Teledyne FALCON GC Operation And Maintenance Manual
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Teledyne FALCON GC Operation And Maintenance Manual

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OPERATION AND MAINTENANCE
Toxic and/or flammable gases or liquids may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
Hazardous voltages exist on certain components internally which may persist for
a time even after the power is turned off and disconnected.
Only authorized personnel should conduct maintenance and/or servicing. Before
conducting any maintenance or servicing, consult with authorized
supervisor/manager.
Information included herein is controlled by the Export Administration Regulations
(EAR) and requires an export license, license exception or other approval from the
appropriate U.S. Government agency before being exported from the United States
or provided to any foreign person. Diversion contrary to U.S. law is prohibited.
MANUAL FOR
FALCON GC
DANGER
Teledyne Analytical Instruments
P/N M
DATE 07/30/19

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  • Page 1 OPERATION AND MAINTENANCE MANUAL FOR FALCON GC P/N M DATE 07/30/19 DANGER Toxic and/or flammable gases or liquids may be present in this monitoring system. Personal protective equipment may be required when servicing this instrument. Hazardous voltages exist on certain components internally which may persist for a time even after the power is turned off and disconnected.
  • Page 2 Any safeguards required such as locks, labels, or redundancy, must be provided by the user or specifically requested of Teledyne at the time the order is placed.

  • Page 3: Safety Messages

    Stand-by but circuits are active. CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL. IF YOU USE THE ANALYZER IN A MANNER OTHER THAN THAT FOR WHICH IT WAS INTENDED, Teledyne Analytical Instruments...
  • Page 4 Manuals do get misplaced. Additional manuals can be obtained from Teledyne at the address given in the Appendix. Some of our manuals are available in electronic form via the internet. Please visit our website at: www.teledyne-ai.com.

  • Page 5: Additional Safety Information

    Since the use of this instrument is beyond the control of Teledyne, no responsibility by Teledyne, its affiliates, and agents for damage or injury from misuse or neglect of this equipment is implied or assumed.
  • Page 6 PRINCIPLES OF OPERATION OF THIS EQUIPMENT ARE UNDERSTOOD BY THE USER. SINCE THE USE OF THIS INSTRUMENT IS BEYOND THE CONTROL OF TELEDYNE, NO RESPONSIBILITY BY TELEDYNE, ITS AFFILIATES AND AGENTS FOR DAMAGE OR INJURY RESULTING FROM MISUSE OR NEGLECT OF THIS INSTRUMENT IS IMPLIED OR ASSUMED.

  • Page 7: Table Of Contents

    3.1 Preparation 3.2 Setup/Installation 3.2.1 User Connections 3.3 Configuring the Falcon GC 3.3.1 Setting the Falcon GC’s IP Address 3.4 Configuring Chromperfect 3.5 The Chromperfect Selection Tab 3.5.1 Claiming the Instrument and Setting the Data Directory 3.6 The Chromperfect Status Tab 3.7 Downloading a Method File...
  • Page 8 Falcon GC 5.3 Outer Case Removal 5.4 FID Removal 5.5 Column Module Installation 5.6 Replacing the Glow Plug Appendix ................... 51 A.1 Specifications: A.2 Recommended Spare Parts List A.3 Drawings viii Teledyne Analytical Instruments...

  • Page 9: List Of Figures

    List of Figures Figure 3-1: Instrument Connections ..........9 Figure 5-1: Glow Plug Wire ............48 Figure 5-2: FID Diagram ............. 50 Teledyne Analytical Instruments...
  • Page 10 Falcon GC Blank Page Teledyne Analytical Instruments...

  • Page 11: Introduction

    PC to GC can either be direct or through a network. This manual presents the standard operating procedure for the general use of the Falcon GC. You should have a general working knowledge of the Chromperfect software, as well as the Falcon GC...
  • Page 12 Introduction Falcon GC before using this guide. Since this is a general SOP, more specialized methods such as ASTM D7798 or D3710 will require additional instruction not present in this document. This guide does not include instruction on the operation of the Palarus or Talon autosamplers.

  • Page 13: Chromperfect File Types

    2.1 Chromperfect File Types There are generally four key Chromperfect files that must work together in order to ensure the effective operation of the Falcon GC. Depending on the application, you may only need two or three of these files. In some cases, even more files may be necessary. A method file (.met) and a setpoint file (.mfl) are required for every application.
  • Page 14 Preparation Falcon GC With the method file now open, click through the tabs to make sure that all of your files are properly linked with the correct pathname. Please note that your method may not require all these file types.
  • Page 15 Falcon GC Preparatio 3. Click on Report. Teledyne Analytical Instruments...
  • Page 16 Preparation Falcon GC Blank Page Teledyne Analytical Instruments...

  • Page 17: Installation

    Falcon GC Installation Installation 3.1 Preparation Installation of the Falcon GC will require: • Carrier Gas Typically H , but may also be He or N in special circumstances. Note: Hydrogen and air must be supplied if the instrument is equipped with an FID (Flame Ionization Detector) or FPD (Flame Photometric Detector).

  • Page 18: Setup/Installation

    5/16” for external nuts. 7/16” for external 1/8” nuts. 3.2 Setup/Installation The Falcon GC is shipped with all the materials needed to install and prepare the system for operation (Calibration Samples excluded). Carefully unpack the unit and inspect it for damage. Immediately report any damage or shortages to the shipping agent.

  • Page 19: User Connections

    See Figure 3-1 . Figure 3-1: Instrument Connections 3.3 Configuring the Falcon GC To properly use the Falcon GC you must connect the GC to a Windows PC. This connection can be made through a shared ethernet Teledyne Analytical Instruments...

  • Page 20: Setting The Falcon Gc's Ip Address

    TCP/IP. The ethernet connection from PC to GC can either be direct or through a network. 3.3.1 Setting the Falcon GC’s IP Address To set the IP address, first, turn on the GC using the power toggle switch on the Utility Panel.
  • Page 21 Falcon GC Installation 3. Click on Configuration at the top left of this new pop up window. This will open the instrument properties pop-up window. 4. After you have entered all the relevant information as seen above, click on Apply Edits to apply your changes. Notice that the small window where it says Mod and COM Port/IP Addr will update with your current settings.
  • Page 22 Installation Falcon GC 6. Click OK to confirm your changes. This should prompt yet another pop-up window to appear. In this window you should notice that the Server Status indicates "Awaiting Download". If the Server Status does not display "Awaiting Download"...

  • Page 23: The Chromperfect Selection Tab

    Falcon GC Installation 3.5 The Chromperfect Selection Tab Now that the instrument has been configured, you should be ready to claim the instrument. This ensures that only the specific PC that you are using will communicate with the GC. 3.5.1 Claiming the Instrument and Setting the Data Directory 1.

  • Page 24: The Chromperfect Status Tab

    Installation Falcon GC 3. Now, in the Run screen with the yellow background, you must first claim the instrument by clicking the Claim button underneath the column labeled Control. This should cause the empty cells to the left of the Claim button to auto-fill.

  • Page 25: Downloading A Method File

    Falcon GC Installation 3.7 Downloading a Method File Right-click anywhere in the white Excel-like fields at the top of the screen and then select "Download" from the list of options. This should open the download screen. Teledyne Analytical Instruments...
  • Page 26 Installation Falcon GC After inputting the information into the download screen click OK to download the method file to the GC. .If any changes are made to the Setpoint file, they must be downloaded to the GC to take effect.

  • Page 27: Operation

    Falcon GC Operation Operation 4.1 Starting the GC 4.1.1 Turning on the GC Modules Now that the method file has been downloaded to the GC you are ready to activate the Falcon modules and heat the instrument. From the home screen on the Falcon touch screen, simply touch each module icon individually and turn on their temperature and pressure controllers.

  • Page 28: Lighting The Fid

    4.1.3 Activating the TCD Filament If you have a TCD module installed in the Falcon GC, you must activate the TCD filament before you can start a run. Once all the modules have reached their setpoints, access the TCD module (Detector 1 or Detector 2) from the home screen by pressing the appropriate button on the Falcon touch screen.

  • Page 29: Calibration

    Falcon GC Operation 1. With the Falcon touch screen From the home screen press the green Start button. If the button is not green then there are still some modules that have yet to reach their setpoints. Check to make sure that any FID flames are lit.
  • Page 30 Operation Falcon GC 1. 1. Click File→Open and then click the “…” icon to search for and open the chromatogram you wish to calibrate with. 2. Click Components→Make New Calibration File a. Unless you had a previous calibration file applied to that chromatogram there is no notification from Chromperfect that you have made a new calibration file;...

  • Page 31: Updating A Current Calibration File

    Falcon GC Operation 4. Left-click the component you wish to identify 5. Right-click to confirm that the component you have selected is correct. 6. A small window should appear. Here you can fill in the Peak Name as well as the Amount.
  • Page 32 Operation Falcon GC 4. You can choose whether you would like update retention times, responses, or both. You can also choose whether you would like to average these new responses with the old calibration responses or if you would like to replace the old data altogether. When you are satisfied with your choices, click OK.

  • Page 33: Maintenance & Troubleshooting

    Falcon GC Maintenance & Troubleshooting Maintenance & Troubleshooting WARNING: DANGEROUS HIGH VOLTAGES EXIST INSIDE THIS INSTRUMENT. BEFORE STARTING ANY OF THESE MAINTENANCE AND TROUBLESHOOTING PROCEDURES, READ THE CAUTIONS AND WARNINGS INCLUDED IN THE SECTION TITLED “ADDITIONAL SAFETY WARNINGS”. PAY SPECIFIC ATTENTION TO THE PROCEDURES FOR REMOVAL OF INTERNAL INACCESSIBLE SHOCK HAZARDS.

  • Page 34: Troubleshooting

    Maintenance & Troubleshooting Falcon GC 5.1 Troubleshooting Columns Problem: Each column, if operated within the proper temperature limits, should have a lifetime of 1 year+. TAI recommends having spare columns on hand in case of emergencies. Over time you may experience a changes in the column phase or column hardware.

  • Page 35: Adjusting Fid Pressures

    Falcon GC Maintenance & Troubleshooting if the flame is lit by holding a reflective surface over the FID exhaust and examining for condensation. Check with a flow meter to ensure that the Air (ignite) Pressure, the Air (Run) Pressure and the Hydrogen Pressure values are consistent with those found in your Data Package shipped with the instrument.
  • Page 36 Maintenance & Troubleshooting Falcon GC 4. Select “Det1 H2 Pressure” from the dropdown menu. Then click “Activate” to turn on the H flow. 5. Adjust flow to 15mL/min with carrier gas flow included. Connect a flow meter to the FID exhaust port. Click the Activate button to turn on the FID H flow.
  • Page 37 Falcon GC Maintenance & Troubleshooting Select “Det1 Ign Air Pressure” from the dropdown menu. 6. Adjust the flow until it is at 65mL/min. i. With the FID H flow off adjust the IGN Air pressure until a flow of 65mL/min is obtained.
  • Page 38 Maintenance & Troubleshooting Falcon GC 9. Select “Edit Method File” from the Chromperfect screen. 10. Select the “Acquisition” tab from the edit method screen. 11. Open the Setpoint file. Teledyne Analytical Instruments...

  • Page 39: Outer Case Removal

    Falcon GC Maintenance & Troubleshooting 12. Select the “Detectors” tab and change the pressure values to the new values you recorded. 13. Close and save all screens and download the changes to the GC. 5.3 Outer Case Removal To remove the outer case to expose the internal components, please follow the steps outlined below.
  • Page 40 Maintenance & Troubleshooting Falcon GC 2. Front Cover Removal Remove 4 bolts circled in red using a 7/64” hex driver. Lean case lid forward and disconnect display cable. Slide cable out from under hook. iii. Set case lid aside. Teledyne Analytical Instruments...
  • Page 41 Falcon GC Maintenance & Troubleshooting 3. Disconnect Detector Exhaust Tubes. Unscrew black top cap from on top of case. Slide metal washer out from underside of the case. Using a 5/16” wrench unscrew the exhaust tube from the iii. detector body. Brace the detector body while unscrewing to ensure that it does not move.
  • Page 42 Maintenance & Troubleshooting Falcon GC Teledyne Analytical Instruments...
  • Page 43 Falcon GC Maintenance & Troubleshooting 4. Removing Rear Case Remove the handle from the rear of the GC by unscrewing the 4 knobs and lifting handle free. Unscrew 6 screws on the back of the GC and remove the rails the screws were in.
  • Page 44 Maintenance & Troubleshooting Falcon GC Check Tubing when Removing GC Case Note: If the case does not easily slide free, push down lightly on these tubes to ensure they are below the gap in the case. Do not try and force the case off. If everything is correctly removed the case should slide off easily.

  • Page 45: Fid Removal

    Falcon GC Maintenance & Troubleshooting 5.4 FID Removal 1. Disconnecting the Flow Restrictor Using a 1/4” and a 3/16” wrench on the fitting for the flow restrictor, disconnect the nut from the FID inlet fitting and gently remove the flow restrictor.
  • Page 46 Maintenance & Troubleshooting Falcon GC 3. Disconnect Power and Communication Cables. Grasp the colored connector and pull it to the right until it is free from the pins. Do NOT pull on the wires to free the connectors. 4. Remove Detector Screws.
  • Page 47 Falcon GC Maintenance & Troubleshooting 5. Separating the FID After everything has been disconnected, grasp the FID oven body and gently slide it away from the oven. There may be an FID installed on the other side of the GC as well.

  • Page 48: Column Module Installation

    Maintenance & Troubleshooting Falcon GC 5.5 Column Module Installation 1. Remove the front cover by removing the 4 screws on the front panel. 2. Remove front cover and ribbon cable. Teledyne Analytical Instruments...
  • Page 49 Falcon GC Maintenance & Troubleshooting 3. Remove the SPU oven lid by unscrewing the 4 hex stand-offs circled below. 4. Remove the foam oven plugs by gently pulling them straight up and out of their slots. 5. Disconnect the column transfer tubes from the column module using a 1/4”...
  • Page 50 Maintenance & Troubleshooting Falcon GC 6. Remove the 4 column module mounting screws shown circled in the picture with a 3/32” hex driver. Teledyne Analytical Instruments...
  • Page 51 Falcon GC Maintenance & Troubleshooting 7. Remove the column module from the instrument by grasping the black cooling fan and lifting straight up and out of the slots. 8. Gently rotate the column module upside down and unplug both the power and communication cables from the module PCB.
  • Page 52 Maintenance & Troubleshooting Falcon GC 9. With the new column module in hand, re-connect the module power and communication cables. 10. Insert the column module between its mounting brackets and press it about half way down into position. Note: Inserting it half-way rather than all of the way allows for easier re-connection of the transfer tubes.
  • Page 53 Falcon GC Maintenance & Troubleshooting 12. Press the column module down into its fully seated position on the mounting brackets. Attach the column module to the brackets with the screws that were removed in Step 6 using a 3/32” hex driver.
  • Page 54 Maintenance & Troubleshooting Falcon GC 14. Gently holding the top of the foam plug with a finger, slowly pull the plastic plug tool out from between the oven insulation and foam plug making sure that the foam plug stays snug against the column end fitting at the bottom.
  • Page 55 Falcon GC Maintenance & Troubleshooting 16. With the SPU top still removed, power on the instrument and activate the carrier gas. (Since the touch screen display is still disconnected, the carrier gas can be activated in Chromperfect in the instrument “Special Features” box under the “Pressures” tab.) Leak check all connections in the oven for leaks.
  • Page 56 Maintenance & Troubleshooting Falcon GC 18. With the instrument turned OFF, carefully reattach the ribbon cable to the touch screen display. 19. Slide the ribbon cable under the hold-down clip. See the picture below. Teledyne Analytical Instruments...

  • Page 57: Replacing The Glow Plug

    Falcon GC Maintenance & Troubleshooting 20. Replace the front on the unit using the 4 screws removed in Step Installation is complete. After powering up the instrument, all of the column's information can be viewed either from the touchscreen display in the “Column Module”...
  • Page 58 Maintenance & Troubleshooting Falcon GC Figure 5-1: Glow Plug Wire Teledyne Analytical Instruments...
  • Page 59 Falcon GC Maintenance & Troubleshooting 2. With glow plug wire removed, the glow plug can be removed from the FID body. Using a 5/16” wrench loosen the glow plug until it comes free of the FID body. Do NOT try to pull the glow plug from the FID body.
  • Page 60 Maintenance & Troubleshooting Falcon GC Figure 5-2: FID Diagram Teledyne Analytical Instruments...

  • Page 61: Appendix

    Falcon GC Appendix Appendix A.1 Specifications: A.2 Recommended Spare Parts List Qty. Description IMPORTANT: Orders for replacement parts should include the part number and the model and serial number of the system for which the parts are intended. Send orders to:...

  • Page 62: Drawings

    Appendix Falcon GC A.3 Drawings Teledyne Analytical Instruments...
  • Page 63 Falcon GC Appendix Teledyne Analytical Instruments...
  • Page 64 Appendix Falcon GC Teledyne Analytical Instruments...
  • Page 65 Falcon GC Appendix Teledyne Analytical Instruments...
  • Page 66 Appendix Falcon GC Teledyne Analytical Instruments...
  • Page 67 Falcon GC Appendix Teledyne Analytical Instruments...

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