Replacing The Thermocouple Assembly - ABB PGC2000 Operation And Service Manual

9. Install the detector outlet adapter into the breather and finger tighten. Finish tightening using 3/4-
inch and 1/2-inch open-end wrenches.
10. Install the 1/4-inch male connector into the breather using 3/4-inch and 1/2-inch open-end
wrenches.
11. Connect the 1/4-inch detector vent tubing to the breather. Finger tighten, then tighten with a
9/16-inch open-end wrench and a 1/2-inch backup wrench.
12. Ensure the detector vent O-ring is in place in the adapter fitting.
13. Finish installing the breather by inserting the cylindrical end of the adapter fitting completely into
the detector outlet and tightening the set screw with a 0.050-inch Allen wrench. Note the set
screw will fit into the groove of the adapter fitting when installed correctly.
14. Reconnect the red coaxial cable to the top of the detector.
15. Close and secure the isothermal oven door.

Replacing the Thermocouple Assembly

1. Disconnect the red coaxial cable located on the top the detector.
2. Locate the thermocouple assembly as identified by the two red and black wires.
3. If applicable, remove any cable ties and free the wiring to expose the wire splices.
4. Cut and remove the heat shrink and glass tape from the red and black wires to expose the
soldered connections.
5. Using a 40 watt soldering iron, disconnect the wiring splice.
6. Using a 3/8-inch open-end wrench, carefully remove the thermocouple.
reassembly.
7. Carefully insert the replacement thermocouple into the detector body and finger tighten, taking
care not to damage it. Finish tightening using a 3/8-inch open-end wrench.
8. Roll each end of the red and black wires of the new thermocouple assembly between your
forefinger and thumb, causing the wire ends to be tightly spiral wrapped.
9. Using the 40 watt soldering iron and approved high temperature solder, "tin" the wire ends.
10. Spread or expand the end of approved heat shrink to allow easy installation over the solder
connection.
11. Install the heat shrink over each of the wires and slide it as far as possible from the connection.
This will prevent premature shrinking of it when the connection is soldered.
12. Overlap the "tinned" ends of the red wire from the analyzer electronics and red element
assembly wire, then solder the wires together using approved high temperature solder and the 40
watt soldering iron.
13. Repeat step 12 for the black wire.
14. Apply a short wrap of glass tape over each connection.
2000-OSM, F1
Note its location for
8-17