Usermanual GC Maintenance 8890 g3540 90015 en Agilent

Agilent 8890 Gas Chromatograph
Maintaining Your Gas Chromatograph (GC)

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Maintaining Your GC
Contents
1 About Maintaining the GC
Overview of Maintenance 10
Tools and Materials Required for Maintenance 11
Preparing for Maintenance 13
Viewing Status Data 14
Finding a Replacement Part Number 16
2 Removing Covers
To Remove the Detector Top Cover 18
To Remove the Pneumatics Cover 19
To Remove the Electronics Cover 20
3 Maintaining the GC
Consumables and Parts for General GC Maintenance 24
Parts Identification 26
To Change the Hydrogen Sensor Calibration Gas Cylinder 27
4 Maintaining Capillary Columns

Consumables and Parts for Columns 30
To Install a Capillary Column Hanger 32
To Install Capillary Column Clips 33
To Condition a Capillary Column 34
To Cut a Loop from a Column 36
To Reverse a Column and Bakeout Contaminants 37
To Attach a Capillary Column Using UltiMetal Plus Flexible Metal Fittings 39
To Remove the Ferrule From a CFT Fitting 47
5 Maintaining the Split/Splitless Inlet

Consumables and Parts for the Split/Splitless Inlet 50
Exploded Parts View of the Split/Splitless Inlet 53
To Install a Capillary Column with the Split/Splitless Inlet 54
To Change the Septum on the Split/Splitless Inlet 58
To Clean the Septum Seat in the Insert Assembly of the Split/Splitless Inlet 60
Maintaining Your GC 3
To Change the Liner and O-Ring on the Split/Splitless Inlet 62
To Replace the Gold Seal on the Split/Splitless Inlet 65
To Replace the Filter in the Split Vent Trap for the Split/Splitless Inlet 67
To Clean the Split/Splitless Inlet 69
To Bakeout Contaminants from the Split/Splitless Inlet 71
6 Maintaining the Purged Packed Inlet

Consumables and Parts for the Purged Packed Inlet 74
Exploded Parts View of the Purged Packed Inlet 77
To Install a Capillary Column with the Purged Packed Inlet 78
To Change the Septum on the Purged Packed Inlet 82
To Clean the Septum Seat in the Purged Packed Inlet 84
To Install an Adapter on the Purged Packed Inlet 86
To Change the O-Ring on the Purged Packed Inlet 87
To Change the Glass Liner on the Purged Packed Inlet 88
To Clean the Purged Packed Inlet 90
To Bakeout Contaminants from the Purged Packed Inlet 92
To Install a Packed Metal Column 93
To Install a Packed Column Adapter onto a Detector 95
To Install a Packed Glass Column 97
To Condition a Packed Column 99
To Install Ferrules on a Packed Metal Column 100
7 Maintaining the COC Inlet

Consumables and Parts for the Cool On-Column Inlet 102
Exploded Parts View of the Cool On-Column Inlet 105
To Install a Capillary Column with the Cool On-Column Inlet 106
To Check the Needle-to-Column Size on the COC Inlet 109
To Change a Septum on the COC Inlet 110
To Install an Insert on the COC Inlet 112
To Clean the COC Inlet 114
To Replace the 7693A Injector Needle Support Guide 116
To Replace a Needle in a Syringe 117
4 Maintaining Your GC
To Replace the Fused Silica Needle in a Syringe for the COC Inlet 118
To Bakeout Contaminants from the COC Inlet 119
8 Maintaining the MMI

Consumables and Parts for the Multimode Inlet 122
Exploded Parts View of the MMI 124
To Install the Column Nut Adapter 125
To Install a Capillary Column with the Multimode Inlet 126
To Change the Septum on the MMI 130
To Clean the Septum Seat in the Insert Assembly of the MMI 132
To Change the Liner and O-Ring on the MMI 134
To Replace the Filter in the Split Vent Trap for the MMI 137
To Clean the Multimode Inlet 139
To Bakeout Contaminants from the MMI 141
9 Maintaining the PTV Inlet

Consumables and Parts for the Programmable Temperature Vaporization Inlet 144
Exploded Parts View of the PTV Inlet 146
To Install a Capillary Column with the Programmable Temperature Vaporization
Inlet 147
To Clean the Septumless Head on the PTV Inlet 150
To Replace the Septumless Head PTFE Ferrule on the PTV Inlet 152
To Change the Septum on the PTV Inlet 154
To Clean the Septum Seat in the Septum Head Assembly of the PTV Inlet 155
To Change the Liner on the PTV Inlet 156
To Replace the Inlet Adapter for the PTV Inlet 158
To Replace the Filter in the Split Vent Trap for the PTV Inlet 160
To Bakeout Contaminants from the PTV Inlet 162
10 Maintaining the VI
Consumables and Parts for the Volatiles Interface 164
Exploded Parts View of the VI 166
To Install a Capillary Column with the Volatiles Interface 167
To Remove the VI Interface 171
To Clean the VI 173
To Install the VI Interface 174
To Replace the Filter in the Split Vent Trap for the VI 175
To Bakeout Contaminants from the VI Inlet 177
11 Maintaining the FID

Consumables and Parts for the FID 180
Exploded Parts Views of the Flame Ionization Detector 182
To Install a Capillary Column in the FID 184
To Replace an FID Jet 187
To Perform Maintenance on the FID Collector Assembly 190
To Check the FID Leakage Current 197
To Check the FID Baseline 198
To Install the Optional FID PTFE Chimney Insert 199
To Bakeout the FID 200
12 Maintaining the TCD

Consumables and Parts for the Thermal Conductivity Detector 202
To Install a Capillary Column in the TCD 204
To Bakeout Contaminants from the TCD 207
13 Maintaining the NPD

Consumables and Parts for the NPD 210
Exploded Parts View of the Nitrogen-Phosphorus Detector 212
To Install a Capillary Column in the NPD 213
To Replace the NPD Bead Assembly 216
To Maintain the NPD Collector, Ceramic Insulators, and Jet 220
To Check the NPD Leakage Current 225
To Bakeout the NPD 226
14 Maintaining the ECD

Important Safety Information About the ECD 228
Consumables and Parts for the ECD 230
Exploded Parts View of the Electron Capture Detector 232
To Replace the ECD Fused Silica Indented Mixing Liner and Install the Makeup Gas
Adapter 233
To Install a Capillary Column in the ECD 236
To Bakeout the ECD 238
15 Maintaining the FPD+

Consumables and Parts for the FPD+ 242
Exploded Parts View of the Flame Photometric Detector Plus 244
To Install a Capillary Column to the FPD+ 245
To Change the FPD+ Wavelength Filter 247
To Remove the FPD+ Cover 250
To Replace the FPD+ Ignitor 251
To Install the FPD+ Cover 253
Cleaning the FPD+ Brazement 254
16 Maintaining EPC Modules

Consumables and Parts for the Aux EPC 256
Installing or Replacing Frits in the Aux EPC 258
Consumables and Parts for the PCM 260
Calibrating the PCM Interface 261
Installing or Replacing Frits in the PCM 262
17 Maintaining a Valve
Consumables and Parts for Valves 266
Exploded Parts View of GC Rotary Valves 267
To Replace a Gas Sampling Valve Loop 268
To Align a Rotary Valve Rotor 270
To Replace a Rotary Valve in the Valve Box 271
To Remove the Upper Valve Box 274
To Install the Upper Valve Box 275
A Swagelok Connections
Making Swagelok Connections 278
Using a Swagelok Tee 281
Overview of Maintenance 10
Tools and Materials Required for Maintenance 11
Preparing for Maintenance 13
Viewing Status Data 14
Finding a Replacement Part Number 16
This section provides an overview of the maintenance procedures included in this document. It
also lists the tools needed for routine maintenance and the information needed to safely
perform the various maintenance task.
Overview of Maintenance
Overview of Maintenance
This manual details the routine tasks needed to maintain the Agilent 8890 Gas Chromatograph
(GC). The procedures assume a basic knowledge of tool use and of GC operation. Readers are,
for example, expected to know how to:
• Safely turn devices on and off
• Load methods
• Change component temperatures, flows, and pressures
• Make typical pneumatic connections using Swagelok and other standard fittings
• Reset GC service counters
• Use the GC touchscreen
Where to find a procedure

Included in this manual are chapters on maintaining the following GC components:
• Capillary Columns
• Split/Splitless Inlet (SSL)
• Purged Packed Inlet (PPI)
• Cool On-Column Inlet (COC)
• Multimode Inlet (MMI)
• Programmable Temperature Vaporization Inlet (PTV)
• Volatiles Interface (VI)
• Flame Ionization Detector (FID)
• Thermal Conductivity Detector (TCD)
• Electron Capture Detector (ECD)
• Nitrogen-Phosphorus Detector (NPD)
• Flame Photometric Detector Plus (FPD+)
• Auxiliary Electronic Pressure Control Module (Aux EPC)
• Pneumatics Control Module (PCM)
• Valves
Each chapter includes:
• A list of the most commonly used consumables and parts for the component
• An exploded parts view of the component
• Detailed procedures for routine maintenance tasks associated with the component
Tools and Materials Required for Maintenance

Table 1 lists the tools needed for most GC maintenance procedures. The specific tools
required to perform a maintenance procedure are listed in step 1 of each procedure.
Table 1 Tools and materials for GC maintenance
Common tools Part number
Wrench, angled, septum nut 19251-00100
Wrench, open-end, 1/4-inch and 5/16-inch 8710-0510*
Wrench, open-end, 9/16-inch and 7/16-inch 8710-0803
Wrench, capillary inlet G3452-20512*
Flathead screwdriver
Column cutter, wafer, 4/pk 5181-8836*
Driver, nut, 1/4-inch 8710-1561*
T-20 Torx key or screwdriver 8710-1807
T-10 Torx key or screwdriver 8710-2140
3-mm hex key wrench 8710-2411
Electronic flow meter(s) or bubble meter(s) capable of calibrated measurements at 1, 10, and
100 mL/min flow ranges
Electronic leak detector
Magnifying loupe, 20X 430-1020
Metric ruler
Bench vise (for setting Swagelok fittings)
Razor or sharp knife
Tweezers, or 8710-0007
thin needle-nose pliers 8710-0004
Needle-nose pliers
ESD wrist strap (for installing new components) 9300-1408
Gloves, heat-resistant (for handling hot parts)
Wooden cotton swab (for removing FID filters)
Tools and materials for cleaning procedures
Cleaning brushes—The FID cleaning kit contains appropriate brushes for cleaning detectors and 9301-0985
inlets
Cleaning brushes—For cleaning split/splitless inlet split vent fitting, FID and collectors 8710-1346
Jet cleaning wire (.010-inch)
Clean, lint-free cloth (to protect contamination-sensitive detector parts)
Small ultrasonic cleaning bath with aqueous detergent (for cleaning detector and inlet parts)
Table 1 Tools and materials for GC maintenance
Common tools Part number
Gloves, clean, lint-free, nylon (for handling contamination-sensitive parts) large: 8650-0030
small: 8650-0029
Steel wool, 0- or 00-grade (for cleaning an inlet’s septum seating surfaces)
* Included with the GC ship kits
Preparing for Maintenance
Preparing for Maintenance

Before routine maintenance procedures, the GC must be made ready. This process can
include:
• Setting low temperatures to avoid burns and other injuries
• Setting reduced flows to avoid safety hazards and to prevent damage to the instrument
• Turning off the GC and disconnecting the GC from power
• Venting a mass selective detector (MSD)
• Making other settings to prevent damage to the instrument (electronics, columns, and so
forth) or to connected instruments (MSD)
To put the GC in a general standby state suitable for most maintenance, use the touchscreen:
Maintenance > Instrument > Perform Maintenance > Maintenance Mode > Start Maintenance.
Follow the prompts. To exit maintenance mode and restore the previous GC settings, select
Finished.
If you turned off the GC or changed other settings, return to the Maintenance Mode screen as
needed. Note that the Maintenance Mode ends when the GC is turned off.
For automated maintenance procedures available through the GC, the GC will make the
instrument safe to work on, and walk you through the steps required to replace the part
selected.
If you choose to perform maintenance without using the GC's built-in features, first cool all
WAR N IN G heated zones in the instrument, including auxiliary heaters or other heated devices you might
contact during maintenance. Then turn off the GC and unplug the power cord. If using
cryogenic cooling, you will also need to turn off the cryogen supply and safely bleed off any
residual backpressure.
Viewing Status Data
Viewing Status Data

The GC can display signal and other data that can be very useful during maintenance. For
example:
• Instrument status: Readiness state, running state.
• Instrument status details: Not ready modules, error modules, warnings.
• Module status details: Actual/Setpoint pairs for each module, quick On/Off for certain
modules, firmware version and instrument IP address.
Add an item to the GC status listing as follows:
Viewing Status Data
Select the desired item from the drop-down list,

then touch Add.
Finding a Replacement Part Number
Finding a Replacement Part Number

Agilent now provides the Parts Finder tool to help you locate replacement and consumable
part numbers. If using an Agilent data system, Parts Finder will be installed. If you want to
install the tool on another computer, Parts Finder is included on the Agilent GC and GC/MS
User Manuals & Tools DVD.
To find a consumable or replacement part using Parts Finder, navigate to the part graphically,
based on the part’s location in the GC.
Figure 1. Quickly navigate to replacement parts by clicking on images of GC components
Part numbers are also included in this manual.
2 Removing Covers
To Remove the Detector Top Cover 18
To Remove the Pneumatics Cover 19
To Remove the Electronics Cover 20
This section describes how to remove covers as needed for routine maintenance.
Only the covers listed in this chapter should be removed. Removing other GC covers can
compromise the safety features of the GC, leading to personal injury or damage to the
instrument.
2 Removing Covers
To Remove the Detector Top Cover
To Remove the Detector Top Cover

This cover protects the detectors, valve box, and valve assembly. To remove the detector top
cover:
1 Turn off the GC and unplug the power cord.
2 Remove the detector cover by raising the cover up, then firmly lift up on the right side of the
cover to free it from the GC. Set the cover aside.
3 When finished with the maintenance procedure, place the detector cover vertically on the
GC and insert the left side first, then gently snap in the right side onto the GC.
Be careful! With the power switch on, potentially dangerous voltages also exist:
WAR N IN G
• All electronics boards in the instrument.
• The internal wires and cables connected to these boards.
• The wires for the oven heater.
The covers shield these parts as the parts may be hot enough to cause burns. Never remove
a cover unless the instrument is unplugged.
Do not force the cover, either when installing it or closing it. This could break the plastic
C AU T I O N parts.
Pneumatics cover Detector cover
Pneumatics cover
release button (on
both sides)
Injection port cover
Left side cover
Power switch
Figure 2. 8890 GC covers
2 Removing Covers
To Remove the Pneumatics Cover
To Remove the Pneumatics Cover

The pneumatics cover protects the flow manifolds in the back top of the GC.
1 Disconnect any vent tubing connected to the split and septum purge vents.
2 Press the buttons located on each side of the pneumatics cover and lift up to remove it
from the GC.
2 Removing Covers
To Remove the Electronics Cover

You may need to raise the electronics cover to perform NPD maintenance. The steps required
depend on whether or not an FPD+ is installed.
Be careful! With the power switch on, potentially dangerous voltages also exist:
WAR N IN G
• All electronics boards in the instrument.
• The internal wires and cables connected to these boards.
• The wires for the oven heater.
The covers shield these parts as the parts may be hot enough to cause burns. Never remove
a cover unless the instrument is unplugged.
Raising the electronics cover exposes the GC electronics.

C AU T I O N
Without FPD+ installed:

2 Raise or remove the detector top cover.
3 Loosen the captive screws on the right side cover, slide the cover backwards, then remove.
4 Loosen the captive screw located on the left side of the electronics cover.
5 Reach under the back of the electronics cover to release the clip holding it in place, then
raise the electronics cover and remove.
With FPD+ installed:
2 Raise or remove the detector top cover.
Loosen screw Electronics cover
Figure 3. 8890 GC electronics cover
2 Removing Covers
Loosen captive screws

Electronics cover on right side cover Pneumatics cover
release button (on
both sides)
GC front
GC back
Figure 4. Loosen captive screws located on the right side of the GC
3 Loosen the two captive screws on the right side cover, slide the cover backwards, then
remove.
4 Loosen the captive screw located on the left side of the electronics cover.
5 Reach under the back of the electronics cover to release the clip holding it in place, then
raise the electronics cover and remove.
6 Loosen the two thumbscrews in the tray below the PMT, and remove the two screws in the
back of the tray.
7 Remove the tray from the electronics cover.
2 Removing Covers
Consumables and Parts for General GC Maintenance 24
Parts Identification 26
To Change the Hydrogen Sensor Calibration Gas Cylinder 27
Consumables and Parts for General GC Maintenance
Consumables and Parts for General GC

Maintenance
Table 2 lists consumable parts for the hydrogen sensor module accessory and for general GC
maintenance.
Table 2 Consumables and parts for general GC maintenance
Description Part number
Hydrogen sensor parts
Calibration gas cylinder, 2 percent hydrogen gas in 17 L compressed air 5190-6890
Cylinder stand with locking screw 1400-3583
Pressure regulator, with gage G3440-80153
Fittings and hardware
Fittings kit, 1/8-inch brass, 20/pk 5080-8750
Plug, 1/8-inch brass 6/pk 5180-4124
Tee, 1/8-inch brass 2/pk 5180-4160
Union, 1/8-inch brass 2/pk 5180-4127
Cross, union 1/8-inch brass 0100-0161
GC Supply Gas Installation Kit with Gas Purifiers 19199N
Installation kit for GCs without gas purifiers 19199M
PTFE tape 0460-1266
Copper tubing, 1/8-inch 12 ft. 5021-7107
Copper tubing, 1/8-inch od, 50 ft 5180-4196
Gas regulators
Regulator, 2-stage, brass body, stainless steel diaphragms, 125 psi max, CGA350, hydrogen, 5183-4642
argon/methane, with 1/8-inch fitting. For 1/4-inch tubing purchase a 1/4-inch adapter.
Regulator, 2-stage, brass body, stainless steel diaphragms, 125 psi max, CGA346, air, with 1/8-inch 5183-4641
fitting. For 1/4-inch tubing purchase a 1/4-inch adapter.
Regulator, 2-stage, brass body, stainless steel diaphragms, 125 psi max, CGA590, industrial air, with 5183-4645
1/8-inch fitting. For 1/4-inch tubing purchase a 1/4-inch adapter.
Regulator, 2-stage, brass body, stainless steel diaphragms, 125 psi max, CGA580, helium, argon, 5183-4644
nitrogen, 1/8-inch fitting. For 1/4-inch tubing purchase a 1/4-inch adapter.
Regulator, 2-stage, brass body, stainless steel diaphragms, 125 psi max, CGA540, oxygen, 1/8-inch 5183-4643
fitting. For 1/4-inch tubing purchase a 1/4-inch adapter.
Gas Clean Filters
Gas Clean connecting unit, 1-position), 1/4-inch CP7980
Consumables and Parts for General GC Maintenance
Table 2 Consumables and parts for general GC maintenance (continued)
Gas Clean Smart Sensor for 8890 (replacement sensor) CP179885
Gas Clean kit (connecting unit for one filter, one carrier gas filter, 1/8-inch connections, mounting
bracket, and Smart Sensor) for new GC
Connect unit, Gas Clean, 4 filter, 1/4-inch, 1/pk CP7989
Gas Clean connecting unit, 4-position), 1/8-inch fittings CP736520
Gas Clean high-flow connecting unit, 2-position), with 1/4-inch fittings, for high-flow applications such CP17984
as ICP-MS or ICP-OES
High flow connecting unit 1/8-inch CP17985
Gas Clean filter GC-MS, 1/pk CP17973
Gas Clean filter oxygen, 1/pk CP17970
Gas Clean filter moisture, 1/pk CP17971
Gas Clean filter charcoal, 1/pk CP17972
Gas Clean filter kit for TCD CP738408
Gas Clean Filter kit (connecting unit for one filter, including one carrier gas filter, 1/8-inch connections, CP179880
a smart sensor, and mounting bracket for the GC) for carrier gas only
Gas Clean Filter kit (connecting unit for four filters, including four filters, 1/4-inch connections) for FID, CP7995
FPD, NPD
Gas Clean Filter kit (connecting unit for four filters, including four filters, 1/8-inch connections) for FID, CP736530
FPD, NPD
GC/MS Gas Clean Filter kit (includes one connecting unit and two GC/MS filters, 1/8-inch CP17976
connections) for ECD, GC/MS
GC/MS Gas Clean Filter kit (includes one connecting unit and two GC/MS filters, 1/4-inch CP17977
connections) for ECD, GC/MS
GC/MS Gas Clean Filter installation kit (includes CP17976, 1 m copper tubing, and two 1/8-inch nuts CP17978
and ferrules) for ECD, GC/MS
TCD filter kit (with oxygen and moisture filters) for TCD CO738408
Flush head, Gas Clean connecting unit, used to purge gas lines after installing connecting unit CP7987
Gas Clean wall-mounting bracket for 1-position) connecting unit only CP7981
For additional general and filters, refer to the Agilent web site and Parts Finder software. For
additional information about choosing the correct gas line filters, see the GC, GC/MS, and ALS
Site Preparation Guide and visit the Agilent web site.
Parts Identification
Parts Identification
1/8-inch Swagelok nut

and ferrule
Pressure regulator
Calibration gas
cylinder 1/8-inch copper tubing,
cut to length needed
Gas cylinder stand
Figure 5. Hydrogen sensor calibration gas cylinder parts identification
To Change the Hydrogen Sensor Calibration Gas Cylinder
To Change the Hydrogen Sensor Calibration Gas

Cylinder
Replace the calibration gas cylinder when you cannot adjust it to provide the correct flow rate
during calibration, or if it expires.
Connect only the Agilent calibration gas to the hydrogen sensor fitting. The calibration gas is
WAR N IN G 2% hydrogen in air and is not potentially explosive. Gases with higher concentrations of
hydrogen can create a dangerous condition in the oven or damage the hydrogen sensor.
Be careful! The oven and/or detector may be hot enough to cause burns. While hydrogen
WAR N IN G sensor calibration can be performed at any temperature, cool the oven and detector to safe
handling temperatures, < 40 °C, before continuing.
1 Make sure the old cylinder is empty.

2 Turn the pressure regulator completely off and set the output pressure as low as possible
(full CCW).
3 Remove the pressure regulator from the old cylinder and install it onto the new cylinder.
4 Install the new cylinder into the stand.
5 Turn on the pressure in the new cylinder.
6 Open the GC oven door and connect a flowmeter tube to the sensor tube in the oven.
Connect the flow meter

to the hydrogen sensor
tube next to the oven
heater shroud
7 Select Settings > Calibration > Hydrogen Sensor > Start Calibration Cycle? > On/Yes. The
calibration cycle begins. The hydrogen sensor module will wait to stabilize, then will begin
to send calibration gas across the sensor.
8 While continuing to measure the flow rate from the tube, adjust the pressure regulator on
the calibration gas cylinder until the flow rate is approximately 30 mL/min. Remove the
flowmeter and close the oven door.
9 Allow the calibration cycle to complete (approximately 5 minutes total).
10 Check for leaks.
To Change the Hydrogen Sensor Calibration Gas Cylinder
Consumables and Parts for Columns 30
To Install a Capillary Column Hanger 32
To Install Capillary Column Clips 33
To Condition a Capillary Column 34
To Cut a Loop from a Column 36
To Reverse a Column and Bakeout Contaminants 37
To Attach a Capillary Column Using UltiMetal Plus Flexible Metal Fittings 39
To Remove the Ferrule From a CFT Fitting 47
Consumables and Parts for Columns

See the Agilent catalog for consumables and supplies for a more complete listing, or visit the
Agilent Web site for the latest information (www.agilent.com/chem/supplies).
Table 3 Nuts, ferrules, and hardware for capillary columns
Column id (mm) Description Typical use Part number/quantity
.530 Ferrule, Vespel/graphite, 0.8-mm id 0.45-mm and 0.53-mm capillary columns 5062-3512 (10/pk)
Ferrule, graphite, 1.0-mm id 0.53-mm capillary columns 5080-8773 (10/pk)
Column nut, finger-tight (for Connect column to inlet or detector 5020-8293

0.53-mm columns)
.320 Ferrule, Vespel/graphite, 0.5-mm id 0.32-mm capillary columns 5062-3514 (10/pk)
Ferrule, graphite, 0.5-mm id 0.1-mm, 0.2-mm, 0.25-mm, and 0.32-mm 5080-8853 (10/pk)
capillary columns
Column nut, finger-tight (for .100- to Connect column to inlet or detector 5020-8292
.320-mm columns)
.250 Ferrule, Vespel/graphite, 0.4-mm id 0.1-mm, 0.2-mm, and 0.25-mm capillary 5181-3323 (10/pk)
columns
capillary columns
.320-mm columns)
.100 and .200 Ferrule, Vespel/graphite, 0.37-mm id 0.1-mm and 0.2-mm capillary columns 5062-3516 (10/pk)
Ferrule, Vespel/graphite, 0.4-mm id 0.1-mm, 0.2-mm, and 0.25-mm capillary 5181-3323 (10/pk)
columns
capillary columns
Ferrule, graphite, 0.4-mm id 500-2114 (10/pk)
.320-mm columns)
All Ferrule, no-hole Testing 5181-3308 (10/pk)
Capillary column blanking nut Testing–use with any ferrule 5020-8294
Column nut, universal Connect column to inlet or detector 5181-8830 (2/pk)
Column cutter, ceramic wafer Cutting capillary columns 5181-8836 (4/pk)
Pencil, diamond tipped Cutting capillary columns 420-1000
Ferrule tool kit Ferrule installation 440-1000
Table 4 Capillary column hangers
Description Part Number
Column hanger 1460-1914
Capillary column clip kit, for 7-inch column basket G1530-61580
To Install a Capillary Column Hanger
To Install a Capillary Column Hanger

Be careful! The oven may be hot enough to cause burns. If the oven is hot, wear
WAR N IN G heat-resistant gloves to protect your hands.
Wear safety glasses to protect your eyes from flying particles while handling, cutting, or
WAR N IN G installing glass or fused silica capillary columns. Use care in handling these columns to
prevent puncture wounds.
1 Place GC in maintenance mode: Maintenance > Instrument > Perform Maintenance >
Maintenance Mode > Start Maintenance. Wait for the GC to become ready.
2 Select either the front or back hanger position. (Hanger is shown in back position.)
Front position
Back position
3 Insert the ends of the hanger into the slots in the selected position.
To Install Capillary Column Clips
To Install Capillary Column Clips

1 Gather the following:

• Capillary column clip kit, see “Consumables and Parts for Columns” on page 30.
• T-20 Torx screwdriver
3 Loosen the four corner mounting screws, but do not remove.
Column
clip
Mounting
screw
4 Slip each corner screw through the large hole on the clip.
5 Slide the clip so that the screw is positioned in the slot.
6 Tighten the screws enough to hold the clips in place. Once the column is installed, fully
tighten the four corner screws to secure the clips and column to the oven wall.
To Condition a Capillary Column

• One 7/16-inch, and 1/4-inch wrenches
• No-hole ferrule. See “Consumables and Parts for Columns” on page 30.
• Column nut
Do not use hydrogen as the carrier for conditioning! It could vent into the oven and present an
WAR N IN G explosion hazard.
2 Manually set the inlet and oven temperature to < 40 °C, and wait for the inlet, oven, and
other parts you might come into contact with inside the oven, to cool before continuing.
Alternately, place the GC in maintenance mode: Maintenance > Instrument > Perform
Maintenance > Maintenance Mode > Start Maintenance.
3 Install the column into the inlet using the new ferrules.
• “To Install a Capillary Column with the Split/Splitless Inlet”
• “To Install a Capillary Column with the Multimode Inlet”
• “To Install a Capillary Column with the Purged Packed Inlet”
• “To Install a Capillary Column with the Cool On-Column Inlet”
• “To Install a Capillary Column with the Programmable Temperature Vaporization
Inlet”
• “To Install a Capillary Column with the Volatiles Interface”
4 Cap the open column fitting, for example, the detector column fitting.
5 Exit maintenance mode. Select Maintenance > Instrument > Perform Maintenance >
Maintenance Mode > Finished.
6 Turn off all detectors.

7 Set a minimum velocity of 30 cm/s, or as recommended by the column manufacturer. Let
gas flow through the column at room temperature for 15 to 30 minutes to remove air.
8 Program the oven from room temperature to the maximum temperature limit for the
column. Increase the temperature at a rate of 10 to 15 °C/min. Hold at the maximum
temperature for 30 minutes.
Maintenance Mode > Start Maintenance and wait for the GC to become ready.
Be careful! The oven and/or detector may be hot enough to cause burns. If the detector is
WAR N IN G hot, wear gloves to protect your hands.
10 Attach the column to the detector. For details, select your specific detector.
• To Install a Capillary Column in the FID
• To Install a Capillary Column in the NPD
• To Install a Capillary Column in the TCD
• To Install a Capillary Column in the ECD
• To Install a Capillary Column to the FPD+
12 Restore the analytical method.
• For FID or any FPD+, immediately turn off the flame.
• For NPD, immediately turn off the bead.
13 After the GC becomes ready, wait 10 minutes, then ignite the detector flame or bead.
To Cut a Loop from a Column
To Cut a Loop from a Column

• New ferrule(s) for the column inlet connection
• Column cutter
Be careful! The oven and/or inlet may be hot enough to cause burns. If the inlet is hot, wear
3 Loosen the inlet column nut and remove the column from the inlet.
4 Uncoil one loop of column from the column hanger.
5 Cut the unwanted loop from the column.
6 Install the column into the inlet using the new ferrules.
Inlet”
To Reverse a Column and Bakeout Contaminants

• 1/4-inch wrench
• Column cutter
3 Disconnect the column from the inlet and detector.

4 If necessary, cut a loop from the column. See “To Cut a Loop from a Column” on page 36.
Do not attach the column to the inlet.
5 Remove the column from the hanger and reverse its position (inlet and detector ends) and
place the column back on the hanger.
6 Attach the column to the inlet.
Inlet”
7 Attach your column to the detector.
9 Set the column flow to the normal operating value, or set the capillary column gas velocity
to 30 cm/s.
For Multimode, Split/Splitless, PTV, and VI inlets, select split mode and set the split vent
flow to 200 mL/min.
10 Purge the column with carrier flow for at least 10 minutes before heating the oven.
11 Set the inlet temperature to 300 °C or 25 °C above the normal operating temperature.
12 Set the column oven 25 °C above the GC method final oven temperature to bake
contaminants out of the inlet, mostly through the split vent. Do not exceed the column
manufacturer’s maximum temperature limit.
13 Bakeout for 30 minutes.
To Attach a Capillary Column Using UltiMetal Plus Flexible Metal Fittings
To Attach a Capillary Column Using UltiMetal Plus

Flexible Metal Fittings
The available UltiMetal Plus Flexible Metal ferrule packages are listed in Table 5 and Figure 6.
Table 5 Available UltiMetal Plus Flexible Metal ferrule packages
Item Part number Ferrule description
1 G3188-27501 0.1 – 0.25 mm column id, 10/pk
2 G3188-27502 0.32 mm column id, 10/pk
3 G3188-27503 0.45 – 0.53 mm column id, 10/pk
4 G3188-27504 Plug, 10/pk
5 G3188-27505 0.25 – 0.32 mm UltiMetal column id, 10/pk
6 G3188-27506 0.53 mm UltiMetal column id, 10/pk
1 2 3 4 5 6
Figure 6. UltiMetal Plus Flexible Metal ferrules
Each UltiMetal Plus Flexible Metal ferrule part number is uniquely designed to prevent
inventory mix-ups, and to help you find the ferrule you need quickly. Color variations between
ferrules are a normal result of the UltiMetal coating.
Preparing the column installation to the CFT fitting

This procedure is used to attach a capillary column to a splitter or switch or an Ultimate Union.
• UltiMetal Plus Flexible Metal ferrules. See Table 5.
• Swaging tool (G3440-80227)
• Two 1/4-inch open-end wrenches
• Column cutting tool (5181-8836)
• Internal nut (G2855-20530)
• Lint free gloves
2 Check the column end. It should be square and free of cracks. If needed, trim it.
3 Pass the column end through the internal nut and the ferrule, as shown in Figure 7.
Figure 7. Thread the column through the internal nut, ferrule, and swaging tool
4 Insert the column into the swaging tool until it bottoms.

5 Thread the internal nut into the swaging tool until finger tight. See Figure 8.
Figure 8. Thread the internal nut into the swaging tool
6 Begin to swage the ferrule to the column using a 1/4-inch open-ended wrench.
The design of UltiMetal Plus Flexible Metal ferrules reduces the probability of column
breakage and minimizes the damage to the thread of the corresponding fittings.
Unlike other ferrule designs, a reliable leak-free seal is best made by tightening the
internal nut to a recommended number of degrees, not by applying more force. Applying
excessive force will not provide a better seal. Also, compressing the flexible ferrule less
minimizes damage to fittings.
To swage the ferrule to the column:
a Find your ferrule type in Table 6 and note the range of degrees to tighten the internal
nut.
b Tighten the internal nut clockwise to the lower end of your ferrule’s range.
c Check if the ferrule is gripping the column. If yes, stop. If not, continue to tighten the
internal nut in small 5- to 15-degree increments. Check after each increment to see if
the ferrule is gripping the column. Stop as soon as gripping occurs. See Figure 9.
Table 6 Degrees to tighten the internal nut for proper swaging
Ferrule part number Degrees to tighten internal nut
G3188-27501 50 – 100 degrees
G3188-27502 30 – 70 degrees
G3188-27503 20 – 50 degrees
G3188-27504 60 degrees
G3188-27505 40 – 90 degrees
G3188-27506 20 – 50 degrees
Figure 9. Tighten the internal nut
7 Using the 1/4-inch open-ended wrench, turn the internal nut an additional 15 to 20 degrees
clockwise to assure the ferrule is properly swaged onto the column. See Figure 10.
Figure 10. Ferrule swaged to column and internal nut
Preparing the column installation to the inlet
8 Using the 1/4-inch open-ended wrench, remove the internal nut from the swaging tool and
column.
Figure 11. Properly-trimmed column and ferrule

This procedure is used to attach a capillary column to a splitter or switch or an Ultimate Union.
• UltiMetal Plus Flexible Metal ferrules. See Table 5.
• Swaging tool (G3440-80218)
• Column cutting tool (5181-8836)
• Column nut
• Lint free gloves
2 Check the column end. It should be square and free of cracks. If needed, trim it. See
Figure 12.
Figure 12.
3 Pass the column end through the column nut, the ferrule, and the swaging tool, as shown
in Figure 13.
Figure 13. Thread the column through the column nut, ferrule, and swaging tool
4 Loosely thread the column nut into the swaging tool until you start to feel resistance. The
column should still slide freely. See Figure 14.
Figure 14. Thread the column nut onto the swaging tool
5 Adjust the column position in the tool until the column end aligns with the correct
dimension for the inlet. See Figure 15.
Figure 15. Align column (split/splitless shown)
6 Begin to swage the ferrule to the column using a 1/4-inch open-ended wrench.
The design of UltiMetal Plus Flexible Metal ferrules reduces the probability of column
breakage and minimizes the damage to the thread of the corresponding fittings.
Unlike other ferrule designs, a reliable leak-free seal is best made by tightening the
column nut to a recommended number of degrees, not by applying more force. Applying
excessive force will not provide a better seal. Also, compressing the flexible ferrule less
minimizes damage to fittings.
To swage the ferrule to the column:
a Find your ferrule type in Table 7 and note the range of degrees to tighten the column
nut.
b Tighten the column nut clockwise to the lower end of your ferrule’s range.
c Check if the ferrule is gripping the column. If yes, stop. If not, continue to tighten the
column nut in small 5- to 15-degree increments. Check after each increment to see if
the ferrule is gripping the column. Stop as soon as gripping occurs. See Figure 16.
Table 7 Degrees to tighten the column nut for proper swaging
Ferrule part number Degrees to tighten internal nut
G3188-27501 50 – 100 degrees
G3188-27502 30 – 70 degrees
G3188-27503 20 – 50 degrees
G3188-27504 60 degrees
G3188-27505 40 – 90 degrees
G3188-27506 20 – 50 degrees
Figure 16. Tighten the column nut
7 Using the 1/4-inch open-ended wrench, turn the column nut an additional 15 to 20 degrees
clockwise to assure the ferrule is properly swaged onto the column. See Figure 17.
Figure 17. Ferrule swaged to column and column nut
8 Using the 1/4-inch open-ended wrench, remove the column nut from the swaging tool and
column.
Swaging Quality Inspection
Swaging Quality Inspection

Figure 18 shows both an incorrect and correct swaging symmetry.
Incorrect Correct
Figure 18. Incorrect and correct swaging symmetry
If your column and ferrule appear like the incorrect example in Figure 18 above, it is possible
that your swaging wrench is defective or worn out. Try swaging with a new wrench or new nut.
To Remove the Ferrule From a CFT Fitting

Loosen and remove the internal nut. If the ferrule does not release from the fitting, do not try to
pull the column free. Insert a pointed object (such as a thumb pin or a paper clip) into the
ferrule release hole, as shown in Figure 19, and press firmly. You will hear a click as the ferrule
releases.
Ferrule release holes
Figure 19. Release the ferrule (Ultimate Union fitting shown)
Consumables and Parts for the Split/Splitless Inlet 50
Exploded Parts View of the Split/Splitless Inlet 53
To Install a Capillary Column with the Split/Splitless Inlet 54
To Change the Septum on the Split/Splitless Inlet 58
To Clean the Septum Seat in the Insert Assembly of the Split/Splitless Inlet 60
To Change the Liner and O-Ring on the Split/Splitless Inlet 62
To Replace the Gold Seal on the Split/Splitless Inlet 65
To Replace the Filter in the Split Vent Trap for the Split/Splitless Inlet 67
To Clean the Split/Splitless Inlet 69
To Bakeout Contaminants from the Split/Splitless Inlet 71
Consumables and Parts for the Split/Splitless Inlet

Table 8 Split, splitless, direct, and direct connect inlet liners
Mode Description Deactivated Part number
Split Low-pressure drop, glass wool, single taper, 870 µL Yes 5183-4647
Split Glass wool, 990 µL No 19251-60540
Split MS Certified, single taper, glass wool Yes 5188-6576
Split—Manual only Empty pin and cup, 800 µL No 18740-80190
Split—Manual only Packed pin and cup, 800 µL No 18740-60840
Split or splitless Ultra Inert, low pressure drop, glass wool Yes 5190-2295
Splitless Single taper, glass wool, 900 µL Yes 5062-3587
Splitless Single taper, no glass wool, 900 µL Yes 5181-3316
Splitless Dual taper, no glass wool, 800 µL Yes 5181-3315
Splitless MS Certified, single taper, glass wool Yes 5188-6568
Splitless—Direct inject 2-mm id, quartz, 250 µL No 18740-80220
Splitless—Direct inject 2-mm id, 250 µL Yes 5181-8818
Direct inject —Headspace or purge 1.5-mm id, 140 µL No 18740-80200

and trap
Direct column connect Single taper, splitless 4-mm id Yes G1544-80730
Direct column connect Dual taper, splitless 4-mm id Yes G1544-80700

0.53-mm columns)
capillary columns
.320-mm columns)
Table 9 Nuts, ferrules, and hardware for capillary columns (continued)
columns
capillary columns
.320-mm columns)
columns
capillary columns
.320-mm columns)
Table 10 Other consumables and parts for the split/splitless inlet
Description/quantity Part number
Septum retainer nut for headspace 18740-60830
Septum retainer nut 18740-60835
11-mm septum, high-temperature, low-bleed, 50/pk 5183-4757
11-mm septum, prepierced, long life, 50/pk 5183-4761
Nonstick fluorocarbon liner O-ring (for temperatures up to 350 °C), 10/pk 5188-5365
Graphite O-ring for split liner (for temperatures above 350 °C), 10/pk 5180-4168
Graphite O-ring for splitless liner (for temperatures above 350 °C), 10/pk 5180-4173
Split vent trap PM kit, single cartridge 5188-6495
Retaining nut G1544-20590
Gold-plated seal (standard application) 5188-5367
Gold-plated seal with cross (high split flows) (includes SS washer) 5182-9652
Stainless steel washer (0.375-inch od), 12/pk 5061-5869
Reducing nut 18740-20800
Table 10 Other consumables and parts for the split/splitless inlet (continued)
Column nut, blanking plug 5020-8294
Capillary inlet preventative maintenance kit, split 5188-6496
Capillary inlet preventative maintenance kit, splitless 5188-6497
Exploded Parts View of the Split/Splitless Inlet
Exploded Parts View of the Split/Splitless Inlet
Merlin cap Septum retainer nut
Merlin Microseal Septum
Insert assembly
O-ring
Liner
Split vent line
Split/splitless inlet body
Retaining nut
Inlet gold seal

Washer
Reducing nut
Insulation
Insulation cup
Ferrule
Column nut
Figure 20. Split/splitless inlet exploded parts
To Install a Capillary Column with the Split/Splitless Inlet
To Install a Capillary Column with the Split/Splitless

Inlet
1 Gather the following, see “Consumables and Parts for the Split/Splitless Inlet” on
page 50:
• Column
• Ferrule(s)
• Column nut
• Septum
• Column cutter
• Isopropanol
• Lab tissue
• Metric ruler
• Lint-free gloves
Be careful! The oven and/or inlet may be hot enough to cause burns. If either is hot, wear
3 Verify that the correct glass liner is installed. See “Consumables and Parts for the
Split/Splitless Inlet” on page 50.
4 Place the column on the hanger with the ends pointing up and the label to the front.
Wear clean, lint-free gloves to prevent contamination of parts with dirt and skin oils.
C AU T I O N
5 Place a septum, capillary column nut, and ferrule on the column.
Ferrule
Column nut
Septum
6 Score the column using a glass scribing tool. The score must be square to ensure a clean
break.
7 Break off the column end by supporting it against the column cutter opposite the scribe.
Inspect the end with a magnifying loupe to make certain there are no burrs or jagged
edges.
Bad
Good
8 Wipe the column walls with a tissue dampened with isopropanol to remove fingerprints
and dust.
9 Position the column so it extends 4 to 6 mm above the end of the ferrule. Slide the septum
up the column to hold the column nut at this position.
4%6 mm
10 Thread the column nut into the inlet but do not tighten.
11 Adjust the column position so that the septum contacts the bottom of the column nut.
Finger-tighten the column nut until it begins to grip the column.
12 Tighten the column nut an additional 1/4 to 1/2 turn with a wrench so that the column
cannot be pulled from the fitting with gentle pressure.
13 Plug in the new column’s Smart ID key. See Figure 21.
Smart ID key
Figure 21. Insert Smart ID key
14 Configure the new column.

15 Condition the column per the manufacturer’s recommendation. See To Condition a
Capillary Column.
16 Install the column into the detector.

18 After the column is installed at both inlet and detector, establish a flow of carrier gas and
purge as recommended by the column manufacturer.
• For FID or FPD+, immediately turn off the flame.
20 After the GC becomes ready, wait 10 minutes then ignite the detector flame or bead.
Be careful! The oven, inlet, and/or detector may be hot enough to cause burns. If they are hot,
WAR N IN G wear heat-resistant gloves to protect your hands.
21 Allow the oven, inlet, and detector to equilibrate at operating temperature, then retighten
the fittings.
22 Perform an inlet Leak & Restriction test and reset the maintenance counters.
To Change the Septum on the Split/Splitless Inlet

• Replacement septum, see “Consumables and Parts for the Split/Splitless Inlet” on
page 50.
• Wrench, hex for changing septum
• 0- or 00-grade steel wool (optional)
• Tweezers
• Wrench, capillary inlet (optional)
2 Launch the GC maintenance wizard: Maintenance > Inlets, select the inlet, then select
Perform Maintenance > Replace Septum > Start Maintenance. The wizard will walk
through the steps needed to replace the septum (those same steps are repeated below).
3 Remove the septum retainer nut or Merlin cap.

4 Use tweezers to remove the septum or Merlin Microseal from the insert assembly. Do not
gouge or scratch the interior of the insert assembly.
Septum retainer nut
Septum
Insert assembly
5 Firmly press the new septum or Merlin Microseal into the fitting. The metal parts side of
the Merlin Microseal should face down (toward the oven).
6 Install the septum retainer nut or Merlin cap and finger-tighten. Tighten the septum retainer
nut until the C-ring is about 1 mm above the nut.
Overtightening the septum nut can cause contamination.

C AU T I O N
1 mm
7 Select Maintenance > Inlets > Septum injections, then touch Reset Counter.
9 Select Finished, then select OK to exit the GC maintenance wizard.
To Clean the Septum Seat in the Insert Assembly of the Split/Splitless Inlet
To Clean the Septum Seat in the Insert Assembly of

the Split/Splitless Inlet
page 50.
• Tweezers
• Compressed, filtered, dry air or nitrogen
3 Slide the locking tab forward (counterclockwise). Lift the insert assembly straight up and
away from the inlet to avoid chipping or breaking the liner.

5 Use tweezers to remove the septum or Merlin Microseal from the retainer nut. See “To
Change the Septum on the Split/Splitless Inlet” on page 58.
To Clean the Septum Seat in the Insert Assembly of the Split/Splitless Inlet
6 Scrub the residue from the retainer nut and septum holder with a small piece of rolled-up
steel wool and tweezers. Do not do this over the inlet.
7 Use compressed air or nitrogen to blow away the pieces of steel wool and septum.
8 Line up the tab on the bottom of the insert assembly with the slot on the inlet body and
push down to connect. Slide the locking tab to the left.
9 Firmly press the new septum or Merlin Microseal into the fitting. See “To Change the
Septum on the Split/Splitless Inlet” on page 58.
10 Replace the septum retainer nut or Merlin cap and finger-tighten. See “To Change the
Septum on the Split/Splitless Inlet” on page 58.
11 On the GC touchscreen select Maintenance > Inlets > Septum injections, then select Reset
Counter.
To Change the Liner and O-Ring on the Split/Splitless Inlet
To Change the Liner and O-Ring on the

Split/Splitless Inlet
• Replacement O-ring, see “Consumables and Parts for the Split/Splitless Inlet” on
page 50.
• Replacement liner
• Tweezers
• Wrench, hex for changing septum (optional)
Perform Maintenance > Replace Liner > Start Maintenance. The wizard will walk through
the steps needed to replace the liner and O-ring (those same steps are repeated below).
4 Loosen the O-ring from the sealing surface with tweezers.
5 Grasp the liner with tweezers and pull it out.
6 Inspect the surface of the gold seal for graphite or rubber septum contamination. If
required, replace the gold seal. See“To Replace the Gold Seal on the Split/Splitless
Inlet” on page 65.
7 Clean the inlet if there is visible or suspected contamination. See “To Clean the
8 Clean O-ring residue from sealing surface.
C AU T I O N
9 Slide a new O-ring onto the replacement liner.

10 Return the liner to the inlet, pushing it all the way in until the liner contacts the gold seal.
push down to connect. Slide the locking tab to the back.
12 Turn on the inlet. Allow the inlet and column to purge with carrier gas for 15 minutes before
heating the inlet or the column oven.
13 Bakeout contaminants. See “To Bakeout Contaminants from the Split/Splitless Inlet” on
page 71.
15 The GC maintenance wizard will perform checks at the appropriate times, including Leak &
Restriction tests, and will automatically reset the maintenance counters.
To Replace the Gold Seal on the Split/Splitless Inlet

• Replacement gold seal, see “Consumables and Parts for the Split/Splitless Inlet” on
page 50.
• Replacement washer
• 1/4-inch wrench (for column)
• 1/2-inch wrench
3 Remove the inlet liner.

4 Remove the column from the inlet. Cap the open end of the column to prevent
contamination. Remove the insulation cup around the base of the inlet.
Remove insulation cup
Disconnected, capped column
5 Loosen and remove the reducing nut. Remove the washer and seal inside the reducing nut.
C AU T I O N
6 Put on gloves to protect the new gold seal and washer from contamination. Put a new
washer in the reducing nut and place the new gold seal on top of it (raised portion facing
down).
Inlet gold seal Gold seal side view
Washer
Reducing nut
Make sure raised portion faces
down.
7 Replace the reducing nut and tighten securely with a wrench.

8 Replace the inlet liner.
9 Install the column and the insulation cup.
page 71.
To Replace the Filter in the Split Vent Trap for the Split/Splitless Inlet
To Replace the Filter in the Split Vent Trap for the

Split/Splitless Inlet
• New split vent filter cartridge. See “Consumables and Parts for the Split/Splitless
Perform Maintenance > Replace Split Vent Trap > Start Maintenance. The wizard will walk
through the steps needed to replace the filter (those same steps are repeated below).
The split vent trap may contain residual amounts of any samples or other chemicals you
WAR N IN G have injected into the GC. Follow your company’s safety procedures for handling these types
of substances while replacing the trap filter cartridge.
3 Remove the pneumatics cover (top, back of GC). See “To Remove the Pneumatics
Cover” on page 19.
4 Completely loosen the knurled nut that secures the split vent trap in place as shown in
Figure 22.
Knurled nut secured Knurled nut loosened
Figure 22. Loosen the knurled nut
5 Slide the trap assembly back from the guided mounting bracket and tilt up to expose the
filter as shown in Figure 23.
To Replace the Filter in the Split Vent Trap for the Split/Splitless Inlet
Filter and O-ring
Knurled nut
Figure 23. Slide trap assembly to expose the filter
6 Remove the old filter cartridge and two O-rings.

7 Verify the new O-rings are seated properly on the new filter cartridge.
8 Install the new filter cartridge then reassemble the trap using your fingers to fully tighten
the knurled nut. The nut should thread easily.
If the knurled nut does not thread easily, loosen, reassemble the 2 parts of the trap, and
thread again. Do not force it.
10 Install the pneumatics cover.
To Clean the Split/Splitless Inlet

page 50.
• Replacement O-ring
• Replacement gold seal
• Replacement washer
• Solvent that will clean the type of deposits in your inlet
• Beaker
• Cleaning brushes—The FID cleaning kit (part number 9301-0985) contains appropriate
brushes
3 Remove the inlet liner, O-ring, and septum. See “To Change the Liner and O-Ring on the
4 Disconnect the column from the inlet.
5 Remove the reducing nut, gold seal, and washer. See “To Replace the Gold Seal on the
6 Place a beaker in the oven under the inlet to catch the solvent.
C AU T I O N
7 Soak a cleaning brush in the solvent and scrub the inside of the insert assembly. Repeat
10 times.
8 Rinse the inlet with the solvent.
9 Blow the inside of the inlet dry with compressed air or nitrogen.
10 Install the gold seal, washer, and reducing nut.
11 Install the liner, O-ring, and septum.
12 Install the column. See “To Install a Capillary Column with the Split/Splitless Inlet” on
page 54.
page 71.
15 On the GC touchscreen, select Maintenance > Inlets, then touch Reset Counter.
To Bakeout Contaminants from the Split/Splitless Inlet
To Bakeout Contaminants from the Split/Splitless

Inlet
1 Put the inlet into split mode.
to 30 cm/s.
3 Set the inlet split vent flow to 200 mL/min.
5 If the column is attached to the detector, set the detector 25 °C above normal operating
temperature.
6 If the column is not attached to the detector, cap the detector fitting.
7 Set the inlet temperature to 300 °C or 25 °C above the normal operating temperature to
bakeout contaminants from the inlet, mostly through the split vent.
contaminants from the column. Do not exceed the column manufacturer’s maximum
temperature limit.
9 Bakeout for 30 minutes or until the detector baseline is free of contamination peaks.
To Bakeout Contaminants from the Split/Splitless Inlet
Consumables and Parts for the Purged Packed Inlet 74
Exploded Parts View of the Purged Packed Inlet 77
To Install a Capillary Column with the Purged Packed Inlet 78
To Change the Septum on the Purged Packed Inlet 82
To Clean the Septum Seat in the Purged Packed Inlet 84
To Install an Adapter on the Purged Packed Inlet 86
To Change the O-Ring on the Purged Packed Inlet 87
To Change the Glass Liner on the Purged Packed Inlet 88
To Clean the Purged Packed Inlet 90
To Bakeout Contaminants from the Purged Packed Inlet 92
To Install a Packed Metal Column 93
To Install a Packed Column Adapter onto a Detector 95
To Install a Packed Glass Column 97
To Condition a Packed Column 99
To Install Ferrules on a Packed Metal Column 100
Consumables and Parts for the Purged Packed Inlet
Consumables and Parts for the Purged Packed

Inlet
Table 11 Purged packed inlet parts
Description Part number/quantity
Preventative maintenance kit 5188-6498
Purged packed glass liners and column adapters
Glass liner 5080-8732 (25/pack) or

5181-3382 deactivated (5/pack)
0.53-mm column adapter 19244-80540
1/8-inch column adapter 19243-80530
1/4-inch column adapter 19243-80540
Recommended septa and O-rings for the purged packed inlet
11-mm solid septum, low-bleed, red 5181-1263 (50/pk)
11-mm septum with partial through-hole, low-bleed, red 5181-3383 (50/pk)
11-mm septum, low-bleed, gray 5080-8896 (50/pk)
Merlin Microseal septum (30 psi) 5181-8815
11-mm high-temperature silicone septum (350 °C and higher) 5182-0739 (50/pk)
Viton O-ring (Top insert weldment) 5080-8898 (12/pk)
Packed column adapters for detectors
1/8-inch Packed column adapter assembly G3435-81340
Table 12 Nuts and ferrules for packed columns
Description Typical use Part number/quantity
1/8-inch id Swagelok stainless steel nut, front ferrule, 1/8-inch column 5080-8751 (20 each/pk)
back ferrule
1/8-inch id Swagelok brass nut, front ferrule, back 1/8-inch column 5080-8750 (20 each/pk)
ferrule
1/8-inch id Vespel/ graphite ferrule 1/8-inch column 0100-1332 (10/pk)
1/8-inch id 1/8-inch column 5180-4103 (10/pk)

brass tubing nut
1/4-inch id Swagelok stainless steel nut, front ferrule, 1/4-inch column 5080-8753 (20 each/pk)
back ferrule
Table 12 Nuts and ferrules for packed columns (continued)
Description Typical use Part number/quantity
1/4-inch id Swagelok brass nut, front ferrule, back 1/4-inch column 5080-8752 (20 each/pk)
ferrule
1/4-inch id Vespel/ graphite ferrule Inlet/detector liner/adapters 5080-8774 (10/pk)

1/4-inch column
1/4-inch id 1/4-inch column 5180-4105 (10/pk)

brass tubing nut

0.53-mm columns)
capillary columns

.100 to 320-mm columns)
columns
capillary columns

.100 to 320-mm columns)
columns
capillary columns
.320-mm columns)
Exploded Parts View of the Purged Packed Inlet
Exploded Parts View of the Purged Packed Inlet
Merlin cap Septum nut
Merlin Microseal Septum
Top insert weldment
O-ring
Glass liner
Ferrule
Adapter nut
Adapter
Insulation
Insulation cup
Ferrule
Column nut
Figure 24. Purged packed inlet exploded parts
To Install a Capillary Column with the Purged Packed Inlet
To Install a Capillary Column with the Purged

Packed Inlet
• Column
• Ferrule, see “Consumables and Parts for the Purged Packed Inlet” on page 74.
• Column nut
• Glass liner
• Viton O-ring
• 0.53-mm column adapter
• Septum
• Two 1/4-inch wrenches
• Metric ruler
3 Install a 0.53-mm column adapter. See “To Install an Adapter on the Purged Packed
C AU T I O N
4 Install a new Viton O-ring. See “To Change the O-Ring on the Purged Packed Inlet” on
page 87.
Ferrule
Column nut
Septum
break.
edges.
Bad
Good
and dust.
9 Position the column so it extends 1 to 2 mm above the end of the ferrule. Slide the septum
up the column to hold the column nut at this fixed position.
1%2 mm
10 Thread the column nut into the inlet adapter but do not tighten.
11 Adjust the column position so that the septum is even with the bottom of the column nut.
Smart ID key

15 Condition the column per the manufacturer’s recommendation. See “To Condition a
Capillary Column”.
• For FPD+, immediately turn off the flame.
20 After the GC becomes ready, wait 10 minutes then ignite the detector flame or adjust
offset on the NPD bead.
Be careful! The oven, inlet, and/or detector may be hot enough to cause burns. If the oven,
WAR N IN G inlet, or detector is hot, wear heat-resistant gloves to protect your hands.
the fittings.
To Change the Septum on the Purged Packed Inlet

• Replacement septum, see “Consumables and Parts for the Purged Packed Inlet” on
page 74.
• Septum nut wrench
• Tweezers

4 Use tweezers to remove the septum or Merlin Microseal from the retainer nut. Do not
gouge or scratch the interior of the septum head.
Septum retainer nut
Septum
Merlin Microseal and cap Standard septum
6 Replace the septum retainer nut or Merlin cap and finger-tighten. Tighten the septum
retainer nut until the C-ring is about 1 mm above the nut.

C AU T I O N
1 mm
7 On the GC touchscreen, select Maintenance > Inlets > Septum injections, then touch Reset
Counter.
To Clean the Septum Seat in the Purged Packed Inlet
To Clean the Septum Seat in the Purged Packed

Inlet
• Replacement septum, see “Consumables and Parts for the Purged Packed Inlet” on
page 74.
• Tweezers
• Ultrasonic cleaning bath

4 Loosen the top insert assembly and remove.
C AU T I O N
5 Use tweezers to remove the septum or Merlin Microseal from the top insert assembly. Do
not gouge or scratch the interior of the septum head.
6 Scrub the residue from the top insert assembly and septum nut with a small piece of
rolled-up steel wool and tweezers. Ultrasonically clean the retainer nut and top insert
assembly.
8 Wearing gloves, inspect the O-ring and replace, if necessary. See “To Change the O-Ring
on the Purged Packed Inlet” on page 87.
9 Install the top insert assembly and hand-tighten firmly.
10 Firmly press the new septum or Merlin Microseal into the fitting.

C AU T I O N
To Clean the Septum Seat in the Purged Packed Inlet
1 mm
Counter.
To Install an Adapter on the Purged Packed Inlet
To Install an Adapter on the Purged Packed Inlet

• Brass tubing nut, see “Consumables and Parts for the Purged Packed Inlet” on
page 74.
• Adapter (0.53 mm, 1/8-inch packed, or 1/4-inch packed)
• 7/16-inch and 9/16-inch wrench
• Vespel/graphite ferrule
• Methanol
C AU T I O N
3 Clean the end of the adapter with a lint-free cloth and methanol to remove contamination
such as fingerprints.
4 Place the tubing nut and Vespel/graphite ferrule on the adapter.
Inlet fitting
Ferrule
Tubing nut
Adapter
5 Insert the adapter straight into the inlet base as far as possible.
6 Hold the adapter in this position and finger-tighten the nut.
7 Tighten an additional 1/4 turn with a wrench.
To Change the O-Ring on the Purged Packed Inlet
To Change the O-Ring on the Purged Packed Inlet

• Replacement O-ring, see “Consumables and Parts for the Purged Packed Inlet” on
page 74.
• Tweezers
Perform Maintenance > Replace Liner and O-Ring > Start Maintenance. The wizard will
walk through the steps needed to replace the liner and O-ring (those same steps are
repeated below).
3 Loosen the top insert assembly to remove the top portion of the inlet.
C AU T I O N
4 Use tweezers to remove the old O-ring.
5 Insert a new O-ring.

6 Install and tighten the top insert assembly.
To Change the Glass Liner on the Purged Packed Inlet
To Change the Glass Liner on the Purged Packed

Inlet
• Replacement glass liner, see “Consumables and Parts for the Purged Packed Inlet” on
page 74.
• 9/16-inch wrench
walk through the steps needed to replace the liner (those same steps are repeated below).
3 Loosen the top insert assembly to remove the top portion of the inlet.
Top insert weldment
Flared end
Glass liner
4 Use a thin wire or wood splint to carefully lift and remove the old glass liner.
C AU T I O N
5 Wearing gloves, inspect the O-ring and replace, if necessary. See “To Change the O-Ring
on the Purged Packed Inlet” on page 87.
To Change the Glass Liner on the Purged Packed Inlet
6 Wearing gloves, grasp the flared end (top) of the replacement glass liner with tweezers and
install it in the inlet. If the glass liner does not seat properly because a capillary column is
installed, remove the column, install the glass liner, and replace the column. See “To Install
a Capillary Column with the Purged Packed Inlet” on page 78.
7 Install the top insert assembly and hand-tighten firmly.
8 Configure the new liner.
To Clean the Purged Packed Inlet

• Replacement O-ring, see “Consumables and Parts for the Purged Packed Inlet” on
page 74.
• Replacement glass liner
• Replacement septum
• Solvent that will clean the type of deposits in your inlet
• Beaker
• Cleaning brushes—The FID cleaning kit (part number 9301-0985) contains appropriate
brushes
3 Remove the column.

4 Remove the septum nut and septum.
5 Remove the top insert assembly.
6 Remove the glass liner and O-ring.
7 If used, remove the adapter.
8 Ultrasonically clean the septum nut, top insert assembly, and adapter (if used) in a suitable
solvent.
9 Place a beaker in the oven under the inlet to catch the solvent.
C AU T I O N
10 Soak a cleaning brush with the solvent and vigorously scrub the interior walls of the inlet.
11 Blow the inside of the inlet dry with compressed air or nitrogen.
12 Install the adapter, if used. See “To Install an Adapter on the Purged Packed Inlet” on
page 86.
13 Install the glass liner and O-ring. See “To Change the Glass Liner on the Purged Packed
14 Install the top insert assembly and finger-tighten.
15 Install the septum and septum nut. See “To Change the Septum on the Purged Packed
16 Attach the column. See “To Install a Capillary Column with the Purged Packed Inlet” on
page 78.
17 Set the septum and glass liner counters.
18 Perform the inlet Leak & Restriction test and reset the maintenance counters.
To Bakeout Contaminants from the Purged Packed Inlet
To Bakeout Contaminants from the Purged Packed

Inlet
to 30 cm/s.
temperature.
If the column is not attached to the detector, cap the detector fitting.
4 Set the inlet temperature to 300 °C or 25 °C above the normal operating temperature.
contaminants out of the inlet. Do not exceed the column manufacturer’s maximum
temperature limit.
To Install a Packed Metal Column

• 7/16-inch, 9/16-inch, and 1/2-inch wrenches
3 Prepare the packed metal column. See “To Install Ferrules on a Packed Metal Column” on
page 100.
4 Install the 1/8-inch or 1/4-inch packed column inlet adapter, if necessary. See “To Install
an Adapter on the Purged Packed Inlet” on page 86.
C AU T I O N
5 Attach the column to the inlet adapter. Finger-tighten the nut.

6 Tighten the nut an additional 1/4 turn with a wrench (for a 1/8-inch column) or an
additional 3/4 turn (for a 1/4-inch column).
Use two wrenches, one on the column nut and the other on the adapter, to prevent the
adapter from rotating.
7 Press Settings > Configuration > Columns, then select Columns 1 through 6. Select
Column Type > Packed, then choose your Inlet and Outlet Connection to identify the inlet
and detector to which the column is attached.
8 Scroll down to manually set your column temperatures.
9 Condition the column, if necessary. See “To Condition a Packed Column” on page 99.
11 If required, install a packed column adapter onto the detector column fitting. See “To
Install a Packed Column Adapter onto a Detector” on page 95.
12 Place a nut and ferrule onto the packed column.
13 Attach the column to the detector or detector adapter. Finger-tighten the nut.
Adapter
Ferrule
Nut
Packed column
14 Using two wrenches, one on the adapter and one on the column nut, tighten the column
nut an additional 1/4 turn (for a 1/8-inch column) or an additional 3/4 turn (for a 1/4-inch
column).
16 Establish a flow of carrier gas and purge as recommended by the packing manufacturer.
Generally:
• 20 to 30 mL/min for 2-mm id glass or 1/8-inch od metal columns
17 Heat the oven to 200 °C, cool it to a safe handling temperature, then re-tighten the column
connection. (Re-tighten until snug, only about 15 degrees rotation.) Repeat two more
times. This process will set the Vespel/graphite ferrule to help prevent leaks.
the fittings.
To Install a Packed Column Adapter onto a Detector
To Install a Packed Column Adapter onto a

Detector
This procedure applies to the FID, FPD+, NPD, and TCD.
• Packed column adapter, see “Consumables and Parts for the Purged Packed Inlet” on
page 74.
• Ferrule, Vespel/graphite, 0.8-mm id
• 7/16-inch wrench (for the packed column adapter and 1/8-inch packed column nuts)
• 9/16-inch wrench (for 1/4-inch packed column nuts)
• 1/8-inch nut and ferrule for a 1/8-inch packed column, or a 1/4-inch nut and ferrule for a
1/4-inch packed column
C AU T I O N
Handle the adapter carefully and install the packed column before installing the adapter into
the detector base. The thin-walled capillary tube that carries the sample into the detector can
be damaged by rough handling.
3 Place a ferrule onto the packed column adapter.
'HWHFWRUÀWWLQJ
Ferrule
Capillary tube
Packed column adapter
4 Carefully install the adapter assembly into the detector fitting. Align the adapter so the it
enters the detector fitting as vertically as possible. Avoid stressing the adapter capillary
tube. Finger-tighten the adapter into the detector base, then tighten an additional 1/8 turn
using a wrench.
To Install a Packed Column Adapter onto a Detector
Detector fitting
After installation, heat the oven to 200 °C, cool it to a safe handling temperature, then re-tighten
the column connection. (Re-tighten until snug, only about 15 degrees rotation.) Repeat two
more times. This process will set the Vespel/graphite ferrule to help prevent leaks.
To Install a Packed Glass Column

• Two 1/4-inch brass nuts, see “Consumables and Parts for the Purged Packed Inlet” on
page 74.
• Two 1/4-inch Vespel/graphite ferrules
C AU T I O N
3 Assemble a brass nut and Vespel/graphite ferrule on each end of the column.
Glass columns must be simultaneously inserted into the inlet and detector and installed
parallel to the oven door. When conditioning the column, do not attach the column to the
detector.
4 If conditioning the column, insert the column into the purged packed inlet until it bottoms.
Withdraw the column 1 to 2 mm. Finger-tighten the inlet column nut. See “To Condition a
Packed Column” on page 99.
Overtightening the column nut or forcing it to bottom in either the inlet or detector may
C AU T I O N shatter the column.
5 Tighten the inlet column nut 1/4 turn with a wrench.
6 After conditioning, remove the column from the inlet.

7 Simultaneously insert the column into the inlet and detector fittings but do not force it. It
may be necessary to start the long end of the column in the inlet at an angle to clear the oven
floor.
8 Withdraw the column 1 to 2 mm from both the inlet and detector. Finger-tighten both
column nuts.
Overtightening the column nut or forcing it to bottom in either the inlet or detector may
C AU T I O N shatter the column.
9 Tighten both column nuts 1/4 turn with a wrench.

10 Press Settings > Configuration > Columns, then select Columns 1 through 6. Select
Column Type > Packed, then choose your Inlet and Outlet Connection to identify the inlet
and detector to which the column is attached.
11 Scroll down to manually set your column temperatures.
13 Establish a flow of carrier gas and purge as recommended by the packing manufacturer.
Generally:
the fittings.
To Condition a Packed Column
To Condition a Packed Column

• Capillary adapter
• Column nut and no-hole ferrule or blanking nut
• 1/4-inch open-end wrench
C AU T I O N
3 Install the proper liner in the inlet and attach the column. See “To Install a Packed Metal
Column” on page 93.
4 If present, remove the packed column adapter from the detector base. (If it is installed to
the column, it can be conditioned with the column.)
5 Cap the detector fitting with the no-hole ferrule and column nut, or with a blanking nut.
6 Enter a column flow as recommended by the packing manufacturer or an appropriate flow
as follows:
7 Raise the oven temperature slowly to the conditioning temperature for the column. The
conditioning temperature is never higher than the maximum temperature limit for the
column; 30 °C less than the maximum is usually sufficient.
8 Continue conditioning overnight at the final temperature. Cool the oven to room
temperature with carrier flow on.
9 Attach the column to the detector and maintain established flow. See “To Install a Packed
Metal Column” on page 93.
To Install Ferrules on a Packed Metal Column
To Install Ferrules on a Packed Metal Column

• Wrenches
• Stainless steel male Swagelok fitting, 1/4- or 1/8-inch od
• Brass Swagelok nut and ferrule set, see “Consumables and Parts for the Purged
Packed Inlet” on page 74.
2 Verify that the column end is cut square and is free of burns and deformation.
3 Secure the fitting in a bench vise.
C AU T I O N
4 Assemble a Swagelok nut and ferrules onto the column.
Front ferrule
Back ferrule
Column nut
5 Fully insert the column into the vise-held fitting, then withdraw 1–2 mm. Finger-tighten the
nut.
6 Tighten the nut an additional 3/4 turn with a wrench (for a 1/8-inch column) or an
additional 1-1/4 turn (for a 1/4-inch column).
7 Unscrew the column nut from the vise-held fitting and remove the column. Ferrules should
now be set in place on the column with the column end correctly positioned.

Consumables and Parts for the Cool On-Column Inlet 102
Exploded Parts View of the Cool On-Column Inlet 105
To Install a Capillary Column with the Cool On-Column Inlet 106
To Check the Needle-to-Column Size on the COC Inlet 109
To Change a Septum on the COC Inlet 110
To Install an Insert on the COC Inlet 112
To Clean the COC Inlet 114
To Replace the 7693A Injector Needle Support Guide 116
To Replace a Needle in a Syringe 117
To Replace the Fused Silica Needle in a Syringe for the COC Inlet 118
To Bakeout Contaminants from the COC Inlet 119

Consumables and Parts for the Cool On-Column Inlet
Consumables and Parts for the Cool On-Column

Inlet
Table 14 Recommended parts for injections onto 0.53-mm fused silica columns
Column type Part number
Insert, fused silica, 0.53 mm id 19245-20580 (no rings)
Septum nut, 530 µm G1545-80530
Syringe barrel, removable needle, 5 µL 5182-0836
Needle, 530 µm (3/pk) 5182-0832
Plunger button, 10/pk, for manual injections using syringe barrel 5182-0836 5181-8866
On-column insert spring 19245-60760
Needle support assembly, 530 µm, for 7683B injector G2913-60977
Table 15 Recommended parts for injections onto 0.53-mm aluminum-clad columns
Insert, aluminum-clad, 0.53 mm id 19245-20780 (4 rings)
Septum nut, 530 µm G1545-80530
Needle, 530 µm (3/pk) 5182-0832
Needle support assembly, 530 µm, for 7683B injector G2913-60977
Insert, fused silica, 0.32 mm id 19245-20525 (5 rings)
Septum nut, 250/320 µm 19245-80521
Needle, 320 µm (3/pk) 5182-0831

Table 16 Recommended parts for injections onto 0.32-mm fused silica columns (continued)
Needle support assembly, 250/320 µm, for 7683B injector G2913-60978
Insert, 0.25 mm id 19245-20515 (6 rings)
Septum nut, 250/320 µm 19245-80521
Needle, 250 µm (3/pk) 5182-0833
Needle support assembly, 250/320 µm, for 7683B injector G2913-60978
Insert, fused silica, 0.20 mm id 19245-20510
Cooling tower assembly 19320-80625
Syringe barrel, for fused silica needle, 10 µL 9301-0658
Replacement needles, fused silica, 0.18 mm 19091-63000 (6/pk)
Replacement PTFE ferrule for fused silica syringe 0100-1389
Removable stainless steel needle syringe, 10 µL 5182-9633
Replacement stainless steel needles, 0.23 mm 5182-9645 (3/pk)
Table 19 Recommended septa for the COC inlet
For 0.53-mm and 0.25/0.32-mm septum nuts
5-mm solid septum for manual and automatic injection 5181-1261
5-mm long-life septum 5183-4762 (50/pk)
5-mm advanced green septum 5183-4760 (50/pk)
5-mm, high-temperature, low-bleed septum 5183-4758 (50/pk)
5-mm through-hole septum for automatic injection 5181-1260 (25/pk)

Table 19 Recommended septa for the COC inlet (continued)
For the duckbill septum
Duckbill septum for manual injection only (must use cooling tower with duckbill) 19245-40050 (10/pk)

0.53-mm columns)
capillary columns
.320-mm columns)
columns
capillary columns
.320-mm columns)
.100 and 200 Ferrule, Vespel/graphite, 0.37-mm id 0.1-mm and 0.2-mm capillary columns 5062-3516 (10/pk)
columns
capillary columns
.320-mm columns)

Exploded Parts View of the Cool On-Column Inlet
Exploded Parts View of the Cool On-Column Inlet
Septum nut
(0.53 mm)
Cooling tower assembly
Septum nut
(0.25-mm and 0.32-mm
columns)
Duckbill septum
Septum
Spring
Insert
Ferrule
Column nut
Figure 26. Cool on-column inlet exploded parts

To Install a Capillary Column with the Cool On-Column Inlet
To Install a Capillary Column with the Cool

On-Column Inlet
• Column nut and ferrule, see “Consumables and Parts for the Cool On-Column Inlet” on
page 102.
• Column cutter
• 1/4-inch and 5/16-inch wrenches
C AU T I O N
3 Before installing the column, be sure the correct insert is installed for the needle and
column. See “To Install an Insert on the COC Inlet” on page 112.
4 Place a capillary column nut and ferrule on the column.
Ferrule
Column nut
break.

edges.
Bad
Good
and dust.
8 Gently insert the column into the inlet until it bottoms. You should feel spring tension as
you push up on the column. (Do not withdraw the column.)
9 Insert the column nut into the inlet fitting and finger-tighten.
To avoid bending the inlet, always use two wrenches. Use a 5/16-inch wrench to support the
WAR N IN G inlet while tightening the column nut with a 1/4-inch wrench.
10 Tighten the column nut an additional 1/4 turn with a wrench or until the column does not
move.
11 If using an automatic injection system with a 0.25-mm or 0.32-mm column, verify that the
column installation by manually pushing the syringe into the inlet.

Smart ID key

Capillary Column.
• For NPD, immediately turn off the bead
the fittings.

To Check the Needle-to-Column Size on the COC Inlet
To Check the Needle-to-Column Size on the COC

Inlet
• Insert, see “Consumables and Parts for the Cool On-Column Inlet” on page 102.
• Syringe needle
3 Check that the needle is the correct size for the desired column id. If needed, replaced the
needle with one of the correct size. See “Consumables and Parts for the Cool On-Column
Inlet” on page 102, and “To Replace a Needle in a Syringe” on page 117 or “To Replace
the Fused Silica Needle in a Syringe for the COC Inlet” on page 118.
4 Identify the correct insert for the column size. See “Consumables and Parts for the Cool
On-Column Inlet” on page 102. Use the insert that is the same size as the syringe needle to
verify that the column you plan to use is the correct size.
5 Make a clean cut on the end of the column. See “To Install a Capillary Column with the
Cool On-Column Inlet” on page 106.
6 Insert the column into one end of the insert.
Syringe
Insert
Column
7 Insert the syringe needle through the other end of the insert and into the column. The
needle should visibly enter the column without any obstruction. If the needle cannot pass
easily into the column, reverse the insert to try the needle and column in the other end.

To Change a Septum on the COC Inlet

• Replacement septum, see “Consumables and Parts for the Cool On-Column Inlet” on
page 102.
• Tweezers
• A thin wire (0.2-inch diameter) for removing septum from inlet
C AU T I O N
3 Replace the septum.

• If you are using a septum nut, grasp the knurling and unscrew. Remove the old septum
with tweezers.
• Use tweezers to install a new septum. Push the septum into the septum nut until
properly seated. Firmly tighten the nut.
For 250/320-µm For 530-µm automated

automated injections injections
• If you are using a cooling tower, grasp the three rings and unscrew. The spring and
duckbill septum may pop out of the inlet when you remove the cooling tower. Be careful
not to lose them. If they do not pop out, use a thin wire to remove them from the inlet.
Insert the replacement duckbill septum into the spring and place in the inlet. Reattach
the cooling tower assembly, then finger-tighten.

For manual 200-µm injections with

fused silica needle
4 Before making an injection, check the alignment of the entire assembly using the proper
size syringe.
5 On the GC touchscreen select Maintenance > Inlets > Septum injections, then touch Reset
Counter.

To Install an Insert on the COC Inlet

• Replacement insert, see “Consumables and Parts for the Cool On-Column Inlet” on
page 102.
C AU T I O N
3 Remove the column from the inlet.

4 Locate the septum nut or cooling tower assembly at the top of the inlet and remove it. If
the septum remains in the septum nut, do not remove it unless you want to change it. If
necessary, replace the existing septum or duckbill with a new one. See “To Change a
Septum on the COC Inlet” on page 110.
5 Remove the spring from the inlet with an extraction wire (or tweezers) and set it aside. Be
careful not to lose or damage it because you will use the spring to keep the new insert in
position.
6 Remove the existing insert from the inlet by gently pushing it out from below with a wire or
piece of column. Store the insert for possible later use.

7 Check that the insert is the correct size for both the needle and column. See “To Check the
Needle-to-Column Size on the COC Inlet” on page 109.
8 Lower the new insert straight into the inlet from the top. The insert can be installed either
end up.
9 Install the spring on top of the insert.
10 Install the septum and septum nut or duckbill septum and cooling tower assembly and
finger-tighten.
11 Install the column. See “To Install a Capillary Column with the Cool On-Column Inlet” on
page 106.

To Clean the COC Inlet

• Cleansing bath
• Aqueous detergent
• Distilled water
• Methanol
C AU T I O N

4 Remove the septum nut or cooling tower and then remove the septum.
5 Remove the existing insert from the inlet by gently pushing it out from below with a wire or
piece of column. Store the insert for possible later use.
6 Fill an ultrasonic cleansing bath with aqueous detergent and place the spring and insert
into it. Sonicate for 1 minute.
7 Drain the aqueous detergent and fill the bath with distilled water. Sonicate for 1 minute.

8 Remove the spring and insert from the bath and rinse thoroughly with water and methanol.
9 Dry the spring and insert with compressed air or nitrogen.
10 Install the insert. See “To Install an Insert on the COC Inlet” on page 112.
11 Install the column. See “To Install a Capillary Column with the Cool On-Column Inlet” on
page 106.

To Replace the 7693A Injector Needle Support Guide
To Replace the 7693A Injector Needle Support

Guide
Before using a 7693A ALS to make injections onto the COC inlet, install the on-column needle
support guide.
Refer to the 7693A ALS documentation for complete details.
Standard needle
support guide
On-column
needle support
guide
1 Open the injector door.

2 Remove the syringe.
3 Slide the syringe carriage up to the top position.
4 Completely remove the T-10 Torx screw from the support foot. Be careful to not let the
screw fall into the turret assembly.
5 Slide off the support foot.
6 Slide on the new support foot.
7 Replace the T-10 Torx screw and tighten.
8 Install the appropriate syringe.
9 Close the injector door.
10 Align the injector.

To Replace a Needle in a Syringe
To Replace a Needle in a Syringe

1 Gather the following, see Table 17, “Recommended parts for injections onto 0.25-mm
fused silica columns,” on page 103:
• Syringe barrel
• Needle, 250-µm or 320-µm
2 Unscrew the syringe barrel cap and remove the spring.
3 Make sure that the needle has the PTFE disk as shown below. If the syringe barrel does not
have the PTFE disk, use the instructions in the syringe box to wrap the needle.
Plunger
Barrel
PTFE disk
Stop
Needle
Needle
Spring
Cap
4 Check the new needle for a small wire inserted for shipment. Remove the wire if present.
5 Slide the spring and the cap over the needle.
6 Insert the needle into the syringe barrel.
7 Screw the cap back on the syringe barrel.

To Replace the Fused Silica Needle in a Syringe for the COC Inlet
To Replace the Fused Silica Needle in a Syringe for

the COC Inlet
The fused silica needle and syringe are only used with the cooling tower and duckbill septum
NOTE for manual, on-column injections onto 200-µm columns.

• New fused silica syringe needle, see “Consumables and Parts for the Cool On-Column
• Solvent
2 Loosen the retaining nut and remove the old needle.

3 Hold the syringe vertically and insert the new fused silica needle so it is visible inside the
syringe barrel. If the needle cannot be inserted into the syringe barrel, the PTFE ferrule may
be blocked. You may need to replace the ferrule.
4 Push the plunger down until it bottoms. The needle will be flush with the plunger end.
Fused silica needle
PTFE ferrule
5 Finger-tighten the retaining nut. Pull the needle gently to be sure the PTFE ferrule has
formed a tight seal with the needle. Tighten the retaining nut further, if necessary.
6 Loosen the retaining nut just enough so the needle is again free.
7 Depress the syringe plunger slowly until it pushes the needle to the end of the barrel, then
finger-tighten the retaining nut.
8 Use a solvent to rinse the syringe and check for leaks or blocks. Leaks may be fixed by
further tightening the retaining nut. Blocks or serious leaks require repeating this
procedure.

To Bakeout Contaminants from the COC Inlet

to 30 cm/s.
3 Set the inlet mode to Oven Track.
temperature.
contaminants out of the inlet. Do not exceed the column manufacturer’s maximum
temperature limit.


Consumables and Parts for the Multimode Inlet 122
Exploded Parts View of the MMI 124
To Install the Column Nut Adapter 125
To Install a Capillary Column with the Multimode Inlet 126
To Change the Septum on the MMI 130
To Clean the Septum Seat in the Insert Assembly of the MMI 132
To Change the Liner and O-Ring on the MMI 134
To Replace the Filter in the Split Vent Trap for the MMI 137
To Clean the Multimode Inlet 139
To Bakeout Contaminants from the MMI 141

Consumables and Parts for the Multimode Inlet

Table 21 Split, splitless, direct, and direct connect inlet liners
Mode Description Deactivated Part number
Split Low-pressure drop, glass wool, single taper, 870 µL Yes 5183-4647
Split Glass wool, 990 µL No 19251-60540
Split—Manual only Empty pin and cup, 800 µL No 18740-80190
Split—Manual only Packed pin and cup, 800 µL No 18740-60840
Splitless Single taper, glass wool, 900 µL Yes 5062-3587
Splitless Single taper, no glass wool, 900 µL Yes 5181-3316
Splitless Dual taper, no glass wool, 800 µL Yes 5181-3315
Splitless—Direct inject 2-mm id, quartz, 250 µL No 18740-80220
Splitless—Direct inject 2-mm id, 250 µL Yes 5181-8818
Direct inject —Headspace or purge 1.5-mm id, 140 µL No 18740-80200

and trap
Direct column connect Single taper, splitless 4-mm id Yes G1544-80730
Direct column connect Dual taper, splitless 4-mm id Yes G1544-80700

0.53-mm columns)
capillary columns
.320-mm columns)
columns
capillary columns
.320-mm columns)

columns
capillary columns
.320-mm columns)
Table 23 Other consumables and parts for the multimode inlet (MMI)
Septum retainer nut for headspace 18740-60830
Septum retainer nut 18740-60835
11-mm septum, high-temperature, low-bleed, 50/pk 5183-4757
11-mm septum, prepierced, long life, 50/pk 5183-4761
Merlin Microseal septum (high-pressure) 5182-3444
Merlin Microseal septum (30 psi) 5181-8815
Nonstick fluorocarbon liner O-ring (for temperatures up to 350 °C), 5188-5365

10/pk
Graphite O-ring for split liner (for temperatures above 350 °C), 10/pk 5180-4168
Graphite O-ring for splitless liner (for temperatures above 350 °C), 5180-4173
10/pk
Column nut, blanking plug 5020-8294
Cleaning kit, multimode inlet. (Contains 5 each abrasive swabs and G3510-60820
5 each cotton swabs.)
Column nut adapter G3510-20018

Exploded Parts View of the MMI
Exploded Parts View of the MMI
Merlin cup Septum retainer nut

Septum
Merlin Microseal
Insert assembly
O-ring
Split vent line
Liner
Cryo for CO2
Split vent line
Inlet base
Column nut
Insulation
Insulation cup
Screws
Figure 28. Multimode inlet exploded parts

To Install the Column Nut Adapter
To Install the Column Nut Adapter

1 Gather the following, see “Consumables and Parts for the Multimode Inlet” on page 122:
• Column nut adapter
3 When the GC is ready, open the GC oven door.

4 Thread the column adapter nut onto the base of the inlet.
Column nut adapter

Orient as shown.
The nut must spin freely before it can be used to install a column.

To Install a Capillary Column with the Multimode Inlet
To Install a Capillary Column with the Multimode

Inlet
1 Gather the following, see “Consumables and Parts for the Multimode Inlet” on page 122:
• Column
• Ferrule(s)
• Column nut
• Septum
• Column cutter
• Isopropanol
• Lab tissue
• Metric ruler
3 Verify that the correct glass liner is installed. See “Consumables and Parts for the
Multimode Inlet” on page 122.
C AU T I O N

Ferrule
Column nut
Septum
break.
edges.
Bad
Good
and dust.
9 Position the column so it extends 10 to 12 mm above the end of the ferrule. Slide the
septum up the column to hold the column nut at this position.

10%12 mm
10 While holding the inlet base with a wrench thread the column nut into the inlet (but do not
tighten).
11 Adjust the column position so that the septum contacts the bottom of the column nut.
12 While holding the inlet base with one wrench, use the second wrench to tighten the column
nut an additional 1/4 to 1/2 turn so that the column cannot be pulled from the fitting with
gentle pressure.

Smart ID key

Capillary Column.
• For FID or FPD+, immediately turn off the flame.
20 After the GC becomes ready, wait 10 minutes then ignite the detector flame or bead.
the fittings.

To Change the Septum on the MMI

• Replacement septum, see “Consumables and Parts for the Multimode Inlet” on
page 122.
• Tweezers
2 Launch the GC maintenance wizard: Maintenance > Inlets, select the multimode inlet, then
select Perform Maintenance > Replace Septum > Start Maintenance. The wizard will walk

4 Use tweezers to remove the septum or Merlin Microseal from the insert assembly. Do not
gouge or scratch the interior of the insert assembly.
Septum retainer nut
Septum
Insert assembly

C AU T I O N

1 mm
7 On the GC touchscreen, select Maintenance > Inlets > Septum injections, then touch Reset
Counter.

To Clean the Septum Seat in the Insert Assembly of the MMI
To Clean the Septum Seat in the Insert Assembly of

the MMI
• Replacement septum, see “Consumables and Parts for the Multimode Inlet” on
page 122.
• Tweezers

5 Use tweezers to remove the septum or Merlin Microseal from the retainer nut. See “To
Change the Septum on the MMI” on page 130.

To Clean the Septum Seat in the Insert Assembly of the MMI
push down to connect. Slide the locking tab to the left.
Septum on the MMI” on page 130.
Septum on the MMI” on page 130.
Counter.

To Change the Liner and O-Ring on the MMI

• Replacement O-ring, see “Consumables and Parts for the Multimode Inlet” on
page 122.
• Tweezers
• Wrench, hex for changing septum (optional)
select Perform Maintenance > Replace Liner > Start Maintenance. The wizard will walk
through the steps needed to replace the liner and O-ring (those same steps are repeated
below).
4 Loosen the O-ring from the sealing surface with tweezers.

5 Grasp the liner with tweezers and pull it out.
6 Inspect the surface of the seal for contamination. If required, clean with cotton swabs.

Clean the inlet if there is visible or suspected contamination. See “To Clean the
Multimode Inlet” on page 139.
Clean O-ring residue from sealing surface.
C AU T I O N
7 Slide a new O-ring onto the replacement liner.

8 Install the liner to the inlet, pushing it all the way in until the liner contacts the seal.
push down to connect. Slide the locking tab to the back.
10 Turn on the inlet. Allow the inlet and column to purge with carrier gas for 15 minutes before
heating the inlet or the column oven.
11 Bakeout contaminants. See “To Bakeout Contaminants from the MMI” on page 141.

To Replace the Filter in the Split Vent Trap for the MMI

MMI
• New split vent filter cartridge, see “Consumables and Parts for the Multimode Inlet” on
page 122.
select Perform Maintenance > Replace Split Vent Trap > Start Maintenance. The wizard
will walk through the steps needed to replace the filter (those same steps are repeated
below).
3 Remove the “To Remove the Pneumatics Cover” on page 19 (top, back of GC).
Figure 30.
Figure 30. Loosen knurled nut

To Replace the Filter in the Split Vent Trap for the MMI
Filter and O-ring
Knurled nut


To Clean the Multimode Inlet

This procedure explains how to clean the Multi Mode Inlet (MMI). Depending on the inlet mode
used, the liner installed, and the cleanliness of the sample, the frequency of cleaning may
range from weekly to monthly. Start with a visual inspection of the inlet bottom whenever
changing the liner. A small ring of material will collect at the bottom of the inlet when injecting
dirty samples such as food extracts or solid waste. Try an initial cleaning schedule of every two
weeks for dirty samples and every two months for clean samples and adjust as needed.
• Cleaning kit, multimode inlet (G3510-60820). Contains 5 each abrasive swabs and
5 each cotton swabs.
• Solvent for cleaning (at least 25 mL of acetone, isopropanol, or hexane, whichever is
most appropriate for your sample matrix).
• 100 mL beaker or similar container to the catch solvent rinse.
3 Turn off the GC.
C AU T I O N
4 Remove the inlet liner. See “To Change the Liner and O-Ring on the MMI” on page 134.
5 Remove the column from the inlet. See “To Install a Capillary Column with the Multimode
6 Place the glass beaker or other container in the GC oven, below the MMI inlet, so it will
catch any solvent that drips through the inlet body.
7 Moisten a cotton swab with solvent and wipe the inside bottom seal of the inlet repeatedly
to remove any loose material from the MMI. If desired, the cotton swab can be used to
clean the bore of the inlet. For most samples, this is not necessary. Dispose of the swab
after a single use.
8 Using a dry abrasive swab, place the swab all the way to the bottom of the inlet and with
moderate pressure, twist the swab forwards and backwards while it is in contact with the
bottom of the MMI (approximately 20 cycles should be sufficient). The abrasive swab can
be used multiple times.

9 Using a second solvent moistened cotton swab, wipe the bottom of the inlet to remove any
residue. Depending on the amount of use and maximum temperature used, the bottom of
the inlet may still show some oxidation (light brown color). This is normal and will not
affect inlet performance. Repeat steps 3-5 (if necessary) to remove any remaining
deposits.
10 Using clean solvent, rinse the inlet volume several times but never overfill the inlet bore.
Position a container under the column opening in the inlet to catch the used solvent exiting
the bottom of the MMI.
11 Allow the inlet to dry.
12 Install the liner and O-ring.
13 Reinstall the column.
14 Turn on the GC.

To Bakeout Contaminants from the MMI

to 30 cm/s.
temperature.
temperature limit.


Consumables and Parts for the Programmable Temperature Vaporization Inlet 144
Exploded Parts View of the PTV Inlet 146
To Install a Capillary Column with the Programmable Temperature Vaporization Inlet 147
To Clean the Septumless Head on the PTV Inlet 150
To Replace the Septumless Head PTFE Ferrule on the PTV Inlet 152
To Change the Septum on the PTV Inlet 154
To Clean the Septum Seat in the Septum Head Assembly of the PTV Inlet 155
To Change the Liner on the PTV Inlet 156
To Replace the Inlet Adapter for the PTV Inlet 158
To Replace the Filter in the Split Vent Trap for the PTV Inlet 160
To Bakeout Contaminants from the PTV Inlet 162

Consumables and Parts for the Programmable Temperature Vaporization Inlet
Consumables and Parts for the Programmable

Temperature Vaporization Inlet
Table 24 PTV liners and ferrules
Single baffle, 2-mm id, 180-µL, deactivated, glass wool 5183-2038
Single baffle, 2-mm id, 200-µL, deactivated 5183-2036
Multi-baffle, 1.5-mm id, 150-µL, deactivated 5183-2037
Fritted glass, 1.5-mm id, 150-µL, deactivated 5183-2041
Graphpak 3D ferrules for liner 5182-9749 (5/pk)
Installation tool for 3D ferrules G2617-80540
Table 25 Other consumables and parts for the PTV inlet
Syringe, 5-µL, 23-gauge fixed-needle 9301-0892
Syringe, 10-µL, 23-gauge fixed-needle 9301-0713
Syringe, 50-µL, 23-gauge fixed-needle, for large volume injections 5183-0318
Syringe, 100-µL, 23-gauge fixed-needle, for large volume injections 5183-2058
Septumless head
Septumless head G2617-60507
PTFE ferrules (needle seal) 5182-9748 (10/pk)
Septumless head rebuild kit (includes Viton seal, Kalrez seal, and pressure spring) 5182-9747
Carrier gas tube for septumless head G2617-80550
Ferrule, 1/16-inch PTFE, for septumless head carrier gas tube 0100-1375
Septum head
Merlin Microseal septum (high-pressure) 5182-3444
11-mm septa, red 5181-1263 (50/pk)
Column adapter parts
Silver seal 5182-9763 (5/pk)
Graphpak 2M inlet adapter, 0.20-mm id* 5182-9754
Graphpak 2M inlet adapter, 0.25- to 0.33-mm id* 5182-9761

Consumables and Parts for the Programmable Temperature Vaporization Inlet
Table 25 Other consumables and parts for the PTV inlet (continued)
Graphpak 2M inlet adapter, 0.53-mm id* 5182-9762
Ferrules for Graphpak 2M inlet, 0.20-mm id 5182-9756 (10/pk)
Split nut for Graphpak adapter 5062-3525
* Includes (1) adapter, (1) silver seal, and (1) split column nut.

Exploded Parts View of the PTV Inlet
Exploded Parts View of the PTV Inlet
Guide cap
Merlin cap Septum nut
PTFE ferrule
Merlin Microseal
Septum
Septumless head Kalrez seal
assembly
Valve body
Pressure spring
Septum head
Viton seal
Carrier gas
tube Sealing element
Ferrule
Graphpak 3D ferrule
Liner
PTV inlet assembly
Silver seal
Graphpak inlet adapter
Ferrule for Graphpak adapter
Column nut
Figure 32. Programmable temperature vaporization inlet exploded parts

To Install a Capillary Column with the Programmable Temperature Vaporization Inlet
To Install a Capillary Column with the

Programmable Temperature Vaporization Inlet
1 Gather the following, see “Consumables and Parts for the Programmable Temperature
Vaporization Inlet” on page 144:
• Column
• Graphpak 2M ferrule
• Column nut
• Column cutter
• Septum
• Isopropanol
• Lab tissue
• Metric ruler
• 5-mm and 6-mm wrenches
• Typewriter correction fluid or a marker
3 Before installing the column, install the correct column adapter. See “To Replace the Inlet
Adapter for the PTV Inlet” on page 158.
C AU T I O N
5 Place a Graphpak 2M ferrule onto the column, with the graphite facing up towards the inlet.
break.

Inspect the end with a magnifying loupe to make certain that there are no burrs or jagged
edges.
Bad
Good
and dust.
9 Position the column so it extends 17 mm above the end of the ferrule. Mark the column
behind the ferrule with typewriter correction fluid or a marker. Slide the nut over the
column.
17 mm
Mark column here
10 Insert the column into the adapter and finger-tighten the column nut. Looking through the
slot in the nut, adjust the column until the mark is correctly positioned below the Graphpak
2M ferrule.
11 Tighten the column nut an additional 1/8 to 1/4 turn with a wrench. Do not overtighten.

Smart ID key

Capillary Column.
the fittings.

To Clean the Septumless Head on the PTV Inlet

• Syringe with 23-gauge needle, see “Consumables and Parts for the Programmable
Temperature Vaporization Inlet” on page 144.
• Septumless head rebuild kit
• Hexane
• Clean, lint-free gloves
3 Disconnect the carrier gas line.
4 Unscrew and remove the septumless head assembly from the inlet.
5 Unscrew the sealing element from the head assembly and carefully remove the Viton seal
and the pressure spring

Guide cap
PTFE ferrule
Ferrule, 1/16-inch
PTFE Kalrez seal
Valve body
Carrier gas tube Pressure spring
Viton seal
Sealing element
6 Unscrew the guide cap from the head and remove the PTFE ferrule.
7 Carefully insert a syringe with a 23-gauge needle into the head to press the valve body and
Kalrez seal slightly out of the head.
8 Gently tap the head on a soft, smooth surface so that the valve body falls out completely or
slips out far enough to grasp with fingers.
9 Remove the Kalrez seal from the valve body.
10 Clean all components in hexane.
C AU T I O N
11 Replace the PTFE ferrule. See “To Replace the Septumless Head PTFE Ferrule on the PTV
12 Wearing clean lint-free gloves, reassemble the head in reverse order. Be sure that the seals
and the pressure spring are not damaged.
13 Finger-tighten the septumless head, then tighten an additional 1/8 turn with a wrench.
14 Reconnect the carrier gas line.
15 Check for leaks; if necessary, slightly tighten the guide cap with the syringe needle inserted.
• If the head leaks with the syringe inserted, replace the PTFE ferrule.
• If the head leaks without the syringe inserted, replace the Kalrez and Viton seals.

To Replace the Septumless Head PTFE Ferrule on the PTV Inlet
To Replace the Septumless Head PTFE Ferrule on

the PTV Inlet
• Syringe with 23-gauge needle, see “Consumables and Parts for the Programmable
• Replacement PTFE ferrule
3 Unscrew the guide cap from the septumless head and remove the PTFE ferrule.
4 Push the guide cap and replacement ferrule over the syringe needle so that at least 10 mm
of the needle tip is exposed.
5 Guide the end of the needle into the septumless head until the ferrule meets the
septumless head.
6 Loosely install the guide cap.
7 If not configured, configure the column.
9 Put the inlet into Splitless mode.
10 Set the column flow to 5 mL/min and the purge flow to 60 mL/min.
11 After the inlet pressurizes, press once.

To Replace the Septumless Head PTFE Ferrule on the PTV Inlet
12 Observe the inlet Total Flow. Tighten the guide cap until the Total Flow stops decreasing
(typically near 8 mL/min).
13 Remove the syringe from the inlet and press .

To Change the Septum on the PTV Inlet
To Change the Septum on the PTV Inlet

• Replacement septum, see “Consumables and Parts for the Programmable
• 5/8-inch wrench
3 Remove the septum retainer nut or Merlin cap. If the septum head begins to turn during
removal, support it manually while removing the cap.
Merlin Microseal and cap Standard septum
6 Replace the septum retainer nut or Merlin cap and finger-tighten. Tighten the septum
retainer nut until the C-ring is about 1 mm above the nut.

C AU T I O N
1 mm

To Clean the Septum Seat in the Septum Head Assembly of the PTV Inlet
To Clean the Septum Seat in the Septum Head

Assembly of the PTV Inlet
• Replacement septum, see “Consumables and Parts for the Programmable
• 5/8-inch wrench
• Tweezers
C AU T I O N
3 Remove the septum retainer nut or Merlin cap. If the septum head begins to turn during
removal, support it manually while removing the cap.
4 Unscrew the septum head assembly from the inlet and move it up and away from the inlet.
8 Replace the septum head assembly on the inlet. Finger-tighten the septum head and then
tighten an additional 1/2 turn with a wrench.
Septum on the PTV Inlet” on page 154.
Septum on the PTV Inlet” on page 154.

To Change the Liner on the PTV Inlet

• Installation tool for 3D ferrules, see “Consumables and Parts for the Programmable
• Assembly tool (part number G2617-80540)
• Graphpak 3D ferrule
walk through the steps needed to replace the liner (those same steps are repeated below).
C AU T I O N
3 Remove the head from the inlet:

• For septumless head, disconnect the carrier gas line and unscrew and remove the
septumless head assembly from the inlet.
• For septum head, loosen the septum head assembly from the inlet. Lift the head to clear
the inlet and push to either side. Do not bend the 1/16-inch lines too much.
4 Grasp the liner by the Graphpak 3D ferrule. Remove the liner from the inlet.
5 Unscrew the assembly tool into two pieces: the ferrule guide and the compression fitting.

Ferrule guide
Graphpak 3D ferrule
Compression fitting
Open baffle liner
6 Slide the compression fitting onto the longer, straight end of the new liner with the threads
pointing toward the end of the liner.
7 Place a Graphpak 3D ferrule on the same end of the liner with the recessed graphite end
towards the compression fitting. Slide the ferrule so that about 2 mm of the liner is
exposed beyond the ferrule.
8 Slide the compression fitting up to meet the ferrule. Finger-tighten the ferrule guide onto
the compression fitting.
9 Unscrew and remove the ferrule guide.
10 Slide the compression fitting off the other end of the liner. The ferrule should now be set
with 1 mm of the liner exposed. Check that the graphite within the ferrule is flush with the
top of the metal collar.
11 Insert the glass liner into the inlet from above until the unpacked side of the ferrule rests on
the top of the inlet.
12 Replace the head:
• For septumless head, screw the head onto the inlet and tighten 1/8 turn past finger-tight
with a wrench. Reconnect the carrier gas line.
• For septum head, align the head with the inlet and manually engage the free-spinning
nut to the inlet. Tighten 1/2 turn past finger-tight with a wrench.
13 Check all connections for leaks. If necessary, tighten them again by hand.
14 Configure the new liner.

To Replace the Inlet Adapter for the PTV Inlet

1 Select from the following list an adapter with the smallest hole diameter that will accept
the column. The adapter number is stamped on the side of the adapter. Also see
“Consumables and Parts for the Programmable Temperature Vaporization Inlet” on
page 144.
Table 26 PTV inlet adapters
Column id Inlet adapter number* Part number
0.20 mm 31 5182-9754
0.25 to 0.33 mm 45 5182-9761
0.53 mm 70 5182-9762
* Includes (1) adapter, (1) silver seal, and (1) split column nut.

• Replacement adapter
• Replacement silver seal
• 6-mm wrench
• 5-mm wrench
C AU T I O N
4 Unscrew the column nut from the adapter. Remove the nut and the column from the inlet.

Silver seal
Graphpak inlet adapter
Column nut
Ferrule for Graphpak adapter
5 Remove the inlet adapter and discard the old silver seal.
6 Insert a new silver seal into the adapter and finger-tighten the adapter onto the inlet.
Tighten an additional 1/16 to 1/8 turn with a wrench; overtightening will damage the inlet.
7 Install the column. See “To Install a Capillary Column with the Programmable
8 Check the adapter for leaks.
9 Reset the silver seal EMF counter.

To Replace the Filter in the Split Vent Trap for the PTV Inlet

PTV Inlet
• New split vent filter cartridge, see “Consumables and Parts for the Programmable
2 Launch the GC maintenance wizard: Maintenance > Inlets, select the PTV inlet, then select
3 Remove the “To Remove the Pneumatics Cover” on page 19 (top, back of GC).
Figure 34.
Knurled nut loosened

Knurled nut secured

To Replace the Filter in the Split Vent Trap for the PTV Inlet
Filter and O-ring
Knurled nut


To Bakeout Contaminants from the PTV Inlet
To Bakeout Contaminants from the PTV Inlet

to 30 cm/s.
temperature.
temperature limit.

Consumables and Parts for the Volatiles Interface 164
Exploded Parts View of the VI 166
To Install a Capillary Column with the Volatiles Interface 167
To Remove the VI Interface 171
To Clean the VI 173
To Install the VI Interface 174
To Replace the Filter in the Split Vent Trap for the VI 175
To Bakeout Contaminants from the VI Inlet 177

Consumables and Parts for the Volatiles Interface

Table 27 Parts for the VI
Clamping plate G2319-20540
Volatiles interface G2319-60505
Long column nut (65 mm) G3504-20504
Nut, for transfer, pressure sensing, or split vent line 19258-20830
Ferrule, for transfer, pressure sensing, or split vent line 19258-20870

0.53-mm columns)
capillary columns

.100- to .320-mm columns)
columns
capillary columns

.100- to .320-mm columns)
columns
capillary columns
.320-mm columns)


Exploded Parts View of the VI
Exploded Parts View of the VI
Nut
Ferrule
Clamping plate
Volatiles interface
Ferrule, column
Column nut, long
Figure 36. Volatiles interface exploded parts

To Install a Capillary Column with the Volatiles Interface
To Install a Capillary Column with the Volatiles

Interface
• Long (65 mm) column nut
• Column
• Ferrule
• Column cutter
• Isopropanol
• Septum
• Lab tissue
• Metric ruler
C AU T I O N
4 Place a septum, long capillary column nut, and ferrule on the column.
Use a long column nut. See “Consumables and Parts for the Volatiles Interface” on
page 164.
If you are using a standard column nut, you must remove the interface. For this reason it
is recommended that you use the long column nut. See “To Remove the VI Interface” on
page 171.

Ferrule
Column nut
Septum
break.
Inspect the end with a magnifying loupe to make certain that there are no burrs or jagged
edges.
Bad
Good
and dust.
8 Position the column so it extends 6 mm above the end of the ferrule. Slide the septum up
the column to hold the column nut at this fixed position.
6 mm

9 Insert the column into the interface and finger-tighten the column nut.
10 Adjust the column (not the septum) position until the septum is snug against the bottom of
the nut.
Smart ID key

14 With the sample transfer line attached and the column attached to the inlet and detector,
establish a flow of carrier gas through the transfer line. Purge as recommended by the
column manufacturer.
Capillary Column.

the fittings.
22 Reset the EMF counter.

To Remove the VI Interface

• 1/4-inch and 7-mm wrench
Be careful! The interface may be hot enough to cause burns. If the interface is hot, wear
WAR N IN G gloves to protect your hands.

4 Remove the transfer line by loosening the nut, then lift it from the interface.
5 Loosen the five inlet cover screws and remove the inlet cover.
6 Remove the clamping plate from the interface by loosening the captive screw.
7 Lift the interface out of the heater block.


To Clean the VI
To Clean the VI
3 Remove the interface. See “To Remove the VI Interface” on page 171.
The split vent trap and line may contain residual amounts of any samples or other chemicals
WAR N IN G you have injected into the GC. Follow your company’s safety procedures for handling these
types of substances.
4 Remove the split vent and pressure sensing lines by loosening the nuts.
C AU T I O N
5 Clean the interface using an ultrasonic bath. Sonicate twice, then rinse and air dry.
6 Inspect the split vent line. If clogged, contact Agilent for service.
7 Install the interface. See “To Install the VI Interface” on page 174.

To Install the VI Interface
To Install the VI Interface

2 Attach the split vent line and pressure sensing lines and finger-tighten the nuts. Tighten an
additional
1/4 turn with a wrench.
3 Place the interface into the heater block and reseat the tubing as needed.
4 Install the clamping plate and tighten the screw.
5 Install the inlet cover. Be sure the cover does not damage any tubing.
6 Attach the sample transfer line.
7 Install the column. See “To Install a Capillary Column with the Volatiles Interface” on
page 167.

To Replace the Filter in the Split Vent Trap for the VI

• New split vent filter cartridge, see “Consumables and Parts for the Volatiles
Interface” on page 164.
3 Remove the pneumatics cover (top, back of GC). See “To Remove the Pneumatics
Cover” on page 19.
Figure 38.
filter as shown in. Figure 39.

Filter and O-ring
Knurled nut


To Bakeout Contaminants from the VI Inlet

to 30 cm/s.
temperature.
6 Set the inlet and oven temperature to 300 °C or 25 °C above the normal operating
temperature to bakeout contaminants from the inlet, mostly through the split vent.
temperature limit.


Consumables and Parts for the FID 180
Exploded Parts Views of the Flame Ionization Detector 182
To Install a Capillary Column in the FID 184
To Replace an FID Jet 187
To Perform Maintenance on the FID Collector Assembly 190
To Check the FID Leakage Current 197
To Check the FID Baseline 198
To Install the Optional FID PTFE Chimney Insert 199
To Bakeout the FID 200

Consumables and Parts for the FID


0.53-mm columns)
capillary columns
.320-mm columns)
columns
capillary columns
.320-mm columns)
columns
capillary columns
.320-mm columns)

Table 30 FID parts and subassemblies
Screw, M4 × 25 mm, Torx, T20 0515-2712 (3/pk)
PTFE chimney (optional) 19231-21050
Collector assembly G4591-60691
Jet, FID, 0.011-inch id G4591-20320
Table 31 FID collector assembly parts
Screw, M4 × 25 mm, Torx, T20 0515-2712 (3/pk)
Collector assembly G4591-60691
Collector nut 19231-20940
Spring washer 3050-1246
Ignitor castle 19231-20910
Ignitor castle, Hastelloy 19231-21060
Upper/lower collector insulator G1531-20700
Collector body G1531-20690
Collector body, Hastelloy G1531-21090
Spanner nut, base 19231-20990
Collector mount G4591-20690
Collector housing 19231-21010
Gasket 5180-4165 (12/pk)
Ignitor (glow plug) assembly with O-ring 19231-60680

Exploded Parts Views of the Flame Ionization Detector
Exploded Parts Views of the Flame Ionization

Detector
PTFE chimney
25-mm screws
Collector assembly
Gasket
Jet
Spring, FID interconnect
Mounting pallet
Ferrule
Column adapter
Ferrule
Column nut
Figure 40. Flame ionization detector (FID) assembly exploded parts

Exploded Parts Views of the Flame Ionization Detector
25-mm screws
Collector assembly
Gasket
Jet
Figure 41. FID exploded parts view
Collector nut
Spring washer
25-mm
screws Ignitor castle Ignitor (glow plug)
assembly with
Collector Upper collector O-ring
assembly insulator
Collector body
Spanner nut
Ignitor cable
(collector)
assembly
Collector mount
Lower collector
insulator
Collector
housing
Gasket
Figure 42. FID collector assembly exploded parts view

To Install a Capillary Column in the FID

1 Gather the following materials, see “Consumables and Parts for the FID” on page 180:
• Column
• Ferrule(s)
• Column nut
• Column cutter
• Septum
• Isopropanol
• Lab tissue
C AU T I O N
3 Place a septum (if the column id is ≤0.1 mm), capillary column nut, and ferrule on the
column.
Ferrule
Column nut
Septum
break.

edges.
Bad
Good
and dust.
7 Install the capillary column.
If the column id is greater than 0.1 mm:
a Gently insert the column into the detector until it bottoms; do not attempt to force it
further.
b Finger-tighten the column nut, then withdraw the column about 2 mm. Tighten the nut
an additional 1/4 turn with a wrench.

If the column id is 0.1 mm or less position the column so it extends above the ferrule by
48 mm. Slide the septum up to hold the column nut and ferrule at this fixed position.
48 mm
c Insert the column into the detector. Slide the nut and ferrule up the column to the
detector base. Finger-tighten the column nut until it grips the column.
d Adjust the column (not the septum) position so that the septum is even with the
bottom of the column nut. Tighten the nut an additional 1/4 turn with a wrench.

To Replace an FID Jet

• Replacement jet
• 1/4-inch nut driver
• Tweezers
• Solvent that will clean the type of deposits in your detector
• Clean cloth
• Cotton swab
2 Launch the GC maintenance wizard: Maintenance > Detectors, select the detector, then
select Perform Maintenance > Replace FID Jet > Start Maintenance. The wizard will walk
through the steps needed to replace the jet (those same steps are repeated below).
3 If installed, remove the capillary column from the detector.
C AU T I O N
4 Remove the FID castle assembly and place it on a clean cloth.

5 Locate the jet inside the housing.

Handle the clean or new jet only with tweezers, or wear gloves.
C AU T I O N
6 Loosen the jet, then lift it out of the housing with tweezers.
Interconnector
spring
7 Clean the detector base cavity using solvent, a swab, and compressed air or nitrogen.
8 Use tweezers to lower the new jet into the housing.
Do not overtighten the jet! Overtightening may permanently deform and damage the jet, the
C AU T I O N detector base, or both. The torque specification is 10 inch-pounds.
9 Carefully screw the jet into the housing. Tighten 1/6-turn past finger-tight (1/6-turn is one
“flat” on a typical screwdriver handle, or the jet head).

10 Install the castle assembly.

13 Attach the capillary column to the detector.
a Install the column in the detector. See “To Install a Capillary Column in the FID” on
page 184.
b After the column is installed at both inlet and detector, establish a flow of carrier gas
and purge as recommended by the column manufacturer.
c Check the FID leakage current. See “To Check the FID Leakage Current” on page 197.
d Bakeout the detector. See “To Bakeout the FID” on page 200.
e Restore the analytical method.
f Allow the oven, inlet, and detector to equilibrate at operating temperature, then
retighten the fittings.
14 Check the FID baseline. See “To Check the FID Baseline” on page 198.

To Perform Maintenance on the FID Collector Assembly
To Perform Maintenance on the FID Collector

Assembly
Perform only the steps and gather only the parts that apply to the desired maintenance
NOTE task(s).

• Replacement ignitor assembly, see “Consumables and Parts for the FID” on page 180.
• Replacement ignitor castle
• Two collector insulators
• Collector
• Spring washer
• Gasket
• 1/4-inch nut driver
• Tweezers
• Clean cloth
To avoid contaminating the FID, wear clean, lint-free gloves when handling the collector
C AU T I O N assembly.
3 Remove the FID ignitor. If you are not replacing the ignitor, skip to step 5.
a Disconnect the ignitor cable assembly.
b Loosen the ignitor with a wrench.

c Turn the nut counterclockwise by hand. Remove the ignitor and copper washer.
4 If replacing only the FID ignitor assembly with copper washer, skip to step 16 for assembly.
5 Remove the three screws that secure the collector assembly to the FID mounting pallet.
This step exposes the interconnect spring. Be careful not to touch or disfigure the spring
C AU T I O N while working on the FID. Any dirt or bending will reduce the sensitivity of your detector.
6 Remove the collector assembly. Place it on a clean cloth for additional disassembly.

7 Remove the gasket from the bottom of the assembly, if necessary.

8 Remove the FID ignitor castle.
a Loosen the collector nut.
b Remove the collector nut and the spring washer.
c Lift the castle out of the collector housing. When removing the castle, some of the
collector parts may be attached. Set these on a clean cloth to protect from scratches
or dirt.
9 If only replacing the FID castle, skip to step 15 for reassembly.

10 Remove the collector and insulators.
a If needed, remove the collector and upper insulator from the FID housing. The lower
insulator may come out with the collector, but often remains in the FID housing. Place
the parts on a clean cloth.

b Remove the lower insulator with tweezers and place the parts on a clean cloth.
11 Remove the collector housing from the mount, if necessary.

12 Use tweezers to remove the gasket from the bottom of the housing.
The collector assembly is now completely disassembled. Reassemble as follows:
13 Use tweezers to install a new gasket onto the housing, being sure that it lays flat on the
brass surface.

14 Install the collector insulators.

a Insert one of the insulators into the base of the housing. Seat the insulator with the flat
surface facing out of the housing.
b Insert the long end of collector into the housing and lower insulator.
c Insert the other insulator onto the top of the collector, with the flat surface facing
towards the housing.
15 Install the FID ignitor castle.

a Orient the castle so that the threaded hole for the ignitor faces toward the electronics.

b Insert the FID castle into the collector housing.

c Install the spring washer over the castle.
d Install the collector nut over the castle and tighten firmly. The seal should be airtight.
Maintain the orientation of the ignitor hole with the base as shown below.
16 Install the FID ignitor.

a Insert the ignitor and copper seal into the threaded hole of the castle. Keep the mating
threads clean.
b Tighten the ignitor with a wrench. Ignition requires a good electrical contact that is
free of any dirt.

17 Lower the collector assembly into the housing.

18 Insert the three screws and tighten (to 18-inch-pounds).
19 Connect the ignitor extension cable.

21 Verify assembly:
a Check the FID leakage current. See “To Check the FID Leakage Current” on page 197.
b Bakeout the detector. See “To Bakeout the FID” on page 200.
c Check the FID baseline. See “To Check the FID Baseline” on page 198.
22 Reset the EMF counters.

To Check the FID Leakage Current
To Check the FID Leakage Current

1 Load the analytical method.
• Make sure flows are acceptable for ignition.
• Heat the detector to operating temperature or 300 °C.
2 Perform a Leakage Current Test from the touchscreen: Diagnostics > Diagnostics Tests >
Detectors, select FID# Leakage Current Tests. Read the Test Details screen then press
Start Test.
3 Turn off the FID flame.
4 Show the detector output signal in Status. On the GC touchscreen go to Home > Status
listing > +Add. Select Detector’s Output from the drop-down list, then touch Add.
5 Verify that the output is stable and < 1.0 pA.
If the output is unstable or > 1.0 pA, turn off the GC and check for proper assembly of the
upper FID parts and contamination. If this contamination is confined to the detector,
bakeout the FID. See “To Bakeout the FID” on page 200.
6 Turn on the flame.

To Check the FID Baseline
To Check the FID Baseline

1 With the column installed, load your checkout method.
2 Set the oven temperature to 35 °C.
3 Show the detector output signal in Status. On the GC touchscreen go to Home > Status
listing > +Add. Select Detector’s Output from the drop-down list, then touch Add.
4 When the flame is lit and the GC is ready, verify that the output is stable and < 20 pA.
If the output is not stable or > 20 pA, the system or gas may be contaminated. If this
contamination is isolated to the detector, then bakeout the FID. See “To Bakeout the
FID” on page 200.

To Install the Optional FID PTFE Chimney Insert
To Install the Optional FID PTFE Chimney Insert

Be careful! The detector may be hot enough to cause burns. If the detector is hot, wear
1 Light the FID flame.

2 Insert the PTFE chimney into the FID castle.
When installed, the PTFE chimney insert prevents ignition.

NOTE

To Bakeout the FID
To Bakeout the FID

1 Bakeout the FID with the column installed or uninstalled. If uninstalled, gather the following,
see “Consumables and Parts for the FID” on page 180:
• Capillary adapter (adaptable FID only)
• Column nut
• No-hole ferrule
2 If the column is uninstalled:

a Cool the GC oven and detector
b Plug the detector connection with the capillary adapter, column nut, and no-hole
ferrule
If using hydrogen as a carrier gas, turn off the hydrogen supply and cap the end of the column
WAR N IN G to prevent an oven explosion.
3 Maintain inert carrier gas flow through the column, or remove the column from the GC.
4 Set the detector temperature at 350 to 375 °C.
5 Set normal operating flows.
6 Light the FID flame.
7 Set the oven temperature to 250 °C or 25 °C above the normal maximum operating
temperature. Do not exceed the column’s temperature limit.
8 Hold at temperature for 30 minutes or until the baseline settles at a lower value. The
baseline will typically rise, then fall to a final value lower than the initial baseline.
9 Restore the analytical method and allow the FID to equilibrate.

10 Check the FID output value. It should be lower than the first reading. If it is not, contact your
Agilent service representative.
Without a column installed, a clean system baseline should be < 20 pA.
11 If the column is not installed in the FID, install it. See “To Install a Capillary Column in the
FID” on page 184.

Consumables and Parts for the Thermal Conductivity Detector 202
To Install a Capillary Column in the TCD 204
To Bakeout Contaminants from the TCD 207

Consumables and Parts for the Thermal Conductivity Detector
Consumables and Parts for the Thermal

Conductivity Detector
Standard TCD column hardware


0.53-mm columns)
capillary columns
.320-mm columns)
columns
capillary columns
.320-mm columns)
columns
capillary columns
.320-mm columns)

Standard TCD column hardware
Table 33 Packed column adapters

To Install a Capillary Column in the TCD

1 Gather the following materials, see “Consumables and Parts for the Thermal Conductivity
Detector” on page 202:
• Column
• Ferrule(s)
• Column nut
• Column cutter
• Septum
• Isopropanol
• Lab tissue
C AU T I O N
column.
Ferrule
Column nut
Septum
break.

edges.
Bad
Good
and dust.
further.

48 mm (capillary optimized fitting). Slide the septum up to hold the column nut and ferrule at this
fixed position.
48 mm

To Bakeout Contaminants from the TCD

The bakeout can be performed with the column installed or the detector capped.
If the column is not installed, you must turn off the TCD filament and cap the detector column
C AU T I O N fitting to prevent irreparable damage to the filament caused by oxygen entering the detector.
1 If the column is not installed, cap the detector.
2 Turn off the TCD filament.

3 If the column is attached to the inlet, maintain inert carrier gas flow through the column.
4 Set the reference gas flow rate between 20 and 30 mL/min.

5 Set the detector temperature to 375 °C.
6 Hold at 375 °C for several hours.
7 If the column is uninstalled, install it. See “To Install a Capillary Column in the TCD” on
page 204.
Be careful! The oven or detector fittings may be hot enough to cause burns.
WAR N IN G
9 Allow the oven, inlet, and detector to equilibrate at operating temperature, then re-tighten
the fittings.


Consumables and Parts for the NPD 210
Exploded Parts View of the Nitrogen-Phosphorus Detector 212
To Install a Capillary Column in the NPD 213
To Replace the NPD Bead Assembly 216
To Maintain the NPD Collector, Ceramic Insulators, and Jet 220
To Check the NPD Leakage Current 225
To Bakeout the NPD 226

Consumables and Parts for the NPD

Table 34 NPD parts
Collector G1534-20530
Screw, M3 × 0.5 × 8 mm 0515-0655
NPD Blos bead assembly G3434-60806
Screw, M4 × 10 mm 0515-2495
J-clamp 1400-0015
NPD ceramic insulator kit 5182-9722

• Metal C-rings, top and bottom
• Ceramic insulators, upper and lower
NPD chemical sample kit solution of 0.65 ppm azobenzene, 1000 ppm octadecane, 18789-60060
1 ppm malathion in isooctane, 3 ampoules
NPD lid standoff G1534-20590
NPD raised jet weldment G4594-81000
Nut, 1/8-inch, brass, for packed column adapters 5180-4103 (10/pk)
Ferrule, Vespel/graphite, 1/8-inch, for packed column adapters 0100-1332 (10/pk)
Ferrule, Vespel, 1/4-inch, for packed column adapters 5080-8774 (10/pk)

0.53-mm columns)
capillary columns
.320-mm columns)

columns
capillary columns
.320-mm columns)
columns
capillary columns
.320-mm columns)

Exploded Parts View of the Nitrogen-Phosphorus Detector
Exploded Parts View of the Nitrogen-Phosphorus

Detector
NPD cover
Screws
Bead assembly
Screws
Lid
Metal C-ring, top
Ceramic insulator, upper
Collector
Metal C-ring, bottom

Ceramic insulator, lower
Jet Electrometer
Insulation cover
Column nut
Figure 43. Nitrogen-Phosphorus Detector (NPD) exploded parts

To Install a Capillary Column in the NPD

1 Gather the following materials:
• Column
• Ferrule(s), see “Consumables and Parts for the NPD” on page 210.
• Column nut
• Column cutter
• Septum
• Isopropanol
• Lab tissue
C AU T I O N
column.
Ferrule
Column nut
Septum
break.

edges.
Bad
Good
and dust.
further.

48 mm (capillary optimized fitting). Slide the septum up to hold the column nut and ferrule at this
fixed position.
48 mm

To Replace the NPD Bead Assembly

• Replacement NPD bead assembly, see “Consumables and Parts for the NPD” on
page 210.
2 Set GC options for a new bead.
a On the GC touchscreen, go to Settings > Configuration > Detectors to enable Dry Bead
and Auto Adjust.
b Then go to Methods > Detectors, scroll to Detectors Specifics, turn off the bead.
Agilent data system users: Make the same changes noted above, apply them to the GC,
and then save the data system method and shut down the instrument session.
Maintenance Mode > Start Maintenance. Wait for the GC to become ready to continue (all
zones cooled to safe handling temperatures).
The bead is delicate. Be careful not to break or crack the bead. When performing
C AU T I O N maintenance on the NPD, avoid touching the bead with your fingers, and prevent it from
coming in contact with other surfaces.
4 Turn off the NPD bead, and enable the Dry Bead and Auto Adjust settings.
Agilent data system users: After turning off the bead, save the data system method and
shut down the instrument session. (Note that in some data system versions, you may
need to use the GC touchscreen for these settings. To do this, the keypad must be
unlocked and you must close the GC parameters screen of the data system. Upload the
revised setting, then save the method and shut down the instrument session.)
5 Remove the GC detector top cover. See “To Remove the Detector Top Cover” on page 18.
Hazardous voltages are present when the electronics top cover is open.
WAR N IN G
6 Remove the electronics cover. See “To Remove the Electronics Cover” on page 20.
7 Put on lint-free gloves before touching any of the detector parts.
WAR N IN G
C AU T I O N
8 Remove the screw from the NPD cover then lift up and set aside. See Figure 44.

Figure 44. Remove NPD cover
9 Twist the ring to disconnect the bead assembly cable. Push and twist the lock so that the
button slides up in the groove, then pull the cable ends apart.

10 Remove the 3 T-10 Torx screws from the bead assembly.
11 Gently lift up and remove the old bead assembly. Avoid bumping the bead on the sides of
the collector.
12 Remove the protective cap covering the new bead.

13 Mount the new bead assembly on the NPD lid. Be careful not to bump the bead on the
sides of the lid or collector.
14 Replace the screws. Finger-tighten the first screw; tighten the remaining screws normally
and then completely tighten the first screw. Do not overtighten the screws.
15 Carefully bend the bead assembly so it will mate with the bead power cable.
16 Reconnect the bead assembly cable to the NPD cable and twist the ring to lock the
connection.

17 Close the NPD cover, install the GC detector top cover, and install the electronics top cover.
All covers must be closed to get a stable NPD baseline.
19 Restore normal NPD operating gas flows.
20 With all gases on, heat the detector to 150 °C and hold for about 15 minutes, then increase
the temperature to 250 °C and hold for 15 minutes.
21 Increase the temperature to operating value (310 to 320 °C recommended). Allow
15 minutes for equilibration.
22 Check the NPD leakage current. See “To Check the NPD Leakage Current” on page 225. If
> 2.0 pA, verify bead installation or see the Troubleshooting manual.
23 If using an Agilent data system, connect to the instrument.
24 Restore the analytical method. Confirm the detector hydrogen, air, makeup gas flow rates.
25 Start the Adjust offset process. Enter the desired offset in the Target offset field. The
default offset is 20 pA for Blos beads. An offset of 25 to 30 pA is sufficient for most
applications. The bead life may be shortened at a higher offset.
26 Reset the bead counter.

To Maintain the NPD Collector, Ceramic Insulators, and Jet
To Maintain the NPD Collector, Ceramic Insulators,

and Jet
When replacing the jet, always install a new collector, ceramic insulators, and metal C-rings.
When replacing the collector, Agilent recommends replacing the ceramic insulators and metal
C-rings.
The insulation around the inlets, detectors, valve box, and the insulation cups is made of
WAR N IN G refractory ceramic fibers. To avoid inhaling fiber particles, we recommend the following
safety procedures: ventilate your work area; wear long sleeves, gloves, safety glasses, and a
disposable dust/mist respirator; dispose of insulation in a sealed plastic bag; wash your
hands with mild soap and cold water after handling the insulation.

• NPD ceramic insulator kit, see “Consumables and Parts for the NPD” on page 210.
• Collector
• Cap for the bead
• T-10 and T-20 Torx screwdrivers
• Tweezers
• Cotton swab
• Solvent
• Methanol
• Jet
• Compressed, filtered dry air or nitrogen
The bead is delicate. Be careful not to break or crack the bead. When performing
C AU T I O N maintenance on the NPD, avoid touching the bead with your fingers, and prevent it from
coming in contact with other surfaces.
2 Turn off the bead and disable Adjust Offset.

3 Check and note the NPD leakage current for reference. See “To Check the NPD Leakage
Current” on page 225.
WAR N IN G
5 Remove the bead. See “To Replace the NPD Bead Assembly” on page 216.

This step exposes the interconnect spring. Be careful not to touch or disfigure the spring
C AU T I O N while working on the FID. Any dirt or bending will reduce the sensitivity of your detector.
C AU T I O N
6 Remove the screws that secure the lid, then lift up the lid and set aside. The top metal
C-ring and upper ceramic insulator may be attached to the lid.
7 Remove the screws that secure the cover base, then lift up the cover base and set aside.

8 Remove the screws that secure the interconnect cover, then lift up the cover and set aside.
9 Remove the screws that secure the electrometer, then lift up and set aside.
10 Pull the electrometer away from the detector to free the interconnect. Turn the
electrometer to the right to obtain working space. Be careful not to touch or bend the
spring. Be careful not to lose the EMI suppressor.
11 Remove the large metal C-ring and the upper ceramic insulator if they were not attached to
the lid.
12 Remove the collector. If the detector is operated at high temperatures, the collector parts
may stick inside the detector. Gently push and wiggle them to break the seal.

Metal C-ring, top
Ceramic insulator, upper
Collector
Figure 45. NPD collector, upper insulator, and metal C-ring
13 Use tweezers to remove the lower ceramic insulator and the two small metal C-rings
located above and below the collector. If these parts are stuck together, do not separate
them. If they are not stuck, remember which metal ring was on top of the insulator and
which was below it. The pieces must be reassembled in the same orientation.
Ceramic insulator, lower
Figure 46. NPD lower ceramic insulator and metal C-ring
14 If not replacing the jet, skip to step 21.

15 Remove the column from the detector.
16 Loosen the jet with a nut driver.

17 Pull the jet straight out of the detector. Use tweezers, if necessary.
The adaptable NPD jet is longer than the capillary optimized NPD extended jet and should
C AU T I O N never be installed in a capillary optimized detector.
18 Place the jet in the detector body.

19 Using a nut driver, tighten the jet 1/6 turn past finger-tight. Do not overtighten.
20 Attach the column to the detector.
21 Use a cotton swab wetted with solvent to clean the residue from the inside of the collector
and around the jet. If the collector appears very dirty, replace it with a new one.
22 Install the bottom metal C-ring, the lower ceramic insulator, and the top metal C-ring. See
Figure 46.
23 Install the collector.
24 Install the upper ceramic insulator and top metal C-ring above the collector. See Figure 45.
25 Install the lid, making sure that the NPD lid standoffs are in their slots. Hold the lid flat while
each of the screws is tightened until they touch the lid. Tighten each screw evenly, 1/2 turn
at a time, until tight. Do not overtighten.
26 Slide the electrometer interconnect into the slot on the lid and lower the electrometer into
the mounting tray. Be careful not to touch or bend the spring.
27 Install the J-clamp and screws to secure the electrometer to the pallet.
29 Install the bead assembly and restore normal operating conditions. See “To Replace the
NPD Bead Assembly” on page 216. Do not reset the bead counter unless replaced.
After installing new collector parts, the NPD leakage current should be lower. See “To
Check the NPD Leakage Current” on page 225. If the leakage current is abnormal, check
for proper reassembly of the detector (especially where the electrometer interconnect
contacts the collector assembly) and for leaks.
30 Reset the EMF counters.

To Check the NPD Leakage Current
To Check the NPD Leakage Current

2 Turn Off the Bead.
• Leave the NPD at operating temperature
• Leave flows on or off
3 Show the detector output signal in Status.
4 Verify that the output (leakage current) is stable and < 2.0 pA.
The output should slowly drop towards 0.0 pA, and should stabilize in the tenths of a
picoamp. Current > 2.0 pA indicates a problem.

To Bakeout the NPD
To Bakeout the NPD

1 Bakeout the NPD with the column installed or uninstalled. If uninstalled, gather the
following, see “Consumables and Parts for the NPD” on page 210:
• Column nut
• No-hole ferrule
3 Turn off the bead.

4 If the column is uninstalled, plug the detector connection with the column nut, and no-hole
ferrule.
Maintain inert carrier gas flow through the column, or remove the column from the GC.
5 Set normal operating flows.
6 Set the detector temperature at 25 °C above the typical method set-point temperature.
7 Set the oven temperature to 250 °C or 25 °C above the normal maximum operating
temperature. Do not exceed the column’s temperature limit.
8 Hold at temperature for 15 to 30 minutes.
9 If the column is not installed in the NPD, install it. See “To Install a Capillary Column in the
NPD” on page 213.
10 Restore the analytical method and allow the NPD to equilibrate at operating temperatures
and flows for 10 to 30 minutes.
11 Check the NPD leakage current. See “To Check the NPD Leakage Current” on page 225.
12 Start the NPD bead Auto Adjust process.
Allow 1 to 2 hours for a new Blos bead to equilibrate.

Important Safety Information About the ECD 228
Consumables and Parts for the ECD 230
Exploded Parts View of the Electron Capture Detector 232
To Replace the ECD Fused Silica Indented Mixing Liner and Install the Makeup Gas
Adapter 233
To Install a Capillary Column in the ECD 236
To Bakeout the ECD 238
This section describes the routine maintenance tasks for the Electron Capture Detector (ECD).
For important regulatory and safety information for this detector, refer to the general
information booklet and CD provided with the detector.

Important Safety Information About the ECD

The ECD contains a cell plated with 63Ni, a radioactive isotope. The beta particles released at
the energy level in the detector have little penetrating power—the surface layer of the skin or a
few sheets of paper will stop most of them—but they may be hazardous if the isotope is
ingested or inhaled. For this reason, handle the cell with care. Cap the detector inlet and outlet
fittings when the detector is not in use. Never introduce corrosive chemicals into the detector.
Vent detector exhaust outside the laboratory environment.
Refer to the safety documentation provided with the detector for important details about
safety, maintenance, and compliance with local government regulation.
Materials that may react with the 63Ni source, either to form volatile products or to cause
WAR N IN G physical degradation of the plated film, must be avoided. These materials include oxidizing
compounds, acids, wet halogens, wet nitric acid, ammonium hydroxide, hydrogen sulfide,
PCBs, and carbon monoxide. This list is not exhaustive but indicates the kinds of compounds
that may cause damage to 63Ni detectors.
In the extremely unlikely event that both the oven and the detector-heated zone should go
WAR N IN G into thermal runaway (maximum, uncontrolled heating in excess of 400 °C) at the same time
and the detector remains exposed to this condition for more than 12 hours, take the following
steps:
• After turning off the main power and allowing the instrument to cool, cap the detector
inlet and exhaust vent openings. Wear disposable plastic gloves and observe normal
laboratory safety precautions.
• Return the cell for disposal, following directions included with the License Verification
Form (part number 19233-90750).
• Include a letter stating the condition of abuse.
It is unlikely, even in this very unusual situation, that radioactive material will escape the cell.
However, permanent damage to the 63Ni plating within the cell is possible; therefore, the cell
must be returned for exchange.
Do not use solvents to clean the ECD.

WAR N IN G
You may not open the ECD cell unless authorized to do so by your local nuclear regulatory
WAR N IN G agency. Do not disturb the four socket-head bolts. These hold the cell halves together. United
States customers removing or disturbing them is a violation of the terms of the exemption
and could create a safety hazard.

When handling ECDs:

• Never eat, drink, or smoke.
• Always wear safety glasses when working with or near open ECDs.
• Wear protective clothing such as laboratory jackets, safety glasses, and gloves, and follow
good laboratory practices. Wash hands thoroughly with a mild nonabrasive cleaner after
handling ECDs.
• Cap the inlet and outlet fittings when the ECD is not in use.
• Connect the ECD exhaust vent to a fume hood or vent it to the outside. See the latest
revision of 10 CFR Part 20 (including Appendix B), or the applicable state regulation. For
other countries, consult with the appropriate agency for equivalent requirements.
Agilent Technologies recommends a vent line internal diameter of 6 mm (1/4-inch) or
greater. With a line of this diameter, the length is not critical.

Consumables and Parts for the ECD

Table 36 ECD consumables and parts
Fused silica indented mixing liner G2397-20540
Makeup gas adapter G3433-63000
ECD wipe test kit 18713-60050
Insulation 19234-60715 (1/pk)
Nut, 1/4-inch Swagelok adapter 5180-4105 (10/pk)
Ferrule, graphitized Vespel, 1/4-inch 5080-8774 (10/pk)
Capillary column blanking nut 5020-8294
1/4-inch Detector adapter, for 1/8-inch packed columns 19301-80530

0.53-mm columns)
capillary columns
.320-mm columns)
columns
capillary columns
.320-mm columns)
columns
capillary columns

.320-mm columns)

Exploded Parts View of the Electron Capture Detector
Exploded Parts View of the Electron Capture

Detector
Perforated cover
Warning tag
Electrometer
Ferrules
Adapter nut
Cap
Liner
Makeup gas line
Makeup gas adapter
Column nut
Figure 47. Electron Capture Detector (ECD) exploded parts

To Replace the ECD Fused Silica Indented Mixing Liner and Install the Makeup Gas Adapter
To Replace the ECD Fused Silica Indented Mixing

Liner and Install the Makeup Gas Adapter
• Fused silica indented mixing liner, see “Consumables and Parts for the ECD” on
page 230.
• 1/4-inch Swagelok nut
• 1/4-inch Vespel/graphite ferrule
• Methanol
3 Remove the column from the makeup gas adapter.
To prevent damage avoid flexing/bending the tubing on the makeup gas adapter.
C AU T I O N
4 Remove the makeup gas adapter.

a Loosen the adapter nut with a wrench and slide out the makeup gas adapter from the
ECD. Remove the ferrule.
The makeup gas adapter will remain attached to the supply tubing and hang
suspended in the oven.
b Adjust the adapter’s position so that maintenance can be performed on the adapter
easily and without obstruction.

5 Unscrew and remove the adapter cap.
C AU T I O N
6 Remove the fused silica indented mixing liner and inspect. Replace it if it is broken or
contaminated with sample or graphite.
7 Ultrasonically clean the adapter cap in methanol. Clean the outer surfaces of the makeup
gas adapter with methanol.
8 Install the fused silica indented mixing liner into the makeup gas adapter, then install the
cap. The indentation on the fused silica indented mixing liner must be at the cap end of the
adapter.
Indentation
Cap
Fused silica indented

mixing liner
Capillary column
makeup gas
adapter
9 Place a new 1/4-inch Swagelok nut and ferrule onto the makeup gas adapter.
Ferrule
1/4-inch nut

10 Slowly install the adapter straight into the detector fitting. Jiggle the adapter, if necessary,
to make sure it is seated all the way into the detector fitting. Be careful not to break the
column end.
Detector fitting
11 Tighten the nut finger-tight and then use a 9/16-inch wrench to tighten until snug.
If the adapter is properly installed, the distance between the 1/4-inch nut and the bottom
of the adapter will be 19 ± 1 mm. If the distance is 22 to 23 mm, install the adapter into
the detector fitting.
19 ± 1 mm
12 Attach the column. See “To Install a Capillary Column in the ECD” on page 236.

To Install a Capillary Column in the ECD

• Ferrule, see “Consumables and Parts for the ECD” on page 230.
• Column nut
• Septum
• Column
• 1/4-inch, 5/16-inch, and 9/16-inch wrenches
• Column cutter
3 Load the inlet maintenance method and wait for the GC to become ready.
C AU T I O N
column.
Ferrule
Column nut
Septum
break.

edges.
Bad
Good
and dust.
8 Install the column.
If the column id is 200 um or more, push the column into the adapter until it stops at the
indentation. Pull it back 1 to 2 mm and tighten the column nut with one 5/16-inch wrench
on the adapter and another 1/4-inch wrench on the column nut.
If the id is less the 200 um, mark the column with a septum 70 ± 1 mm from the end.
Insert column and nut into the adapter with the septum at the rear of the column nut, and
tighten the column nut with one 5/16-inch wrench on the adapter and another 1/4-inch
wrench on the column nut.
70 ± 1 mm
Septum
9 After heating the detector, retighten the 9/16-inch makeup adapter nut and 1/4-inch
column nut.

To Bakeout the ECD
To Bakeout the ECD

Detector disassembly and/or cleaning procedures other than thermal should be performed
WAR N IN G only by personnel trained and licensed appropriately to handle radioactive materials. Trace
amounts of radioactive 63Ni may be removed during other procedures, causing possible
hazardous exposure to b- and x-radiation.
To prevent possible hazardous contamination of the area with radioactive material, the
C AU T I O N detector exhaust vent always must be connected to a fume hood or otherwise vented in
compliance with the latest revision of 10 CFR Part 20, or with state regulations with which the
Nuclear Regulatory Commission has entered into an agreement (USA only). For other
countries, consult with the appropriate agency for equivalent requirements.

• Column nut and no-hole ferrule, see “Consumables and Parts for the ECD” on page 230.
• Blanking nut with any column ferrule
3 With the detector oven at normal operating temperatures, show the detector output signal
in Status. Note the value of the Output for later comparison.
a On the GC touchscreen go to Home > Status listing > +Add.
b Select Detector 1 Output (or Detector 2 Output) from the drop-down list.
c Touch Add.
4 If the column maximum temperature is < 250 °C, remove the column from the detector.
5 If the column is uninstalled, plug the detector connection with the column nut and no-hole
ferrule.
Maintain inert carrier gas flow through the column, or remove the column from the GC.
6 Set the ECD temperature to 350 to 375 °C, the makeup gas flow to 60 mL/min, and the
oven temperature to 250 °C. If the column is uninstalled, leave the oven off to protect the
column.
7 If the column is installed in the ECD, set the oven temperature to 250 °C. If the column is
uninstalled, leave the oven off to protect the column.

To Bakeout the ECD
8 Allow thermal cleaning to continue for several hours and then cool the system to normal
operating temperatures. The figure below shows detector output during a typical cleaning
cycle.
9 Check the ECD output value on the control table. It should be lower than the first reading. If
it is not, contact your Agilent service representative.
10 Reinstall the column.

To Bakeout the ECD

Consumables and Parts for the FPD+ 242
Exploded Parts View of the Flame Photometric Detector Plus 244
To Install a Capillary Column to the FPD+ 245
To Change the FPD+ Wavelength Filter 247
To Remove the FPD+ Cover 250
To Replace the FPD+ Ignitor 251
To Install the FPD+ Cover 253
Cleaning the FPD+ Brazement 254

Consumables and Parts for the FPD+

See the Agilent catalog for consumables and supplies for a more complete listing, or visit the Agilent
Web site for the latest information (www.agilent.com/chem/supplies).
Table 38 FPD supplies
Sulfur filter 1000-1437
Sulfur filter spacer 19256-20910
Phosphorus filter 19256-80010
Exit tube assembly G3435-60330
O-ring for exit tube assembly 0905-1014
Ignitor 19256-60750
Screw, M3 × 6 mm, T-10 0515-0680
Collet 19256-20690
Column measuring tool G3435-81380
Spring to secure photomultiplier tube 1460-1160
Ferrule, Vespel/graphite, 1/8-inch, for packed column adapters 0100-1332 (10/pk)
Ferrule, Vespel, 1/4-inch, for packed column adapters 5080-8774 (10/pk)
Preventive maintenance kit, single FPD+ G3435-67000
Preventive maintenance kit, dual FPD+ G3436-67000

0.53-mm columns)

capillary columns
Column nut, finger-tight (for .100- Connect column to inlet or detector 5020-8292
to .320-mm columns)
columns
capillary columns
to .320-mm columns)
columns
capillary columns
to .320-mm columns)

Exploded Parts View of the Flame Photometric Detector Plus
Exploded Parts View of the Flame Photometric

Detector Plus
Single wavelength
FPD+ cover Filter
Spacer (for
sulfur filter)
Ignitor (glow plug)
Spring
Collar
Screw
PMT assembly
Ignitor cable
assembly
Column ferrule Adapter ferrule

Capillary column nut Adapter nut
1/8-inch Packed
column adapter
Figure 48. Flame Photometric Detector Plus (FPD+) single wavelength exploded parts
Dual wavelength FPD

cover Spring
PMT assembly, left,

usually with phosphorus
filter installed PMT assembly, right,
usually with sulfur filter
installed
Column measuring tool

Figure 49. Flame Photometric Detector Plus (FPD+) dual wavelength exploded parts

To Install a Capillary Column to the FPD+

• Column measuring tool, see “Consumables and Parts for the FPD+” on page 242.
• Column cutter
• Column nut
• Ferrule
• Capillary column
C AU T I O N
3 Assemble a septum, column nut, and ferrule on the end of the column.
4 Insert the end of the column through the column measuring tool so that the end protrudes
beyond the tool.
Score column here
Column measuring tool
Column nut
137.5 mm
Ferrule
5 Tighten the column nut until it grips the column. Tighten the nut an additional 1/8 to 1/4
turn with a pair of wrenches. Snug the septum against the base of the column nut.
6 Use a wafer cutter at 45 ° to score the column.
7 Snap off the column end. The column may protrude about 1 mm beyond the end of the
tool. Inspect the end with a magnifying loupe to make certain that there are no burrs or
jagged edges.

Bad
Good
8 Remove the column, nut, and swaged ferrule from the tool.
and dust.
10 Carefully thread the swaged column up into the detector fitting. Finger-tighten the column
nut, then use a wrench to tighten an additional 1/8 turn.

To Change the FPD+ Wavelength Filter

Do not touch the filter with your bare hands. For optimum performance and to avoid
C AU T I O N scratches, use lint-free gloves for assembling and inserting the filter into the assembly.

• Sulfur filter with filter spacer, see “Consumables and Parts for the FPD+” on page 242.
• Phosphorus filter
• Cotton swab
• Lens tissue
3 Verify that the PMT voltage is off.
a On the GC touchscreen, select Overview. When prompted, select Exit to exit the
current screen while remaining in Maintenance Mode. (Do not Abort.)
b Navigate to Methods > Active Method > Edit > Detectors, scroll to Detector Specifics,
then select the Photomultiplier High Voltage.
c If the voltage is enabled, turn it off and apply the updated method.
d Return to the maintenance mode screen: Maintenance > Instrument.
The photomultiplier tube (PMT) is extremely sensitive to light. Always turn off the
C AU T I O N electrometer (which turns off the high voltage to the PMT) before removing the PMT housing
or opening the emissions chamber. Failing to do this can destroy the PMT.
Even with the electrometer off, protect the PMT from room light. Cap the housing after it is
removed, place it end down to exclude light, or reduce the room light level before exposing
the PMT. A brief exposure (always with the electrometer turned off) will not damage it, but
prolonged exposure will cause a gradual loss of sensitivity.
4 Disconnect the retaining spring that holds the PMT assembly to the bracket. With a
rotating motion, pull the assembly away from the filter housing.

5 To prevent light from damaging the PMT, cap the end or place it face down.
6 Place a clean cloth under the filter housing to catch the filter.
• For phosphorus filter, use the sharpened wooden tip of a toothpick or cotton swab to
dislodge the filter from the housing.
• For sulfur filter (shown below), use the wooden tip of the cotton swab to remove the
filter spacer. Then dislodge the filter from the housing.

Sulfur filter
Filter spacer
Do not use cleaning fluids. Cleaning fluids will damage lens coatings.
C AU T I O N
7 Clean the new filter with lens tissue.
Filters are designed for the light of the flame to pass through in a specific direction. The
C AU T I O N triangle (on the edge of the phosphorus filter) and the arrow (on the edge of the sulfur filter)
should face away from the flame and toward the PMT.
8 Install the filter in the filter housing. Install the sulfur filter spacer, if necessary.
9 Replace the PMT assembly and secure with the spring.
10 Route the PMT wires through the clips as shown. Avoid placing the wires very near heated
areas (such as the emission block or oven top).

To Remove the FPD+ Cover
To Remove the FPD+ Cover

2 Turn off the flame, then turn off the GC.
When turning off the GC, first turn off the flame to prevent condensation from dripping into
C AU T I O N the jet and column.
3 Open the FPD detector top cover.

4 Loosen the screws securing the FPD cover to the top of the detector.
5 For a single wavelength FPD, remove the two screws at the bottom left of the cover.
6 Lift the cover off the detector.

To Replace the FPD+ Ignitor

• Ignitor replacement kit, see “Consumables and Parts for the FPD+” on page 242.
• Torx screwdrivers, T-20 and T-10
• 5/16-inch nut driver (or wrench)
3 Remove the FPD cover. See “To Remove the FPD+ Cover” on page 250.
4 Loosen the collet screw holding the cable assembly to the ignitor. Remove the collet and
cable assembly.
5 Use a nut driver to loosen and remove the glow plug.

• If using a 5/16-inch wrench, you may need to remove the exit tube assembly using a
T-10 Torx driver

6 Install the new ignitor assembly and tighten with the nut driver. Do not overtighten. (If the
ignitor comes with a copper washer, discard the copper washer.)
7 Replace the ignitor collet and cable assembly and tighten the screw. Align the collet set
screw as shown. Do not let the collet screw touch metal parts, such as the emission block
or PMT bracket (dual wavelength detector).
8 Replace the FPD cover. See “To Install the FPD+ Cover” on page 253.
11 Wait 20 min. for the detector to heat up, then ignite the flame.

To Install the FPD+ Cover
To Install the FPD+ Cover

2 Install the cover.
Single-wavelength detector:
a Start the two screws on the right side of the cover.
b Start and tighten the screws at the base on the left side.
c Tighten the screws on the right side.
Dual-wavelength detector: Install the cover (two screws).
3 Close the FPD detector top cover.

Cleaning the FPD+ Brazement
Cleaning the FPD+ Brazement

The brazement uses an inert coating layer. Abrasives may scratch this layer. Hard scrubbing
C AU T I O N can scratch this layer. Solutions or soaps with a pH > 8 can also damage this layer. Do not
steam clean.
The FPD+ brazement, which consists of the transfer line and emission block assemblies, uses
an inert coating layer to provide better performance. Normally, manually cleaning the
brazement is not required. However, if it becomes necessary to clean the brazement to
remove contamination, note that exposing the inert coating to abrasives or certain solvents
will degrade the coating. If cleaning is needed, follow the recommendations below for best
results:
• Rinse with a solvent appropriate to dissolve the expected contaminants. Avoid abrasive or
highly basic solutions (see the caution above). Recommended solvents: dichloromethane,
acetone, or methanol.
• Mildly sonicate if needed, but excessive sonication can damage the coating layer.
• Gently remove solids using a soft, nylon bristle brush. Do not scrub hard. Recommended
brush: Use the MMI inlet cleaning brush from the MMI cleaning kit (G3510-80820). (Do
NOT used the MMI inlet abrasive cleaning swab, G3510-80829.)

Consumables and Parts for the Aux EPC 256
Installing or Replacing Frits in the Aux EPC 258
Consumables and Parts for the PCM 260
Calibrating the PCM Interface 261
Installing or Replacing Frits in the PCM 262
This chapter describes the maintenance procedures for Auxiliary EPC (Aux) and Pneumatics
Control Module (PCM). Pneumatic Switching Devices (PSD) do not have any required routine
maintenance.

Consumables and Parts for the Aux EPC

Table 40 Aux EPC consumables
O-rings, package of 6 5181-3344
Blue dot frit, high flow resistance G3430-80063
Red dot frit, medium flow resistance G3430-80062
Brown dot frit, low flow resistance G3430-80061
No frit (brass tube), zero flow resistance G3430-20011
Table 41 Auxiliary channel frits
Frit marking Flow resistance Flow characteristic Often used with
Three rings High 3.33 ± 0.3 SCCM @ 15 PSIG NPD Hydrogen

Blue
Two rings Medium 30 ± 1.5 SCCM H2 @ 15 PSIG FID Hydrogen

Red
One ring Low 400 ± 30 SCCM AIR @ 40 PSIG FID Air, QuickSwap, Purged
Brown splitters, Deans Switch

Table 41 Auxiliary channel frits (continued)
Frit marking Flow resistance Flow characteristic Often used with
None (brass tube) Zero No restriction Headspace vial

pressurization, purged
splitter and Deans Switch
when using backflush

Installing or Replacing Frits in the Aux EPC

To install or replace a frit in the Aux EPC block:
• Appropriate O-ring and frit
• Tweezers
When hydrogen is used, dangerously high flows are possible if insufficient flow resistance is
WAR N IN G provided downstream of the supply tube. Always use either the High (Blue dot) or Medium
(Red dot) frit with hydrogen.
2 Turn off the gas supply to the channel.

3 To select the appropriate auxiliary channel frit. See Table 41.
4 Identify which frit needs to be changed. Trace the tubing as needed to confirm.
5 Remove the screw to the molded partner fitting.
6 Lift the molded partner fitting away from the Aux EPC module.
7 Remove the tubing weldment for the desired channel. This will expose the frit and its
O-ring.
8 Gently remove the frit and O-ring using the tweezers. Be careful to avoid scratching the
metal surfaces.
9 Place a new O-ring onto the end of the new frit, and insert the frit into the open end of the
tubing weldment.

Screw
Molded Partner fitting
Frit O-ring
Tubing weldment
Figure 50. Replace an Aux EPC frit (2 flow tube channels not shown)
10 Place the tubing weldment into the Aux EPC module, and secure in place using the molded
partner fitting and screw.
11 Restore gas flows and check for leaks at the fitting.
After installing or replacing a frit, be sure to update the Aux EPC module PIDs used with your
module. If needed, update the Aux EPC module PIDs using the GC Firmware Update Tool
available on www.agilent.com. To download the GC Firmware Update Tool, open a web
browser, navigate to www.agilent.com, then in the search box type in “GC Firmware Update” to
search for the tool.

Consumables and Parts for the PCM
Consumables and Parts for the PCM

Table 42 PCM consumables
O-rings, package of 12 5180-4181
Proportional valve, Carrier G3430-67013
Proportional valve, AUX G3430-67016

Calibrating the PCM Interface
Calibrating the PCM Interface

The interface's flow module contains a pressure sensor that must be zeroed after it is installed
on the GC. Calibration ensures an accurate interface pressure display.
Do not connect the carrier gas to the flow module until you have zeroed the interface's
pressure sensor.
Complete the following steps:
1 If the gas supply is connected to the GC, turn off the supply at the source, then disconnect
the supply line from the PCM inlet fitting.
2 Turn on the GC and wait 15 minutes to allow it to reach thermal equilibrium.
3 When the GC has reached thermal equilibrium, press Options, scroll to Calibration and
press Enter.
4 Scroll to the module to be zeroed and press Enter.
5 Scroll to a zero line and press Info. The GC will remind you of the conditions necessary for
zeroing that specific sensor.
Flow sensors. Verify that the gas is connected and flowing (turned on).
Pressure sensors. Disconnect the gas supply line at the back of the GC. Turning it off is
not adequate; the valve may leak.
6 Press On/Yes to zero or Clear to cancel.
7 Turn off the GC.
8 Plumb the carrier gas to the flow module.
9 Turn on the GC.
If you were calibrating the flow sensor after replacing the PCM, check for leaks.

Installing or Replacing Frits in the PCM

To install or replace a frit:
• O-rings, package of 12, p/n 5180-4181
• Frit
• Tweezers
2 Turn off the gas supply to the channel.
3 Select the appropriate frit.
4 Remove the screw holding the partner fitting with the output tubing.
5 Remove the tubing block. Remove the frit and O-ring using the tweezers. Be careful to
avoid scratching the metal surfaces.
6 Remove the other O-ring as well. Replace it with a new O-ring.
Screw
Frit
Molded Partner fitting
O-ring
Channel 1
Channel 2
7 Place a new O-ring on the new frit and press it down into the block.
8 Place the block on the module and tighten the screw firmly.
9 Restore the gas supply.

When hydrogen is used, dangerously high flows are possible if insufficient flow resistance is
WAR N IN G provided downstream of the supply tube. Always use either the High (Blue dot) or Medium
(Red dot) frit with hydrogen.
After installing or replacing a frit, be sure to update the PIDs used with your PCM.


Consumables and Parts for Valves 266
Exploded Parts View of GC Rotary Valves 267
To Replace a Gas Sampling Valve Loop 268
To Align a Rotary Valve Rotor 270
To Replace a Rotary Valve in the Valve Box 271
To Remove the Upper Valve Box 274
To Install the Upper Valve Box 275

Consumables and Parts for Valves
Consumables and Parts for Valves

Table 43 Valve supplies
Valves, gas sampling
6-port, 300 psi 0101-0584
6-port, 400 psi, 225 °C maximum temperature 5062-9508
6-port, 300 °C maximum temperature 0101-0460
6-port Hastelloy, 400 psi, 225 °C maximum temperature 5062-9509
10-port, 400 psi, 225 °C maximum temperature 5062-9510
10-port Nitronic 60, 300 psi, 350 °C maximum temperature 0101-0585
10-port Hastelloy, 400 psi, 225 °C maximum temperature 5062-9511
Valves, liquid sampling
0.2-µL, 1000 psi, stainless steel, 175 °C maximum temperature 0101-0636
0.5-µL, 5000 psi, 175 °C maximum temperature 0101-0639
Gas sampling valve sample loops
0.25-cc 0101-0303
0.50-cc 0101-0282
1.00-cc 0101-0299
2.00-cc 0101-0300
2.0-mL nickel loop, 1/16-inch 0101-0955
5.00-cc 0101-0301
10.00-cc 0101-0302
Ferrule, 1/16-inch stainless steel (10/pk) 5181-1291
Nut, 1/16-inch (10/pk) 5181-1292

Exploded Parts View of GC Rotary Valves
Exploded Parts View of GC Rotary Valves
Valve actuator
Upper valve box assembly
Valve body
Rotor index pin
Valve rotor
Preload assembly
Figure 51. GC rotary valve exploded parts

To Replace a Gas Sampling Valve Loop

• Replacement sample loop, see “Consumables and Parts for Valves” on page 266.
• 1/4-inch wrench
• Vacuum cleaner
3 Turn off the detector.
The oven, inlet, detector, and valve box may be very hot.
WAR N IN G
Sample and/or harmful gases may be present. Refer to your company’s standard operating
procedures for purging the chemicals from the sample line.
4 Set all valve box valves to Off.

5 Leave on the GC and valve actuator air.
6 Turn off the carrier gas and sample line flows and relieve any back pressure to the valve.
The valve box insulation is made of refractory ceramic fibers (RCFs). To avoid inhaling RCF
WAR N IN G particles, we recommend these safety procedures:
• Ventilate your work area
• Wear long sleeves, gloves, safety glasses, and a disposable dust/mist respirator
• Dispose of insulation in a sealed plastic bag
• Vacuum any residual particles and discard
• Wash your hands with mild soap and cold water after handling RCFs.
7 Remove the upper valve box. See “To Remove the Upper Valve Box” on page 274.
8 Vacuum any loose particulate insulation.
9 When the valve is cool, loosen the sample loop’s two 1/4-inch fittings on the valve head
and remove the loop.
Sample loop

10 Install the new sample loop.

11 Repressurize the sample loop and check for leaks.
12 Install the upper valve box. See “To Install the Upper Valve Box” on page 275.
13 Exit maintenance mode: Select Maintenance > Instrument > Perform Maintenance >

To Align a Rotary Valve Rotor
To Align a Rotary Valve Rotor

• Flathead screwdriver
• 3-mm hex key wrench
2 Set the oven and valve box heated zones to a safe handling temperature (25 °C).
3 Set all valves to Off.
The oven, inlet, detector, and valve box may be very hot. If they are hot, wear heat-resistant
4 Loosen the adjustment set screw.
Rotor adjustment
slotted shaft
Adjustment set screw
5 Locate the rotor adjustment shaft on top of the actuator. Using a flathead screwdriver,
rotate the valve rotor counterclockwise until it stops, then back it off a small amount to set
one end of the rotor’s motion (< 1 mm).
6 Tighten the adjustment set screw.
7 Turn the valve On, turn Off to check for smooth operation.

To Replace a Rotary Valve in the Valve Box

Do not install a liquid sampling valve (LSV) in the valve box if you plan to heat the box above
WAR N IN G 75 °C. Heating an LSV over 75 °C can cause a leak and subsequent explosion. LSVs should
be mounted in the side location to avoid potential explosions.

• Replacement valve, see “Consumables and Parts for Valves” on page 266.
• 1/4-inch wrench
• Needle-nosed pliers
• Vacuum
The oven, inlet, detector, and valve box may be very hot.
WAR N IN G
Sample and/or harmful gases may be present. Refer to your company’s standard operating
procedures for purging the chemicals from the sample line.
3 Set all valves to Off.

4 Leave on the GC and valve actuator air.
5 Turn off the carrier gas and sample line flows and relieve any back pressure to the valve.
6 Remove the upper valve box. See “To Remove the Upper Valve Box” on page 274.
Vacuum any RCF insulation particulates from the valve box area.
7 Note the tubing connections to the existing valve and label if desired.
8 Disconnect the existing valve fittings.
9 Remove the two T-10 Torx screws attaching the valve to the valve box, then remove the
valve from the valve box.
10 Place the new valve in the valve box. The gap in the index ring on top of a 6-port valve
points toward the back of the GC if installed correctly. This is the On position. Install and
tighten the two screws with a screwdriver.

11 Use needle-nosed pliers to move the valve rotor index pin of the valve counterclockwise
until the pin touches the valve stop Off position.
Valve rotor index pin
Valve stop Off position
12 Plumb the new valve using the existing fittings.
Hazardous sample gases may be present.

WAR N IN G
4. Column
5. Carrier gas in
2. Sample out
1. Sample in
13 Turn on the carrier and sample gases, then check for leaks at the valve fittings.
• Using the needle-nosed pliers to toggle the valve, check both the On and Off positions.
• When leak free, set the valve to Off. See step 11.
14 Install the upper valve box assembly. See “To Install the Upper Valve Box” on page 275.
15 Reset the valve EMF counters.


To Remove the Upper Valve Box
To Remove the Upper Valve Box

1 Gather a T-20 Torx screwdriver.
2 Set the valve box to a safe handling temperature (25 °C), or prepare for maintenance:
Maintenance > Instrument > Perform Maintenance > Maintenance Mode > Start
Maintenance. Wait for the GC to become ready.
The oven, inlet, detector, and valve box may be very hot. If they are hot, wear heat-resistant
3 Lift and remove the detector cover.

4 Remove the mounting screws from the upper valve box.
5 Lift up and set aside.


To Install the Upper Valve Box

• 3-mm hex key wrench
• Flathead screwdriver
2 Verify that all valve rotors are in the full counterclockwise position (valve Off).
3 For each actuator that mates with a newly installed valve:
a Loosen the adjustment set screw.
Rotor adjustment
slotted shaft
Adjustment set screw
b Locate the rotor adjustment shaft on top of the actuator. Use a screwdriver to rotate
the valve rotor counterclockwise until it stops.
Rotor adjustment shaft
4 Locate the two half-moon cutouts at the bottom back of the upper valve box. Place the
upper valve box on top of the lower valve assembly, routing the heater/sensor wires
through the cutouts. Secure with two T-20 mounting screws.
5 Push each coupling/shaft assembly downward with a flathead screwdriver until the slot on
the coupling engages the rotor index pin.
If the coupling and valve do not engage, check that both are fully counterclockwise and
try again. If necessary, turn the shaft slightly to engage the coupling.
6 For each newly installed valve:
a Using a flathead screwdriver, turn the rotor adjustment shaft counterclockwise until it
stops, then back it off a small amount (< 1 mm) to set one end of the rotor’s motion.
b Tighten the adjustment set screw.
7 Install the detector cover.
8 Restore normal operating condition.


Making Swagelok Connections 278
Using a Swagelok Tee 281
The gas supply tubing is attached with Swagelok fittings. If you are not familiar with Swagelok
connections, review the following procedures.

Making Swagelok Connections

Objective
To make a tubing connection that does not leak and that can be taken apart without damaging
the fitting.
Materials needed:
• 1/8-inch (or 1/4-inch, if used) preconditioned copper tubing
• 1/8-inch (or 1/4-inch, if used) Swagelok nuts
• Front and back ferrules
• Two 7/16-inch (for 1/8-inch nuts) or 9/16-inch (for 1/4-inch nuts) wrenches
1 Place a Swagelok nut, back ferrule, and front ferrule to the tubing as shown in Figure 52.
Front ferrule IMPORTANT!

The narrow end of the back
Back ferrule ferrule fits into the rear of
the front ferrule.
Nut
Tubing
Figure 52. Swagelok nuts and ferrules
2 Clamp a stainless steel plug or similar fitting in a bench vise.
Use a separate stainless steel fitting in a vise for initial tightening of the nut. Do not use an
C AU T I O N inlet or detector fitting. Strong forces are required to properly set the ferrules, and damage to
an inlet or detector fitting is very costly to repair.
3 Push the tubing into the stainless steel plug. See Figure 53.
4 Make sure that the front ferrule is touching the plug. Slide the Swagelok nut over the ferrule
and thread it onto the plug.
Nut and ferrules
Plug or fitting
held in a vise Tubing
Figure 53. Assemble the fitting

5 Push the tube fully into the plug, then withdraw it approximately 1 to 2 mm as shown in
Figure 54.
Front Nut
ferrule
Insert tubing fully
Back
ferrule
Withdraw tubing 1 to 2 mm
Tighten nut
Figure 54. Insert the tubing
6 Finger-tighten the nut.

7 Mark the nut with a pencil line. See Figure 55.
Pencil line
Figure 55. Mark the fitting
8 For 1/8-inch Swagelok fittings, use a pair of 7/16-inch wrenches to tighten the fitting 3/4 of
a turn. See Figure 56.
For 1/4-inch fittings, use a pair of 9/16-inch wrenches to tighten them 1-1/4 turn, as
shown in Figure 56.
Figure 56. Final tightening

9 Remove the plug from the fitting. To connect the tubing, with nut and ferrules, to another
fitting, finger-tighten the nut, then use a wrench to tighten it 3/4 (1/8-inch fittings) or 1-1/4
(1/4-inch fittings) of a turn.
10 Both correctly- and incorrectly-swaged connections are shown in Figure 57. Note that the
end of the tubing in a correctly-swaged fitting is not crushed and does not interfere with the
action of the ferrules.
Figure 57. Completed fitting

Using a Swagelok Tee
Using a Swagelok Tee

To supply gas from a single source to more than one input, use a Swagelok Tee.
Do not combine valve actuator air with flame ionization air. The valve action will cause major
NOTE upsets in the detector signal.
Materials needed:
• 1/8-inch preconditioned copper tubing
• Tubing cutter
• 1/8-inch Swagelok nuts and front and back ferrules
• 1/8-inch Swagelok Tee
• 1/8-inch Swagelok cap (optional)
1 Cut the tubing where you want to install the Tee. Connect the tubing and Tee with a
Swagelok fitting. See Figure 58.
Cap
Tee fitting
Nut and ferrules
Figure 58. Swagelok tee
2 Measure the distance from the Tee to the GC inlets. Attach copper tubing to the open Tee
ends with Swagelok fittings.

www.agilent.com
© Agilent Technologies, Inc. 2019
First edition, January 2019
*G2790-90015*
G3540-90015

Usermanual GC Maintenance 8890 g3540 90015 en Agilent

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Agilent 8890 Gas Chromatograph

Maintaining Your Gas Chromatograph (GC)

4 Maintaining Capillary Columns

5 Maintaining the Split/Splitless Inlet

6 Maintaining the Purged Packed Inlet

7 Maintaining the COC Inlet

8 Maintaining the MMI

9 Maintaining the PTV Inlet

11 Maintaining the FID

12 Maintaining the TCD

13 Maintaining the NPD

14 Maintaining the ECD

15 Maintaining the FPD+

16 Maintaining EPC Modules

Tools and Materials Required for Maintenance 11

Preparing for Maintenance 13

Viewing Status Data 14

Finding a Replacement Part Number 16

Where to find a procedure

Tools and Materials Required for Maintenance

Table 1 Tools and materials for GC maintenance

Common tools Part number

Wrench, angled, septum nut 19251-00100

Wrench, open-end, 1/4-inch and 5/16-inch 8710-0510*

Wrench, open-end, 9/16-inch and 7/16-inch 8710-0803

Wrench, capillary inlet G3452-20512*

Column cutter, wafer, 4/pk 5181-8836*

Driver, nut, 1/4-inch 8710-1561*

T-20 Torx key or screwdriver 8710-1807

T-10 Torx key or screwdriver 8710-2140

3-mm hex key wrench 8710-2411

Electronic leak detector

Magnifying loupe, 20X 430-1020

Bench vise (for setting Swagelok fittings)

Razor or sharp knife

ESD wrist strap (for installing new components) 9300-1408

Gloves, heat-resistant (for handling hot parts)

Wooden cotton swab (for removing FID filters)

Tools and materials for cleaning procedures

Jet cleaning wire (.010-inch)

Clean, lint-free cloth (to protect contamination-sensitive detector parts)

Table 1 Tools and materials for GC maintenance

Common tools Part number

Steel wool, 0- or 00-grade (for cleaning an inlet’s septum seating surfaces)

* Included with the GC ship kits

Preparing for Maintenance

Viewing Status Data

Select the desired item from the drop-down list,

Finding a Replacement Part Number

Figure 1. Quickly navigate to replacement parts by clicking on images of GC components

Part numbers are also included in this manual.

To Remove the Pneumatics Cover 19

To Remove the Electronics Cover 20

To Remove the Detector Top Cover

Pneumatics cover Detector cover

Injection port cover

Left side cover

Figure 2. 8890 GC covers

To Remove the Pneumatics Cover