G8 Galileo

G8 Galileo
Maintenance Guide

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1 Overview
1.1 Release Notes

Topic: Maintenance Guide G8 Galileo

Requirement for maintenance

Date: 03. March 2016

Author: Mike Kraues / Wolfgang Rostig
Release: Karl Josef Weifels

Release Version: C
Release Date: March 2016

If there are any remarks or suggestions about the content of this manual and what should be included, please send us
an e-mail.

Best regards

Your Service Team from Bruker Elemental GmbH

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1.2 Content overview

1 Overview .......................................................................................................................... 2
1.1 Release Notes ............................................................................................................... 2
1.2 Content overview .......................................................................................................... 3
1.3 Security Warning .......................................................................................................... 4
2 Maintance Work ............................................................................................................... 5
2.1 First steps ...................................................................................................................... 5
2.2 The following picture shows G8 Galileo ...................................................................... 6
2.3 Start to remove the side panel like in Fig.2 .................................................................. 7
2.4 Cleaning the furnace ..................................................................................................... 8
2.5 Post oxidations furnace ............................................................................................... 15
2.6 Cooling water system ................................................................................................. 18
2.7 Air maintenance unit .................................................................................................. 19
2.8 Change Gas Filter and check gas pressure ................................................................. 20
2.9 Leak check .................................................................................................................. 21
2.10 Change chemicals ....................................................................................................... 22
3 Voltage and adujstment .................................................................................................. 23
3.1 Check mainboard voltage ........................................................................................... 23
3.2 TCD check ALC auto adjust: ..................................................................................... 24
4 Software settings ............................................................................................................ 25
4.1 Keyboard Shortcuts .................................................................................................... 25
5 Appendix ........................................................................................................................ 26

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1.3 Security Warning

!!! WARNING !!!

High voltage is present within the system; these voltages are hazardous!

Watch out for pneumatic parts! This pneumatics parts are strong enough to cause
harm.

If it is required to measure currents inside the instrument it is highly

recommended to use only tools for work with high voltage.

Never work on energized equipment alone!

Before opening the instrument for any service work the power switched off and
the power plug should be removed.

This document is applying together with “Maintenance Protocol G8 Galileo

Version1.3.0 EN”.

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2 Maintance Work
2.1 First steps

Before starting the maintenance, it is strongly recommended to do a quick system check.

When the system is demonstrated to be running properly, press “end standby” (F6) and
leave the main switch in position two.
Ensure that the furnace and window are open for the operations below.

A quick check option could include:

- an visual check of the furnace area (damage / cleanliness)

- a combustion check
- a calibration check
- a parameter check
- a leek check
- open the system window (Ctrl. + D) to check the detector information

Please note:
The quick check is not required but strongly recommended. It gives a system
overview and it could be helpful to find any preexisting issues.

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2.2 The following picture shows G8 Galileo

Fig.1: G8 Galileo (ONH)

Tip:
Start to remove the reagent from the oxidation furnace. Remove the reagent and set it
aside to cooling down for later in section 2.5. Be careful, the temperature of this glass
can be up to 550°C (1022°F)!.

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2.3 Start to remove the side panel like in Fig.2

Fig.2

NOTE: Disconnect the panel ground wires before fully removing them!!!

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2.4 Cleaning the furnace

1- Gather all the tools shown below in figures 3 through 8. These tools were supplied
with the system and should be available at the customer site.

Fig.3 (Q100404 brush) Fig.4 (JW-S433200560 key

for electrode head

Fig.5 (JW-S296200010 Fig.6 (Q103275 knurled screw)

cleaning brush for impulse
furnace)

Fig.7 (JW-S412235A00 key for electrode) Fig.8 (JW-Z010112002 twist grip)

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2- Remove the upper electrode using the (key for electrode head) tool (Fig.9). Turn
clockwise!

Fig.9

3- Now remove the pyrometer module and remove the light guide, use the (twist grip)
tool (Fig.8).

Fig.10

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4- To disconnecting the sample port use the tool Fig.6 (knurled screw) and remove
the sample port as shown in (Fig.11).

Fig.11

5- Fig. 7 (key for electrode) shows the right tool to remove the lower electrode below
(Fig.12).

Fig.12

6- O-Ring 222 (JW-R17222E000) has to replace and the isolation ring

(JW-Z010111001) has to disconnect. To remove the top electrode (Fig.13). For
this operation use both hands and turn it counterclockwise.

Note: For cleaning the threads only use tap, die or scotch bright!

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Fig.13 Fig.14 [thread M40 x 1.5]

Tip:
First turn off tap water and use pieces of paper for catching water which dropping out.

7- Clean the electrode using pieces of scotch bright (JW-P006000001). Use a M40 x
1.5 die for cleaning the threads of the furnace. When a die is not available, use
scotch bright instead. Clean the M5 thread in the middle of this electrode with a
tap. Change all O-rings (JW-R1640X2K55E & JW-R17222E000). O-rings are
available in the G8 O-ring kit (JW-L970000ONH). [This work is important for a
good furnace contact!]

Note: Don’t use silicone grease on the O-ring (JW-R1640X2K55E)! Use a small amount
of silicone grease for all other O-rings.

8- Figure 15 shows a
worn electrode. When
the M5 thread wares a
circle in the top,
change this electrode.

Fig.15- Worn electrode

9- After cleaning connect all parts back!

!!! Warning !!!

Don’t forget to reinstall the isolations ring!!!

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10-Start to clean the upper electrode (Fig. 16) with scotch bright and a pipe cleaner
(Fig.17). Take the pipe cleaner and clean all 6 holes. Move the cleaner up and
down as well as in and out. [These ports are the path for the carrier gas through
the furnace.] Take the scotch bright or grinding paper (400 grit) to clean.
Important: Clean the surface where the crucible is connected (Fig.18).

Fig.16 Fig.17 Fig.18

11-Disconnect the trap and change the following items (Fig.19).

o 1x O-Ring Plug JW-R17008E000
o 2x O-Ring Furnace/wall JW-R17006E000
o Glass wool JW-L040000011

Fig.19

12-Clean all inside parts of the furnace and use a pipe cleaner for the small holes.
After cleaning, reconnect all parts as the originally were connected.

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Hightemperature Impulsfurnace G8 Galileo

Qty. Part No. Description Remarks Pos.

1 Q105611 Hightemperature Imp. Furnace complete furnace
2 JW-R17013E000 O-ring V013 220
2 Q104801 O-ring 19.5x1.5 140
1 Q105686 Axis Connector, long 60
1 Q103405 RWDR DIN3760-A6x16x7-FKM 40
2 JW-R17006E000 O-ring V006 180
1 JW-J010112003 QUARTZ LIGHT GUIDE ROD, G8 120
1 Q103404 O-RING 123, 29.82x2.62 150
1 Q103407 Ball Bearing, sample port G8, front 170
1 Q103406 Ball Bearing, sample port G8, back 160
1 Q104660 Electrode for G8 AL 130

Dust trap connenction

2 JW-R17006E000 O-ring V006
1 JW-J010112026 Dust trap
1 JW-R16008E000 O-ring V008
1 JW-S329311A00 Seal

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Hightemperature Impulsfurnace G8 Galileo

Qty. Part No. Description Remarks Pos.

1 Q104877 HT graphite crucible 80
1 Q103941 Crusible carrier G8 Galileo HT 70
1 JW-R17222E000 O-ring V222 60
1 JW-S412222A00 Insulation the electrode head 50
1 JW-S412220000 LOWER ELECTRODE BASE, G8 40
1 JW-R1740X2K5E O-ring 40x2.5 30
1 Q105781 Tube for Electrode flush 20
1 JW-Z010111002 LOWER ELECTRODE BASE w/o Water Fittings 10

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2.5 Post oxidations furnace

The following procedure explains how to clean the post oxidation furnace.

Fig.20

WARNING:
THE FURNACE COMPONANTS ARE HOT!!!
70°C (158°F)!

1- Disconnect the both

screws on the top (Fig.21).

Fig.21

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2- Carefully remove the aluminum connection cap (use gloves to take the caps
off) and lift it up and out together with the reagents tube.

!!! Warning !!!

Use caution, the temperature of this glass can be up to 550°C (1022°F)!

3- Find a heat resisted place to set the tube and let the quartz tube cool down for
approximately 15 minutes, or until it can be safely handled.
4- When cool, remove the old copper oxide and quartz wool. Refill it with new
quartz wool and copper oxide (AR170/JW-L014000170). Change all three O-
rings 110 (JW-R17110E000) (Fig.22 & 23).

Fig.22 [top] Fig.23 [bottom]

5- Figure 23 shows the bottom part this part is appointed with one O-Ring!
Replace the O-rings (JW-R17110E000), using a small amount of silicone
grease (JW-L040000001) on these O-rings.

6- After cleaning put all parts back together as before. Inspect all O-rings, 004
(JW-R17004E000), for flat surfaces and cracks. If abnormalities are found,
replace the O-rings.

Tip:
Leave the top furnace cap open to let out the water vapor for approximately 15
minutes. This will increase the working life of the copper oxide.

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Post Oxidation furnace 24VDC

Qty. Part No. Description Remarks Pos.

1 Q105665 Post Oxidation furnace complete furnace
1 JW-Z010104001 Quartz tube oxidation furnace not incl. In Q105665 90
Heating coil 24VDC 3A with temp.
1
Q105638 sens 150
3 JW-R17110E000 O-Ring V110 110
2 Q105939 Connection Cap POX lower con. only one O-ring 240
1 JW-L014000170 Rare Earth Copper Oxide CO to CO2 converter

other Pos. Parts are not requiered

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2.6 Cooling water system

The flow sensor operates with ultrasonic sound. There is no mechanical / moving
parts (Fig.24).

Fig.24 Fig.25

1- Check the water flow (Fig.25). One left PC-mouse click “on” click again “off”. If
the flow does not stop check the water in solenoid valve on the back side
(Fig.26).

Fig.26

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2.7 Air maintenance unit

Fig.27

1- Set the air pressure to 4 – 4.5 bar (58 – 65 psi).

2- Empty the water and oil (Fig.28).

Fig.28

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2.8 Change gas filter and check gas pressure

Fig.29

1- Figure 29 shows the position of the gas filter.

This filter has a 1 year life span and should be
replaced yearly. The contamination is visible on
the filter surface. The customer should also
change this as needed. It is possible to replace
from the furnace door.

2- The gas pressure (N2 & He) is 2,5 bar (40 psi).
Turn the screw below the pressure switch (Fig.30)
where the cable is connected.
Only change the setting when it is necessary! Fig.30

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2.9 Leak check

Fig.31

1- Press F4 on the key board and wait. After the furnace is closed, press the F8
button. Now turn off the carrier and purge gas and close the top of the furnace
with a cap (Fig.32 or Fig.33).

Fig.32 Fig.33

2- Watch the “pump flow” visual flow meter. If the system is leak free, the marker
ball will drop all the way to the bottom. It may take up to 3 minutes. If the ball
does not go all the way to the bottom, the gas system must be checked for
leaks.

Information flow rate l/min:

Carrier and purge gas: N2 = 0.9 / He = 1.0
Reference gas: N2 = 0.3 / He = 0.4
Pump flow: N2 = 0.4 / He = 0.8 [approximate]
Calibration gas: H2 = 0.2 / He = 0.2

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2.10 Change chemicals

Fig.34

Figure 34 shows the chemical part (ONH).

A = molecular sieve [re-usable]
B1 = activated carbon and schuetze reagent
C1 = molecular sieve [re-usable]
B2 = sodium hydroxide
C2 = sodium hydroxide/magnesium perchlorate
or special application (like the picture) only magnesium perchlorate

1- Change all 10 O-rings 110 (JW-R17110E000 or JW-R16110E000). Make sure

there is no glass wool between the O-ring and the reagent glass!

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3 Voltage and adujstment

3.1 Check mainboard voltage

Fig.35

1- Check the +/ - 15VDC on the mainboard (Fig.35). The three circles show the
MP (measure point), the blue circle indicates the ground.
2- Check the remaining voltages in the software using “Crtl. D”(Fig.36).
3- If the voltage are not correct call the service help desk.

Fig.36

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3.2 TCD check - ALC auto adjust:

ALC = off

approx. 32000

Fig.37

1- If the compensation level is lower than 20000 or higher than 40000, use the
auto adjust.

2- To adjust the ALC (automatic level control) following the steps:

 Check that the Galileo and software are in an operational mode

 Check the carrier gas and purge gas are between 0.9l/min and 1.1 l/min
 Check that end standby is set to a minimum of 5 minutes
 Check leave ALC to 50% “ALC 50%” (Fig.37)
 Start to adjust “ALC AUTO ADUST” (Fig.37)

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4 Software settings
4.1 Keyboard Shortcuts

Here are the most important key combinations for quick operation of the software.

Key combination Function

Ctrl+ D(1) Call of the diagnosis window

Ctrl+ E Showing and hiding the control window
Ctrl+ G Showing and hiding the weight memory
Ctrl+ Y Showing and hiding the window for recalculation
Ctrl+ Alt+ S(2) Showing and hiding the status window
Ctrl+ Alt+ C Call of the service window
Alt+ S Showing and hiding the current data

Alt+ F9 Opens additional weight memories

F9 Move cursor to the field for weight input

F2(1) Cleaning
F3(1) Open furnace
F5 Analysis
F6 Standby
F8(1) Cleaning
F10 End standby

(1) Not available in all software versions

(2) Only available for Service

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5 Appendix

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