PGC5000
PGC5000 Series Service Instructions
7 Subassembly repair
SI/PGC5000-EN, Rev B
55
7. Roll each end of the green wire of the new polarizer between your forefinger and thumb, causing the wire ends to be
tightly spiral wrapped.
8. Using the 40 watt soldering iron and approved high temperature solder, “tin” the wire ends.
9. Spread or expand the end of approved heat shrink to allow easy installation over the solder connection.
10. Install heat shrink over each wire and slide it as far as possible from the connection. This will prevent premature shrinking
when the connection is soldered.
11. Overlap and solder the “tinned” ends of the green wire from the wiring harness and the green polarizer assembly wire
using approved high temperature solder and 40 watt soldering iron.
12. Apply a short wrap of glass tape over the connection.
13. Slide the heat shrink over the taped connection and shrink it with a heat gun.
7.2.5 Replacing the igniter assembly
1. Locate the igniter identified by the element with the two white wires.
2. If applicable, remove any cable ties and free the wiring to expose the wire splices.
3. Cut and remove the heat shrink and glass tape from the two white wires to expose the soldered connections.
4. Using a 40 watt soldering iron, disconnect the wiring splice.
5. Using a 3/8-inch open-end wrench, continue loosening and carefully remove the Igniter assembly.
6. Carefully insert the replacement igniter into the detector body and finger tighten, taking care not to damage it. Finish
tightening using a 3/8-inch open-end wrench.
7. Roll each end of the two white wires of the new igniter between your forefinger and thumb, causing the wire ends to be
tightly spiral wrapped.
8. Using the 40 watt soldering iron and approved high temperature solder, “tin” the wire ends.
9. Spread or expand the end of approved heat shrink to allow easy installation over the solder connection.
10. Overlap and solder the “tinned” ends of one wire from the wiring harness and one white igniter assembly wire and solder
the wires together using approved high temperature solder and 40 watt soldering iron.
11. Repeat this operation for the remaining white wire.
12. Apply a short wrap of glass tape over each connection.
13. Slide the heat shrink over the taped connection and shrink it with a heat gun.
7.2.6 Cleaning the fid jet
CENELEC and CSA flame ionization detectors are identified by the presence of three packing adapter nuts (5/8-inch, 1/2-inch
and 7/16-inch). Other models contain only two packing adapter nuts (5/8-inch and 1/2-inch).
1. On CENELEC AND CSA models, loosen the 7/16-inch packing adapter nut using a 7/16-inch open-end wrench, backed up
with a 1/2-inch open-end wrench on the 1/2-inch packing adapter nut. Continue to loosen by hand until disconnected.
2. For all models, loosen the 1/2-inch packing adapter nut using a 1/2-inch open-end wrench with a 5/8-inch open-end back-
up wrench. Continue to loosen by hand until disconnected.
3. Withdraw the column and associated ferrules and adapters from the detector.
4. Loosen the 5/8-inch adapter fitting from the bottom of the detector. Extract the jet with the adapter fitting from the jet
cavity in the detector. (It may be necessary to loosen or remove the polarizing voltage nut to get the jet to drop out of the
detector.)
5. Inspect the end of the jet for damage. It should not be pitted or plugged. If pitted, replace with a new jet.
6. Insert a 0.016-inch diameter piano wire into the jet and rod it out. If the piano wire will not pass through, replace the jet.
7. Using a syringe, protective equipment and clothing, flush the jet with a mild solvent such as acetone; then blow dry with
15 psig clean air, nitrogen or helium.
8. Use a 5/8-inch adapter fitting to insert the jet into the jet cavity. Finger tighten and finish tightening using a 5/8-inch
open-end wrench.
9. Insert the column end, ferrule and adapter nut into the detector inlet and finger tighten.
10. If the ferrule was loose and slides any length on the column, continue to push the column into the detector inlet until it
stops.
11. Withdraw the column approximately one mm and tighten the 1/2-inch adapter nut finger tight.
12. Tighten the nut 1/4 turn more with a 1/2-inch open-end wrench, then check it for a secure fit by gently attempting to pull
the column slightly away from the detector. Carefully tighten the adapter until the column is secure.
13. For CENELEC and CSA models, slide the 7/16-inch packing adapter nut and ferrule toward the detector and install finger
tight. Tighten the nut an additional 1/4 turn with a 7/16-inch open-end wrench.
