of force majeure, (iii) misuse, fault or negligence of or by Buyer, (iv) use of the Products in a manner for which

Warranty

Warranty Warranty

A-2 Model 83i GC Instruction Manual Thermo Fisher Scientific

they were not designed, (v) causes external to the Products such as, but not limited to, power failure or electrical power surges, (vi) improper storage and handling of the Products or (vii) use of the Products in combination with equipment or software not supplied by Seller. If Seller determines that Products for which Buyer has requested warranty services are not covered by the warranty hereunder, Buyer shall pay or reimburse Seller for all costs of investigating and responding to such request at Seller's then prevailing time and materials rates. If Seller provides repair services or replacement parts that are not covered by the warranty provided in this warranty, Buyer shall pay Seller therefor at Seller's then prevailing time and materials rates. ANY INSTALLATION, MAINTENANCE, REPAIR, SERVICE, RELOCATION OR ALTERATION TO OR OF, OR OTHER TAMPERING WITH, THE PRODUCTS PERFORMED BY ANY PERSON OR ENTITY OTHER THAN SELLER WITHOUT SELLER'S PRIOR WRITTEN APPROVAL, OR ANY USE OF REPLACEMENT PARTS NOT SUPPLIED BY SELLER, SHALL IMMEDIATELY VOID AND CANCEL ALL WARRANTIES WITH RESPECT TO THE AFFECTED PRODUCTS.

THE OBLIGATIONS CREATED BY THIS WARRANTY STATEMENT TO REPAIR OR REPLACE A DEFECTIVE PRODUCT SHALL BE THE SOLE REMEDY OF BUYER IN THE EVENT OF A DEFECTIVE PRODUCT. EXCEPT AS EXPRESSLY PROVIDED IN THIS WARRANTY STATEMENT, SELLER DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED, ORAL OR WRITTEN, WITH RESPECT TO THE PRODUCTS, INCLUDING WITHOUT LIMITATION ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE. SELLER DOES NOT WARRANT THAT THE PRODUCTS ARE ERROR-FREE OR WILL ACCOMPLISH ANY PARTICULAR RESULT.

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