SERVICE ENGINEERING BULLETIN

REVISIONS
REV DESCRIPTION DATE CHG APPR

A Initial Release, PCR

B Update Bulletin Dec. 2014

C Update Bulletin Mar. 2015

D Update for install only Jul. 2015

D2 Update to add Alarms Aug 6 2015

D3 Correct errors Aug 11 2015

D4 Add LED Analyzer Setup Aug 24 2015

D5 Correct alarms listing Sep 14 2015

D6 Add temp. setpoint Jan 9 2016

D7 Add interconnect cable Mar. 2016

D8 Update J1 wire colors Mar. 9 2016

APPROVALS ABB INC.

Lewisburg, WV 24901 USA
ORIGINATOR: BULLETIN, UPGRADING THE PUV3402 TO LED
PRODUCT ENG: SOURCE
CHECKED: Rev: D8
ENGINEERING: 843J001-1 Sheet: 1 of 14
QUALITY:
1 SCOPE
This bulletin describes how to replace the older PUV3402 Source Assembly with the new LED Source
Assembly and associated components.

The LED source replaces the deuterium source that was in the old PUV3402 analyzers. Since the LED
source emits discrete wavelengths, the chopper motor and filter wheel are no longer necessary and should
be removed. The panel containing the Source Control PCB is replaced by the panel containing the LED
Source Driver PCB, to correctly power the LEDs. The Detector is replaced to pair with the new source.
Several cables are replaced, modified, or eliminated as appropriate.

2 SAFETY CONSIDERATIONS

Before starting to install this upgrade, read the safety information in this section.

Before working on this analyzer contact the local Safety Department to ensure that
all safety guidelines, regulations, and procedures are followed. This includes
obtaining the proper work permits and consulting the Material Safety Data Sheets for
safety requirements.

Before working on the analyzer, be prepared to work correctly with lethal voltages,
infrared light sources, hazardous gases, and hot surfaces.

Wear protective clothing and use protective equipment appropriate for the specific
job, such as rubber gloves, and goggles, or safety glasses with side shields.

When working on the analyzer there is the possibility of exposure to hazardous

sample (liquid and vapor) as well as nitrogen. Although nitrogen is an inert gas, it
does not support human life. All appropriate precautions and care should be taken.

Ensure that there is adequate ventilation while work is being done on the analyzer.

Because the actual configuration of the analyzer depends on the application, this
manual cannot address all of the associated safety problems. It is the responsibility
of the user to know and comply with all safety and health guidelines, regulations,
and procedures that apply.

Before opening the analyzer enclosure doors, be sure the area is safe.

When removing electronic parts and assemblies, it is necessary that proper

electrostatic discharge (ESD) precautions be taken (i.e., wear an ESD wrist strap with
a grounding cable and use an ESD shielded bag to protect the items removed).

3 TOOLS AND EQUIPMENT REQUIRED

3.1 Tools required

Small flat blade screwdriver

Phillips screwdriver

843J001‐1, Rev D8  2 
 
Square end screwdriver
9/64-ich Balldriver (supplied with the analyzer)
1/16-inch hex key wrench
1/4-inch box-end or ratchet wrench
5/32-inch hex key bit

3.2 Upgrade parts list

843J001-1 Installation Bulletin MW LED Upgrade Kit
843K004-1 Kit Source Housing Mounting H/W
843A140-X UV Source Assembly
843A067-1 Cable Source
843A149-1 Cable Interconnect
843A142-1 Panel Assembly
811331 Nut
843A147-1 Capillary Assembly
843A068-1 Cable Detector
843A148-X Detector Assembly UV LED
851Z061-1 Jumper Shorting 2 PL
843D061-1 Label Logo Multiwave LED
843D064-1 Insulation
800T057-1 Modification Label

4 REMOVING THE SAMPLE CELL ASSEMBLY

If the sample cell is heated, do not purge it with cold sample; it may cause thermal
shock damage to the cell windows.

If the cell has contained a hazardous substance be sure to purge the cell thoroughly
with a non-hazardous sample.

Allow the cell to cool before working on it.

1. Stop flow through analyzer by closing valves for all types of sample flow; allow the cell to drain.
2. Remove power following local lock-out tag-out procedures.
3. Disconnect Sample Ports 1 and 2 (see Figure 1). Sample Port 1 is Sample In for vapor systems and
Sample Out for liquid systems. Sample Port 2 is Sample Out for vapor systems and Sample In for liquid
systems.
4. If the sample cell is not electrically heated, go to step 6.
5. If the cell is electrically heated, remove the insulation from the cell.
6. Remove the 9/64-inch hex key screws from the top of the block(s), then lift off the block(s).

843J001‐1, Rev D8  3 
 
7. Loosen the set screw in the stabilizer block (see Figure 1) on each side of the cell by turning it
approximately three full turns with a 1/16-inch hex key wrench.
Set Screw Sample Port 1

Socket Head Screws Sample Port 2

Figure 1. Sample Cell

8. Using the 9/64-inch balldriver, remove the two socket head screws on each side of the cell that hold the cell
retainer to the subassemblies.
 
9. With both hands, grasp the knurled cell retainer and pull it toward the center of the cell until the retainer
touches the optical purge vent (see Figure 2). Do this for each side.
 

Figure 2. Knurled Retainer

 
10. With hands in the center of the cell, slowly remove the cell as evenly as possible (see Figure 3).

Figure 3. Removing the Cell

843J001‐1, Rev D8  4 
 
5 REMOVING THE OLD SOURCE ASSEMBLY

Ultraviolet radiation is harmful. UV-resistant safety glasses with side shields must
be worn when the Source Enclosure will be open with power on, and when adjusting
the source to maximize the radiation level.

When removing or installing the source assembly, gloves should be worn and only
the metal components should be handled. If the deuterium lamp is touched, all
fingerprints must be removed with a soft, clean, dry cloth. The nipple area of the
source assembly must be kept clean and free of fingerprints.

1. Remove the power following local lock-out tag-out procedures.

2. Open the Source Enclosure.
3. Locate the Source Control PCB on the right inside wall of the Source Enclosure (see Figure 4).
4. Cut and remove any cable ties securing the source control wiring.
5. Disconnect all wiring from the Source Control PCB.
6. Remove the Panel with Source Control PCB from the Source Enclosure (see Figure 4), retaining the
hardware for the new panel installation.
7. Disconnect the chopper motor control cable from the Optical Filter Wheel Housing Cover (see Figure 4).
8. Remove all tubing lines from the Optical Housing Casting and Source.
9. Disconnect the capillary tubing line from the manifold (see Figure 4) and remove it from the unit.

REMOVE CAPILLARY
FROM MANIFOLD

RETAIN FOR RE‐USE
REMOVE PANEL WITH 
SOURCE CONTROL PCB

REMOVE 4 SCREWS THAT 
RETAIN OPTICAL 
HOUSING CASTING
AND SOURCE

DISCONNECT CHOPPER MOTOR 
CABLE; REMOVE SOURCE

Figure 4. Removing the Optical Housing Casting and Source Assembly

10. Remove the four screws that hold the Optical Housing Casting and Source in place.
11. Remove the Optical Housing Casting and Source Assembly from the Source Enclosure.
12. Using wire cutters, cut the heater wires where they enter the Optical Housing Casting, leaving the wires as
long as possible.
13. Strip 1/8-inch off the sleeving, preparing the wires for re-use.
 
6 REMOVING THE OLD DETECTOR
1. Remove power following local lock-out-tag-out procedures.

843J001‐1, Rev D8  5 
 
2. Open the Detector Enclosure.
3. Follow the signal cable from the Detector to the Backplane PCB and disconnect it from J27 (see Figure 5).

DETECTOR

SIGNAL
CABLE

 
Figure 5. Removing the Detector

4. Remove all tubing lines and fittings from the Detector Assembly and retain them for the new detector
installation, and discard the detector cable.
5. Remove the four screws and washers that hold the Detector in place, and retain them for the new detector
installation.
6. Remove the Detector Assembly from the Detector Enclosure.
7. Disconnect the mating connector from J30 on the Backplane PCB in the Detector Enclosure and remove
wires from pins 1, 3, and 4. These signals are not used in the upgraded unit. If y, z, or environmental purge
is installed, pins 9 and 10 remain connected at J30; otherwise this connector will not be used.

7 INSTALLING THE NEW DETECTOR ASSEMBLY

1. Attach the new detector cable 843A068-1 to the new Detector Assembly 843A148-X.
2. Connect the ground wire in the detector cable to the rear face (connector end) of the Detector Assembly,
securing it with the provided socket head screw (MS16995-10), split washer (MS35338-135), and flat
washer (MS27182-3), as shown in Figure 6.

Figure 6. Attaching the Ground Wire

843J001‐1, Rev D8  6 
 
3. If the old detector has an optical span filter, install the span filter from the old detector in the new Detector
Assembly 843A148-2. Note that the optical span filter will need to be adjusted once the source is installed in
the unit. Refer to the 3402Led Manual for the optical span filter adjustment procedure. Please record the
span reading for future use.
4. Insert the provided O-ring 45051-4-55 in the front face of the Detector Assembly.
5. Attach the new Detector Assembly in the Detector Enclosure, using the original hardware.
6. Reattach all tubing lines and retained fittings.
7. Connect the detector cable to Backplane PCB J27 as shown in Figure 7.
 
J27
1 RED
2 BLK
3
4 WHT
5 YEL
6 ORG
 
 
Figure 7. Connecting the Detector Cable

8 INSTALLING THE NEW SOURCE ASSEMBLY

 
1. Unplug the Motor Control Cable where it plugs into the source casting (see Figure 8).
 

 
 
Figure 8. Unplug Motor Control Cable for Reuse
 
 
2. Connect provided Interconnect Cable 843A149-1 to Motor Control Cable.

843J001‐1, Rev D8  7 
 
  
 
Figure 9. Wiring of the Interconnect Cable
 
3. Connect the other end of the Interconnect Cable to J1 on the provided Panel with LED Source Driver PCB
(the PCB will not yet be installed in the Enclosure). Wiring should be as shown in Figure 9 (reference only).
Note that older kits may have different wire colors.
4. The provided Source Cable (843A067-1) may have shipped with the 8-pin terminating connector attached.
If it did not, this connector must be attached as follows. Using the mating connector at J2 of the provided
LED Source Drive PCB, connect the wires of the provided Source Cable (843A067-1) as shown in Figure
10. The dot on the PCB identifies the location of pin 1 of J2.
 
J2
8
7
6 BLU
5 ORG
4 YEL
3 WHT
2 BLK
1 RED
 
 
Figure 10. Connecting the Source Cable Wires to J2
 
5. Connect the Source Cable to J2 on the LED Source Driver PCB (the PCB will not yet be installed in the
Enclosure).
6. Unplug the mating connector from J3 of the Panel Assembly (the PCB will not yet be installed in the
Enclosure).
7. Identify the two white wires from the new Source Assembly (843A140-X), noting hole location for future
reference.
8. Remove the attached sensor from the Source Assembly.

843J001‐1, Rev D8  8 
 
9. Connect the two white wires to connector J3 pins 1 and 2 on the Source Driver PCB (which is not yet
installed in the Source Enclosure), in no particular order (see Figure 11).

J3
4
3
2 WHT
1 WHT  
 
Figure 11. Connections to J3
 
10. Install the Panel with LED Source Driver PCB (843A142-1), using existing hardware and supplied hex nut
811331.
11. Identify terminal block TB102 on the Panel with LED Source Driver PCB.
12. Connect the wires from TB6 (already attached to pins 6 and 7) on the I/O Power PCB 759A008C-1 in the
Detector Enclosure, previously used to heat the source casting, to the bottom terminals on TB102.
13. Install the provided LED Source Assembly (843A140-X) and O-ring (45051-4-55) in the Source Enclosure,
using source housing mounting hardware 843K004-1 (see Figure 12). Ensure the Belleville washers are
paired in opposite directions (see Figure 13), and the tubing ports in the Source Assembly face upward.
 
 

           
 
VIEW FROM RIGHT, DURING SOURCE INSTALLATION                  VIEW FROM LEFT, AFTER INSTALLATION 
 
Figure 12. Installing the Source Assembly
 

843J001‐1, Rev D8  9 
 
 804Z002‐2
WASHER, BELLEVILLE 843M055‐1
(3 PLCS) WASHER, PAPER, 0.375 OD
(P/O 843k004‐1) (P/O 843k004‐1)

843M055‐1
WASHER, PAPER, 0.375 OD
(P/O 843k004‐1)

NOTE:  ORIENTATION OF 
WASHERS WHEN STACKED
(3 EACH PER STACK)
 
 
Figure 13. Pairing the Belleville Washers
 
14. Locate the hole in the Source Assembly previously occupied by the sensor, and install the sensor.
15. Connect the remaining two pairs of wires from the source assembly into the top terminals of TB102 (no
orientation needed).
16. Attach the provided source cable (843A067-1) to the new UV Source Assembly.
17. Position the clamp such that the cable cannot back out, and tighten it with the 9/64-inch balldriver (see
Figure 14).

CLAMP

 
 
Figure 14. Attaching the Clamp
 

843J001‐1, Rev D8  10 
 
18. Install the capillary assembly (843A147-1) between the manifold block and the new source assembly (see
Figure 15).
19. Remove tube union from existing 759A044B-4 capillary that was reserved for re-use. Bend the capillary as
shown in Figure 15 and connect it to the new source assembly.
 

CAPILLARY
#
ASSEMBLY #3
843A147‐1 2 #
1
#
4
REMOVE UNION AND 
ATTACH TO NEW 
SOURCE, BENDING AS 
SHOWN

 
 
Figure 15. Installing the Capillary Assembly
 
20. Slide insulation (843D064-1) over end of Source Assembly as shown in Figure 16, positioning the slot in the
insulation upward. Sensor cable and heater and sensor wires should route through slot opening.
21. Secure with provided cable tie.

Cable Tie

Insulation

Figure 16. Location of Insulation and Cable Tie

843J001‐1, Rev D8  11 
 
9 INSTALLING THE SAMPLE CELL ASSEMBLY
 
1. Slide the cell as evenly as possible into its original position; make sure the optical purge vents are pointing
down (see Figure 17).

Optical Purge Vent
 
 
Fig. 17. Installing the Sample Cell
 
2. Locate the line on the knurled cell retainer and match this line with the line on the subassembly. Do this for
each side of the sample cell. This aligns the mounting holes of the cell retainer to the holes in the cell.
3. Replace and tighten the two socket head screws on both sides of the cell that secure the cell retainers.
4. To stabilize the cell, tighten the set screws in the stabilizer block on each side of the cell.
5. If the cell is electrically heated, reconnect the blocks and install the insulation.
6. Reconnect Sample Ports 1 and 2. Sample Port 1 is Sample In for vapor systems and Sample Out for liquid
systems. Sample Port 2 is Sample Out for vapor systems and Sample In for liquid systems.

10 POSITIONING THE JUMPER

1. Jumper positions 1 and 2 on JP1 on the Calc/Control Board, using jumper 851Z061-1 supplied in the kit
(see Figure 18).
 

JUMPER
1 2 3
JP1

U39

JP 2 3
11 U
39

JUMPER DETAIL

J2
1

7
8

C CALC/CONTROL PCB

DETECTOR ENCLOSURE  
 
Figure 18. Calc/Control PCB Jumper Location
 
 

843J001‐1, Rev D8  12 
 
 
11 ATTACHING THE LABELS
 
1. Remove the backing from the 843D061-1 Label Logo Multiwave LED and affix to the front door of the right
hand enclosure as shown in Figure 19.

Figure 19. Attaching the LED Label

2. Affix the new Sales Order Modification label adjacent to the old Sales Order label (see Figure 20).

Figure 20. Attaching the Sales Order Modification Label

843J001‐1, Rev D8  13 
 
12 LED ANALYZER SET-UP
1. On the Mode Selection Panel, press MODE SELECTION.
2. Select SET-UP TABLES.
3. Press MODIFY SET-UP (F2), then FACTORY (F3), then ANALYZER (F3), then OPTIONS (F3), then
OPTICS (F1).
4. Set WHEEL FILTERS to 8.
5. Set REFERENCE POSITION to 1.
6. Set SOURCE to IR.
7. Press ACCEPT (F1), then EXIT (F4), then EXIT (F4), then EXIT (F4), then EXIT (F4).
8. Change the casting setpoint to 50° C. This setpoint is used in operation for the LED source.

13 UPDATING THE MATRIX COEFFICIENTS

Refer to the 3402LED Manual to change the Measure Component matrix. If you received an application-
specific matrix with your Upgrade Kit, use those coefficients. Otherwise, use the coefficients listed below.

F1 0
F2 0
F3 +0.5
F4 0
F5 -0.5
F6 0
F7 +0.5
F8 0

14 UPDATING THE ALARMS AND WARNINGS

Refer to the 3402LED Manual to change the following alarms and warnings.

Detector voltage alarms should be reset to reflect the new values in the Data Package that accompanied
your LED Upgrade Kit. The following alarms and warnings need to be adjusted.
 High detector DC voltage Alarm
 Low detector DC voltage Alarm
 High detector DC voltage Warning
 Low detector DC voltage Warning
 High detector AC voltage Alarm
 Low detector AC voltage Alarm
 High detector AC voltage Warning
 Low detector AC voltage Warning

Refer to the 3402 Manual to change the following alarms and warnings. These alarms are not used in the
LED Multiwave, so they are not referred to in the 3402LED Manual.

Alarms and warnings specific to the old deuterium lamp source and related component should be disabled.
 Improper Chopper Signal Slow
 Improper Chopper Signal Missing
 Improper Chopper Signal Fast
 Improper Chopper Signal Noisy

843J001‐1, Rev D8  14