6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

Printed Circuit Board Replacement for Sievers® Model PPT TOC Analyzer 1. Purpose

Replace printed circuit boards (PCB’s) in the Sievers® Model PPT TOC analyzer.

2. Scope This procedure describes how to replace power control, CPU and analog PCB’s in the Sievers® Model PPT TOC Analyzers. 3. Responsibilities Properly trained personnel are responsible for the documentation and performance of this procedure. Personnel must have thoroughly read the Operation and Maintenance Manual. Personnel performing this procedure must have been trained and demonstrated performance operating the analyzer prior to performing this procedure. 4. Safety This procedure requires access to the inside of the analyzer. To avoid potentially dangerous shock, unplug the analyzer before opening the analyzer’s door. Follow normal ESD precautions when handling electronic components. 5. Materials 5.1 Replacement Printed Circuit Board(s). Referred to hereafter as PCB(s). 5.2 ESD Wrist Strap

CAUTION: These printed circuit boards contain ESD sensitive components. Prior to performing the following instructions, it is essential to be grounded according to established procedures. Failure to be properly grounded will result in ESD damage to the boards and void the warranty.

GE Analytical Instruments, Inc. ©2005H

Page 1 of 13

DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

6. Procedure CAUTION: Prior to performing the following instructions it is essential to be grounded according to established procedures. Failure to be properly grounded will result in damage to the boards and void the warranty. 6.1 Disconnect all power to the analyzer before removing any PCB. WARNING: The wall plug of the AC power cord is the mains disconnect device for the PPT. High voltage is present in the analyzer when power is connected. The door switch automatically turns off the analyzer when the door is open, minimizing the risk of shock; however, the switch can be overridden by pulling it out or pushing it in. In addition, the power connection and electronics before the switch are still powered. To eliminate all risk of shock, you must disconnect the power to the analyzer before working inside the analyzer. The power cord should only be detached from the analyzer AFTER disconnecting the mains plug from the AC wall outlet. WARNUNG: Das Netzkabel ist die einzige Möglichkeit das PPT Meßgerät vollständig von der Spannungsversorgung zu trennen. Bei verbundenem Netzkabel liegt Hochspannung am System an. Zwecks Personenschutz setzt ein interner Türschalter das Gerät beim Öffnen der Fronttür automatisch spannungsfrei. Allerdings bleiben die Spannungszuführung und die Stomkreise vor dem Schalter spannungsführend. Der Schalter kann durch Herausziehen überbrückt werden (auf eigene Gefahr). Um allen Personenschäden vorzubeugen ist vor Arbeiten im Geräteinnern die Spannungszufuhr zum Gerät zu unterbrechen.

6.2 Follow the instructions in the sections listed below to replace the necessary PCBs. 6.2.1 Power Control Board —Section 6.3. 6.2.2 Central Processing Unit Board—Section 6.4. 6.2.3 Analog Board—Section 6.5.

GE Analytical Instruments, Inc. ©2005H

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DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

6.3 Power Control Board 6.3.1 Remove the Power Control Board. 6.3.1.1. 6.3.1.2. 6.3.1.3.

Stop flow to the analyzer. Unplug analyzer. Open analyzer door.

WARNING: The wall plug of the AC power cord is the mains disconnect device for the PPT. High voltage is present in the analyzer when power is connected. The door switch automatically turns off the analyzer when the door is open, minimizing the risk of shock; however, the switch can be overridden by pulling it out or pushing it in. In addition, the power connection and electronics before the switch are still powered. To eliminate all risk of shock, you must disconnect the power to the analyzer before working inside the analyzer. The power cord should only be detached from the analyzer AFTER disconnecting the mains plug from the AC wall outlet. WARNUNG: Das Netzkabel ist die einzige Möglichkeit das PPT Meßgerät vollständig von der Spannungsversorgung zu trennen. Bei verbundenem Netzkabel liegt Hochspannung am System an. Zwecks Personenschutz setzt ein interner Türschalter das Gerät beim Öffnen der Fronttür automatisch spannungsfrei. Allerdings bleiben die Spannungszuführung und die Stomkreise vor dem Schalter spannungsführend. Der Schalter kann durch Herausziehen überbrückt werden (auf eigene Gefahr). Um allen Personenschäden vorzubeugen ist vor Arbeiten im Geräteinnern die Spannungszufuhr zum Gerät zu unterbrechen.

GE Analytical Instruments, Inc. ©2005H

Page 3 of 13

DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

6.3.1.4.

Remove card cage cover by loosening the three screws by hand.

Location of Card Cage Screws

Figure 1: Location of screws that secure the Card Cage Cover

Location of Power Control Board

Figure 2-Location of Power Control Board

GE Analytical Instruments, Inc. ©2005H

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DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

NOTE: The cables and the boards are labeled with either a J or P and then a matching number. Sometimes the board connection is labeled with a J, sometimes a P. The same situation occurs with the cables. This procedure will provide both the cable letter/number and the board letter/number.

NOTE: Throughout this procedure there will be insets of Figure One. These insets will provide direction for connecting or disconnecting electrical and plumbing components.

Figure 3: Label on Card Cage Cover

GE Analytical Instruments, Inc. ©2005H

Page 5 of 13

DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

6.3.1.5.

Unplug the gray display cable labeled CPU BOARD J2 from the CPU board.

Connector labeled PS J2

Gray display cable labeled CPU BOARD J2

Green Terminal Block Header UV lamp power supply connector Calibration Syringe connectors Labeled PWR BRD J1 and PWR BRD J5 Sample Pump connector labeled PWR BRD J2 Figure 4: Location of all the necessary connections to unplug in order to remove the Power Control Board 6.3.1.6. 6.3.1.7. 6.3.1.8. 6.3.1.9. 6.3.1.10.

Unplug the connector labeled PS J2 located near the top of the power control board that connects the power control board to the 24 VDC power supply. Unplug the green terminal block header. Unplug the connector for the UV lamp power supply. Unplug the cable connectors for the calibration syringe system labeled PWR BRD J1 and PWR BRD J5. Unplug the cable connector for the sample pump labeled PWR BRD J2.

GE Analytical Instruments, Inc. ©2005H

Page 6 of 13

DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

6.3.1.11.

Using the two card ejectors, detach the board from the card cage.

Card Ejectors

Figure 5: Location of Card Ejectors 6.3.1.12. 6.3.1.13. 6.3.2

Holding the board by the card ejectors, slide the board completely out of the analyzer. Set the removed Power Control Board aside.

Installing the replacement Power Control Board. Refer to figures used in the removal process. These steps are basically the same, but in reverse order.

6.3.2.1. 6.3.2.2.

6.3.2.3. 6.3.2.4. 6.3.2.5. 6.3.2.6. 6.3.2.7.

Remove the replacement Power Control Board from the anti-static packaging. Holding the board by the card ejectors, insert the new power control board into the card guides in the card cage and slide the Power Control Board into the card cage until it is firmly inserted into the back plane board. Place the removed Power Control Board into the anti-static packaging. Plug the sample pump cable connector labeled PWR BRD J2 into the power control board. Plug the calibration syringe cable connectors labeled PWR BRD J1 and PWR BRD J5 into the power control board. Plug the UV lamp power supply connector into the power control board. Plug the green terminal block header into the power control board.

GE Analytical Instruments, Inc. ©2005H

Page 7 of 13

DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

6.3.2.8. 6.3.2.9. 6.3.2.10. 6.3.2.11. 6.3.2.12. 6.3.2.13. 6.3.2.14.

Plug the 24 VDC power supply connector labeled PS J2 into the power control board. Plug the gray display cable labeled CPU BOARD J2 into the CPU board. Secure the card cage cover to the card cage. Close and latch the analyzer door. Plug in the analyzer. Restore flow. Pack the removed Power Control Board for return to GE Analytical Instruments. Be sure to record the RA # on the provided return label.

6.4 CPU Board 6.4.1

Removing the CPU board.

6.4.1.1. 6.4.1.2. 6.4.1.3.

Stop flow to the analyzer. Unplug analyzer. Open analyzer door.

WARNING: The wall plug of the AC power cord is the mains disconnect device for the PPT. High voltage is present in the analyzer when power is connected. The door switch automatically turns off the analyzer when the door is open, minimizing the risk of shock; however, the switch can be overridden by pulling it out or pushing it in. In addition, the power connection and electronics before the switch are still powered. To eliminate all risk of shock, you must disconnect the power to the analyzer before working inside the analyzer. The power cord should only be detached from the analyzer AFTER disconnecting the mains plug from the AC wall outlet. WARNUNG: Das Netzkabel ist die einzige Möglichkeit das PPT Meßgerät vollständig von der Spannungsversorgung zu trennen. Bei verbundenem Netzkabel liegt Hochspannung am System an. Zwecks Personenschutz setzt ein interner Türschalter das Gerät beim Öffnen der Fronttür automatisch spannungsfrei. Allerdings bleiben die Spannungszuführung und die Stomkreise vor dem Schalter spannungsführend. Der Schalter kann durch Herausziehen überbrückt werden (auf eigene Gefahr). Um allen Personenschäden vorzubeugen ist vor Arbeiten im Geräteinnern die Spannungszufuhr zum Gerät zu unterbrechen.

6.4.1.4.

Remove card cage cover, as described in step 6.3.1.4.

GE Analytical Instruments, Inc. ©2005H

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DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

6.4.1.5.

Unplug the gray display cable labeled CPU BOARD J2 from the CPU board. Gray Display cable labeled CPU BOARD J2

Gray ID Board cable labeled CPU J3

Figure 6: Location of all the necessary connections to unplug in order to remove the Central Processing Unit Board 6.4.1.6. 6.4.1.7.

Unplug the gray ID board cable labeled CPU J3 from the CPU board. Remove the data card. Data Card Location

Figure 7: Location of the Data Card GE Analytical Instruments, Inc. ©2005H

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DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

6.4.1.8. 6.4.1.9. 6.4.1.10. 6.4.2

Using the two card ejectors, detach the board from the card cage. Holding the board by the card ejectors, slide the board completely out of the analyzer. Set the removed power control board aside.

Installing the replacement CPU Board. Refer to figures used in the removal process. These steps are basically the same, but in reverse order.

6.4.2.1. 6.4.2.2. 6.4.2.3. 6.4.2.4. 6.4.2.5. 6.4.2.6. 6.4.2.7. 6.4.2.8. 6.4.2.9. 6.4.2.10. 6.4.2.11.

Remove the replacement CPU board from the anti-static packaging. Holding the board by the card ejectors, insert the replacement CPU board into the card guides in the card cage and slide the CPU board into the card cage until it is firmly inserted into the back plane board. Place the removed CPU board into the anti-static packaging. Insert the data card into the CPU board. Plug the gray ribbon cable labeled CPU J3 into the CPU board. Plug the gray ribbon cable labeled CPU BOARD into the CPU board. Secure the card cage cover to the card cage. Close and latch the analyzer door. Plug in the analyzer. Restore flow. Pack the removed CPU Board for return to GE Analytical Instruments. Be sure to record the RA # on the provided return label.

GE Analytical Instruments, Inc. ©2005H

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DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

6.5 Analog Board 6.5.1

Removing the Analog Board.

6.5.1.1. 6.5.1.2. 6.5.1.3.

Stop flow to the analyzer. Unplug analyzer. Open analyzer door.

WARNING: The wall plug of the AC power cord is the mains disconnect device for the PPT. High voltage is present in the analyzer when power is connected. The door switch automatically turns off the analyzer when the door is open, minimizing the risk of shock; however, the switch can be overridden by pulling it out or pushing it in. In addition, the power connection and electronics before the switch are still powered. To eliminate all risk of shock, you must disconnect the power to the analyzer before working inside the analyzer. The power cord should only be detached from the analyzer AFTER disconnecting the mains plug from the AC wall outlet. WARNUNG: Das Netzkabel ist die einzige Möglichkeit das PPT Meßgerät vollständig von der Spannungsversorgung zu trennen. Bei verbundenem Netzkabel liegt Hochspannung am System an. Zwecks Personenschutz setzt ein interner Türschalter das Gerät beim Öffnen der Fronttür automatisch spannungsfrei. Allerdings bleiben die Spannungszuführung und die Stomkreise vor dem Schalter spannungsführend. Der Schalter kann durch Herausziehen überbrückt werden (auf eigene Gefahr). Um allen Personenschäden vorzubeugen ist vor Arbeiten im Geräteinnern die Spannungszufuhr zum Gerät zu unterbrechen.

6.5.1.4.

Remove card cage cover as described in step 6.3.1.4.

GE Analytical Instruments, Inc. ©2005H

Page 11 of 13

DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

6.5.1.5.

Unplug the gray ID board cable labeled CPU J3 from the CPU board.

Connections labeled ANALOG J1, ANALOG J2, ANALOG J3, and the transfer module cable connector labeled ANALOG J4

Figure 8: Location of all the necessary connections to unplug in order to remove the Analog Board 6.5.1.6. 6.5.1.7. 6.5.1.8. 6.5.1.9. 6.5.2

Unplug the three cell cable connectors labeled ANALOG J1, ANALOG J2, ANALOG J3, and the transfer module cable connector labeled ANALOG J4 from the analog board. Using the two card ejectors, detach the board from the card cage. Holding the board by the card ejectors, slide the board completely out of the analyzer. Set the removed analog board aside.

Instructions for Installing the Analog Board. Refer to figures used in the removal process. These steps are basically the same, but in reverse order.

6.5.2.1. 6.5.2.2. 6.5.2.3. 6.5.2.4.

Holding the board by the card ejectors, insert the new analog board into the card guides in the card cage and slide the analog board into the card cage until it is firmly inserted into the back plane board. Place the old analog board into the anti-static packaging. Plug the conductivity cell cable connectors labeled ANALOG J1, ANALOG J2, ANALOG J3 and the transfer module cable connector labeled ANALOG J4 into the analog board. Plug the gray ribbon cable labeled CPU J3 into the CPU board.

GE Analytical Instruments, Inc. ©2005H

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DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION

6060 Spine Road Boulder, CO 80301 USA T 303 444 2009 F 303 444 9543

6.5.2.5. 6.5.2.6. 6.5.2.7. 6.5.2.8. 6.5.2.9.

Secure the card cage cover to the card cage. Close and latch the analyzer door. Plug in the analyzer. Restore flow. Pack the removed CPU Board for return to GE Analytical Instruments. Be sure to record the RA # on the provided return label.

GE Analytical Instruments, Inc. ©2005H

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DIN 35036 Rev. A TOC, PPT BOARD INSTRUCTION