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Varian GC 3800 Assembly Procedures

Gas chromatography
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Summary of Contents for Varian GC 3800

  • Page 1 Maneuvering the Assembly Documentation 1. Select your bookmark of interest 2. Click on the (+) to expand your selection and select the submenu 3. Navigate through the document with these buttons...
  • Page 2 DOC: 03-925914-01/02 PARTS TOOLS DESC: Micro - TCD Installation MENU LIST HISTORY 1 of 3 PAGE: INSTALLATION OF MICRO-TCD STATION #3, ASSEMBLY PROCEDURES TEE (SEE NEXT PAGE) ADAPTER (SEE NEXT PAGE) Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 3 DOC: 03-925914-01/02 PARTS TOOLS DESC: Micro - TCD Installation MENU LIST HISTORY 2 of 3 PAGE: CLICK HERE FOR MICRO-TCD ASSEMBLY SCHEMATIC OF MICRO-TCD WITH ADAPTOR REFERENCE SCHEMATIC OF MICRO-TCD WITH INJECTOR REFERENCE MICRO-TCD CELL (REF.) INJECTOR (REF.) 28-694581-00 CP-470100 FERRULE FERRULE, Ø0.32 COLUMN 03-949551-00...
  • Page 4 DOC: 03-925914-01/02 PARTS TOOLS DESC: Micro - TCD Installation MENU LIST HISTORY 3 of 3 PAGE: INSTALLATION OF MICRO-TCD: 1. ENSURE GC OVEN INSULATION IS CAREFULLY WRAPPED UNDER AND AROUND, THE MICRO-TCD TO PREVENT COLUMN OVEN CONDITIONS COUPLING WITH DETECTOR. 2.
  • Page 5 DOC: 03-925914-01/02 PARTS TOOLS DESC: Micro - TCD Installation MENU LIST HISTORY 4 of 3 PAGE: Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 03 - 10 - 00 SHOWN...
  • Page 6 DOC: 03-925862-00 PARTS TOOLS DESC: MENU 3800GC W/DEFC Leak Test Procedure LIST HISTORY 1 of 2 PAGE: INJECTOR EFC LEAK TEST PROCEDURE Install ETS software Version 1.6.2 or newer. (be sure to discharge yourself before touching ROM pwa.) Set the DIP Switches on the main board as shown: Turn on power and connect Carrier Gas inlet tube.
  • Page 7 DOC: 03-925862-00 PARTS TOOLS DESC: MENU 3800GC W/DEFC Leak Test Procedure LIST HISTORY 2 of 2 PAGE: DETECTOR EFC LEAK TEST PROCEDURE Connect Helium to makeup line for FID, TSD, ECD and TCD. Connect Helium to H2 line for PFPD and TCD(H2). Cap off all other gas inlets Make sure DEFC position jumpers in correct position.
  • Page 8 DOC: 03-925709-01 PARTS TOOLS DESC: MENU Assy, Column Oven Cryogenics, (CO2) LIST HISTORY 1 of 3 PAGE: ASSY, COLUMN OVEN CRYOGENICS, (CO2) 3800GC SUB-ASSEMBLIES STATION, ASSEMBLY PROCEDURES Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 05 - 00 SHOWN...
  • Page 9 DOC: 03-925709-01 PARTS TOOLS DESC: MENU Assy, Column Oven Cryogenics, (CO2) LIST HISTORY 2 of 3 PAGE: 03-925497-01 CO2 OUTLET TUBE 03-925567-01 3800 CO2 VALVE FACTORY INSTALL CO2 OUTLET TUBE (REF.) ° (REF.) 28-609966-00 3800 CO2 VALVE ADAP, COMP., 1/8 X 1/8 SST FACTORY INSTALL 28-694205-00 1/8IN ADAPTER...
  • Page 10 DOC: 03-925709-01 PARTS TOOLS DESC: MENU Assy, Column Oven Cryogenics, (CO2) LIST HISTORY 3 of 3 PAGE: 03-925489-01 ASSY, CABLE, CRYO EXTENSION NOTE: CONNECT CRYOU EXTENSIO WIRES PIN TO (J-47) ON PWA (J-47) 22-799995-00 BUSHING, STRAIN REL. CONNECTOR (REF.) 12-901163-00, 2 PLCS COLUMN OVEN SCREW, 8-32 X 3/8 SEM CRYOGENICS ASSEMBLY (REF.)
  • Page 11 DOC: 03-925709-01 PARTS TOOLS DESC: MENU Assy, Column Oven Cryogenics, (CO2) LIST HISTORY 4 of 3 PAGE: Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 05 - 00 SHOWN...
  • Page 12 DOC: 03-925708-01 PARTS TOOLS DESC: Assy, Column Oven Cryogenics MENU LIST HISTORY 1 of 4 PAGE: ASSY, COLUMN OVEN CRYOGENICS (LN2 VERSION) 3800GC STATION #3, ASSEMBLY PROCEDURES Micheal Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 25 - 00 SHOWN...
  • Page 13 DOC: 03-925708-01 PARTS TOOLS DESC: Assy, Column Oven Cryogenics MENU LIST HISTORY 2 of 4 PAGE: SEE NOTE #2 03-925378-01 LIQUID NITROGEN OUTLET TUBE OUTLET SIDE 03-925557-01 3800 LN2 VALVE OUTLET TUBING (REF.) 28-691979-00 1/4 T X 1/8 P BR MALE CONN. INLET SIDE 28-695130-00 B-4-TA-1-2 ADAPTER, COMPRESSION 1/4 TUBE...
  • Page 14 DOC: 03-925708-01 PARTS TOOLS DESC: Assy, Column Oven Cryogenics MENU LIST HISTORY 3 of 4 PAGE: BULK ISSUE ITEMS (03-925515-XX) 3 INJECTORS 2 INJECTORS 1 INJECTOR NO INJECTOR 03-925651-01 TUBE, 1/4” CROSS, TEE, CONNECTOR 03-925654-01 DEFLECTOR, AIR FLOW LN2 OVEN CRYO 28-691946-00 TEE, UNION 1/4”...
  • Page 15 DOC: 03-925708-01 PARTS TOOLS DESC: Assy, Column Oven Cryogenics MENU LIST HISTORY 4 of 4 PAGE: 12-901163-00, 2 PLCS 88-494510-00, 5” LG SCREW, 8-32 X 3/8, SEM PIPE INSULATION 3/8” ID .42” 23-230938-00 COVER, SQUARE VALVE ARRANGEMENT (REF.) Micheal Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING...
  • Page 16 DOC: 03-925632,633,634&635-XX PARTS TOOLS DESC: Assy, 1177 Manual and Type 5 EFC Installation MENU LIST HISTORY 1 of 4 PAGE: ASSY, 1177 MANUAL AND TYPE 5 EFC INSTALLATION 3800GC STATION #3, ASSEMBLY PROCEDURES Steve Swihart PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 17 DOC: 03-925632,633,634&635-XX PARTS TOOLS DESC: Assy, 1177 Manual and Type 5 EFC Installation MENU LIST HISTORY 2 of 4 PAGE: 03-918853-07 03-917142-00 03-917142-00 03-925467-01 PEEK TUBING 1/8” NAT. VITON FERRLE VITON FERRLE 3EA 03-918853-03 SOLENOID VALVE 3- WAY PEEK TUBING, GREEN 03-917157-00 28-849067-00 12-901162-00...
  • Page 18 DOC: 03-925632,633,634&635-XX PARTS TOOLS DESC: Assy, 1177 Manual and Type 5 EFC Installation MENU LIST HISTORY 3 of 4 PAGE: NOTE: BE SURE INJ. IS IN ONE OF THE (4) A/S LOCATIONS. SEE INJ. COVER FOR ALIGNMENT. 03-925996-XX 1177 INJECTOR, EFC 03-918532-01 VAR SEPTUM PURGE 12-901163-00...
  • Page 19 DOC: 03-925632,633,634&635-XX PARTS TOOLS DESC: Assy, 1177 Manual and Type 5 EFC Installation MENU LIST HISTORY 4 of 4 PAGE: PRESSURE SENSE (TO 1177) CARRIER IN FROM CROSS FITTING SPLIT VENT SEPTUM PURGE TO SPORT VALVE (NO COLORED MARKER) CARRIER IN - FROM EFC CARRIER (GREEN COLORED MARKER) VENT THRU...
  • Page 20 DOC: 03-925630&631-XX PARTS TOOLS DESC: Assy, 1177 EFC Injector Installation MENU LIST HISTORY 1 of 4 PAGE: ASSY, 1177 EFC INJECTOR INSTALLATION 3800GC STATION #3, ASSEMBLY PROCEDURES Steve Swihart PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 12 - 1 - 99 SHOWN...
  • Page 21 DOC: 03-925630&631-XX PARTS TOOLS DESC: Assy, 1177 EFC Injector Installation MENU LIST HISTORY 2 of 4 PAGE: 3800 TWIN 8200 A/S INJ. & DET. LOCATION & ORIENTATION NOTE: DETECTORS MOUNTED IN LOCATION CLOSEST TO PNEUMATICS COMPARTMENT. INJ. POSITION 1 & 3 Steve Swihart PREPARED BY: Sax Makthepharack REVISED BY:...
  • Page 22 DOC: 03-925630&631-XX PARTS TOOLS DESC: Assy, 1177 EFC Injector Installation MENU LIST HISTORY 3 of 4 PAGE: NOTE: BE SURE INJ. IS IN ONE OF THE (4) A/S LOCATIONS. SEE INJ. COVER FOR ALIGNMENT. 03-925996-XX 1177 INJECTOR, EFC 03-918532-01 VAR SEPTUM PURGE 12-901163-00 SCREW, 8-32 X 3/8”...
  • Page 23 DOC: 03-925630&631-XX PARTS TOOLS DESC: Assy, 1177 EFC Injector Installation MENU LIST HISTORY 4 of 4 PAGE: PRESSURE SENSE (TO 1177) CARRIER IN FROM CROSS FITTING SPLIT VENT PRESSURE SENSE - TO EFC (YELLOW COLORED MARKER) SEPTUM PURGE TO SPORT VALVE (NO COLORED MARKER) CARRIER IN - FROM EFC CARRIER...
  • Page 24 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 1 of 11 PAGE: TCD (H2) EFC INSTALLATION Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 18 - 98 SHOWN...
  • Page 25 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 2 of 11 PAGE: DET. DET. DET. FRONT MIDDLE FRONT MIDDLE REAR REAR 12-901163-00 SCREW, 4EA 03-925607-01 MANIFOLD PLUMBING ASSY., TCD AND OVEN, 120V 03-925607-02 ASSY., TCD AND OVEN, 230V NOTE: 03-925607-03 SEE PAGE 10...
  • Page 26 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 3 of 11 PAGE: CABLE INSTALLATION CABLE PLUG-IN TO MAIN BOARD 03-925798-01 CABLE, FLAT FOR DETECTOR EFC Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 27 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 4 of 11 PAGE: INLET MANIFOLD SUBASSEMBLY 03-925842-24 TUBING, PEEK 1/8 26” (NATURAL) 03-917084-00, 3 PLCS NUT, VITON FERRULE 03-917157-00, 3 PLCS WASHER, FERRULE 03-917142-00, 3 PLCS VITON, FERRULE 03-918153-00 INLET MANIFOLD Michael Slaughter...
  • Page 28 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 5 of 11 PAGE: MODULE INSTALLATION 12-901163-00, 2 PLCS SCREW, 6-32 24-389051-00 GROMMET, FLEXIBLE 7” Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 18 - 98 SHOWN...
  • Page 29 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 6 of 11 PAGE: INLET MANIFOLD INSTALLATION NOT USE (REF.) (03-925839-22, RED) H2 INLET (NOT USE REFERENCE ONLY) (03-925842-24, 1/8” NATURAL) CARRIER INLET NOT USE (REF.) Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING...
  • Page 30 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 7 of 11 PAGE: MODULE INSTALLATION NOTES: 1. CONNECT CABLE TO MODULE, THEN MOUNT MODULE TO FRONT PANEL. 2 MOVE MODULE LOCATION JUMPER TO SPECIFY FRONT, MIDDLE, OR REAR. 3.
  • Page 31 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 8 of 11 PAGE: ADDITIONAL MODULE CABLEING (IF REQ’D) NOTE CABLE SERVICE LOOP FOR ADDITIONAL DETECTOR EFC MODULE Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 32 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 9 of 11 PAGE: MODULE PNEUMATICS CONNECTIONS PNEUMATICS SIDE MANIFOLD REFERENCE ONLY PNEU. MANIFOLD NOTES: REFERENCE LINE FROM MODULE TO DETECTOR RED (26”) 1. DRESS PLUMBING IN PNEUMATICS MAKE UP LINE FROM COMPARTMENT USING CABLE TIE.
  • Page 33 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 10 of 11 PAGE: NOTE: POSITION & ROUTING OF CABLE AND TIES NOT NESS. AS SHOWN. DRESS CABLE W/ QTY. NEEDED USING AVAILABLE SPACE. 03-925037-01 ASSY., TCD, PCB CONNECTION TO TCD PWA CLICK HERE FOR HEATER CLICK HERE...
  • Page 34 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 11 of 11 PAGE: TCD DETECTOR LOCATION 1. TCD (4) IS FRONT (5) IS MIDDLE (6) IS REAR TCD WITH ONE OTHER DETECTOR USE (4) AND (5) Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING...
  • Page 35 DOC: 03-925615-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 12 of 11 PAGE: Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 18 - 98 SHOWN...
  • Page 36 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 1 of 15 PAGE: PFPD EFC INSTALLATION Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 18 - 98 SHOWN...
  • Page 37 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 2 of 15 PAGE: 03-925194-01 SCREW, CAP 8-32X 3/4” LG, CLEANED 2EA 03-925134-00 ASSY., IGNITOR CAP 03-925461-01 ASSY., IGNITOR CABLE, PFPD 15-003347-00 NOTE: SEE P.5 WASHER CRUNCH, .040 THK, ALUM FOR CABLE CONNECTION TO PFPD PWA 03-925194-02...
  • Page 38 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 3 of 15 PAGE: DET. DET. DET. FRONT MIDDLE FRONT MIDDLE REAR REAR HEAT ZONE 1 INJECTOR 1 INJECTOR 2 HEAT ZONE 2 HEAT ZONE 3 INJECTOR 3 HEAT ZONE 4 DETECTOR 1 HEAT ZONE 5...
  • Page 39 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 4 of 15 PAGE: CABLE INSTALLATION CABLE PLUG-IN TO MAIN BOARD 03-925798-01 CABLE, FLAT FOR DETECTOR EFC Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 40 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 5 of 15 PAGE: INLET MANIFOLD SUBASSEMBLY 03-925839-22 TUBING, PEEK 22” (RED) 03-925840-21 TUBING, PEEK 21” (BLACK) 03-917084-00, 3 PLCS NUT, VITON FERRULE 03-917157-00, 3 PLCS WASHER, FERRULE 03-917142-00, 3 PLCS VITON, FERRULE 03-918153-00...
  • Page 41 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 6 of 15 PAGE: MODULE INSTALLATION 12-901163-00, 2 PLCS SCREW, 6-32 24-389051-00 GROMMET, FLEXIBLE 7” Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 18 - 98 SHOWN...
  • Page 42 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 7 of 15 PAGE: INLET MANIFOLD INSTALLATION (03-925840-21, BLACK) AIR INLET (03-925839-22, RED) H2 INLET NOT USED (REF.) NOT USED (REF.) Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 43 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 8 of 15 PAGE: MODULE INSTALLATION NOTES: 1. CONNECT CABLE TO MODULE, THEN MOUNT MODULE TO FRONT PANEL. 2 MOVE MODULE LOCATION JUMPER TO SPECIFY FRONT, MIDDLE, OR REAR. 3.
  • Page 44 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 9 of 15 PAGE: ADDITIONAL MODULE CABLEING (IF REQ’D) NOTE CABLE SERVICE LOOP FOR ADDITIONAL DETECTOR EFC MODULE Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 45 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 10 of 15 PAGE: MODULE PNEUMATICS CONNECTIONS PNEUMATICS SIDE MANIFOLD 03-917142-00 VITON FERRULE REFERENCE ONLY (REF.) 12-901150-00 NOTES: PNEU. MANIFOLD SCREW ONLY 03-917141-00 1. DRESS PLUMBING IN PNEUMATICS CONDYNE PLATE COMPARTMENT USING CABLE TIE.
  • Page 46 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 11 of 15 PAGE: PNEUMATIC PFPD SHEMATIC Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 18 - 98 SHOWN...
  • Page 47 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 12 of 15 PAGE: DETAIL A 12-901163-00, 2 PLCS SCREW, 6-32 ASSEMBLY VIEW 03-925799-01 BRACKET, VALVE 03-917142-00, 2 PLCS VITON, FERRULE 03-917084-00, 2 PLCS NUT, VITON FERRULE 57-000028-00 NEEDLE VALVE 03-925841-12, 2 PLCS TUBING, PEEK NATURAL...
  • Page 48 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 13 of 15 PAGE: DETAIL B 22-119650-00 TIE WRAP 17-699907-00 RIVET, BLIND ASSEMBLY VIEW ORANGE TUBING TO NEEDLE VALVE 22-130018-00, 2 PLCS CLIP, COMPONENT 28-691944-00 FROM DETECTOR MODULE EXPLODED VIEW Michael Slaughter PREPARED BY: Sax Makthepharack...
  • Page 49 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 14 of 15 PAGE: INSTALLATION OF CHECK VALVE 22-130017-00, 2 PLCS CLIP, COMPONENT, .640 DIA. 27-180166-00, 2 PLCS CHECK VALVE, 1/8 17-699907-00 RIVET, BLIND (IF REQUIRED) Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING...
  • Page 50 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 15 of 15 PAGE: PFPD PWA INSTALLATION 03-917830-00 ASSY., CABLE SIGNAL 18” 03-925066-01 PFPD PWA 03-925461-01 ASSY., IGNITOR CABLE, PFPD 03-908339-02 ASSY., CABLE HIGH VOLT.,34” LG. 14-112007-00 FLAT, WASHER 12-901163-00 SCREW, 6-32 X 1/4 14-998237-00, 2 PLCS...
  • Page 51 DOC: 03-925614-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 16 of 15 PAGE: Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 18 - 98 SHOWN...
  • Page 52 DOC: 03-925613-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 1 of 10 PAGE: TSD EFC INSTALLATION Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 08 - 98 SHOWN...
  • Page 53 DOC: 03-925613-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 2 of 10 PAGE: DET. DET. DET. FRONT MIDDLE FRONT MIDDLE REAR REAR HEAT ZONE 1 INJECTOR 1 INJECTOR 2 HEAT ZONE 2 HEAT ZONE 3 INJECTOR 3 HEAT ZONE 4 DETECTOR 1 HEAT ZONE 5...
  • Page 54 DOC: 03-925613-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 3 of 10 PAGE: CABLE INSTALLATION CABLE PLUG-IN TO MAIN BOARD 03-925798-01 CABLE, FLAT FOR DETECTOR EFC Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 55 DOC: 03-925613-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 4 of 10 PAGE: INLET MANIFOLD SUBASSEMBLY 03-925838-23 TUBING, PEEK 23” (BLUE) 03-925842-24 03-925839-22 TUBING, PEEK 1/8 26” (NATURAL) TUBING, PEEK 22” (RED) 03-925840-21 TUBING, PEEK 21” (BLACK) 03-917084-00, 3 PLCS NUT, VITON FERRULE 03-917157-00, 3 PLCS...
  • Page 56 DOC: 03-925613-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 5 of 10 PAGE: MODULE INSTALLATION 12-901163-00, 2 PLCS SCREW, 6-32 24-389051-00 GROMMET, FLEXIBLE Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 08 - 98 SHOWN...
  • Page 57 DOC: 03-925613-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 6 of 10 PAGE: INLET MANIFOLD INSTALLATION (03-925840-21, BLACK) AIR INLET (03-925839-22, RED) H2 INLET (03-925842-24,, 1/8” NATURAL) CARRIER INLET (03-925838-23, BLUE) MAKEUP INLET Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 58 DOC: 03-925613-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 7 of 10 PAGE: MODULE INSTALLATION NOTES: 1. CONNECT CABLE TO MODULE, THEN MOUNT MODULE TO FRONT PANEL. 2 MOVE MODULE LOCATION JUMPER TO SPECIFY FRONT, MIDDLE, OR REAR. ADD CABLE CLAMP WHEN NO REAR MODULE PRESENT.
  • Page 59 DOC: 03-925613-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 8 of 10 PAGE: ADDITIONAL MODULE CABLEING (IF REQ’D) NOTE CABLE SERVICE LOOP FOR ADDITIONAL DETECTOR EFC MODULE Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 60 DOC: 03-925613-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 9 of 10 PAGE: PNEUMATICS SIDE MANIFOLD MODULE PNEUMATICS CONNECTIONS REFERENCE ONLY PNEU. MANIFOLD AIR LINE FROM MODULE MAKEUP LINE TO MODULE, BLUE (16”) TO DETECTOR BLACK (26”) H2 LINE TO MODULE, RED (16”) HYDROGEN LINE AIR LINE TO MODULE, BLACK (16”)
  • Page 61 DOC: 03-925613-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 10 of 10 PAGE: 03-925487-01 IGNITOR CABLE 03-925070-01 TSD PWA 03-917830-00 SIGNAL CABLE 18” SIGNAL & IGNITOR CABLE CONNECTION 14-112007-00 FLAT, WASHER 12-901163-00 SCREW, 6-32 X 1/4 TSD PWA INSTALLATION 14-998237-00, 2 PLCS SET SPRING WASHER MOUNTING SCREWS DETAIL...
  • Page 62 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 1 of 11 PAGE: TCD EFC INSTALLATION Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 08 - 98 SHOWN...
  • Page 63 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 2 of 11 PAGE: DET. DET. DET. FRONT MIDDLE FRONT MIDDLE REAR REAR 12-901163-00 SCREW, 4EA 03-925607-01 MANIFOLD PLUMBING ASSY., TCD AND OVEN, 120V 03-925607-02 ASSY., TCD AND OVEN, 230V NOTE: 03-925607-03 SEE PAGE 10...
  • Page 64 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 3 of 11 PAGE: CABLE INSTALLATION CABLE PLUG-IN TO MAIN BOARD 03-925798-01 CABLE, FLAT FOR DETECTOR EFC Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 65 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 4 of 11 PAGE: INLET MANIFOLD SUBASSEMBLY 03-925842-24 TUBING, PEEK 1/8 26” (NATURAL) 03-917084-00, 3 PLCS NUT, VITON FERRULE 03-917157-00, 3 PLCS WASHER, FERRULE 03-917142-00, 3 PLCS VITON, FERRULE 03-918153-00 INLET MANIFOLD Michael Slaughter...
  • Page 66 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 5 of 11 PAGE: MODULE INSTALLATION 12-901163-00, 2 PLCS SCREW, 6-32 24-389051-00 GROMMET, FLEXIBLE Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 08 - 98 SHOWN...
  • Page 67 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 6 of 11 PAGE: INLET MANIFOLD INSTALLATION NOT USE (REF.) NOT USE (REF.) (03-925842-24,, 1/8” NATURAL) CARRIER INLET NOT USE (REF.) Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 68 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 7 of 11 PAGE: MODULE INSTALLATION NOTES: 1. CONNECT CABLE TO MODULE, THEN MOUNT MODULE TO FRONT PANEL. 2 MOVE MODULE LOCATION JUMPER TO SPECIFY FRONT, MIDDLE, OR REAR. ADD CABLE CLAMP WHEN NO REAR MODULE PRESENT.
  • Page 69 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 8 of 11 PAGE: ADDITIONAL MODULE CABLEING (IF REQ’D) NOTE CABLE SERVICE LOOP FOR ADDITIONAL DETECTOR EFC MODULE Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 70 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 9 of 11 PAGE: MODULE PNEUMATICS CONNECTIONS PNEUMATICS SIDE MANIFOLD REFERENCE ONLY PNEU. MANIFOLD MAKEUP LINE TO MODULE, BLUE (16”) REFERENCE LINE FROM MODULE TO DETECTOR BLUE (26”) REFERENCE MODULE, BLUE (16”) MAKE UP LINE FROM MODULE TO DETECTOR BLUE (26”)
  • Page 71 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 10 of 11 PAGE: NOTE: POSITION & ROUTING OF CABLE AND TIES NOT NESS. AS SHOWN. DRESS CABLE W/ QTY. NEEDED USING AVAILABLE SPACE. 03-925037-01 ASSY., TCD, PCB CONNECTION TO TCD PWA CLICK HERE CLICK HERE FOR...
  • Page 72 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 11 of 11 PAGE: TCD DETECTOR LOCATION 1. TCD (4) IS FRONT (5) IS MIDDLE (6) IS REAR TCD WITH ONE OTHER DETECTOR USE (4) AND (5) Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING...
  • Page 73 DOC: 03-925612-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 12 of 11 PAGE: Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 08 - 98 SHOWN...
  • Page 74 DOC: 03-925611-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 1 of 10 PAGE: ECD EFC INSTALLATION Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 08 - 98 SHOWN...
  • Page 75 DOC: 03-925611-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 2 of 10 PAGE: DET. DET. DET. FRONT MIDDLE FRONT MIDDLE REAR REAR 03-917142-00 VITON FERRULE 12-901150-00 SCREW ONLY BOTTOM MANIFOLD PLUMBING 03-917141-00 LINE FROM CONDYNE PLATE DET. BASE, BLUE LINE FROM DET.
  • Page 76 DOC: 03-925611-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 3 of 10 PAGE: CABLE INSTALLATION CABLE PLUG-IN TO MAIN BOARD 03-925798-01 CABLE, FLAT FOR DETECTOR EFC Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 77 DOC: 03-925611-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 4 of 10 PAGE: INLET MANIFOLD SUBASSEMBLY 03-925838-23 03-925842-24 TUBING, PEEK 23” (BLUE) TUBING, PEEK 1/8 26” (NATURAL) 03-917084-00, 3 PLCS NUT, VITON FERRULE 03-917157-00, 3 PLCS WASHER, FERRULE 03-917142-00, 3 PLCS VITON, FERRULE 03-918153-00...
  • Page 78 DOC: 03-925611-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 5 of 10 PAGE: MODULE INSTALLATION 12-901163-00, 2 PLCS SCREW, 6-32 24-389051-00 GROMMET, FLEXIBLE Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 08 - 98 SHOWN...
  • Page 79 DOC: 03-925611-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 6 of 10 PAGE: INLET MANIFOLD INSTALLATION (03-925842-24,, 1/8” NATURAL) CARRIER INLET (03-925838-23, BLUE) MAKEUP INLET Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 08 - 98 SHOWN...
  • Page 80 DOC: 03-925611-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 7 of 10 PAGE: MODULE INSTALLATION NOTES: 1. CONNECT CABLE TO MODULE, THEN MOUNT MODULE TO FRONT PANEL. 2 MOVE MODULE LOCATION JUMPER TO SPECIFY FRONT, MIDDLE, OR REAR. ADD CABLE CLAMP WHEN NO REAR MODULE PRESENT.
  • Page 81 DOC: 03-925611-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 8 of 10 PAGE: ADDITIONAL MODULE CABLEING (IF REQ’D) NOTE CABLE SERVICE LOOP FOR ADDITIONAL DETECTOR EFC MODULE Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 82 DOC: 03-925611-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 9 of 10 PAGE: MODULE PNEUMATICS CONNECTIONS PNEUMATICS SIDE MANIFOLD PNEU. MANIFOLD (REF.) MAKE UP LINE FROM MODULE TO DETECTOR BLUE (26”) TO LEFT TOP POSITION BLANK OF RIGHT TOP MAKEUP LINE TO MODULE, BLUE (16”) 03-917142-00 VITON FERRULE...
  • Page 83 DOC: 03-925611-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 10 of 10 PAGE: 03-925487-01 IGNITOR CABLE 03-925041-01 ECD PWA 03-917830-00 SIGNAL CABLE 18” SIGNAL & IGNITOR CABLE CONNECTION 14-112007-00 FLAT, WASHER 12-901163-00 SCREW, 6-32 X 1/4 ECD PWA INSTALLATION 14-998237-00, 2 PLCS SET SPRING WASHER MOUNTING SCREWS DETAIL...
  • Page 84 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 1 of 11 PAGE: FID EFC INSTALLATION Bob Vickroy PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 29 - 98 SHOWN...
  • Page 85 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 2 of 11 PAGE: 3800 TWIN 8200 A/S INJ. & DET. LOCATION & ORIENTATION DET. POSITION 4 & 6 INJ. POSITION 1 & 3 Bob Vickroy PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 86 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 3 of 11 PAGE: DET. DET. DET. FRONT MIDDLE FRONT MIDDLE REAR REAR HEAT ZONE 1 INJECTOR 1 INJECTOR 2 HEAT ZONE 2 HEAT ZONE 3 INJECTOR 3 HEAT ZONE 4 DETECTOR 1 HEAT ZONE 5...
  • Page 87 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 4 of 11 PAGE: CABLE INSTALLATION CABLE PLUG-IN TO MAIN BOARD 03-925798-01 CABLE, FLAT FOR DETECTOR EFC Bob Vickroy PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 88 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 5 of 11 PAGE: INLET MANIFOLD SUBASSEMBLY 03-925838-23 TUBING, PEEK 23” (BLUE) 03-925842-24 03-925839-22 TUBING, PEEK 1/8 26” (NATURAL) TUBING, PEEK 22” (RED) 03-925840-21 TUBING, PEEK 21” (BLACK) 03-917084-00, 3 PLCS NUT, VITON FERRULE 03-917157-00, 3 PLCS...
  • Page 89 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 6 of 11 PAGE: MODULE INSTALLATION 12-901163-00, 2 PLCS SCREW, 6-32 24-389051-00 GROMMET, FLEXIBLE Bob Vickroy PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 29 - 98 SHOWN...
  • Page 90 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 7 of 11 PAGE: INLET MANIFOLD INSTALLATION (03-925840-21, BLACK) AIR INLET (03-925839-22, RED) H2 INLET (03-925842-24,, 1/8” NATURAL) CARRIER INLET (03-925838-23, BLUE) MAKEUP INLET Bob Vickroy PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 91 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 8 of 11 PAGE: MODULE INSTALLATION NOTES: 1. CONNECT CABLE TO MODULE, THEN MOUNT MODULE TO FRONT PANEL. 2 MOVE MODULE LOCATION JUMPER TO SPECIFY FRONT, MIDDLE, OR REAR. 3 ADD CABLE HOLDER WHEN NO REAR MODULE.
  • Page 92 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 9 of 11 PAGE: ADDITIONAL MODULE CABLING (IF REQ’D) NOTE CABLE SERVICE LOOP FOR ADDITIONAL DETECTOR EFC MODULE Bob Vickroy PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 93 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 10 of 11 PAGE: PNEUMATICS SIDE MANIFOLD MODULE PNEUMATICS CONNECTIONS REFERENCE ONLY PNEU. MANIFOLD AIR LINE FROM MODULE MAKEUP LINE TO MODULE, BLUE (16”) TO DETECTOR BLACK (26”) H2 LINE TO MODULE, RED (16”) HYDROGEN LINE AIR LINE TO MODULE, BLACK (16”)
  • Page 94 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 11 of 11 PAGE: 03-925487-01 IGNITOR CABLE 03-925021-01 FID PWA 03-917830-00 SIGNAL CABLE 18” SIGNAL & IGNITOR CABLE CONNECTION 14-112007-00 FLAT, WASHER 12-901163-00 SCREW, 6-32 X 1/4 FID PWA INSTALLATION 14-998237-00, 2 PLCS SET SPRING WASHER MOUNTING SCREWS DETAIL...
  • Page 95 DOC: 03-925610-00 PARTS TOOLS DESC: Assembly Procedure Station #3 MENU LIST HISTORY 12 of 11 PAGE: Bob Vickroy PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 29 - 98 SHOWN...
  • Page 96 DOC: REF 03-925604-00 PARTS TOOLS DESC: PFPD Installation MENU LIST HISTORY PAGE: of 5 PFPD Installation PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 09 - 22 - 99 SHOWN...
  • Page 97 DOC: REF 03-925604-00 PARTS TOOLS DESC: PFPD Installation MENU LIST HISTORY PAGE: of 5 03-925194-01 SCREW, CAP 8-32X 3/4”LG, CLEANED 2EA 03-925134-00 ASSY., IGNITOR CAP 03-925461-01 15-003347-00 ASSY., IGNITOR CABLE, PFPD WASHER CRUNCH, .040 THK, ALUM NOTE: SEE P.5 FOR CABLE CONNECTION TO PFPD PWA 03-918663-07 SCREW, CAP 8-32X1 1/2”LG, MICROSEAL 2EA...
  • Page 98 DOC: REF 03-925604-00 PARTS TOOLS DESC: PFPD Installation MENU LIST HISTORY PAGE: of 5 03-925476-01 DETECTOR BASE PFPD 03-917142-00 VITON FERRULE REF. ONLY 12-901150-00 SCREW REF. 03-917141-00 ONLY CONDYNE PLATE H2 BOTTOM AIR TOP LINE FROM LINE FROM DET. BASE, 12-901163-00 DET.
  • Page 99 DOC: REF 03-925604-00 PARTS TOOLS DESC: PFPD Installation MENU LIST HISTORY PAGE: of 5 03-918853-02 PEEK TUBING , NATURAL, H2 03-918853-13 03-925469-01 PEEK TUBING , ORANGE 30”LG BRACKET, SPLIT VALVE MOUTING RED/CLR/BLK 16-000589-00 03-918959-01 1/16” TEE TUBE, SST FILTER, FLOW MODULE 57-000028-00 NEEDLE VALVE 03-917146-03...
  • Page 100 DOC: REF 03-925604-00 PARTS TOOLS DESC: PFPD Installation MENU LIST HISTORY PAGE: of 5 03-917830-00 03-925461-01 ASSY., CABLE SIGNAL 18” ASSY., IGNITOR CABLE, PFPD 03-925066-01 PFPD PWA 03-908339-02 ASSY., CABLE HIGH VOLT.,34”LG. PFPD PWA INSTALLATION PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 101 DOC: 03-925603-00 PARTS TOOLS DESC: TSD Detector Installation, 3800 MENU LIST HISTORY PAGE: of 5 TSD Detector Installation PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 8/20/97 SHOWN...
  • Page 102 DOC: 03-925603-00 PARTS TOOLS DESC: TSD Detector Installation, 3800 MENU LIST HISTORY PAGE: of 5 DET. DET. DET. FRONT MIDDLE FRONT MIDDLE REAR REAR 03-917142-00 VITON FERRULE REF. ONLY 12-901150-00 SCREW REF. 03-917141-00 ONLY CONDYNE PLATE H2 BOTTOM LINE FROM AIR TOP DET.
  • Page 103 DOC: 03-925603-00 PARTS TOOLS DESC: TSD Detector Installation, 3800 MENU LIST HISTORY PAGE: of 5 89-999028-00 STOPPER 12-142008-04 08-000229-00 SCREW, 8-32 X 1/4” , TOP CLAMP PH, HD, SST 2EA. REF ONLY 03-917151-01 27-409282-00 21-000031-00 TSD ASSY. O-RING, .487 ID X .103 WIDE INSULATOR, UPPER 03-906079-00 S/A, COLLECTOR ,TSD...
  • Page 104 DOC: 03-925603-00 PARTS TOOLS DESC: TSD Detector Installation, 3800 MENU LIST HISTORY PAGE: of 5 03-917065-00 VALVE, AIR , 450 cc/min., BLACK 03-918853-06 PEEK TUBING, BLACK, AIR IN 12-222008-05 23-599813-00 03-917065-01 SCREWS 2EA DIAL, TURNS COUNT- VALVE, H2 , 60 cc/min., RED VALVE 03-918853-06 ING, 10 TURNS...
  • Page 105 DOC: 03-925603-00 PARTS TOOLS DESC: TSD Detector Installation, 3800 MENU LIST HISTORY PAGE: of 5 03-917830-00 SIGNAL CABLE 18” 03-925070-01 TSD PWA 03-925488-01 TSD BEAD CABLE 12-901163-00 SCREW, SEMS 8-32 X 3/8 SIGNAL & BEAD CABLE CONNECTION TSD PWA INSTALLATION PARTS NOT SHOWN 22-300001-00 NOTE: POSITION &...
  • Page 106 DOC: 03-925602-00 PARTS TOOLS DESC: TCD Detector Installation MENU LIST HISTORY PAGE: of 3 TCD DETECTOR Installation PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 8/20/97 SHOWN...
  • Page 107 DOC: 03-925602-00 PARTS TOOLS DESC: TCD Detector Installation MENU LIST HISTORY PAGE: of 3 12-901163-00 SCREW, 4EA Notes: 03-925607-01 NOTE: ASSY., TCD AND OVEN, 120V 1. FOR OPTIONS WITH SEE PAGE 3 TRANSFER LINE ONLY. 03-925607-02 FOR PWA ASSY., TCD AND OVEN, 230V CONNECTION 03-925607-03 ASSY., TCD AND OVEN, 101V...
  • Page 108 DOC: 03-925602-00 PARTS TOOLS DESC: TCD Detector Installation MENU LIST HISTORY PAGE: of 3 03-925037-01 ASSY., TCD, PCB CONNECTION TO TCD PWA CLICK HERE CLICK HERE FOR FOR PROBE HEATER CONNECTION CONNECTION TO J41 ON POWER BOARD J7 ON MAIN BD. TCD PWA INSTALLATION NOTE: POSITION &...
  • Page 109 DOC: 03-925601-00 PARTS TOOLS DESC: ECD Detector MENU LIST HISTORY PAGE: of 5 ECD DETECTOR Installation PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 03 - 13 - 98 SHOWN...
  • Page 110 DOC: 03-925601-00 PARTS TOOLS DESC: ECD Detector MENU LIST HISTORY PAGE: of 5 DET. DET. DET. FRONT MIDDLE FRONT MIDDLE REAR REAR 03-917142-00 VITON FERRULE PRESS. 12-901150-00 CARR. SENSE SCREW REF. 03-917141-00 ONLY CONDYNE PLATE BOTTOM LINE FROM DET. BASE, MAKE MAKE SPARE...
  • Page 111 DOC: 03-925601-00 PARTS TOOLS DESC: ECD Detector MENU LIST HISTORY PAGE: of 5 01-001023-00 S/A, COVER, TOP, ECD TOWER 24-000732-00 INSUL, CVR, ECD TOWER 12-142008-04 03-918663-00 SCREW, 8-32 X 1/4” LG., PH. HD, SST. SCREW, 8-32 X 3 1/8” MICROSEAL 02-001972-00 ASSY., 63Ni, ECD GEN.
  • Page 112 DOC: 03-925601-00 PARTS TOOLS DESC: ECD Detector MENU LIST HISTORY PAGE: of 5 03-917142-00 03-918853-04 VITON FERRULE PEEK TUBING, BLUE, MAKE UP IN REF. 12-901150-00 ONLY SCREW 12-222008-05 REFERENCE ONLY 03-917141-00 SCREW 2EA. PNEU. MANIFOLD CONDYNE PLATE 03-918853-04 PEEK TUBING, BLUE, MAKE-UP TO MANIFOLD HYDROGEN LINE MAKE-UP FROM PNEU PANEL...
  • Page 113 DOC: 03-925601-00 PARTS TOOLS DESC: ECD Detector MENU LIST HISTORY PAGE: of 5 03-908376-03 ASSY., CABLE PULSER 03-925041-01 ECD, PWA 03-917830-00 ASSY., SIGNAL CABLE PARTS NOT SHOWN NOTE: POSITION & ROUTING OF CABLE AND TIES NOT SHOWN. DRESS CABLE W/ QTY. NEEDED USING AVAILABLE SPACE.
  • Page 114 DOC: 03-925600-00 PARTS TOOLS DESC: FID Installation MENU LIST HISTORY PAGE: of 6 FID INSTALLATION Subassembly Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 26 - 00 SHOWN...
  • Page 115 DOC: 03-925600-00 PARTS TOOLS DESC: FID Installation MENU LIST HISTORY PAGE: of 6 3800 TWIN 8200 A/S INJ. & DET. LOCATION & ORIENTATION DET. POSITION 4 & 6 INJ. POSITION 1 & 3 Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 116 DOC: 03-925600-00 PARTS TOOLS DESC: FID Installation MENU LIST HISTORY PAGE: of 6 DET. DET. DET. FRONT MIDDLE FRONT MIDDLE REAR REAR 03-917142-00 VITON FERRULE 12-901150-00 SCREW REF. 03-917141-00 ONLY CONDYNE PLATE AIR TOP LINE FROM H2 BOTTOM DET. BASE, LINE FROM BLANK BLACK...
  • Page 117 DOC: 03-925600-00 PARTS TOOLS DESC: FID Installation MENU LIST HISTORY PAGE: of 6 NOTE: 21-000032-00 FOR SIGNAL & IGNITER INSULATOR, LOWER FID 03-949587-00 CABLE CONNECTION TUBE, COLLECTOR FID TO DET. PCB SEE P.5 12-142008-04 SCREW, 8-32 X 1/4” , FILL HD, SST 2EA. 03-918663-02 SCREW, MICROSEAL, 8-32 2EA.
  • Page 118 DOC: 03-925600-00 PARTS TOOLS DESC: FID Installation MENU LIST HISTORY PAGE: of 6 REFERENCE ONLY 03-917065-00 PNEU. MANIFOLD VALVE, COMB-S, BLACK, AIR 03-918853-06 12-222008-05 PEEK TUBING, BLACK, AIR IN 8-32 X 3/8” LG. SCREW 6EA HYDROGEN LINE 03-917065-01 FROM PNUE PANEL VALVE, COMB-S, RED, HYDROGEN TO DETECTOR RED MAKE-UP...
  • Page 119 DOC: 03-925600-00 PARTS TOOLS DESC: FID Installation MENU LIST HISTORY PAGE: of 6 03-925487-01 IGNITOR CABLE 03-925021-01 FID PWA 03-917830-00 SIGNAL CABLE 18” SIGNAL & IGNITOR CABLE CONNECTION FID PWA INSTALLATION Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 120 DOC: 03-925517-01 PARTS TOOLS DESC: 1079/Manual Pneu. Installation MENU LIST HISTORY 1 of 3 PAGE: 1079/Manual Pneu. Installation Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 26 - 00 SHOWN...
  • Page 121 DOC: 03-925517-01 PARTS TOOLS DESC: 1079/Manual Pneu. Installation MENU LIST HISTORY 2 of 3 PAGE: 03-925516-01 S/A 1079 INJ. MOD. MANUAL 120v 03-925516-02 S/A 1079 INJ. MOD. MANUAL 230v 03-918532-00 03-925516-03 VAR SEPTUM PURGE S/A 1079 INJ. MOD. MANUAL 101v CLICK HERE FOR PROBE CONNECTION TO J7 ON MAIN BOARD...
  • Page 122 DOC: 03-925517-01 PARTS TOOLS DESC: 1079/Manual Pneu. Installation MENU LIST HISTORY 3 of 3 PAGE: 03-918853-07 03-917142-00 03-917142-00 03-925467-01 03-918853-03 PEEK TUBING 1/8” NAT. VITON FERRLE VITON FERRLE 3EA SOLENOID VALVE 3- WAY PEEK TUBING, GREEN 03-917157-00 12-901162-00 03-917157-00 28-849067-00 WASHER , VITON FERRLE SCREW (2 PL) WASHER , VITON FERRLE 3EA...
  • Page 123 DOC: 03-925502-00 PARTS TOOLS DESC: 1061 Injector/EFC MENU LIST LIST HISTORY PAGE: of 4 1061 Injector With EFC Installation MICHAEL HARRAL PREPARED BY: REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 8/20/97 SHOWN...
  • Page 124 DOC: 03-925502-00 PARTS TOOLS DESC: 1061 Injector/EFC MENU LIST LIST HISTORY PAGE: of 4 03-908127-00 ASSY., INJECTOR NUT HEATED 03-908206-01 00-997628-00 ASSY., ACTUATOR SWITCH SEPTA 03-918339-00 03-925458-01 INSERT, MEGABORE INJ. 03-917204-00 INSJECTOR SWITCH CABLE SPRING 03-925483-01 CLICK HERE S/A 1061 INJ. EFC OR ON PICTURE TO SEE 1061 SUB-ASSEMBLY 03-925512-01...
  • Page 125 DOC: 03-925502-00 PARTS TOOLS DESC: 1061 Injector/EFC MENU LIST LIST HISTORY PAGE: of 4 03-925502-01 1061 INJECTOR, 3800 03-925502-02 1061 INJECTOR, 3800 03-925502-03 1061 INJECTOR, 3800 12-901163-00 SCREW, 8-32 X 3/8” EXT. LW 4EA. 8 TOTAL 03-925374-01 PROBE, TEMPERATURE 03-925458-01 INSJECTOR SWITCH CABLE 03-925396-01 120V HTR.
  • Page 126 DOC: 03-925502-00 PARTS TOOLS DESC: 1061 Injector/EFC MENU LIST LIST HISTORY PAGE: of 4 CLICK HERE TO MANIFOLD / PRESSURE SENSE OR ON PICTURE TO SEE 1061 INJECTOR EFC SUB-ASSEMBLY CARRIER IN TO MANIFOLD / TO MANIFOLD / CARRIER OUT PRESSURE SENSE CARRIER OUT 1061 EFC INJECTOR, 3800...
  • Page 127 DOC: 03-925501-00 PARTS TOOLS DESC: 1041 Injector/EFC MENU LIST LIST HISTORY PAGE: of 4 1041 Injector With EFC Installation MICHAEL HARRAL PREPARED BY: REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 8/20/97 SHOWN...
  • Page 128 DOC: 03-925501-00 PARTS TOOLS DESC: 1041 Injector/EFC MENU LIST LIST HISTORY PAGE: of 4 03-908127-00 03-918204-00 ASSY., INJECTOR NUT HEATED BAKE-OUT SEPTA 00-997628-00 03-908206-01 SEPTA ASSY., ACTUATOR SWITCH 03-917204-00 03-925482-01 REFERENCE: SPRING S/A 1041 INJ. EFC 03-925458-01 INSJECTOR SWITCH CABLE CLICK HERE OR ON PICTURE TO MANIFOLD...
  • Page 129 DOC: 03-925501-00 PARTS TOOLS DESC: 1041 Injector/EFC MENU LIST LIST HISTORY PAGE: of 4 12-901163-00 SCREW, 8-32 X 3/8” EXT. LW 4EA. 8 TOTAL 03-925374-01 PROBE, TEMPERATURE REFERENCE 03-925458-01 INJECTOR SWITCH CABLE 03-925396-01 120V HTR. ION 03-925396-02 220V HTR. ION 03-925396-03 101V HTR.
  • Page 130 DOC: 03-925501-00 PARTS TOOLS DESC: 1041 Injector/EFC MENU LIST LIST HISTORY PAGE: of 4 TO MANIFOLD / PRESSURE SENSE CARRIER IN TO MANIFOLD / TO MANIFOLD / CARRIER OUT PRESSURE SENSE CARRIER OUT 1041 INJECTOR, 3800 DET. DET. DET. MIDDLE FRONT MIDDLE REAR...
  • Page 131 DOC: 03-925500-2X PARTS TOOLS DESC: 1079/EFC/CO2 CRYO Installation MENU LIST HISTORY 1 of 4 PAGE: 1079 W / CO2 CRYO & EFC, Installation PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 03 - 13 - 98 SHOWN...
  • Page 132 DOC: 03-925500-2X PARTS TOOLS DESC: 1079/EFC/CO2 CRYO Installation MENU LIST HISTORY 2 of 4 PAGE: 03-925445-01 1079 INJECTOR W/ EFC 03-918532-01 VAR SEPTUM PURGE 12-901163-00 SCREW, 8-32 X 3/8” EXT. LW 4EA. 8 TOTAL 28-211457-00 1/16-1/16 VALCO UNION 88-48071-00 1/18” INSULATION TUBING 03-925110-01 EFC TYPE 1 03-918853-00...
  • Page 133 DOC: 03-925500-2X PARTS TOOLS DESC: 1079/EFC/CO2 CRYO Installation MENU LIST HISTORY 3 of 4 PAGE: 88-189609-00 TEFLON TAPE 28-694205-00 APADT, COMP 1/8” X 1/8” NOTE: PORT FACING INJECTOR TO BE ARROW DIRECTION. 28-695110-00 ADAPT, COMP 1/16” X 1/8” 88-189609-00 03-925567-01 TEFLON TAPE CO2 CRYO VALVE 03-925562-01...
  • Page 134 DOC: 03-925500-2X PARTS TOOLS DESC: 1079/EFC/CO2 CRYO Installation MENU LIST HISTORY 4 of 4 PAGE: PRESSURE PRESSURE SENSE SENSE (TO 1079) (TO EFC) CARRIER IN FROM CROSS FITTING TO SEPTUM PURGE (TO SPORT VALVE) CARRIER IN SPLIT (FROM EFC) VENT SPLIT VENT CARRIER VENT THRU...
  • Page 135 DOC: 03-925500-1X PARTS TOOLS DESC: 1079/EFC/LN2 CRYO Installation MENU LIST HISTORY PAGE: 1 of 5 1079 W / LN2 CRYO & EFC, Installation PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 03 - 13 - 98 SHOWN...
  • Page 136 DOC: 03-925500-1X PARTS TOOLS DESC: 1079/EFC/LN2 CRYO Installation MENU LIST HISTORY PAGE: 2 of 5 03-925445-01 1078 INJECTOR W/ EFC 03-918532-01 VAR SEPTUM PURGE 88-489071-00 1/8” INSUL. CRYO TUBE 12-901163-00 SCREW, 8-32 X 3/8” EXT. LW 4EA. 8 TOTAL TOP (SHORT) TUBE - INLET 03-925110-01 EFC TYPE 1...
  • Page 137 DOC: 03-925500-1X PARTS TOOLS DESC: 1079/EFC/LN2 CRYO Installation MENU LIST HISTORY PAGE: 3 of 5 PRESSURE PRESSURE SENSE SENSE (TO 1079) (TO EFC) CARRIER IN FROM CROSS FITTING TO SEPTUM PURGE (TO SPORT VALVE) CARRIER IN SPLIT (FROM EFC) VENT SPLIT VENT CARRIER VENT THRU...
  • Page 138 DOC: 03-925500-1X PARTS TOOLS DESC: 1079/EFC/LN2 CRYO Installation MENU LIST HISTORY PAGE: 4 of 5 28-695130-00 ADAP., COMP. 1/4” X 1/8” AS REQ. 28-691946-00 1/4” TEE #B-400-3 VENT / CONDENCE’ 88-489071-00 1/8” TEFLON CRYO TUBE UNDER INSULATION 88-489071-00 1/8” TEFLON CRYO TUBE 88-494510-00 3/8”...
  • Page 139 DOC: 03-925500-1X PARTS TOOLS DESC: 1079/EFC/LN2 CRYO Installation MENU LIST HISTORY PAGE: 5 of 5 CLICK HERE TO SEE CONNECTION TO J44 ON POWER BOARD 03-925557-01 CRYO VALVE SHOULD HAVE GROUND WIRE CUT. (GREEN & YELLOW) 03-925562-01 23-230938-00 NOTE FLOW DIRECTION, CO2 CRYO BRKT CRYO DRIP TRAY PORT FACING INJECTOR...
  • Page 140 DOC: 03-925500-0X PARTS TOOLS DESC: 1079/EFC Installation MENU LIST HISTORY 1 of 5 PAGE: 1079/EFC Installation Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 08 - 18 - 98 SHOWN...
  • Page 141 DOC: 03-925500-0X PARTS TOOLS DESC: 1079/EFC Installation MENU LIST HISTORY 2 of 5 PAGE: 3800 TWIN 8200 A/S INJ. & DET. LOCATION & ORIENTATION NOTE: DETECTORS MOUNTED IN LOCATION CLOSEST TO PNEUMATICS COMPARTMENT. INJ. POSITION 1 & 3 Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING...
  • Page 142 DOC: 03-925500-0X PARTS TOOLS DESC: 1079/EFC Installation MENU LIST HISTORY 3 of 5 PAGE: 3800 TWIN 8200 A/S INJ. & DET. LOCATION & ORIENTATION MOVE CABLE CLIP TO LOCATION SHOWN. INJ. POSITION 1 & 4 NOTE: FRONT INJECTOR ROTATED 180 FROM STANDARD AND MOUNTED IN FRONT MOST HOLES.
  • Page 143 DOC: 03-925500-0X PARTS TOOLS DESC: 1079/EFC Installation MENU LIST HISTORY 4 of 5 PAGE: NOTE: BE SURE INJ. IS IN ONE OF THE (4) A/S LOCATIONS. SEE INJ. COVER FOR ALIGNMENT. 03-925445-00 1079 INJECTOR W/ EFC 03-918532-01 VAR SEPTUM PURGE 12-901163-00 SCREW, 8-32 X 3/8”...
  • Page 144 DOC: 03-925500-0X PARTS TOOLS DESC: 1079/EFC Installation MENU LIST HISTORY 5 of 5 PAGE: PRESSURE PRESSURE SENSE SENSE (TO 1079) (TO EFC) CARRIER IN FROM CROSS FITTING TO SEPTUM PURGE (TO SPORT VALVE) CARRIER IN SPLIT (FROM EFC) VENT SPLIT VENT CARRIER VENT THRU PNEU.
  • Page 145 DOC: 03-925500-00 PARTS TOOLS TOOLS DESC: 1041 Manual Pneumatics MENU LIST LIST HISTORY PAGE: PAGE: of 3 1041 Injector With Manual Pneumatics Installation MICHAEL HARRAL PREPARED BY: REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 07 - 02 - 99 SHOWN...
  • Page 146 DOC: 03-925500-00 PARTS TOOLS TOOLS DESC: 1041 Manual Pneumatics MENU LIST LIST HISTORY PAGE: PAGE: of 3 03-908127-00 ASSY., INJECTOR NUT HEATED 00-997628-00 03-908206-01 SEPTA ASSY., ACTUATOR SWITCH 03-925482-01 03-917204-00 REFERENCE S/A 1041 INJ. MANUAL SPRING 03-925458-01 INJECTOR SWITCH CABLE CLICK HERE OR ON PICTURE TO MANIFOLD...
  • Page 147 DOC: 03-925500-00 PARTS TOOLS TOOLS DESC: 1041 Manual Pneumatics MENU LIST LIST HISTORY PAGE: PAGE: of 3 FROM BULKHEAD TO MANIFOLD/ INJECTOR 03-917084-00 NUT, VITON FERRULE 27-239920-00 GAGE, PRESSURE, 0-30 03-917146-00 03-918959-01 FLOW CONTROLLER, PORTER FILTER, FLOW MODULE 03-917130-00 ASSY., FLOW CONTROL OUT TUBE 23-599813-00 DIAL TURNS COUNTER...
  • Page 148 DOC: 03-925321-00 PARTS TOOLS DESC: FAST G.C. MENU LIST HISTORY PAGE: of 4 Fast G.C. Side Cover & Cryo Mixer Sub. Subassembly PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 4-11-96 SHOWN...
  • Page 149 DOC: 03-925321-00 PARTS TOOLS DESC: FAST G.C. MENU LIST HISTORY PAGE: of 4 03-918860-00 SIDE PANEL, FAST GC. 28-247071-00 CAP, PLUG, 1/8” BRASS 03-905960-09 O-RING, VITON 28-996044-00 CAP 5/16 - 20 #C-2 OUTPUT PORT 03-917130-03 ASSY, DUAL TUBING INPUT PORT 01-001047-00 03-917128-00 03-918886-00...
  • Page 150 DOC: 03-925321-00 PARTS TOOLS DESC: FAST G.C. MENU LIST HISTORY PAGE: of 4 88-494510-00 PIPE INSULATION (LOCATION ONLY, INSULATION NOT SHOWN. INSUL. TO COVER ALL FITTINGS) 28-691946-00 1/4” BRASS TEE 28-995808-00 VINYL CAP .250 DIA. 28-995813-00 VINYL CAP .625 DIA. 28-995806-00 VINYL CAP, .125 DIA.
  • Page 151 DOC: 03-925321-00 PARTS TOOLS DESC: FAST G.C. MENU LIST HISTORY PAGE: of 4 27-239934-00 GAUGE, 100PSI 03-917128-00 03-925322-00 NUT, 1/8”NPS - O-RING MIXER ASSY. BASE 03-917142-00 VITON FERRULE SEE NOTE 2 03-917157-00 WASHER, FERRULE 88-189609-00 TFE TAPE, 1/4” WIDE 28-849718-00 FITTING, 1/16 BARB TO 1/8 NPT, 90DEG.
  • Page 152 DOC: INSPECTION PARTS TOOLS DESC: O-RING MENU LIST HISTORY 1 of 1 PAGE: O-RING INSPECTION O-RINGS PEEK TUBING OPERATION NOTES 1. DO NOT TOUCH BAKED O-RINGS AT ANY TIME. 2. REMOVE BAKED O-RINGS FROM STORAGE JAR WITH TWEEZERS. 3. INSPECT BOTH SIDES OF THE BAKED O-RING FOR CRACKS UNDER A MICROSCOPE.
  • Page 153 DOC: INSPECTION PARTS TOOLS DESC: O-RING MENU LIST HISTORY 2 of 1 PAGE: PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 6-9-97 SHOWN...
  • Page 154 DOC: FILTER PARTS TOOLS DESC: FLOW MODULE MENU LIST HISTORY 1 of 1 PAGE: FILTER SUB-ASSEMBLY 03-917084-00 BESWICK FITTING FILTER ASSY. 03-918959-01 FILTER, FLOW MODULE FLOW 03-917084-00 BESWICK FITTING PARTS LIST FOR: EFC 1079 TYPES I, III, IV, V 03-917157-00 WASHER, VITON FERRULE 03-917142-00 FERRULE, VITON...
  • Page 155 DOC: FILTER PARTS TOOLS DESC: FLOW MODULE MENU LIST HISTORY 2 of 1 PAGE: PREPARED BY: HOWIE PLITSCH REVISED BY: AJB CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 5/14/98 SHOWN...
  • Page 156 DOC: 03-925996-01 PARTS TOOLS DESC: MENU Assy, 1177 Injector, W/Pressure Sense LIST HISTORY 1 of 9 PAGE: ASSY, 1177 INJECTOR, W/PRESSURE SENSE STATION #3 3800GC, ASSEMBLY PROCEDURES Steve Swihart PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 12 - 24 - 99 SHOWN...
  • Page 157 DOC: 03-925996-01 PARTS TOOLS DESC: MENU Assy, 1177 Injector, W/Pressure Sense LIST HISTORY 2 of 9 PAGE: 03-925975-01 ASSY, INJECTOR NUT, 1177 03-925971-01 INJECTOR SWITCH ASSEMBLY (REF.) ACTUATOR KNOB, 1177 03-925989-01 SEPTUM, HI-TEMP, 9MM THERMOGREEN SEE STEPS 1.2.16 THRU 1.2.18 03-925998-01 TO BEND TUBING TO REQUIRED ASSY, INJECTOR SWITCH...
  • Page 158 DOC: 03-925996-01 PARTS TOOLS DESC: MENU Assy, 1177 Injector, W/Pressure Sense LIST HISTORY 3 of 9 PAGE: 03-925994-01 03-925995-01 ASSY, 1177 INJ., W/PRESS. SENSE ASSY, 1177 INJ., NO PRESSURE SENSE 03-925994-11 ASSY, 1177 INJ., W/PRESS. SENSE, 03-925995-11 SILCOSTEEL (BLUE COLOR) ASSY, 1177 INJ., NO PRESSURE SENSE, SILCOSTEEL (BLUE COLOR) FIGURE 1...
  • Page 159 DOC: 03-925996-01 PARTS TOOLS DESC: MENU Assy, 1177 Injector, W/Pressure Sense LIST HISTORY 4 of 9 PAGE: 1177 INJECTOR W/PRESSURE SENSE, ASSEMBLY PROCEDURES INJECTOR SWITCH ASSEMBLY INSTALLATION 1.1.1 Place an Injector Actuator Spacer, (03-925981-01) on the stud protruding from the top of the Injector assembly. 1.1.2 Place the Injector Switch Assembly (03-908206-01) over the 1177 Injector W/Press.
  • Page 160 DOC: 03-925996-01 PARTS TOOLS DESC: MENU Assy, 1177 Injector, W/Pressure Sense LIST HISTORY 5 of 9 PAGE: 1.2.3 Bend the leads from a Platinum Probe (03-925374-01), 90 degrees about 1/4” from body. 1.2.4 Insert the probe end between the tube and the injector bracket. 1.2.5 Place the Platinum Probe into a Heater Block (03-925964-02).
  • Page 161 DOC: 03-925996-01 PARTS TOOLS DESC: MENU Assy, 1177 Injector, W/Pressure Sense LIST HISTORY 6 of 9 PAGE: 1.2.10 Repeat the previous step with the lower hole. 1.2.11 Orient the Heater Blocks so they're straight. Make sure the heater blocks still touch the tubing coming out of the side of the body near the top.
  • Page 162 DOC: 03-925996-01 PARTS TOOLS DESC: MENU Assy, 1177 Injector, W/Pressure Sense LIST HISTORY 7 of 9 PAGE: 1.2.14 Install the Insulation Cover (03-925967-01), over the injector and snap in place. If the injector cover doesn’t snap in place, the legs of the injector need to be bent outward.
  • Page 163 DOC: 03-925996-01 PARTS TOOLS DESC: MENU Assy, 1177 Injector, W/Pressure Sense LIST HISTORY 8 of 9 PAGE: 1.2.16 Bend the lowest tubes coming out of the slot in the injector bracket down, then out, so that they are parallel to the base of the injector and as close to it as possible.
  • Page 164 DOC: 03-925996-01 PARTS TOOLS DESC: MENU Assy, 1177 Injector, W/Pressure Sense LIST HISTORY 9 of 9 PAGE: 1.2.18 Rotate the body of the tee fitting so that the line coming out the side of it points horizontally, as shown. THIS LINE MUST COME OUT HORIZONTALLY Steve Swihart PREPARED BY: Sax Makthepharack REVISED BY:...
  • Page 165 DOC: 03-925996-01 PARTS TOOLS DESC: MENU Assy, 1177 Injector, W/Pressure Sense LIST HISTORY 10 of PAGE: Steve Swihart PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 12 - 24 - 99 SHOWN...
  • Page 166 DOC: 03-925914-11/12 PARTS TOOLS DESC: Sub-Assembly Micro - TCD MENU LIST HISTORY 1 of 3 PAGE: SUB-ASSEMBLY MICRO - TCD SUB-ASSEMBLIES STATION, ASSEMBLY PROCEDURES Seamus Flanagan PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 02 - 05 - 99 SHOWN...
  • Page 167 DOC: 03-925914-11/12 PARTS TOOLS DESC: Sub-Assembly Micro - TCD MENU LIST HISTORY 2 of 3 PAGE: NOTES: 1. DEPENDING ON APPLICATION USE 120V AC 50W HEATER (03-925899-01) OR 230V AC 50W HEATER (03-925899-02). 2. MAKE SURE HEATER AND PLATINIUM TEMP PROBE ARE FULLY SEATED. CP-738632 3.
  • Page 168 DOC: 03-925914-11/12 PARTS TOOLS DESC: Sub-Assembly Micro - TCD MENU LIST HISTORY 3 of 3 PAGE: CLICK HERE FOR MICRO-TCD INSTALLATION CP-847232, 2 PLCS CP-738640 SCREW, M3 FRONT COVER CP-738563 INSULATION UPPER 12-901164-00, 2 PLCS SCR, SEMS, 8-32 X 1/4”, SS 738948, 2 PLCS INSULATION L/R NOTE:...
  • Page 169 DOC: 03-925914-11/12 PARTS TOOLS DESC: Sub-Assembly Micro - TCD MENU LIST HISTORY 4 of 3 PAGE: Seamus Flanagan PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 02 - 05 - 99 SHOWN...
  • Page 170 DOC: 03-925844-91 PARTS TOOLS DESC: Assembly Procedure ICONS MENU LIST HISTORY chromatography 1 of 2 PAGE: ASSY, KIT, DETECTOR EFC INLET PLUM Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 05 - 13 - 98 SHOWN...
  • Page 171 DOC: 03-925844-91 PARTS TOOLS DESC: Assembly Procedure ICONS MENU LIST HISTORY chromatography 2 of 2 PAGE: 03-925842-24 NOTES: TUBING, PEEK 1/8” X 26” xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx DETAIL B 03-917142-00, 4 PLCS DETAIL A VITON FERRULE Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 172 DOC: 03-925702-01 PARTS TOOLS DESC: Assy, 3800GC Keyboard/Button-up MENU LIST HISTORY 1 of 6 PAGE: ASSY, 3800GC KEYBOARD/BUTTON-UP SUB-ASSEMBLY STATION, ASSEMBLY PROCEDURES Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 19 - 00 SHOWN...
  • Page 173 DOC: 03-925702-01 PARTS TOOLS DESC: Assy, 3800GC Keyboard/Button-up MENU LIST HISTORY 2 of 6 PAGE: WARNING: 1. Be careful around the high voltage area PS1 on (03-925800-01) PWA you could receive an electrical shock. Remove all jewelry while performing adjustments. Be careful with tools 12-222002-04, 4 PLCS you could cause a short circuit.
  • Page 174 DOC: 03-925702-01 PARTS TOOLS DESC: Assy, 3800GC Keyboard/Button-up MENU LIST HISTORY 3 of 6 PAGE: 3800GC KEYBOARD/BUTTON-UP, ASSEMBLY PROCEDURES KEYBOARD HOUSING ASSEMBLY 1.1.1 Feed Keyboard Overlay (03-925277-01) connector through slotted hole on Keyboard Housing Display (03-925207-01), using two 4-40 x 7/16 Hex Standoffs (22-431139-00) and four 4-40 Keps Nuts (13-312004-00) secure in place as shown.
  • Page 175 DOC: 03-925702-01 PARTS TOOLS DESC: Assy, 3800GC Keyboard/Button-up MENU LIST HISTORY 4 of 6 PAGE: 1.1.10 Un-clamp the display and turn it so it is facing you. 1.1.11 Turn the power back on being careful not to touch any circuitry. STEP 12 STEP 14 STEP 15...
  • Page 176 DOC: 03-925702-01 PARTS TOOLS DESC: Assy, 3800GC Keyboard/Button-up MENU LIST HISTORY 5 of 6 PAGE: The Object is to align Left, Right, Up and Down Margins equally with the edge of the housing. The display should show no tilt. Note: Avoid touching the high voltage supply behind the clamp. Prior to adjusting the LCD Display make sure to clamp the Keyboard Display Assembly down into the fixture.
  • Page 177 DOC: 03-925702-01 PARTS TOOLS DESC: Assy, 3800GC Keyboard/Button-up MENU LIST HISTORY 6 of 6 PAGE: Figure #2 Figure #3 Figure #4 Pry against the standoff to move the display left. Pry here to move both boards to the right. Pry here, between the two boards to tilt the right side of the display up.
  • Page 178 DOC: 03-925700-00 PARTS TOOLS DESC: Main Door MENU LIST HISTORY 1 of PAGE: Main Door Assembly PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 1/29/98 SHOWN...
  • Page 179 DOC: 03-925700-00 PARTS TOOLS DESC: Main Door MENU LIST HISTORY 2 of PAGE: 03-925311-01 PIN, HINGE, 2EA. 03-925208-01 MAIN DOOR NOTES: 14-112007-00 WASHER, FLAT, 2EA. 1. USE LOCTITE #222 ON BOTH SCREWS OF 12-901163-00 RETAINER LATCH. SCRW, 8-32 X 3/8, EXT.,LW, PH 2EA. TIGHTEN SCREWS UNTIL SNUG OR LATCH PLATE MOVES.
  • Page 180 DOC: 03-925697-00 PARTS TOOLS DESC: AUTODRIVE MENU LIST HISTORY 1 of 6 PAGE: AUTODRIVE SUB-ASSEMBLY PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 1/26/98 SHOWN...
  • Page 181 DOC: 03-925697-00 PARTS TOOLS DESC: AUTODRIVE MENU LIST HISTORY 2 of 6 PAGE: 03-925670-01 ROD, CYLINDER SUPPORT 03-925663-01 BLOCK 3 03-925598-01 SHAFT, SLED 03-925665-01 STOP “A/B” 2 PLACES 21-179882-00 PRECISION BALL BUSHING 2 PLACES 03-925667-01 SLED CLEAN GREASE OFF BUSHING AND ADD LOCTITE RC/609 TO OUTSIDE OF BUSHING AND INSIDE HOLES OF SLED, 4 PLACES...
  • Page 182 DOC: 03-925697-00 PARTS TOOLS DESC: AUTODRIVE MENU LIST HISTORY 3 of 6 PAGE: 28-849074-00 12-901163-00 BARB FITTING, 2 PLACES SCREW 8-32 x 3/8” SEMS 2 PLACES 28-849066-00 SWIVEL - ELL, 2 PLACES 27-300063-00 12-222060-10 PNEU. ACTUATOR SCREW 10-32 x 5/8” 03-925658-01 2 PLACES PUSHER...
  • Page 183 DOC: 03-925697-00 PARTS TOOLS DESC: AUTODRIVE MENU LIST HISTORY 4 of 6 PAGE: 12-901163-00 28-849817-00 SCREW #8-32 x 3/8 SEM #10-32 BULKHEAD FITTING W/ HARDWARE NOTES: (UNLESS OTHERWISE SPECIFIED) 2 PLACES SEE NOTE 2 1. REPLACE THE 1/8” BARB FITTINGS ON THE SEE NOTE 1 03-918707-01 5”...
  • Page 184 DOC: 03-925697-00 PARTS TOOLS DESC: AUTODRIVE MENU LIST HISTORY 5 of 6 PAGE: ADD RELAY WIRE SET LABELS, SEE WIRING SCHEMATIC 88-488028-00 ADD SHRINK TUBING 4 PLACES 22-119650-00 TO END OF SLEEVE CABLE TIE 24-799873-00 5/8” GROMMET 88-360032-00 1/4” I.D. x 3’ POLY SLEEVE TEST PER PROCEDURE #03-914203-00 PAGE 11 OF THE OPERATORS MANUAL.
  • Page 185 PARTS TOOLS DESC: AUTODRIVE MENU LIST HISTORY 6 of 6 PAGE: 03-925763-01 COVER 03-925760-01 LABEL, VARIAN AUTODRIVE 03-925764-02 CAP, END, LEFT HAND 03-925765-01 BRACKET, COVER 3 PLACES 03-925764-01 13-312008-00 CAP, END, RIGHT HAND #6 KEP NUT 6 PLACES 12-901164-00 SCREW #8-32 x 1/4 SEM...
  • Page 186 DOC: 03-925693-11/12 PARTS TOOLS DESC: Assy, Big Valve Oven MENU LIST HISTORY PAGE: of 5 Assy, Big Valve Oven PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 12 - 15 - 99 SHOWN...
  • Page 187 DOC: 03-925693-11/12 PARTS TOOLS DESC: Assy, Big Valve Oven MENU LIST HISTORY PAGE: of 5 NOTES: 1. PLACE THE HEATER PLATE AS SHOWN ON A FLAT, STEADY SURFACE. 2. INSTALL CLAMP RING SIX PLACE WITH 6-32 X 3/8 SCREWS. (CLAMP RING ORIENTATION AS SHWON). 3.
  • Page 188 DOC: 03-925693-11/12 PARTS TOOLS DESC: Assy, Big Valve Oven MENU LIST HISTORY PAGE: of 5 NOTES: 03-925550-01 1. PLACE THE OVEN BRACKET AS SHOWN ON A FLAT, INSULATION, BRKT STEADY SURFACE. VALVE OVEN 12-903134-00, 4 PLCS 2. ALIGN FOUR HOLES WITH INSULATION TO STANDOFFS ON BRACKET 8-32 X 5/8, KNLD THUMB AND GENTLY PRESS INSULATION INTO BRACKET.
  • Page 189 DOC: 03-925693-11/12 PARTS TOOLS DESC: Assy, Big Valve Oven MENU LIST HISTORY PAGE: of 5 NOTES: 1. SECURE HEATER WIRE CABLE CLAMP (2) TO OVEN BRACKET. 2. POSITION HEATER ASSEMBLY AND OVEN BRACKET AS SHOWN. 3. PLACE THE COVER INSULATION OVER THE OVEN COVER AND A FIRMLY PRESS DOWN INTO COVER.
  • Page 190 DOC: 03-925693-11/12 PARTS TOOLS DESC: Assy, Big Valve Oven MENU LIST HISTORY PAGE: of 5 Typical Installation of Big Valve Oven PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 12 - 15 - 99 SHOWN...
  • Page 191 DOC: 03-925693-11/12 PARTS TOOLS DESC: Assy, Big Valve Oven MENU LIST HISTORY PAGE: of 5 PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 12 - 15 - 99 SHOWN...
  • Page 192 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 1 of 17 PAGE: ASSY, DETECTOR EFC Sax Makthepharack PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 02 - 03 - 00 SHOWN...
  • Page 193 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 2 of 17 PAGE: O-RING INSPECTION O-RINGS PEEK TUBING NOTES: (UNLESS OTHERWISE SPECIFIED) 1. DO NOT TOUCH BAKED O-RINGS AT ANY TIME. 2. REMOVE BOTH TYPES OF BAKED O-RINGS FROM STORAGE JAR WITH TWEEZERS.
  • Page 194 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 3 of 17 PAGE: NOTES: (UNLESS OTHERWISE SPECIFIED) 1. INSTALL FRITT INTO BLOCK WITH ARBOR PRESS TOOL. PRESS UNTIL FRITT IS FULLY SEATED AGAINST BLOCK FACE. 2. FRITT TABLE 1 BLOCK LABEL FRITT P/N (03-9256XX-01) LABEL 03-925568-01...
  • Page 195 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 4 of 17 PAGE: NOTES: (UNLESS OTHERWISE SPECIFIED) 1. ASSEMBLE PART AS SHOWN. START SCREWS (3 TURNS) BUT DO NOT TORQUE COMPLETELY. 2. REPEAT FOR EACH CHANNEL WITH BLOCK PER TABLE 1. 3.
  • Page 196 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 5 of 17 PAGE: NOTES: (UNLESS OTHERWISE SPECIFIED) 1. ORIENT VALVE CABLES. LABEL 2. MOUNT VALVES & MOUNTING PLATE TO BLOCK ONE AT A TIME. 3. ASSEMBLE PWA TO MOUNTING PLATE SCREWS. TIE WRAP 4.
  • Page 197 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 6 of 17 PAGE: NOTES: (UNLESS OTHERWISE SPECIFIED) 1. ASSEMBLE TUBING/MANIFOLD/FERRULE AND 28-691944-00 SCREWS TO BLOCK. (SEE TUBING TABLES) HAND TIGHT. (-01, -02 & 05 ONLY) 2. CONNECT PIN OUT AS REQUIRED. 2 4 6 8 10 12 14 16 1 3 5 7 9 11 13 15 CHANNEL 1 VALVE...
  • Page 198 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 7 of 17 PAGE: TUBING TABLES NOTE: ITEM 1, 3 & 5 ARE INLET TO BLOCKS TABLE FOR -01, -02 & -05 TABLE FOR -04 & -06 TABLE FOR -03 TUBE P/N -01 TUBE P/N -02 TUBE P/N -05...
  • Page 199 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 8 of 17 PAGE: TEST AND CALIBRATION PROCEDURE DETECTOR EFC NOTES: (UNLESS OTHERWISE SPECIFIELD 1. CONNECT FLAT CABLE. DEFC P/N CARRIER IN CARRIER OUT (03-925609-XX) 2. CONNECT DEFC CARRIER INLET(s) TO TEST BENCH CARRIER INLET (MANIFOLD WITH CROSS “T”...
  • Page 200 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 9 of 17 PAGE: LABVIEW TEST AND CALIBRATION PROGRAM DETECTOR EFC 1. IN THE PROGRAM MANAGER LAB VIEW WINDOW, DOUBLE CLICK ON LAB VIEW ICON. A WINDOW WITH HEADING “ UNTITLED 1” WILL APPEAR, CLOSE IT.
  • Page 201 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 10 of 17 PAGE: 3. HIGHLIGHT AND OPEN Sax Makthepharack PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 02 - 03 - 00 SHOWN...
  • Page 202 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 11 of 17 PAGE: 4. HIGHLIGHT AND OPEN Sax Makthepharack PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 02 - 03 - 00 SHOWN...
  • Page 203 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 12 of 17 PAGE: 5. HIGHLIGHT AND “OK” Sax Makthepharack PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 02 - 03 - 00 SHOWN...
  • Page 204 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 13 of 17 PAGE: 7. CLICK ON ARROW TO GO TO “QUICK TEST”. 9.02 6. FROM FUNCTIONS PULLDOWN MENU, SELECT “QUICK TEST”. CURRENT REVISION IS 9.02 DO NOT RUN FIXTURE W/WRONG SOFTWARE REVISION Sax Makthepharack PREPARED BY: Sax Makthepharack REVISED BY:...
  • Page 205 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 14 of 17 PAGE: NOTES: (UNLESS OTHERWISE SPECIFIED) 1. REFER TO THE DEFC TROUBLESHOOTING FLOW CHART TO TEST ERRORS. 10. IN THE GRP BOX, INDICATE THE TYPE CODE OF THE DEFC IN EACH 2.
  • Page 206 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 15 of 17 PAGE: NOTES: (UNLESS OTHERWISE SPECIFIED) 1. REFER TO THE DEFC TROUBLESHOOTING FLOW CHART TO TEST ERRORS. 2. IF NO TEST ERRORS, ENTER DEFC TYPE AND PWA REV. ON APPRORIATE LABEL. 14.
  • Page 207 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 16 of 17 PAGE: 17. APPLY LABEL. NOTES: (UNLESS OTHERWISE SPECIFIELD 1. AFTER LABEL APPLIED, BAG & SEAL IMMEDIATELY. Sax Makthepharack PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 208 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 17 of 17 PAGE: DEFC Trouble-shooting Flow Chart Conduct Full Test or Calibration Diagnostic Rules: 1. Always investigate Leak and Flow Error Label and Package Sensor Errors first Message DEFC Module 2.
  • Page 209 DOC: 03-925609-00 PARTS TOOLS DESC: Assembly Procedure MENU LIST HISTORY 18 of 17 PAGE: Sax Makthepharack PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 02 - 03 - 00 SHOWN...
  • Page 210 DOC: 03-925607-00 PARTS TOOLS DESC: TCD Detector MENU LIST HISTORY PAGE: of 3 TCD DETECTOR Subassembly Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 05 - 04 - 98 SHOWN...
  • Page 211 DOC: 03-925607-00 PARTS TOOLS DESC: TCD Detector MENU LIST HISTORY PAGE: of 3 03-925333-01 -01, -02, & -03 STANDARD LID, OUTER OVEN -11, -12, & -13 W/ TRANSFER LINE 24-000739-00 INSULATION TOP & BOTTOM 24-000741-00 INSULATION, SIDE, TCD Notes: 1. CUT OFF EXISTING CONNECTOR AND PREPARE WIRES TO RECEIVE THE WIRE PINS AND NOTE:...
  • Page 212 DOC: 03-925607-00 PARTS TOOLS DESC: TCD Detector MENU LIST HISTORY PAGE: of 3 03-925333-01 LID, OUTER OVEN -21, -22, & -23 DUAL TCD 24-000739-00 INSULATION TOP & BOTTOM Notes: 1. CUT OFF EXISTING CONNECTOR AND PREPARE WIRES TO RECEIVE THE WIRE PINS AND 24-000741-00 NOTE: CONNECTOR SHOWN BELOW IN...
  • Page 213 DOC: 03-925512-04 PARTS TOOLS DESC: Assy, Oven Single Catalyst MENU LIST HISTORY 1 of 2 PAGE: ASSY, OVEN SINGLE CATALYST SUB-ASSEMBLIES STATION, ASSEMBLY PROCEDURES Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 20 - 99 SHOWN...
  • Page 214 DOC: 03-925512-04 PARTS TOOLS DESC: Assy, Oven Single Catalyst MENU LIST HISTORY 2 of 2 PAGE: 1. OVEN SINGLE CATALYST, ASSEMBLY PROCEDURES 03-925499-01 COVER, 1041 INJ OVEN BLOCK 1.1 OVEN BLOCK ASSEMBLY 1.1.1 Assemble the 1041 Oven Block Assembly (03-918648-00) and two Injector Mounting Brackets (04-000994-00), using four 8-32 x 3/8 Sems Screws (12-901163-00) to secure in place as shown.
  • Page 215 DOC: 03-925512-03 PARTS TOOLS DESC: Assy, Oven Dual Valve MENU LIST HISTORY 1 of 2 PAGE: ASSY, OVEN DUAL VALVE SUB-ASSEMBLIES STATION, ASSEMBLY PROCEDURES Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 20 - 99 SHOWN...
  • Page 216 DOC: 03-925512-03 PARTS TOOLS DESC: Assy, Oven Dual Valve MENU LIST HISTORY 2 of 2 PAGE: 1. OVEN DUAL VALVE, ASSEMBLY PROCEDURES 03-925676-01 COVER, VALVE OVEN, DUAL 1.1 OVEN BLOCK ASSEMBLY 1.1.1 Assemble Dual Valve Block (03-917170-00) to Injector Mounting Brackets (04-000994-00), using four 8-32 x 3/8 Sems Screws (12-901163-00) to secure in place.
  • Page 217 DOC: 03-925512-02 PARTS TOOLS DESC: Assy, Oven Injector/Valve MENU LIST HISTORY 1 of 2 PAGE: ASSY, OVEN INJECTOR/VALVE SUB-ASSEMBLIES STATION, ASSEMBLY PROCEDURES Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 19 - 99 SHOWN...
  • Page 218 DOC: 03-925512-02 PARTS TOOLS DESC: Assy, Oven Injector/Valve MENU LIST HISTORY 2 of 2 PAGE: 1. OVEN INJECTOR/VALVE, ASSEMBLY PROCEDURES 1.1 OVEN BLOCK ASSEMBLY 03-918442-00 COVER, HTD, INJ-VLV, OVEN 1.1.1 Assemble the Injector/Valve Block Assembly (03-917174-00) and two Injector Mounting Brackets (04-000994-00), using four 8-32 x 3/8 THD Cutting Screws (10-351308-06) to secure in place.
  • Page 219 DOC: 03-925512-01 PARTS TOOLS DESC: Assy, Oven Single Injector MENU LIST HISTORY 1 of 2 PAGE: ASSY, OVEN SINGLE INJECTOR SUB-ASSEMBLIES STATION, ASSEMBLY PROCEDURES Seamus Flanagan PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 16 - 99 SHOWN...
  • Page 220 DOC: 03-925512-01 PARTS TOOLS DESC: Assy, Oven Single Injector MENU LIST HISTORY 2 of 2 PAGE: 1. OVEN SINGLE INJECTOR, ASSEMBLY PROCEDURES 03-925499-01 COVER, 1041 INJ OVEN BLOCK 1.1 OVEN BLOCK ASSEMBLY 1.1.1 Assemble the 1041 Oven Block Assembly (03-925548-01) and two Injector Mounting Brackets (03-917588-00), using four 8-32 x 3/8 Sems Screws (12-901163-00) to secure in place as shown.
  • Page 221 DOC: 03-925445-03 PARTS TOOLS DESC: 1079 INJECTOR SUBASSEMBLY MENU LIST HISTORY PAGE: of 2 1079 INJECTOR W\CO2 CRYO Subassembly 03-925445-11 (120v CO2) 03-925445-12 (230v CO2) 03-925445-13 (101v CO2) Sax Makthepharack -11,12,13 PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 222 DOC: 03-925445-03 PARTS TOOLS DESC: 1079 INJECTOR SUBASSEMBLY MENU LIST HISTORY PAGE: of 2 TOOLS LIST 03-925575-01 TOP COVER OTHER PARTS NOT 1. T-3734 ASSY. FIX. SHOWN. 03-949666-01 03-925572-01 INJECTOR NUT ASSY CLAMP, TUBING 03-908206-01 ACTUATOR SWIT. ASSY. 14-920005-00 WAVE SPRING 2 EA. 03-925374-01 03-918679-00 PROBE...
  • Page 223 DOC: 03-925445-02 PARTS TOOLS DESC: 1079 INJECTOR SUBASSEMBLY MENU LIST HISTORY PAGE: of 2 1079 INJECTOR WITH LN2 CRYO Subassembly 03-925445-21 (120v LN2) 03-925445-22 (230v LN2) 03-925445-23 (101v LN2) Sax Makthepharack -21,22,23 PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 224 DOC: 03-925445-02 PARTS TOOLS DESC: 1079 INJECTOR SUBASSEMBLY MENU LIST HISTORY PAGE: of 2 TOOLS LIST 03-925575-01 TOP COVER OTHER PARTS NOT 1. T-3734 ASSY. FIX. SHOWN. 03-949666-01 INJECTOR NUT ASSY 03-925572-01 03-908206-01 CLAMP, TUBING ACTUATOR SWIT. ASSY. 14-920005-00 WAVE SPRING 2 EA. 03-925374-01 03-918679-00 PROBE...
  • Page 225 DOC: 03-925445-01 PARTS TOOLS DESC: 1079 Injector Subassembly MENU LIST HISTORY PAGE: of 2 1079 INJECTOR Subassembly 03-925445-01 (120v NO CRYO) 03-925445-02 (230v NO CRYO) 03-925445-03 (101v NO CRYO) Sax makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 226 DOC: 03-925445-01 PARTS TOOLS DESC: 1079 Injector Subassembly MENU LIST HISTORY PAGE: of 2 TOOLS LIST 03-925575-01 TOP COVER OTHER PARTS NOT 1. T-3734 03-949666-01 ASSY. FIX. SHOWN. INJECTOR NUT ASSY 03-908206-01 03-925572-01 ACTUATOR SWIT. ASSY. TUBING CLAMP 14-920005-00 WAVE SPRING 2 EA. 03-925374-01 PROBE INSERT FULLY INTO HOLE...
  • Page 227 DOC: 03-925250-01 PARTS TOOLS DESC: Rear Panel Assy. MENU LIST HISTORY PAGE: OF 2 Rear Cover Subassembly PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 3-20-97 SHOWN...
  • Page 228 DOC: 03-925250-01 PARTS TOOLS DESC: Rear Panel Assy. MENU LIST HISTORY PAGE: OF 2 NOTE: CLICK HERE TO SEE CONNECTION TO J 51 ON POWER BOARD 13-312008-00 KEPNUT, #6 , SST 4EA. 20-839825-00 03-925305-01 BEZEL, CHASSIS FAN 2ea. ASSY., CHASSIS FAN 12-222008-24 SCREW, 6-32 X 5/8”...
  • Page 229 DOC: 03-925211-01/-02 PARTS TOOLS DESC: Pneumatic Bezel Assembly MENU LIST HISTORY 1 of 2 PAGE: 3800 GC Pneumatics Bezel Assembly PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 16 - 99 SHOWN...
  • Page 230 DOC: 03-925211-01/-02 PARTS TOOLS DESC: Pneumatic Bezel Assembly MENU LIST HISTORY 2 of 2 PAGE: 23-620818-00 BALLSTUD, 2 EA. 03-925405-01 BRACKET, PNEUMATICS DOOR PIVOT 12-901134-00 SCREW, SEMS, 6-32 X 3/8, 2 EA. 03-925415-01 RIVET, LATCHING 03-925211-01 BEZEL, PNEUMATICS, FRONT NOTE: FOR -02 3380 VERSION, 12-901163-00 DELETE THE FOLLOWING:...
  • Page 231 DOC: 03-925133-00 PARTS DESC: PFPD Assembly MENU LIST HISTORY PAGE: of 4 PFPD Subassembly PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 3-27-97 SHOWN...
  • Page 232 DOC: 03-925133-00 PARTS DESC: PFPD Assembly MENU LIST HISTORY PAGE: of 4 12-901131-00 NITROGEN MODE SCREW, SEMS, INT., 8-32 X 3/8” LG, STL 4EA 03-925120-00 SOCKET ASSY., PMT, N MODE CLICK HERE FOR 03-925128-00 INSTALLATION PMT TUBE, NITROGEN MODE INSTRUCTIONS 11-622004-03 SET SCREW, 4-40 X 3/16”...
  • Page 233 DOC: 03-925133-00 PARTS DESC: PFPD Assembly MENU LIST HISTORY PAGE: of 4 SULFER PHOSPHEROUS 03-925147-00 03-925139-00 ASSY., LIGHT PIPE TOWER, BODY MODE 12-901131-00 03-925145-00 SCREW, SEMS, INT, 8-32 X 3/8” LG, STL 4EA ASSY, SAPHIRE WINDOW 03-925143-00 WASHER, SAPHIRE WINDOW DETAIL ‘A’...
  • Page 234 DOC: 03-925133-00 PARTS DESC: PFPD Assembly MENU LIST HISTORY PAGE: of 4 12-901131-00 SCREW, SEMS, INT., 8-32 X 3/8” LG, STL UPGRADE TO 03-925120-00 SOCKET ASSY., PMT, N MODE N2 MODE 27-402826-00 O-RING, 1.487 ID X .103 WALL, SLCN 11-622004-03 SET SCREW, 4-40 X 3/16”...
  • Page 235 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 1 of 16 PAGE: 24 VOLT SHORT TEST FOR EFC TYPES I, III, IV, AND 5 METER READING SHOULD BE O.L. OR IN THE MEGA OHMS METER SET TO OHMS BLACK PROBE TO MANIFOLD BLOCK RED PROBE TO...
  • Page 236 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 2 of 16 PAGE: TRANSDUCER SHORT TEST FOR EFC TYPES I, III, IV, AND 5 METER READING BE O.L. OR IN THE MEGA OHMS METER SET TO OHMS CHECK ALL 13 TRANSDUCER HOLES BLACK PROBE TO TRANSDUCER HOLE...
  • Page 237 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 3 of 16 PAGE: TEST FIXTURE CONNECTIONS GROUP 2 GROUP 0 GROUP 1 NOTES: (UNLESS OTHERWISE SPECIFIED) 1. EFC TYPES CANNOT BE MIXED WITHIN A GROUP. Sax Makthepharack PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 238 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 4 of 16 PAGE: TEST FIXTURE CONNECTIONS FOR EFC TYPE I NOTES: (UNLESS OTHERWISE SPECIFIED) 1. EFC CALIBRATION WILL BE ADVERSLY AFFECTED IF THE TUBING IS SHORTENED. Sax Makthepharack PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING...
  • Page 239 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 5 of 16 PAGE: TEST FIXTURE CONNECTIONS FOR EFC TYPE III NOTES: (UNLESS OTHERWISE SPECIFIED) 1. EFC CALIBRATION WILL BE ADVERSLY AFFECTED IF THE TUBING IS SHORTENED. Sax Makthepharack PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING...
  • Page 240 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 6 of 16 PAGE: TEST FIXTURE CONNECTIONS FOR EFC TYPE IV NOTES: (UNLESS OTHERWISE SPECIFIED) 1. EFC CALIBRATION WILL BE ADVERSLY AFFECTED IF THE TUBING IS SHORTENED. Sax Makthepharack PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING...
  • Page 241 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 7 of 16 PAGE: TEST FIXTURE CONNECTIONS FOR EFC TYPE V NOTES: (UNLESS OTHERWISE SPECIFIED) 1. EFC CALIBRATION WILL BE ADVERSLY AFFECTED IF THE TUBING IS SHORTENED. Sax Makthepharack PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING...
  • Page 242 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 8 of 16 PAGE: EFC Fixture Startup Procedure Turn on the computer Power. Enter password, "PASSWORD" to get logged on to the network if you intend to transfer files, then Press "OK". If no files are going to be transferred, press "CANCEL".
  • Page 243 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 9 of 16 PAGE: The following is the main menu that should be in the middle of the screen. ACTIVE INACTIVE * Fields that are required to go to any other screen are as follows. After required fields are filled in, press RUN to invoke: 1.
  • Page 244 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 10 of 16 PAGE: General Description of Functions No Function - Default Serial # and Config Changer - Only use the Serial Number function of this utility. Other settings to be set by the Manufacturing Engineer. Set Function to "Change Det Serial Number"...
  • Page 245 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 11 of 16 PAGE: Module Leak - Tool used to pressurize individual modules and test manually for leaks. Set Function to "Pressurize" Select the "Type", "Module" and "Gas" Press "Run". The Mensor Pressure should increase to about 90 psig. In the Function, Select "Isolate", Press "Run".
  • Page 246 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 12 of 16 PAGE: Detector Controller - Used to control individual gasses in any channel for a given calibrated DEFC. Enter the Module #, Gas Type and Function (Run Controller). Enter the desired flow and channel Press the "Valve Power"...
  • Page 247 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 13 of 16 PAGE: Print Memory - Used to print out the contents of the memory of any EFC, calibrated or not Enter the appropriate Type in the Function pull down menu. Enter the Module # Press the arrow in the upper left hand corner to start.
  • Page 248 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 14 of 16 PAGE: Quick Test - A Pre-Calibration test designed to weed out bad EFC modules. Other more advanced functions of this module are to "Test Controller" of individual EFC’s.
  • Page 249 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 15 of 16 PAGE: Fixture Leak - Used to diagnose fixture leaks. By jumping Carrier in to Carrier out, blocking off Pressure Sense and Jumping Split Vent to Vent and Capping off the Low and High vent of the Master Flow Sensors, Leaks to the atmosphere can be determined.
  • Page 250 DOC: ATP-03-925110-XX PARTS TOOLS DESC: TEST & CALIBRATION MENU LIST HISTORY 16 of 16 PAGE: Reference Flow Sensor Calibration - Used to facilitate and check Master Flow Sensor calibration. From the Pull down menu, select High or Low Sensor to check. Enter the Password of "1951"...
  • Page 251 DOC: 03-925110-BX PARTS TOOLS DESC: MENU Assy, Shipping Container, EFC Module LIST HISTORY 1 of 4 PAGE: FIGURE 1 FIGURE 2a FIGURE 2b FIGURE 3 FIGURE 4 Michelle Wu PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 08 - 23 - 00 SHOWN...
  • Page 252 DOC: 03-925110-BX PARTS TOOLS DESC: MENU Assy, Shipping Container, EFC Module LIST HISTORY 2 of 4 PAGE: SHIPPING CONTAINER EFC MODULE ASSEMBLY PROCEDURES BAGGING THE EFC MODULE 1.1.1 Determine EFC Type (Detector EFC 03-925609-XX, Injector EFC 03-925110-XX or Type 21/25 03-933016-XX). 1.1.2 Install one each Short Natural Nylon Typ-Wrap (22-119650-00) to tubing as shown in Figure 1.
  • Page 253 DOC: 03-925110-BX PARTS TOOLS DESC: MENU Assy, Shipping Container, EFC Module LIST HISTORY 3 of 4 PAGE: FIGURE 5 FIGURE 6 FIGURE 7 FIGURE 8 FIGURE 9a FIGURE 9b Michelle Wu PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 254 DOC: 03-925110-BX PARTS TOOLS DESC: MENU Assy, Shipping Container, EFC Module LIST HISTORY 4 of 4 PAGE: FOAM CAP 2 EA. SHIPPING BOX ASSEMBLY & PACKING INSTRUCTIONS 1.2.1 Assemble the Inner Box by taping bottom of inner box, using Tape Gun to seal one end.
  • Page 255 DOC: 03-925110-05 PARTS TOOLS DESC: EFC 1079 TYPE V MENU LIST HISTORY 1 of 4 PAGE: EFC MODULE V SUB-ASSEMBLY 24” 10” 8” 6” 8” 22” NATURAL 22” 12” Sax Makthepharack PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 256 DOC: 03-925110-05 PARTS TOOLS DESC: EFC 1079 TYPE V MENU LIST HISTORY 2 of 4 PAGE: 12-222006-04 SCREW, 6-32 X 1/4” PHMS 4 PLACES 03-918853-03 14-202006-00 TUBING, PEEK, .062 X .030 ID, GREEN 03-917157-00 8” WASHER, LOCK, #6 6 PLACES WASHER, VITON FERRULE PIN-1...
  • Page 257 DOC: 03-925110-05 PARTS TOOLS DESC: EFC 1079 TYPE V MENU LIST HISTORY 3 of 4 PAGE: DETAIL A WIRE TERMINATION 03-918853-03 TUBING, PEEK, .062 X .030 ID, GREEN, 8” 1/8” FROM MANIFOLD MOUNTING PLATE POSITION A REFERENCE PAGE 1 OR PAGE 4 TAB LOCKS IN OPENING CUT SOLENOID...
  • Page 258 DOC: 03-925110-05 PARTS TOOLS DESC: EFC 1079 TYPE V MENU LIST HISTORY 4 of 4 PAGE: 03-925783-06 03-925783-24 (USE 03-918853-03) (USE 03-918853-03) TUBING, PEEK, .062 X .030 ID, GREEN, 6” TUBING, PEEK, .062 X .030 ID, GREEN, 24” FROM BACK PRESSURE MANIFOLD BLOCK POSITION A REFERENCE PAGE 1 OR PAGE 3 03-925783-10 12-222004-08...
  • Page 259 DOC: 03-925110-04 PARTS TOOLS DESC: 3800GC EFC 1079 TYPE IV MENU LIST HISTORY 1 of 3 PAGE: EFC MODULE IV SUB-ASSEMBLY 6” 4” 17” 24” 4” 22” 1.75” 6” Sax Makthepharack PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 260 DOC: 03-925110-04 PARTS TOOLS DESC: 3800GC EFC 1079 TYPE IV MENU LIST HISTORY 2 of 3 PAGE: 12-222006-04 03-918853-12 03-917142-00 SCREW, 6-32 X 1/4” PHMS .062 X .015 ID X 17” FERRULE, VITON 4 PLACES PEEK TUBING 8 PLACES 14-202006-00 03-917157-00 WASHER, LOCK, #6 PEEK TUBING, 6”...
  • Page 261 DOC: 03-925110-04 PARTS TOOLS DESC: 3800GC EFC 1079 TYPE IV MENU LIST HISTORY 3 of 3 PAGE: 03-925783-04 03-925783-24 (USE 03-918853-03) (USE 03-918853-03) TUBING, PEEK, .062 X .030 ID, GREEN, 4” TUBING, PEEK, .062 X .030 ID, GREEN, 24” FROM BACK PRESSURE MANIFOLD BLOCK POSITION A REFERENCE PAGE 1 OR PAGE 3 03-925783-04 12-222004-08...
  • Page 262 DOC: 03-925110-03 PARTS TOOLS DESC: 3800GC EFC 1079 TYPE III MENU LIST HISTORY 1 of 3 PAGE: EFC MODULE III SUB-ASSEMBLY 4” 24” 22” 28” YELLOW PREPARED BY: HOWIE PLITSCH REVISED BY: Sax Makthepharack CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 22 - 99 SHOWN...
  • Page 263 DOC: 03-925110-03 PARTS TOOLS DESC: 3800GC EFC 1079 TYPE III MENU LIST HISTORY 2 of 3 PAGE: 12-222006-04 SCREW, 6-32 X 1/4” PHMS 4 PLACES 14-202006-00 NOTES: (UNLESS OTHERWISE SPECIFIED) WASHER, LOCK, #6 1. SEE O-RING PRE-ASSEMBLY INSPECTION 6 PLACES PROCEDURE.
  • Page 264 DOC: 03-925110-03 PARTS TOOLS DESC: 3800GC EFC 1079 TYPE III MENU LIST HISTORY 3 of 3 PAGE: 03-925783-04 03-925783-24 (USE 03-918853-03) (USE 03-918853-03) TUBING, PEEK, .062 X .030 ID, GREEN, 4” TUBING, PEEK, .062 X .030 ID, GREEN, 24” 03-925851-28 12-222004-08 (USE 03-918853-14) SCREW, 4-40 X 1/2”, 2 PLACES...
  • Page 265 DOC: 03-925110-01 PARTS TOOLS DESC: 3800GC EFC 1079 TYPE I MENU LIST HISTORY 1 of 4 PAGE: Peek Tubing EFC MODULE I 1. 03-925783-06 SUB-ASSEMBLY 2. 03-925783-08 24” 3. 03-925783-12 4. 03-925783-22 28” YELLOW 8” 5. 03-925783-24 6. 03-925841-22 6” 7.
  • Page 266 DOC: 03-925110-01 PARTS TOOLS DESC: 3800GC EFC 1079 TYPE I MENU LIST HISTORY 2 of 4 PAGE: 12-222006-04 SCREW, 6-32 X 1/4” PHMS 4 PLACES 14-202006-00 03-917157-00 WASHER, LOCK, #6 6 PLACES WASHER, VITON FERRULE PIN-1 28-849067-00 03-925013-01 03-917142-00 BESWICK FITTING, 1/8” VITON SEE DETAIL EIC PWB FERRULE, VITON...
  • Page 267 DOC: 03-925110-01 PARTS TOOLS DESC: 3800GC EFC 1079 TYPE I MENU LIST HISTORY 3 of 4 PAGE: DETAIL A WIRE TERMINATION 03-918853-03 TUBING, PEEK, .062 X .030 ID, GREEN, 8” 1/8” FROM MANIFOLD MOUNTING PLATE POSITION A REFERENCE PAGE 1 OR PAGE 4 TAB LOCKS IN OPENING CUT SOLENOID...
  • Page 268 DOC: 03-925110-01 PARTS TOOLS DESC: 3800GC EFC 1079 TYPE I MENU LIST HISTORY 4 of 4 PAGE: 03-925783-06 03-925783-24 (USE 03-918853-03) (USE 03-918853-03) TUBING, PEEK, .062 X .030 ID, GREEN, 6” TUBING, PEEK, .062 X .030 ID, GREEN, 24” FROM BACK PRESSURE MANIFOLD BLOCK POSITION A REFERENCE PAGE 1 OR PAGE 3 03-925851-28 12-222004-08...
  • Page 269 DOC: 03-918800-00 PARTS TOOLS DESC: MENU 3800GC, Installation, Basic, SPT (LN2) LIST HISTORY 1 of 2 PAGE: Installation, Basic, SPT (LN2) 03-925541-01 SPT ADAPTER USE #3 POSITION POWER PLUG INLET CONN. & CHECK VALVE NOT SHOWN LN2 VALVE SHEET METAL CUT OUT REMOVEAL NOT REQ’D 03-918713/714-XX TRAP ASSEMBLY...
  • Page 270 DOC: 03-918800-00 PARTS TOOLS DESC: MENU 3800GC, Installation, Basic, SPT (LN2) LIST HISTORY 2 of 2 PAGE: 03-925542-01 HARNESS PCB CONNECT TO J52 03-925305-01 ASSY, FAN 24V CONNECT TO J51 03-918795-00 TRANSFORMER CABLE HARNESS SPT TO THE SPT CONNECT TO TRANSFORMER Bob Vickroy PREPARED BY: Sax Makthepharack REVISED BY:...
  • Page 271 DOC: 03-918681-XX PARTS TOOLS DESC: 1078 Injector Subassembly MENU LIST HISTORY PAGE: of 2 1078 INJECTOR Subassembly PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 03 - 26 - 98 SHOWN...
  • Page 272 DOC: 03-918681-XX PARTS TOOLS DESC: 1078 Injector Subassembly MENU LIST HISTORY PAGE: of 2 TOOLS LIST 03-918678-00 TOP COVER 03-949666-01 OTHER PARTS NOT 1. T-3734 INJECTOR NUT ASSY 1078 ASSY. FIX. SHOWN. 03-908206-01 ACTUATOR SWIT. ASSY. 03-918334-00 HTR., HARNESS ASSY., 120V.
  • Page 273 DOC: 03-918153-00 PARTS TOOLS DESC: Assy, Inlet Manifold MENU LIST HISTORY 1 of 2 PAGE: ASSY, INLET MANIFOLD SUB-ASSEMBLY STATION, ASSEMBLY PROCEDURES Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 06 - 11 - 99 SHOWN...
  • Page 274 DOC: 03-918153-00 PARTS TOOLS DESC: Assy, Inlet Manifold MENU LIST HISTORY 2 of 2 PAGE: NOTES: 1. ASSEMBLE THE FERRULE HOLDER PLATES IN ORDER SHOWN AND FINGERTIGHT THE 8-32 X 1/2 SEM SCREW. 03917084-00, 3 PLCS CAPILARY COLUMN FITTING NUT 2.
  • Page 275 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 1 of 18 PAGE: ASSY, BASIC 3800GC STATION #2, ASSEMBLY PROCEDURES Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 31 - 00 SHOWN...
  • Page 276 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 2 of 18 PAGE: 22-799995-00 GROMMET ROUTE TRANSFORMER AND FAN MOTOR WIRES (PAGE 7) THROUGH GROMMET. Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 31 - 00 SHOWN...
  • Page 277 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 3 of 18 PAGE: 03-925307-01 FAN MOTOR 120V. & 101V 03-925307-02 FAN MOTOR 230V FOR ASSEMBLY OF MOTOR TO TO MOTOR MOUNT USE FIXTURE: T-8989 13-122060-00 NUT, HEX 10-32, SST. 4EA. 12-222008-14 SCREW,8-32 X 7/8 SST.PH, 4EA.
  • Page 278 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 4 of 18 PAGE: 03-917946-01 BLADES FOR BLADE PLACEMENT ON MOTOR SHAFT USE TOOL T-8915, P/N 03-917887-00. NOTE: TEST FAN PER “FAN BALANCE TEST” PRIOR TO INSTALLATION FAN MOTOR ASSEMBLY Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY:...
  • Page 279 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 5 of 18 PAGE: 230V 120V 03-925294-01 MAIN HARNESS 03925295-01 MAIN HARNESS BLUE BLUE MAIN BLUE FROM WHITE MAIN HARNESS POWER CORD FROM HARNESS PWR. HARNESS CORD BROWN BROWN MAIN MAIN HARNESS 03-925594-01...
  • Page 280 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 6 of 18 PAGE: 101V BLUE MAIN HARNESS BROWN 03-925294-01 MAIN MAIN HARNESS HARNESS LOAD 03-925595-00 LINE FILTER LINE BLACK FROM PWR. CORD YELLOW/GREEN MAIN HARNESS CHASSIS GROUNDING GRN/YEL WHITE CHASSIS FROM PWR.
  • Page 281 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 7 of 18 PAGE: FILTER WIRING DETAIL WHITE BLUE FROM FROM POWER MAIN CORD HARNESS BROWN FROM BLACK MAIN FROM HARNESS POWER CORD 12-901161-00 SCREW, #6-32,x 3/8” SEM, 4 PLACES (101V) 12-901163-00 SCREW, SEM, 8-32 3/8”...
  • Page 282 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 8 of 18 PAGE: KNURLED PASTIC NUT INCLUDED WITH Note: SWITCH. 1. Finger tight First WIRING SCHEME. FOR 230V & 101V CIRCUIT BREAKER 03-925210-01 POWER SWITCH HOUSING 120V, 230V, BROWN &...
  • Page 283 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 9 of 18 PAGE: CIRCUIT BREAKER ASSEMBLY 12-901163-00 SCREW #8-32 x 3/8 SEMS 2 PLACES Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 31 - 00 SHOWN...
  • Page 284 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 10 of 18 PAGE: 03-925209-01 POWER BOARD SUPPORT 12-901161-00 SCREW, SEM 6-32 X 3/8 4EA. 51-408925-00 TERM, BLK, PLUG 8C 03-925480-01 ASSY., CONNECTOR, HEATER 51-408923-00 TERM, BLK, PLUG68C 03925082-01 POWER BOARD 51-406933-00 CONN.
  • Page 285 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 11 of 18 PAGE: VENT DOOR HEAT ZONE 1 INJECTOR 1 BLACK/WHITE BLUE/WHITE INJECTOR 2 HEAT ZONE 2 BLUE HEAT ZONE 3 INJECTOR 3 FRONT REAR WHITE BLACK HEAT ZONE 4 DETECTOR 1 CRYO 1 CRYO 1...
  • Page 286 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 12 of 18 PAGE: 12-901163-00 SCREW #8-32 x 3/8 SEMS 2 PLACES POWER BOARD ASSEMBLY Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 31 - 00 SHOWN...
  • Page 287 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 13 of 18 PAGE: NOTE: RED LINE ON ALL CABLES FACE UP. 03-925111-01 EFC FLAT CABLE 03-925296-01 ASSY., CBLE, PWRCTRL. NOTE: NOT INSTALLED FOR FACELESS SATURN 03-925450-01 ASSY., CABLE FRONT PANEL NOTE: USE T-XXXX (CABLE FOLDING FIXTURE)
  • Page 288 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 14 of 18 PAGE: OPTION 03-925300-01 START ANALOG IN/OUT OPTION OPTION COL. OVN. PROBE DET. 3 51-408783-00 SAMPLE INTRODUCTION DET. 2 PROBE CONNECTOR DET. 1 INJ. 3 INJ. 2 INJ. 1 CONNECT TO INJ.
  • Page 289 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 15 of 18 PAGE: 51-959920-00 SCREW, LOCK SET 6EA NOTE: USE SCREW ONLY 12-901165-00 SCREW 8-32 X 1/4, INT LW 12 EA Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 290 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 16 of 18 PAGE: REF: 03-925235-02 BAFFLE, INNER OVEN, W/O LOGO 04-000200-00 INSULATOR CLIP, 12 EA. 21-000017-00 INSULATOR, HEATER COIL, 12EA. Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 291 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 17 of 18 PAGE: 03-925233-01 Note: HEATER COIL,COL. OVN. 12-222006-05 1500W. (120 V) SCREW, 6-32 X 5/16, SS, PH. See note 3 2EA. 03-925412-01 HEATER COIL,COL. OVN. (230 V) NOTES 03-925411-01 HEATER COIL,COL.
  • Page 292 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 18 of 18 PAGE: 22-119785-00 12-901163-00 12-901163-00 CLAMP, CABLE 03925375-01 SCREW, 8-32 X 3/8 SCREW, 8-32 X 3/8 COLUMN OVEN PROBE ASSY EXT. SST 4EA COLUMN OVEN BAFFLE AND HEATER ASSEMBLY Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY:...
  • Page 293 DOC: 03-925001-00 PARTS TOOLS DESC: BASIC ASSEMBLY MENU LIST HISTORY 19 of 18 PAGE: Sax Makthepharack PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 31 - 00 SHOWN...
  • Page 294 DOC: 03-917946-02 PARTS TOOLS DESC: Fan Balance Test MENU LIST HISTORY 1 of 1 PAGE: Fan Balance Test 3800 GC Station 2 TEST 1. Mount fan blade (PN 03-917946-01) on test fixture with set screws at 12 o’clock on shaft flat and 3 o’clock on shaft diameter. Use the grooved end of tool PN 03-917887-00 to set the back spacing of the fan and to counter the torque of the hex wrench.
  • Page 295 DOC: 03-917946-02 PARTS TOOLS DESC: Fan Balance Test MENU LIST HISTORY 2 of 1 PAGE: CALIBRATION 1. Mount the 4.6 oz-in calibration weight to the motor shaft with the set screw closer to the end of the motor shaft. Use the grooved end of the tool PN 03-917887-00 to position the weight and counter the torque of the hex wrench.
  • Page 296 DOC: 03-925794-01 PARTS TOOLS DESC: Assy, Chassis, Twin Towers MENU LIST HISTORY 1 of 10 PAGE: ASSY, CHASSIS, TWIN TOWERS 3800GC STATION #1, ASSEMBLY PROCEDURES Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 06 - 00 SHOWN...
  • Page 297 DOC: 03-925794-01 PARTS TOOLS DESC: Assy, Chassis, Twin Towers MENU LIST HISTORY 2 of 10 PAGE: 23-622018-00 03-925315-02 FOOT, LEVELER FOOT, .87” x .87” 2 PLACES 2 PLACES 13-111114-00 12-222008-12 HEX NUT SCREW #8-32 x 7/8” 2 PLACES 12-901163-00 2 PLACES SCREW #8-32 x 3/8”...
  • Page 298 DOC: 03-925794-01 PARTS TOOLS DESC: Assy, Chassis, Twin Towers MENU LIST HISTORY 3 of 10 PAGE: 17-699907-00 RIVET 4 PLACES 03-925246-01 CHASSIS BULKHEAD (*) USE TEMPORARY RIVET HERE 03-925242-01 PARTITION (*) 17-699907-00 RIVET Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 299 DOC: 03-925794-01 PARTS TOOLS DESC: Assy, Chassis, Twin Towers MENU LIST HISTORY 4 of 10 PAGE: 17-699907-00 RIVET 3 PLACES 03-925245-01 03-925466-01 PANEL MOUNTING. MAIN PCB (*) SUPPORT AND STIFFENER (*) 17-699907-00 RIVET 2 PLACES ASSEMBLY PANEL MNTG., MAIN PCB Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY:...
  • Page 300 DOC: 03-925794-01 PARTS TOOLS DESC: Assy, Chassis, Twin Towers MENU LIST HISTORY 5 of 10 PAGE: 17-699907-00 RIVET 4 PLACES 03-925239-01 PANEL, REAR (*) 03-925241-01 PLATFORM, MOUNTING (*) 17-699907-00 RIVET 11 PLACES Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 301 DOC: 03-925794-01 PARTS TOOLS DESC: Assy, Chassis, Twin Towers MENU LIST HISTORY 6 of 10 PAGE: 03-925240-01 BRACE, TOP LEFT (*) COUNTERSINK THESE TWO HOLES TO 1/4” DIA. AT 82 AND USE COUNTERSINK RIVETS P/N 17-699961-00 17-699907-00 RIVET 4 PLACES 03-925237-01 PANEL, FRONT (*) 17-699907-00...
  • Page 302 DOC: 03-925794-01 PARTS TOOLS DESC: Assy, Chassis, Twin Towers MENU LIST HISTORY 7 of 10 PAGE: 17-699907-00 03-925262-01 RIVET BRACKET, FAN MOTOR (*) 6 PLACES 03-925793-01 OVEN ASSEMBLY (*) 12-222006-06 SCREW, 6-32 X 3/8 17-699907-00 6 EA. RIVET USE 13-312006-00 20 PLACES #6 KEP NUT W/SCREW (NOT SHOWN)
  • Page 303 DOC: 03-925794-01 PARTS TOOLS DESC: Assy, Chassis, Twin Towers MENU LIST HISTORY 8 of 10 PAGE: 17-699907-00 12-901165-00 RIVET SCREW #8-32 x 3/16”, SEMS 8 PLACES 17-699907-00 RETAINER CLIP 4 PLACES 12-901163-00 SCREW #8-32 x 3/8” 7 PLACES 03-925285-01 HOOK LATCH (*) ALIGN TOP HINGE PLATE UP AGAINST OUTER OVEN TOP...
  • Page 304 DOC: 03-925794-01 PARTS TOOLS DESC: Assy, Chassis, Twin Towers MENU LIST HISTORY 9 of 10 PAGE: 03-925565-01 COUPLING, FLEXIBLE 03-925314-01 ASSY, VENT DOOR 21-128961-00 BEARING, NYLON SLEEVE 12-901161-00 SCR, SEM, 6-32 X 3/8 NOTES: 1. WHEN ASSEMBLE THE FLEXIBLE COUPLING (03-925565-01) ONTO THE VENT DOOR ASSEMBLY (03-925314-01) SHAFT, MAKE SURE IS FLUSH AGAINST SHOULDER OF SHAFT.
  • Page 305 DOC: 03-925794-01 PARTS TOOLS DESC: Assy, Chassis, Twin Towers MENU LIST HISTORY 10 of 10 PAGE: 28-693973-00 WITH END CAP, 1 ONLY 4 PLACES 17-699907-00 RIVET 6 PLACES 23-620801-00 RETAINING CLIP 2 PLACES NOTE: FOR 101V &120V VERSIONS COVER SQUARE HOLE. FOR 230V VERSION COVER ROUND HOLE.
  • Page 306 DOC: 03-925794-01 PARTS TOOLS DESC: Assy, Chassis, Twin Towers MENU LIST HISTORY 11 of 10 PAGE: Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 06 - 00 SHOWN...
  • Page 307 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 1 of 12 PAGE: ASSY, CHASSIS (STANDARD) 3800GC STATION #1, ASSEMBLY PROCEDURES Arden Yambao PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 10 - 27 - 00 SHOWN...
  • Page 308 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 2 of 12 PAGE: 23-622018-00 03-925315-02 FOOT, LEVELER FOOT, .87” x .87” 2 PLACES 2 PLACES 13-111114-00 12-222008-12 HEX NUT SCREW #8-32 x 7/8” 2 PLACES 12-901132-00 2 PLACES SCREW #8-32 x 3/8” 2 PLACES 17-699938-00 RIVET, LARGE...
  • Page 309 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 3 of 12 PAGE: 17-699961-00 COUNTER SINK RIVET 17-699907-00 RIVET 3 PLACES 03-925246-01 CHASSIS BULKHEAD (*) USE TEMPORARY RIVET HERE 03-925242-01 PARTITION (*) 17-699907-00 RIVET Arden Yambao PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 310 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 4 of 12 PAGE: 17-699907-00 RIVET 3 PLACES 03-925245-01 03-925466-01 PANEL MOUNTING. MAIN PCB (*) SUPPORT AND STIFFENER (*) 17-699907-00 RIVET 2 PLACES ASSEMBLY PANEL MNTG., MAIN PCB Arden Yambao PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING...
  • Page 311 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 5 of 12 PAGE: 17-699907-00 RIVET 4 PLACES 03-925239-01 PANEL, REAR (*) 03-925241-01 PLATFORM, MOUNTING (*) 17-699907-00 RIVET 13 PLACES Arden Yambao PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 312 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 6 of 12 PAGE: 03-925240-01 BRACE, TOP LEFT (*) 17-699961-00 COUNTER-SINK RIVET 17-699907-00 RIVET 4 PLACES 03-925237-01 PANEL, FRONT (*) 17-699907-00 RIVET 6 PLACES Arden Yambao PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV.
  • Page 313 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 7 of 12 PAGE: 17-699938-00 RIVET, SST 17-699907-00 RIVET, 2 PLACES 4 EA. 03-925251-01 AFTER INSTALLING 03-925251-00 PAINTED GRILL PAINTED GRIL 17-699907-00 03-925262-01 RIVET BRACKET, FAN MOTOR (*) 8 PLACES 03-925701-01 OVEN ASSEMBLY (*) 12-222006-06...
  • Page 314 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 8 of 12 PAGE: DOOR HEIGHT ADJUSTMENT: 17-699907-00 1. TIGHTEN LOWER AND UPPER HINGE PLATE WHILE PULLING RIVET UP AND ALIGNING NOTCH IN HINGE PLATE WITH OUTER PNEU- 8 PLACES MATICS BOX.
  • Page 315 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 9 of 12 PAGE: 03-925565-01 COUPLING, FLEXIBLE 03-925314-01 SCREWS SHOULD ASSY, VENT DOOR FACE OUT. 21-128961-00 BEARING, NYLON SLEEVE 12-901161-00 SCR, SEM, 6-32 X 3/8 NOTES: 1. WHEN ASSEMBLE THE FLEXIBLE COUPLING (03-925565- 01) ONTO THE VENT DOOR ASSEMBLY (03-925314-01) SHAFT, MAKE SURE IS FLUSH AGAINST SHOULDER OF SHAFT.
  • Page 316 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 10 of 12 PAGE: 28-693973-00 WITH END CAP, 1 ONLY 4 PLACES 17-699907-00 RIVET 6 PLACES 23-620801-00 RETAINING CLIP 2 PLACES NOTE: 6 14/16” LONG GROMMET FOR 101V &120V VERSIONS COVER SQUARE HOLE.
  • Page 317 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 11 of 12 PAGE: PFPD CHASSIS: CLIP INSTALLATION 22-130017-00 17-699961-00 MEDIUM CLIP RIVET 1. USE MEDIUM CLIP (22-130017-00) W/ RIVET (17-699961-00) 2. USE SMALL CLIP (22-130018-00 W/ RIVET (17-69907-00) 22-130018-00 17-69907-00 SMALL CLIP RIVET...
  • Page 318 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 12 of 12 PAGE: 03-925291-01 TRANSFORMER,120V 03-925292-01 TRANSFORMER, 230V 03-925293-01 TRANSFORMER, 101V 14-122010-00 WASHER,FLAT, #10 SST. 4EA 12-222060-40 SCREW 4EA SEE CONNECTION TO NOTE: POWER PCB, J50 ON PAGE 14 88-299284-00 LOCTITE #222 ON ALL FOUR...
  • Page 319 DOC: 03-925700-01 PARTS TOOLS DESC: Assy, Chassis MENU LIST HISTORY 13 of 12 PAGE: TRANSFORMER ASSEMBLY Arden Yambao PREPARED BY: HOWIE PLITSCH REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 10 - 27 - 00 SHOWN...
  • Page 320 DOC: 03-925461-00 PARTS TOOLS DESC: Assy, PFPD Ignitor W/Cable MENU LIST HISTORY 1 of 7 PAGE: ASSY, PFPD IGNITOR W/CABLE GC PROBE AREA, ASSEMBLY PROCEDURES Bob Vickroy PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 13 - 00 SHOWN...
  • Page 321 DOC: 03-925461-00 PARTS TOOLS DESC: Assy, PFPD Ignitor W/Cable MENU LIST HISTORY 2 of 7 PAGE: NOTE: 03-925166-00, 2 PLCS 1. NOTE THAT THE.200 INCH DIMENSION IS ESTABLISHED WITH A SPECIAL TOOL AND ASSY, PIN TUBE IS DIFFERENT FROM THE ONES USED FOR THE MODEL 3500 TSD/FID PROBES. 58-200020-00 CONNECTOR 03-925164-00...
  • Page 322 DOC: 03-925461-00 PARTS TOOLS DESC: Assy, PFPD Ignitor W/Cable MENU LIST HISTORY 3 of 7 PAGE: PFPD IGNITOR W/CABLE ASSEMBLY PROCEDURES IGNITOR CONNECTOR ASSEMBLY - (03-925162-00) 1.1.1 Place Ignitor Probe Insert (03-925164-00) into the holding tool T-8876. Obtain Connector (58-200020-00), screw onto the holding tool T-8876 until it bottoms out.
  • Page 323 DOC: 03-925461-00 PARTS TOOLS DESC: Assy, PFPD Ignitor W/Cable MENU LIST HISTORY 4 of 7 PAGE: NOTES: 1. USE WHITE NYLON ON GLOVES WHEN HANDLING CERAMIC PARTS. 2. SOLDER BLACK AND CLEAR WIRES TO PINS IN PLACE INDICATED. DO NOT ALLOW SILVER SOLDER BETWEEN GAPS IN COIL.
  • Page 324 DOC: 03-925461-00 PARTS TOOLS DESC: Assy, PFPD Ignitor W/Cable MENU LIST HISTORY 5 of 7 PAGE: 1.4.3 Slide the Sleeve over the Pin Tube Assembly and heatshrink in place not shown. 1.4.4 Place the PFPD Ignitor with Cable into a fixture T-8958 and apply epoxy where indicated with the Ignitor Coil pointed downward. While the epoxy is not yet cured, slide the 8”...
  • Page 325 DOC: 03-925461-00 PARTS TOOLS DESC: Assy, PFPD Ignitor W/Cable MENU LIST HISTORY 6 of 7 PAGE: IGNITOR W/CABLE ASSEMBLY (REF.) Bob Vickroy PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 13 - 00 SHOWN...
  • Page 326 DOC: 03-925461-00 PARTS TOOLS DESC: Assy, PFPD Ignitor W/Cable MENU LIST HISTORY 7 of 7 PAGE: TIMING 1-99 CYCLES TIMING 50 PFPD IGNITOR W/CABLE NOTE: COIL TO PINS ALIGNMENT TO BE WITH ± TO EACH OTHER ESTABLISH DIMENSION WITH FIXTURE T-3740 CURRENT 50 TRANSFORMER TAP HIGHT (MAX)
  • Page 327 DOC: 03-925461-00 PARTS TOOLS DESC: Assy, PFPD Ignitor W/Cable MENU LIST HISTORY 8 of 7 PAGE: Bob Vickroy PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 13 - 00 SHOWN...
  • Page 328 DOC: 03-925721-XX PARTS TOOLS DESC: Button-up, Twin Towers MENU LIST HISTORY 1 of 5 PAGE: BUTTON-UP, TWIN TOWERS 3800GC BUTTON-UP STATION, ASSEMBLY PROCEDURES Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 31 - 00 SHOWN...
  • Page 329 DOC: 03-925721-XX PARTS TOOLS DESC: Button-up, Twin Towers MENU LIST HISTORY 2 of 5 PAGE: 03-925702-01 KEYBOARD, ASSY. NOTE: OPERATION SEQUENCE 12-901163-00 CLICK ON S/A PICTURES SHOWN TO SEE S/A SCREW, 8-32, X3/8 EXT.SST., SEM 2EA 1. THE MAIN DOOR IS INSTRUCTIONS DESIGNED TO SEAL PROP- ERLY, HOWEVER SOME...
  • Page 330 DOC: 03-925721-XX PARTS TOOLS DESC: Button-up, Twin Towers MENU LIST HISTORY 3 of 5 PAGE: 03-925243-01 TOP COVER 23-620803-00 STUD, BALL 6-32 X .437 CS 03-925700-01 CHASSIS 12-901131-00 SCREW, 8-32 X 3/8” INT LW 4EA. 12-901132-00 SCREW, 8-32 X 3/8” EXT. LW 9 03-925250-01 03-925248-01 REAR PANEL...
  • Page 331 DOC: 03-925721-XX PARTS TOOLS DESC: Button-up, Twin Towers MENU LIST HISTORY 4 of 5 PAGE: 03-925788-01 22-120209-00, 2 EA. DETECTOR, COVER CABLE, CLAMP, 3/4 12-902733-00, 4 EA. SCREW, 8-32 X 3/8” INT LW 23-620795-00, 2 EA. FASTENER, BALL STUD 03-925790-01 INJECTOR, COVER REAR VIEW REF.
  • Page 332 DOC: 03-925721-XX PARTS TOOLS DESC: Button-up, Twin Towers MENU LIST HISTORY 5 of 5 PAGE: GENERAL PLUMBING & WIRING LAYOUT (EXCEPTIONS TCD & PFPD) CRYO VLV1 NOTE: USE BOW TIE MAIN DOOR WRAPS TO ANCHOR AND ORGANIZE CABLE ROUTINGS AS NEC. CRYO VLV2 INJECTOR SWITCH...
  • Page 333 DOC: 03-925721-XX PARTS TOOLS DESC: Button-up, Twin Towers MENU LIST HISTORY 6 of 5 PAGE: Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 31 - 00 SHOWN...
  • Page 334 DOC: 03-925620-00 PARTS TOOLS DESC: Assy, Hitachi Button-up MENU LIST HISTORY 1 of 3 PAGE: ASSY, HITACHI BUTTON-UP GC3800 BUTTON-UP STATION, ASSEMBLY PROCEDURES Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 10 - 00 SHOWN...
  • Page 335 DOC: 03-925620-00 PARTS TOOLS DESC: Assy, Hitachi Button-up MENU LIST HISTORY 2 of 3 PAGE: OPERATION SQUENCE 1. THE MAIN DOOR IS DESIGNED TO SEAL PROPERLY, HOWEVER SOME 03-925700-01, (REF.) ADJUSTMENT MAY NEED TO BE MADE ASSY, CHASSIS FOR ASTHETIC PURPOSES. 036-925619-01 NAMEPLATE, HITACHI G-7000 GC 036-925619-02...
  • Page 336 DOC: 03-925620-00 PARTS TOOLS DESC: Assy, Hitachi Button-up MENU LIST HISTORY 3 of 3 PAGE: 03-925212-11 DETECTOR, COVER 23-620795-00, 3 PLCS FASTENER, BALL STUD 12-902733-00, 4 PLCS SCREW, 8-32 X 3/8” INT LW 03-925243-11 TOP COVER 03-925267-11 23-620803-00 INJECTOR, COVER STUD, BALL 6-32 X .437 CS OPERATION SQUENCE REMOVE THE REAR PANEL FROM THE...
  • Page 337 DOC: 03-925620-00 PARTS TOOLS DESC: Assy, Hitachi Button-up MENU LIST HISTORY 4 of 3 PAGE: Michael Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 04 - 10 - 00 SHOWN...
  • Page 338 DOC: 03-925012-01 PARTS TOOLS DESC: ASSY, LOW COST GC MENU LIST HISTORY 1 of 4 PAGE: ASSY, LOW COST GC 3800GC BUTTON-UP STATION, ASSEMBLY PROCEDURES Micheal Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 01 - 07 - 99 SHOWN...
  • Page 339 DOC: 03-925012-01 PARTS TOOLS DESC: ASSY, LOW COST GC MENU LIST HISTORY 2 of 4 PAGE: 23-620803-00 03-925243-01 STUD, BALL 6-32 X .437 CS COVER, TOP, ELECTRONIC 12-902733-00, 6 PLCS SCREW, 8-32 X 3/8” INT LW 03-925861-01 COVER, INJECTOR, WIDE 12-901131-00, 9 PLCS SCREW, 8-32 X 3/8”...
  • Page 340 DOC: 03-925012-01 PARTS TOOLS DESC: ASSY, LOW COST GC MENU LIST HISTORY 3 of 4 PAGE: LOW COST GC, SATURN 2000R GC (03-930090-01, -02 & -03), ASSEMBLY PROCEDURES This is a Saturn GC shipped with a large face replacing the keyboard and the pneumatics bezel alone with no detector cover. The following is a summary of the differences to a regular Saturn GC: 1.1.1 BASICS...
  • Page 341 DOC: 03-925012-01 PARTS TOOLS DESC: ASSY, LOW COST GC MENU LIST HISTORY 4 of 4 PAGE: 1.1.4 BUTTON UP Using 2 Cable Clamps (22-120202-00), retain the Ribbon Cable (03-925855-01) along the Chassis walls. Feed light through Face and install using Clip (67-599272-00). Attach the Face Panel (03-925854-01) to left side of the Chassis, using four Washer (14-3023006-00) and four Screws (12-312006-04).
  • Page 342 DOC: 03-925001-XX PARTS MENU TOOLS DESC: Button-up LIST HISTORY PAGE: Covers, Door, Pneumatics Bezel & Keyboard Installation PREPARED BY: MICHAEL HARRAL REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 1/29/98 SHOWN...
  • Page 343 DOC: 03-925001-XX PARTS MENU TOOLS DESC: Button-up LIST HISTORY PAGE: 03-925702-01 KEYBOARD, ASSY. NOTE: OPERATION SEQUENCE 12-901163-00 CLICK ON S/A PICTURES SHOWN TO SEE S/A SCREW, 8-32, X3/8 EXT.SST., SEM 2EA 1. THE MAIN DOOR IS INSTRUCTIONS DESIGNED TO SEAL PROP- ERLY, HOWEVER SOME 03-925700-01 CHASSIS...
  • Page 344 DOC: 03-925001-XX PARTS MENU TOOLS DESC: Button-up LIST HISTORY PAGE: 03-925212-01 DETECTOR, COVER 23-620795-00 03-925243-01 FASTENER, BALL STUD, 3EA. TOP COVER 12-902733-00 23-620803-00 SCREW, 8-32 X 3/8” INT LW 4EA. STUD, BALL 6-32 X .437 CS 03-925700-01 CHASSIS 03-925267-01 INJECTOR, COVER 12-901131-00 SCREW, 8-32 X 3/8”...
  • Page 345 DOC: 03-925001-XX PARTS MENU TOOLS DESC: Button-up LIST HISTORY PAGE: GENERAL PLUMBING & WIRING LAYOUT (EXCEPTIONS TCD & PFPD) CRYO VLV1 NOTE: USE BOW TIE MAIN DOOR WRAPS TO ANCHOR AND ORGANIZE CABLE ROUTINGS AS NESS. CRYO VLV2 INJECTOR SWITCH NOTE: CRYO TIE WRAP ALL...
  • Page 346 DOC: 03-925880-00 PARTS TOOLS DESC: 3800GC, Burn-In Test Procedure MENU LIST HISTORY 1 of 7 PAGE: 3800GC BURN-IN PROCEDURE TOOLS AND EQUIPMENT REQUIRED: 1.1.1 Flow meter 1.1.2 Injector nuts/seals T-8941 1.1.3 Torque wrench, 15 in/lbs with 3/32 hex tip 1.1.4 Test column, 6 ft. long (cut to three Feet long) P/N 03-912403-35) 1.1.5 #2 Philips screw driver 1.1.6 Straight Slot screw driver 1.1.7 Open end wrench, 5/16-1/4...
  • Page 347 DOC: 03-925880-00 PARTS TOOLS DESC: 3800GC, Burn-In Test Procedure MENU LIST HISTORY 2 of 7 PAGE: 1.3.4 Remove J-41 Harness from power PWA (03-925082-01) & install into Analyzer cable. 1.3.5 Install Analyzer Cable into J41. 1.3.6 Connect Instrument Power Cable to correct Voltage (101,120,220) Adapter made for Hy-Pot Tester. 1.3.7 Turn on Instrument Power Switch.
  • Page 348 DOC: 03-925880-00 PARTS TOOLS DESC: 3800GC, Burn-In Test Procedure MENU LIST HISTORY 3 of 7 PAGE: 1.5.8 Verify Time & Date (see diagram). 1.5.9 Edit Heated Zones (type, temp. limit, location, coolant) for GSV’s, see labels & flow diagram for temp. limits (see diagram). 1.5.10 Edit Column Parameters (see diagram).
  • Page 349 DOC: 03-925880-00 PARTS TOOLS DESC: 3800GC, Burn-In Test Procedure MENU LIST HISTORY 4 of 7 PAGE: 1.7.5 For 1060, install Glass Insert 37-000813-00 in Burn-In. For 1061 install Glass Insert 03-918339-00 in Burn-In. 1.7.6 Remove & replace septum with aluminum seal. 1.7.7 Perform steps 1.7.1-1.7.6 for each 1041/60/61 injector.
  • Page 350 DOC: 03-925880-00 PARTS TOOLS DESC: 3800GC, Burn-In Test Procedure MENU LIST HISTORY 5 of 7 PAGE: 1.10 DETECTOR EFC Flow rate check 1.10.1 Turn on all gas supplies 1.10.2 Plug all other detector inlets (top) 1.10.3 Press “Detector” key to get to the Detector Menu 1.10.4 For each detector: Select Detector Go to the “adjustments”...
  • Page 351 DOC: 03-925880-00 PARTS TOOLS DESC: 3800GC, Burn-In Test Procedure MENU LIST HISTORY 6 of 7 PAGE: Flow (cc/min) Detector Type Channel Gas Min/Max Range He 90/110 Ref. + 10% full scale He 45/55 He 90/110 PFPD Air 45/55 He 27/33 Air 27/33 TCD (H2) H 45/55...
  • Page 352 DOC: 03-925880-00 PARTS TOOLS DESC: 3800GC, Burn-In Test Procedure MENU LIST HISTORY 7 of 7 PAGE: 1.5.7 1.5.8 1.5.9 1.5.10 1.5.11 1.6.1 1.9.1 F.Faili/M.Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 07 - 30 - 99 SHOWN...
  • Page 353 DOC: 03-925880-00 PARTS TOOLS DESC: 3800GC, Burn-In Test Procedure MENU LIST HISTORY 8 of 7 PAGE: F.Faili/M.Slaughter PREPARED BY: Sax Makthepharack REVISED BY: CONTROL: INDUSTRIAL ENGINEERING REV. DATE: 07 - 30 - 99 SHOWN...