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Replacing the Measurement Module in the Sievers* 500 RLe TOC Analyzer
1.
Purpose:
To replace the measurement module in a Sievers 500 RLe TOC Analyzer.
2.
Scope:
This procedure applies to all Sievers 500 RLe Analyzer configurations.
3.
Safety:
This procedure requires access to electrical components of the Analyzer. Be sure to follow
ESD safety precautions, as instructed. This procedure should be performed by personnel
skilled in the maintenance of electromechanical instruments.
4.
Materials:
5.
6.
•
Measurement module replacement kit
•
Long #2 Phillips screwdriver
•
Small Phillips screwdriver
•
1/4" open-end wrench
•
John Guest fitting tool (from Analyzer accessories kit)
•
Tray (from Analyzer accessories kit)
•
Water bottle (from Analyzer accessories kit)
Definitions:
•
Fluidics module: the portion of the Analyzer dealing with water, comprising the DI and sample side
fluidics.
•
Measurement module: the module in the Analyzer, situated behind the DI water cartridge, comprising
the CO2 transfer manifold and the sample conductivity cell.
Procedure:
6.1 If the Analyzer is taking measurements, press the Stop Analysis button.
6.2 Insert a USB flash memory drive into the port labeled USB on the side of the Analyzer and back up
the current Analyzer settings (Maintenance → Advanced → USB I/O → Save System). For more
information, see the section called “Saving System Settings” in the Analyzer’s Operation and
Maintenance Manual.
6.3 Remove the USB flash memory drive from the USB port and store it in a safe place.
GE Analytical Instruments, Inc. ©2007H
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DIN 74702-01 Rev. A
Kit, Measurement Module Repl., 500RLe
6.4 Turn off power to the Analyzer. Also shut off the circuit breaker for the Analyzer.
6.5 Disable the flow of water to the Analyzer.
6.6 Open the Analyzer door.
6.7 Drain the DI water cartridge as follows:
6.7.1 Lift the spring clip at the top of the DI water cartridge, and rotate the cartridge clockwise (as
viewed from the top) so it slides out of the retaining hook.
6.7.2 Place the DI water cartridge over the tray from the accessories kit or a different receptacle into
which water can drain.
6.7.3 Use the John Guest fitting removal tool from the accessories kit to remove the fitting on the
bottom of the cartridge labeled “A.”
6.7.4 Remove the rubber inlet cover from the cartridge. Let the water drain out.
6.7.5 When the water has drained from the DI water cartridge, replace the rubber inlet cover and
reconnect the fitting to the “A” port on the bottom of the cartridge.
6.7.6 Slide the DI water cartridge into the bracket and rotate it into the retaining clip until it snaps into
place.
6.8 Put on the ESD strap and it to a metal component of the Analyzer.
6.9 Remove the analog board cover by loosening the captive screw and pulling the cover away from the
Analyzer.
6.10 Determine if the cables that connect to the analog board are secured to the bottom of the analog
board enclosure with a reclosable fastener strip. If the fastener strip is present, remove the bottom
portion of the strip to free the cables; retain this portion of the fastener strip.
6.11 Disconnect the cables from the analog board, labeled P1, P2, P3, and P6 (see Figure 1).
Figure 1
Analog Board Connections
6.12 Disconnect the UV power connector (see Figure 2).
GE Analytical Instruments, Inc. ©2007H
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DIN 74702-01 Rev. A
Kit, Measurement Module Repl., 500RLe
6.13 Using a 1/4" open-end wrench, disconnect the Valco fitting leading to the sample inlet line on the
right bulkhead (see Figure 2).
6.14 Remove the Masterflex tubing from the waste line on the right bulkhead (see Figure 2).
Figure 2
The Inlet and Waste Lines on the Right Bulkhead
6.15 Disconnect the three cables located to the right of the fan and immediately behind the UV power
connector.
6.16 Begin removing the fluidics module by loosening the three captive screws that attach the fluidics
module to the Analyzer (see Figure 3). You will need a long Phillips screwdriver.
Figure 3
GE Analytical Instruments, Inc. ©2007H
Loosening the Captive Screws
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DIN 74702-01 Rev. A
Kit, Measurement Module Repl., 500RLe
6.17 Pull the fluidics module forward, and then disconnect the ribbon cable that attaches to the ID board
(see Figure 4).
Figure 4
Disconnecting the ID Board Cable
6.18 Pull the fluidics module the rest of the way out of the Analyzer.
6.19 Remove the DI water cartridge from the bracket. At this point, you may want to lay the fluidics
module down on a flat surface, so it rests on the back of the bracket.
6.20 At the measurement module, disconnect the tube with the blue ring using the John Guest tool. This
tube leads to the “C” port on the cartridge (see Figure 5). Push the blue ring toward the measurement
module to disconnect the tubing.
6.21 At the measurement module, disconnect the tube with the red ring using the John Guest tool (this
tube leads to the “D” port on the cartridge). Push the red ring toward the measurement module to
disconnect the tubing.
Note: your configuration may look slightly different than the configurations in the following figures.
Figure 5
Disconnecting Tubing on the DI Side of the Measurement Module
GE Analytical Instruments, Inc. ©2007H
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DIN 74702-01 Rev. A
Kit, Measurement Module Repl., 500RLe
6.22 Remove the PEEK nut that connects to the right side (sample side) of the measurement module
bracket. This nut connects to the UV reactor (see Figure 6).
6.23 Remove the sample pump tubing from the two stainless steel posts on the right side (sample side) of
the measurement module bracket. This tubing connects the outlet lines of the measurement module
to the sample pump (see Figure 6).
Figure 6
Disconnecting Tubing from the Sample Side of the Measurement Module
6.24 Using a 1/4" open-end wrench, disconnect the Valco fitting leading to the stream splitter tee (see
Figure 7).
Figure 7
Disconnect the Fitting from the Stream Splitter Tee
6.25 Loosen the three captive screws securing the measurement module to the bracket. Pull the
measurement module free of the bracket.
GE Analytical Instruments, Inc. ©2007H
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DIN 74702-01 Rev. A
Kit, Measurement Module Repl., 500RLe
6.26 Remove the new measurement module from the packaging. To ensure safe transport, the
measurement module is attached to a bracket in the shipping box; to remove it, simply loosen the
three captive screws.
6.27 To further protect the measurement module during transit, there are five plugs attached to the new
measurement module. Remove them as follows.
6.27.1 On the DI side of the bracket, remove the two plugs with the John Guest tool (see Figure 8).
6.27.2 On the sample side of the bracket, remove the knurled plastic plug (see Figure 9).
6.27.3 Also on the sample side of the bracket, remove the two plugs consisting of Norprene tubing
with posts. Firmly but gently remove the Norprene tubing from the stainless steel tubing. Be
sure to remove the Norprene tubing; do not merely remove the posts (see Figure 9).
Figure 8
Figure 9
Removing the Shipping Plugs from the DI Side
Removing the Shipping Plugs form the Sample Side
6.28 To ensure safe transport, the ID board is shipped in special packaging. Make sure you are following
ESD precautions. Remove the new ID board from the packaging and attach it to the top of the
measurement module bracket with the three small screws (see Figure 10).
GE Analytical Instruments, Inc. ©2007H
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DIN 74702-01 Rev. A
Kit, Measurement Module Repl., 500RLe
Figure 10
Attaching the ID Board
6.29 Attach the measurement module to the bracket by securing the three captive screws.
6.30 Reconnect the sample pump tubing to the two stainless steel posts on the sample side of the
measurement module.
6.31 Reconnect the fitting to the stream splitter tee using the 1/4 in wrench. Tighten the fitting one-quarter
turn past finger-tight. Do not over-tighten the fitting.
6.32 Reconnect the PEEK nut on the sample side of the measurement module.
6.33 Reconnect the tubing with the red ring to the DI side of the measurement module.
6.34 Reconnect the tubing with the blue ring to the DI side of the measurement module.
6.35 Return the DI water cartridge to the bracket.
6.36 Slide the fluidics module part way into the Analyzer, and then connect the cable to the ID board.
6.37 Carefully slide the fluidics module the rest of the way into the Analyzer. Align the bracket with the set
pin.
6.38 Secure the fluidics module to the Analyzer by tightening the three captive screws.
6.39 Reconnect the three quick connects behind the UV lamp power connector.
6.40 Reconnect the waste outlet and sample inlet tubing to the right bulkhead.
6.41 Reconnect the UV power connector.
6.42 Reconnect the cables to the analog board, labeled P1, P2, P3, and P6 (see Figure 1).
6.43 If the analog board cables were secured with a reclosable fastener strip, secure them again by
replacing the bottom portion of the fastener strip.
6.44 Replace the analog board cover.
6.45 Lift the spring clip at the top of the DI water cartridge, and rotate the cartridge so it slides out of the
retaining hooks.
GE Analytical Instruments, Inc. ©2007H
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DIN 74702-01 Rev. A
Kit, Measurement Module Repl., 500RLe
6.46 Remove the John Guest fittings labeled “B” and “D” from the barbs on the top of the DI water
cartridge. To loosen a fitting, use the John Guest tool from the accessories kit to push up on the
bottom ring on the fitting, so that the ring moves toward the fitting
6.47 Remove the rubber inlet cover from the top of the DI water cartridge.
6.48 Slide the water bottle nozzle into the inlet hole. Make sure the tubing that connects to Port “B” is
positioned higher than the DI water cartridge, and then gently squeeze the water bottle. Be sure to fill
the reservoir until the water reaches the Full line.
6.49 Connect the fitting labeled “B” to the barb labeled “D” on top of the DI water cartridge.
6.50 Slide the DI water cartridge into the bracket and rotate it into the retaining clip until it snaps into
place.
6.51 Visually check for leaks from the reservoir after the DI water cartridge has been filled.
6.52 Turn on the Analyzer using the main power switch. This will start the DI pump. Check for large air
bubbles in all the tubing that connects to the DI water cartridge. If large air bubbles are present, tap
or manipulate the tubing to work the air bubbles out.
6.53 Keep the Analyzer powered on for 2 minutes.
6.54 After 2 minutes, turn the Analyzer off.
6.55 Lift the spring clip at the top of the DI water cartridge, and rotate the cartridge so it slides out of the
retaining hooks.
6.56 Remove the John Guest fitting labeled “B” from the barb on the top of the DI water cartridge.
6.57 Connect the fitting labeled “B” to the barb labeled “B” on the top of the cartridge.
6.58 Connect the fitting labeled “D” to the barb labeled “D” on the top of the cartridge.
6.59 Slide the DI water cartridge into the bracket and rotate it into the retaining clip until it snaps into
place.
6.60 Replace the rubber inlet cover.
6.61 Turn the Analyzer on.
6.62 Check the level of the DI water cartridge. If the water level has dropped below the Full line, remove
the rubber inlet cover from the top of the cartridge, add more water, and replace the inlet cover.
6.63 Close the Analyzer door.
6.64 Calibration/Verification
6.64.1While the replacement measurement module has been fully tested at the GE Analytical
Instruments factory, it is recommended that you calibrate the instrument after installation of
the new part. Refer to the “Calibration and System Protocols” chapter in the Analyzer’s
Operation and Maintenance Manual for instructions on performing the calibration and
accuracy/precision/verification protocols.
*Trademark of General Electric Company; may be registered in one or more countries.
GE Analytical Instruments, Inc. ©2007H
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DIN 74702-01 Rev. A
Kit, Measurement Module Repl., 500RLe