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PICARRO G2000 Series Maintenance Manual
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PICARRO G2000 Series Maintenance Manual

Inlet particulate filter replacement for picarro analyzers
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Maintenance Guide
Inlet Particulate Filter Replacement
for Picarro Analyzers
Picarro Inc.
3105 Patrick Henry Drive
Santa Clara, CA 95054, USA
Phone: +1 408 962 3900 • Fax +1 408 962 3200
www.picarro.com
Document Number 40-0086 Revision B

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  • Page 1 Maintenance Guide Inlet Particulate Filter Replacement for Picarro Analyzers Picarro Inc. 3105 Patrick Henry Drive Santa Clara, CA 95054, USA Phone: +1 408 962 3900 • Fax +1 408 962 3200 www.picarro.com Document Number 40-0086 Revision B...
  • Page 2 DISCLAIMER AND RESERVATION OF RIGHTS Picarro has prepared this manual solely for the information and use by its customers as a guide for the selection, installation, operation, and maintenance of the products described.
  • Page 3 Contact Information Please contact Picarro for questions regarding specific applications and additional information. General Technical Support: Email: support@picarro.com Phone: + 1 408 962 3991 European Technical Support: Email: support@picarro.com Phone: +31 85 888 1650 Customer Service: Email: orders@picarro.com Phone: + 1 408 962 3992 Analyzer Filter Maintenance P/N 40-0086 Rev.
  • Page 4 Table of Contents Table of Contents Picarro Notices ......................2 Contact Information ..................... 3 Table of Contents......................4 List of Figures ......................6 Introduction ......................8 Applicability....................8 Symptoms of a Clogged Filter ............... 8 Safety ........................10 System Shutdown and Preparation..............11 Shutdown (Windows OS) ................
  • Page 5 Table of Contents Externally-Mounted PTFE Particulate Filter Replacement ....... 31 Required Parts and Tools ................31 Remove the Old Particulate Filter ............... 31 Installing the New Filter ................34 PI2114 PTFE Particulate Filter Replacement ............ 35 Required Parts and Tools ................35 Remove the Old Particulate Filter ...............
  • Page 6 List of Figures List of Figures Figure 1: Shutdown Confirmation Pop-Up Dialog ............11 Figure 2: Shutting Down Analyzer from Stop Instrument Icon ........12 Figure 23: Analyzer Shutdown Dialog ................13 Figure 3: Cover Removal ..................... 14 Figure 4: Bulkhead Foam Removal ................15 Figure 5: Bulkhead Retaining Nut Loosened ..............
  • Page 7 List of Figures Figure 27: PTFE Filter Mounting Assembly (Filter Housing Removed) ......32 Figure 28: PTFE Filter Disconnection ................33 Figure 29: Replacing PTFE Ferrules ................33 Figure 30: PTFE Filter Orientation for Correct Gas Flow Direction ....... 34 Figure 31: Cover Removal ...................
  • Page 8 Gases are filtered by two in-line, sub-micron particulate filters before reaching the measurement cavity. Only one of these, the inlet filter, is user-replaceable. Replacement filters can be purchased from Picarro and installed by the user. Picarro recommends replacing the inlet particulate filter every 12 months.
  • Page 9 Introduction Dry the filter by running Clean Dry Air (CDA) through the analyzer. If the • analyzer functions normally after drying, a filter replacement is not necessary. If drying the filter does not fix the problem, replace the filter. • Analyzer Filter Maintenance P/N 40-0086 Rev.
  • Page 10 2. Safety Read the following safety warnings prior to servicing the analyzer. Picarro analyzers weigh 20 kg (44 lbs) or more. Use the technique described below (or follow your local regulations) when lifting the analyzer. a. Before lifting, inspect the unit for slippery substances or sharp edges.
  • Page 11 System Shutdown and Preparation 3. System Shutdown and Preparation Complete this section before servicing the analyzer. Shutdown (Windows OS) Use the following procedure to shutdown the analyzer on Windows operating systems. Note this procedure is not applicable to G430x analyzers, please refer to Chapter 10 G4301/G4302 Inlet Filter Replacement.
  • Page 12 This section describes how to safely shutdown the analyzer om Linux operating systems using dry gas, closing the CRDS application, and powering off the instrument from the Picarro Launch Pad. A flow of clean, dry gas should always be directed to the instrument for several minutes prior to shutting down.
  • Page 13 Leave any dry gas or desiccant attached to the inlet during this process. NOTE From the Picarro Launch Pad select Power Off to tun off the hardware. When the instrument fans audibly turn off, and when the green power button light on the front of the instrument turns off, shut off the pump manually from the rocker switch located on the pump.
  • Page 14 Stainless Steel Particulate Filter Replacement 4. Stainless Steel Particulate Filter Replacement This section provides instructions for G2000 and L2000 analyzer models that have an internally mounted stainless steel first filter. Required Parts and Tools S1020 Particulate filter kit for input sample line (replace every 12 months) •...
  • Page 15 Stainless Steel Particulate Filter Replacement Remove small foam piece. Back Panel Right Side Panel Figure 5: Bulkhead Foam Removal Using the 5/8” wrench, loosen the retaining nut on the input bulkhead as shown in Figure 5 (about 1 full turn should be enough). Retaining Nut Foam Filter Cover 5/8’...
  • Page 16 Stainless Steel Particulate Filter Replacement Filter Filter Outlet Inlet Filter Gas Inlet/Bulkhead Fitting Right Side Panel Figure 7: Foam Filter Cover Removal Using the 9/16” and 11/16” wrenches, disconnect the filter inlet Swagelok nut, then remove the bulkhead fitting through the back panel (Figure 7).
  • Page 17 Stainless Steel Particulate Filter Replacement 11/16” wrench 9/16 wrench Lift filter out Figure 9: Filter Outlet Nut Disconnection and Filter Removal Installing the New Filter When reattaching 1/4” Swagelok fittings, the nut should be hand-tightened and then turned an additional 1/8 of a turn using a wrench. NOTE Place an absorbent cloth or paper in the area that will be occupied by the filter and fittings.
  • Page 18 Stainless Steel Particulate Filter Replacement 9/16 wrench 11/16” wrench Connect filter and hand-tighten outlet nut New Filter in Correct Flow Tighten an additional 1/8 of Direction a turn past hand-tight with wrench. Figure 10: Connect New Filter to Outlet Swagelok Fitting and Tighten Leak Test after Reassembly With the instrument still turned off, and absorbent cloth or paper under all relevant fittings, connect a tank of dry gas to the analyzer inlet and...
  • Page 19 Stainless Steel Particulate Filter Replacement Final Assembly Reposition the foam filter cover and using the 5/8” wrench, tighten the retaining nut on the bulkhead fitting to secure it. Reposition the small piece of foam around the input bulkhead fitting. Using the 2 mm hex driver, reattach the analyzer top cover with 3 screws on each side.
  • Page 20 PTFE Particulate Filter Replacement 5. PTFE Particulate Filter Replacement This section provides instructions for Picarro G2000 analyzers that use an internally mounted PTFE (Teflon) filter: G2103 (NH ), G2114 (H , CH ), G2205 (HF), G2307 (CH O), G2108 (HCl) Required Parts and Tools S1021 Particulate filter kit for input sample line;...
  • Page 21 PTFE Particulate Filter Replacement Filter Location Figure 13: Filter Location Remove the small foam piece surrounding the bulkhead as shown below in Figure 13. Remove bulkhead foam piece Right Side Retaining Nut at Bulkhead Back Panel Figure 14: Bulkhead Foam Removed and Retaining Nut Loosened Using the 5/8”...
  • Page 22 PTFE Particulate Filter Replacement Filter Cover PTFE Filter Loosen this retaining nut at the input bulkhead to remove filter cover. Figure 15: Foam Filter Cover Removal Using a 9/16” wrench and pliers or Vice-grips, loosen input and output nuts that are connecting the filter to the analyzer. When using pliers to hold the filter, grip with just enough pressure to prevent it from turning.
  • Page 23 PTFE Particulate Filter Replacement Inspect PTFE ferrules for damage on input and output connectors. Figure 17: Ferrule Inspection Installing the New PTFE Filter Equipment Damage: To prevent cross-thread damage to the new filter during installation, carefully align the connector nuts with the filter before threading them on.
  • Page 24 PTFE Particulate Filter Replacement Put absorbent cloth or paper New Filter in Correct in place before filter is Flow Direction installed for later leak test. Back Panel Figure 18: New Filter Installed Leak Test after Reassembly With the instrument still turned off, and absorbent cloth or paper under all relevant fittings, connect a tank of dry gas to the analyzer inlet and set the pressure to 2-3 PSIG (Figure 18).
  • Page 25 PTFE Particulate Filter Replacement Final Assembly Reposition the foam filter cover and using the 5/8” wrench, tighten the retaining nut on the bulkhead fitting to secure it. The metal edge of the filter cover should be under the foam of the top of the enclosure. Reposition the piece of foam around the input bulkhead fitting.
  • Page 26 Externally-Mounted Stainless Steel Particulate Filter Replacement 6. Externally-Mounted Stainless Steel Particulate Filter Replacement This procedure applies to PI2910/PI2920 analyzers with externally mounted stainless steel filters. Required Parts and Tools S1020 Particulate filter kit for input sample line (Replace every 12 months) •...
  • Page 27 Externally-Mounted Stainless Steel Particulate Filter Replacement Figure 21: Filter Housing Removal Loosen (but do not remove) the two 2mm hex head screws that clamp the Sliding Swagelok Mounting Block to the main mounting plate (see Figure 21). Mounting Block Filter Filter Heated Block Upper 2mm Screw...
  • Page 28 Externally-Mounted Stainless Steel Particulate Filter Replacement Using 11/16” and 9/16” wrenches, loosen the left (outlet end) nut then hand turn the 9/16 nut to remove it completely from the filter. Remove the filter, noting its flow orientation. Sliding Swagelok Mounting Block loosened, moves to the right as inlet nut is disconnected.
  • Page 29 Externally-Mounted Stainless Steel Particulate Filter Replacement Carefully slide the mounting block with the ferrules and nut into position at the filter inlet. Carefully align and hand-tighten the right (inlet) nut to be sure it is threaded correctly, then tighten the nut one flat (60 degrees) turn using the 11/16”...
  • Page 30 Externally-Mounted Stainless Steel Particulate Filter Replacement Apply leak check fluid to the Leak Check Leak Check fittings that were separated. Leak Check Leak Check Point Points Point Points Connect and apply 2-3 PSIG Dry Gas to Place absorbent cloth or inlet Place absorbent cloth or paper under each fitting...
  • Page 31 Externally-Mounted PTFE Particulate Filter Replacement 7. Externally-Mounted PTFE Particulate Filter Replacement This procedure applies to analyzers with externally mounted PTFE filters. Required Parts and Tools S1021 Particulate filter kit for input sample line; includes PTFE filter and • PTFE ferrules (Replace every 12 months) 2 mm Hex driver •...
  • Page 32 Externally-Mounted PTFE Particulate Filter Replacement Figure 27: Filter Housing Removal Loosen (but do not remove) the two 2mm hex head screws clamping the Swagelok Mounting Block to the main mounting plate (Figure 27). Using a 9/16” open-end wrench, loosen the right (inlet side) nut while sliding the Mounting Block to the right for clearance, then hand turn the 9/16 nut to remove it completely from the filter inlet.
  • Page 33 Externally-Mounted PTFE Particulate Filter Replacement Remove the filter, noting its flow orientation. 9/16” open-end Sliding Swagelok Mounting Block loosened, moves to the right as inlet nut is disconnected. Inlet Swagelok nut disconnected Figure 29: PTFE Filter Disconnection Replace the Swagelok ferrules on the filter inlet and outlet tubes. Figure 29: shows the left (filter outlet) tube with ferrules.
  • Page 34 Externally-Mounted PTFE Particulate Filter Replacement Installing the New Filter Position the new filter between the tube ends and press it into the heater block. Ensure the filter is in full contact with the heater block. The arrow on the filter points to the left side of the analyzer (in the direction of gas flow).
  • Page 35 PI2114 PTFE Particulate Filter Replacement 8. PI2114 PTFE Particulate Filter Replacement This procedure applies to the PI2114 analyzer. Required Parts and Tools S1021 Particulate filter kit for input sample line; includes PTFE filter and • PTFE ferrules (Replace every 12 months) 7/8"...
  • Page 36 PI2114 PTFE Particulate Filter Replacement Filter Cover Bulkhead Foam Figure 33: Filter Cover and Bulkhead Foam Carefully slide the bulkhead foam to the side of the analyzer, and then lift it up and out. This will reveal the bulkhead nut. Figure 34: Removing the Bulkhead Foam Use the 7/8"...
  • Page 37 PI2114 PTFE Particulate Filter Replacement Bulkhead Nut Figure 35: Loosening the Bulkhead Nut With the bulkhead nut loose, slide the filter cover toward the side of the analyzer and lift up to remove it. Figure 36: Removing the Filter Cover Figure 37: Filter Assembly Exposed Analyzer Filter Maintenance P/N 40-0086 Rev.
  • Page 38 PI2114 PTFE Particulate Filter Replacement Use Vise-Grips or pliers to hold the filter while using the 9/16" wrench to unscrew the Output Filter Nut. (Once loosened with the wrench, it may be easier to unscrew the nut by hand.) When using pliers to hold the filter, grip with just enough pressure to prevent it from turning.
  • Page 39 PI2114 PTFE Particulate Filter Replacement Installing the New Filter Place an absorbent cloth or paper in the area that will be occupied by the filter and fittings. See Figure 41. This will be used to absorb fluid during the leak test perormed after installtion of the new filter. Remove the new filter from its packaging.
  • Page 40 PI2114 PTFE Particulate Filter Replacement Leak Test after Reassembly With the instrument still turned off, and absorbent cloth or paper under all relevant fittings, connect a tank of dry gas to the analyzer inlet and set the pressure to 2-3 PSIG (Figure 41). Ensure the absorbent cloth or paper is situated correctly to prevent ingress of leak test solution into the instrument.
  • Page 41 The outer filter (located just behind the Sample inlet) is user-replaceable. The inner filter (in the sample path) is NOT user replaceable. Do NOT open the analyzer. Inner filters must be replaced by a Picarro certified technician. USER REPLACEMENT OF THE INNER FILTER OR BREAKING THE ANTI-TAMPER TAPE ON THE INNER FILTER VOIDS THE WARRANTY.
  • Page 42 PI5310 Particulate Filter Replacement Required Parts and Tools • S3152 Teflon Particulate Filter with ferrule sets (Qty 2) 9/16 open end wrench • Flathead screwdriver for releasing captive screws (if needed). • Pressure Inlet Port Particulate Filter Replacement Shut down the analyzer by following Section 3, System Shutdown and Preparation, and move the analyzer to a clean work environment.
  • Page 43 PI5310 Particulate Filter Replacement Barbed pressure Compression Nut Inlet Port Male Quick-disconnect Captive Screw (2 ea.) Figure 44: Pressure Inlet Filter Assembly – Removed from Housing Remove the old filter from the bulkhead assembly by loosening the compression nut (Figure 44). Remove the ferrules and discard. Figure 45: Removing Filter from Pressure Inlet Bulkhead Remove the male quick-disconnect from the filter outlet by loosening the compression nut (Figure 45).
  • Page 44 PI5310 Particulate Filter Replacement Install the new ferrules onto the bulkhead compression fitting. Attach a new filter to the bulkhead compression fitting. Ensure the flow direction arrow on the filter is pointing away from the bulkhead compression fitting. Also ensure the tube and ferrules are fully seated into the filter fitting before fully tightening the nut.
  • Page 45 PI5310 Particulate Filter Replacement Sample Inlet Port Particulate Filter Replacement Release the captive screws (Figure 47) and slide the filter assembly out of the analyzer filter bay. There may be some resistance as the filter is removed. This is due to the frictional resistance of the male quick- disconnect O-rings within the female receptacle.
  • Page 46 PI5310 Particulate Filter Replacement Figure 50: Removing Filter from Sample Inlet Bulkhead Compression Quick-disconnect Removed Gas Flow Direction Figure 51: Filter Removed from Sample Inlet Bulkhead Install the new ferrules onto the bulkhead compression fitting. Attach a new filter to the bulkhead compression fitting. Ensure the flow direction arrow on the filter is pointing away from the bulkhead compression fitting.
  • Page 47 G4301/G4302 Inlet Filter Replacement 10. G4301/G4302 Inlet Filter Replacement The first particulate filter for G4301/G4302 Gas Scouter is mounted externally at the sample inlet. Required Parts and Tools S1021 Particulate filter kit for input sample line; includes PTFE filter and •...

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