5400 Afterburner & Oven Bulb Replacement

5400 Afterburner Bulb Replacement

Purpose:  Follow the steps below to exchange a burner in one of the afterburners:

Located on the right side of the bulkhead inside of the 5400, there are 10 burners that heat the collectors to the desired temperature for sampling.  For each side A&B, there is one burner used to heat the afterburner coil and four burners for the oven.

Required Equipment:  Burner Removal Tool

                                          Flat Blade Screwdriver

                                          Gloves

                                          Burners/ Bulbs required

                                          12 inch adjustable wrench

Reference:  Section 3: Service Procedures Page 3-21

1. Down OC, TC, and CO2 Purge channels with "set flag" button located on the right side of the site manager screen.

2. Press the RUN/STOP button once.

3. Select F1 (Immed).  This stops the collection of data.

4. Allow 10 minutes for the instrument to cool down.

5. Turn off and unplug the instrument.

6. Allow the monitor to cool down.

7. Disconnect the inlet sample line inside the instrument, there is a swagelock fitting located on the left side of the bulkhead just above the pinch valve.

8. Pull out the bulkhead to its fully outward position.

9. Using the flat blade screwdriver, loosen the four screws that secure the Furnace/Afterburner Guard to the platform.  Do not remove the screws completely.

10. Lift the guard off the platform and set aside.

11. Reach beneath the plate that supports the furnaces and afterburners, and locate the afterburner support corresponding to the burner being changed.  Push upward so that the afterburner burner sticks up above the surrounding housing.  Using the Burner Removal Tool, remove the burner from the afterburner.  The Burner Removal Tool is a piece of silicone tubing of a specific diameter. Slip one end of the tubing over approximately 0.25 inches (0.65 cm) of the burner (Figure 3-7).  Push downward on the burner and turn counter-clockwise approximately 10°.  Pull the burner out.

NOTE: Do not touch new burners with your fingers.

1. Continuing to push upward on the afterburner support, place a new burner into the afterburner.  Using the Burner Removal Tool, place the burner into the proper location, push down on the burner, and turn clockwise approximately 10°.  Ensure that the burner is properly seated and remove the Burner Removal Tool.  Release the afterburner support, ensuring that it returns to its proper position.  It is extremely important never to touch the burner with your fingers.

2. Reinstall the Furnace/Afterburner Guard to the platform and reattach by tightening the four screws using the flat blade screwdriver.

3. Push the bulkhead into its fully inward position.

4. Replace the sample inlet line.

5. Plug in and turn on the instrument.

6. Test the new bulb in the Heat Zones Screen by entering the Service Menu, and pressing <F3: HeatPID> with the cursor point- pointing to “Manual Motion Tests.”

7. You may at this time do other checks/maintenance or put the instrument back in RUN mode by pressing the RUN/STOP button.

5400 Oven Bulb Replacement

Purpose:  Follow the steps below to exchange a burner in one of the ovens:

Located on the right side of the bulkhead inside of the 5400, there are 10 burners that heat the collectors to the desired temperature for sampling.  For each side A&B, there is one burner used to heat the afterburner coil and four burners for the oven.

Required Equipment:  Burner Removal Tool

                                          Flat Blade Screwdriver

                                          Gloves

                                          Burners/ Bulbs required

                                          12 inch adjustable wrench

Reference:  Section 3: Service Procedures Page 3-40

1. Down OC, TC, and CO2 Purge channels with "set flag" button located on the right side of the site manager screen.

2. Press the RUN/STOP button once.

3. Select F1 (Immed).  This stops the collection of data.

4. Allow 10 minutes for the instrument to cool down.

5. Turn off and unplug the instrument.

6. Allow the monitor to cool down.

7. Disconnect the inlet sample line inside the instrument, there is a swagelock fitting located on the left side of the bulkhead just above the pinch valve.

8. Pull out the bulkhead to its fully outward position.

9. Using the flat blade screwdriver, loosen the four screws that secure the Furnace/Afterburner Guard to the platform.  Do not remove the screws completely.

10. Lift the guard off the platform and set aside.

11. Remove the oven cylinder by lifting it straight up.

12. Using the Burner Removal Tool, remove the burner from the furnace.  The Burner Removal Tool is a piece of silicone tubing of a specific diameter.  Slip one end of the tubing over approximately 0.25 inches (0.65 cm) of the burner (Figure 3-7).  Push downward on the burner and turn counter-clockwise approximately 10°.  Pull the burner out.

NOTE: Do not touch new burners with your fingers.

1. Place a new burner into the furnace.  Using the Burner Removal Tool, place the burner into the proper location, push down on the burner, and turn clockwise approximately 10°.  Ensure that the burner is properly seated and remove the Burner Removal tool.  It is extremely important never to touch the burner with your fingers.

2. Replace the furnace cylinder.

3. Reinstall the Furnace/Afterburner Guard to the platform and reattach by tightening the four screws using the flat blade screwdriver.

4. Push the bulkhead into its fully inward position.

5. Replace the sample inlet line.

6. Plug in and turn on the instrument.

7. Test the new bulb in the Heat Zones Screen by entering the Service Menu, and pressing <F3: HeatPID> with the cursor point- pointing to “Manual Motion Tests.”

8. You may at this time do other checks/maintenance or put the instrument back in RUN mode by pressing the RUN/STOP button.