November

Document Number NIC-704-2017-01 Date of Issue

PE-1000 Service Manual 20, 2017
Control Department Technical Service Gr Page 0 / 66

PE-1000 Type-C
(S/N: 16870026-)
Service Manual

Nippon Instruments Corporation

Technical Service Gr

Date Prepared Checked Approved

First Edition November Mamezaki Yamada Kato

20, 2017 Kinoshita

0
 November
PE-1000 (Type-C) Document Number NIC-704-2017-01 Date of Issue
20, 2017
Service Manual
Control Department Technical Service Gr Page 1/ 66

Revision History
Revision
Revision Date Reason for Changes Prepared Approved
No.
Mamezaki Kato
01 March 31, 2017 First Edition issued
Kinoshita

1
NIC-.704-2009-01

Mercury Analyzer
Mercury/PE-1000 (Type-C) Service Manual

Contents
1. Introduction ..................................................................................................................... 4

2. Troubleshooting .............................................................................................................. 5

2.1. Alarm/error messages .............................................................................................................................. 5

2.1.1. PE-1 ................................................................................................................ 5
2.1.2. HT-3103A ........................................................................................................ 7
2.2. Other problems ............................................................................................................................................ 8

3. Maintenance (how to replace and adjust the parts and components) ........................ 9

3.1. Cautions on maintenance....................................................................................................................... 9

3.2. PE-1 ................................................................................................................................................................... 9
3.2.1. Mercury collector tube ..................................................................................... 9
3.2.2. Sample heating tube ..................................................................................... 12
3.2.3. Disassembling the sample injection section and replacing the septum ......... 15
3.2.4. Replacing the tube of the automatic discharge pump.................................... 16
3.2.5. Replacing the automatic discharge pump ..................................................... 16
3.2.6. Replacing and cleaning the solenoid valves (V1-V5) .................................... 17
3.2.7. Solenoid valves (V6-V7) ................................................................................ 18
3.2.8. Mass flow controllers (HIGH and LOW) ........................................................ 20
3.2.9. Adjusting the mercury lamp and reference voltage ....................................... 21
3.2.10. Heaters (H-1 to 3).......................................................................................... 22
3.2.11. Heater (H-5) .................................................................................................. 23
3.2.12. H5 thermocouple ........................................................................................... 24
3.2.13. Main board .................................................................................................... 25
3.2.14. Activated charcoal on the outlet side ............................................................. 26
3.2.15. Activated charcoal on the inlet side ............................................................... 27
3.2.16. Cell ................................................................................................................ 27
3.2.17. SSRs ............................................................................................................. 29
3.2.18. Switching power supplies .............................................................................. 30
3.2.19. Calibrating the flow sensor ............................................................................ 32
3.2.20. Adjusting the sensitivity of the optical unit ..................................................... 33
3.3. HT-3103A ...................................................................................................................................................... 34

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NIC-.704-2009-01

3.3.1. Replacing the syringe .................................................................................... 34

3.3.2. Adjusting the origin in the vertical direction (Touch and Plunger Zero) .......... 38
3.3.3. Adjusting the sample injector position ........................................................... 40
3.3.4. Adjusting the origin in the horizontal direction (Borders Mark-Out) ............... 44
3.3.5. Cleaning the metal block and touch sensor ................................................... 49
3.3.6. Replacing the flex cable ................................................................................ 50
3.3.7. Replacing the turret motor assembly and encoder ........................................ 53
3.3.8. Replacing the turret head .............................................................................. 55
3.3.9. Replacing the plunger motor assembly ......................................................... 60
3.3.10. Replacing the antifriction tape ....................................................................... 64
3.4. Flow diagram of PE-1000 ..................................................................................................................... 65

3
NIC-.704-2009-01
1. Introduction

1. Introduction
This document describes procedures and methods for replacing and adjusting the
components and parts of the PE-1000 Type-C (S/N: 16870026 and later). The work requires
disassembly, reassembly, and reinspection of the analyzer. For basic operations, refer to the
Instruction Manual.

4
NIC-704-2009-01 2. Troubleshooting

2. Troubleshooting
2.1. Alarm/error messages
2.1.1. PE-1
Message Description and Corrective Action
Appears for 20 minutes after the power is turned on.
Because the heater and the optical system are still unstable
STAND-BY xx:xx
during the countdown period, any measured data in the
period is unreliable.
Appears when the time for which the lamp has been
LAMP LIFE EXCEEDED
powered on exceeds 5,000 hours.
Appears when 1.5 g or more of mercury has been absorbed
CARBON FILTER FULL!!
in the activated carbon on the outlet side of measured gas.
Appears when the measurements are made more than 500
SEPTUM COUNTS EXCEEDED!!
times. Replace the septum.
Appears when the syringe has been driven more than
SYRINGE LIFE EXCEEDED!!
10,000 times. Replace the syringe.
Possible cable break at the thermocouple of the H1 heater
or possible short-circuit with the heater line.
H1 INTERLOCK
Check that the tip of the thermocouple is not in contact with
the heater line.
Possible cable break at the thermocouple of the H2 heater
or possible short-circuit with the heater line.
H2 INTERLOCK
Check that the tip of the thermocouple is not in contact with
the heater line.
Possible cable break at the thermocouple of the H3 heater
or possible short-circuit with the heater line.
H3 INTERLOCK
Check that the tip of the thermocouple is not in contact with
the heater line.
Possible cable break at the thermocouple of the H4 heater
or possible disconnection of the H4 heater.
H4 INTERLOCK
If the connector has come off, turn off the power and plug in
the connector.
Possible cable break at the thermocouple of the H5 heater.
H5 INTERLOCK
Replace it.
Possible cable break at the thermocouple of the RH heater
or possible disconnection of the RH interlocking cable.
RH INTERLOCK
If the cable has come off, turn off the power and connect the
cable.

H2 is still warming up. The heater has not reached the setup temperature.

H3 is still warming up. The heater has not reached the setup temperature.

H4 is still warming up. The heater has not reached the setup temperature.

Appears when the SIG voltage is high during standby.

CELL is dirty.
Wipe the optical cell with alcohol or the like.

5
NIC-704-2009-01 2. Troubleshooting

Message Description and Corrective Action

A/D FULL Appears when the detected voltage of the optical unit rises
above the specified value (the Sig or Ref voltage is equal to
or higher than 5V). Wipe the optical cell with alcohol or the
like.
HT INJECTION ERROR Appears when the syringe washing bottle of the sample
changer is not set in place. Set the bottle and restart the
process.
LAMP BROKEN Appears when the light quantity of the lamp (REF voltage)
drops below the specified value (0.5V).
FLOW ERROR Appears when the flow rate of the carrier gas drops below
the specified value (equal to or lower than half the setup
value).
HEATER BROKEN (H1) Appears when the temperature does not rise at the H1
heater.
Possible cable break or possible failure of the control
system.
HEATER BROKEN (H5) Appears when the temperature does not rise at the H5
heater.
Possible cable break or possible failure of the control
system.
HEATER BROKEN (RH) Appears when the temperature does not rise at the RH
heater.
Check that the RH-PE is powered on.
COOLING ERROR (H1) Appears when the H1 heater cools down too slowly.
FAN-1 may not be running.
COOLING ERROR (H5) Appears when the H5 heater cools down too slowly.
FAN-2 may not be running.
COOLING ERROR (RH) Appears when the RH heater cools down too slowly.
FAN-RH may not be running.
HEATER TEMP ERROR (H1) The H1 heater is overheated. Possible problem with the
heater control.
HEATER TEMP ERROR (H2) The H2 heater is overheated. Possible problem with the
heater control.
HEATER TEMP ERROR (H3) The H3 heater is overheated. Possible problem with the
heater control.
HEATER TEMP ERROR (H4) The H4 heater is overheated. Possible problem with the
heater control.
CASING FAN BROKEN The rotation of the casing fan is not detected.
It is necessary to replace the casing fan.

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NIC-704-2009-01 2. Troubleshooting

2.1.2. HT-3103A
Message
HT Communication error
HT Invalid communication
Invalid syringe type
HT not stand-by
Description and Corrective Action
Appears when the PE-1 cannot establish communication
with the sample changer.
Appears when an undefined command has been sent from
the PE-1 to the sample changer.
Appears when the syringe size specified with the
application software is different from the size set in the
sample changer.
Appears when the sample changer is not on standby; for
example, the sample changer is moving or an error has
occurred.

* If the HT-3103A generates any errors other than the above—such as an operation stop, the
measurement stops and the Err light of the HT-3103A’s main unit lights up in red as shown
in the following photo. Click [Run][HT Start Maintenance Software] to confirm the error
information.

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NIC-704-2009-01
2.2. Other problems
Problem Cause
High blank value Contamination inside the
line
Low sensitivity Contamination inside the
line
Poor calibration of the
standard sample
Presence of leak
Bad peak shape Improper method and
sample volume
Defective mercury
collector tube or defective
sample heating tube
Presence of leak Disconnected or loose
line
Poor calibration of the
flow sensor
Failure of the flow sensor
Misalignment of Poor adjustment of the
injector position injector position
Vial detection Poor adjustment in the
failure detection of vertical
positions (The horizontal
positions are detected
properly)
Poor adjustment in the
detection of horizontal
positions
Malfunction and Failure of the touch
abnormal noise of sensor
needle Failure of the needle
motor assembly
Malfunction and Failure of the plunger
abnormal noise of motor assembly
plunger
Malfunction and Breakage of antifriction
abnormal noise of tape
turret Failure of the motor
assembly and encoder
2. Troubleshooting
Action Refer to
Continuously carry out measurement 3.2.1–3
with distilled water.
Replace the syringe and septum.
Replace the sample heating tube,
collector tube, and joints.
Replace the valve.
Continuously carry out measurement 3.2.1–3
with distilled water.
Replace the syringe and septum.
Replace the sample heating tube,
collector tube, and joints.
Replace the valve.
Recalibrate the standard sample.
Conduct leak check and identify the
leak spot.
Review the analysis method.
Replace the mercury collector tube. 3.2.1
Replace the sample heating tube. 3.2.2
Retighten the joint or replace the line.
Recalibrate the flow sensor.
Replace the flow sensor.
Realign the injector position
Execute the Touch and Plunger Zero.
Execute the Borders Mark-Out
(BMO).
Clean the metal blocks and touch
sensor.
Replace the turret head and flex
cable.
Replace the plunger motor assembly
and flex cable.
Replace the antifriction tape.
Replace the turret motor assembly,
encoder, and flex cable.
8
3. Maintenance (how to replace and adjust the parts and
components)
This chapter describes methods and procedures for replacing and adjusting the parts and
components.

3.1. Cautions on maintenance

Warning
• Shut off the power supply before starting the maintenance work. Otherwise, you may
suffer an electric shock.

Caution
• Before you conduct the maintenance of the heater section, be sure to turn off the power
switch and allow the heater to cool down to roughly room temperature. Otherwise, you
may burn yourself.
• Be careful when you touch any glass parts. Otherwise, you may damage them.

3.2. PE-1
3.2.1. Mercury collector tube
(1) Turn off the power, and allow it to cool down for at least 30 minutes.
* It is very dangerous to conduct this work while the machine is activated. Be sure to
cool down the machine before work.
(2) Open the front cover of the measuring section.
(3) Remove the jacket heater.

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NIC-704-2009-01 3. Maintenance

(4) Loosen the screw of the retaining plate of the sample heating tube, and slide the plate to the
left.

(5) Loosen the joint connected to the sample injection section as well as the joint connected to
the gas-liquid separating bottle.

(6) Loosen the five screws fixing the heaters H1, 2, and 3.

(7) Loosen the nut of the reducing T-joint.

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NIC-704-2009-01 3. Maintenance

(8) Slide the heaters H1, 2, and 3 to the left, and remove the reducing T-joint.

(9) Loosen the nut of the T-joint on the right side of the collector tube, and pull out the collector
tube to the left. If it is difficult to pull out the collector tube, remove the cover of the heater H5
and pull it out.

(10) Remove the T-joint.

* When attaching the collector tube, ensure that the three lugs of the dents are located on the
right side from the collector agent (cell side).
* To attach the tube, reverse the removal procedure.
* After tightening the Teflon joint by hand, further tighten it 1/8 turn. Too much tightening damages
the screw thread.

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NIC-704-2009-01 3. Maintenance

3.2.2. Sample heating tube

(1) Turn off the power, and allow it to cool down for at least 30 minutes.
* It is very dangerous to conduct this work while the machine is activated. Be sure to
cool down the machine before work.
(2) Open the front cover of the measuring section.
(3) Remove the jacket heater.

(4) Loosen the screw of the retaining plate of the sample heating tube, and slide the plate to the
left.

(5) Loosen the joint connected to the sample injection section as well as the joint connected to the
gas-liquid separating bottle, and remove them.

(6) Loosen the lower screw of the sample injection section, and remove the sample injection
section.

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NIC-704-2009-01 3. Maintenance

(7) Loosen the metal nuts on the upper and right side of the reducing T-joint.

(8) Loosen the upper, lower, left, and right screws (five screws) fixing the heater unit, and slide the
unit to the left.

(9) Remove the two hand screws on top and bottom of the heater cover, remove the cover, and
remove the heat insulation of H2 and H3.

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NIC-704-2009-01 3. Maintenance

(10) Loosen the screws fixing the thermocouples for H1, H2, and H3, and pull out the
thermocouples from the heater wire.

(11) Pull out the sample heating tube upward, and replace it.
(12) Assemble the parts by reversing the above procedure.

Tip of
thermocouple

* To set each thermocouple again, push it in from the left side so that its exposed tip
touches the dent of the sample heating tube but does not touch the heater wire.
* If any of the tips touch the heater wire, the thermocouple malfunctions and the heater
cannot increase its temperature normally.
(13) After assembly, conduct the leak check.
(14) Readjust the sample injector position of the sample changer.

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NIC-704-2009-01 3. Maintenance

3.2.3. Disassembling the sample injection section and replacing the septum
(1) Check that the power is turned off.
* After turning off the power, cool down the machine for at least 30 minutes and then carry out
the following work.
(2) Open the front cover of the measuring section.
(3) Hold the branch line at the sample injection section, rotate the dish plate counterclockwise,
and then remove it.

(4) Take out the septum with tweezers or other tools, and replace it.

(5) Attach the sample injection section by reversing the removal procedure.
(6) Conduct the leak check.
(7) Readjust the sample injector position of the sample changer.

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NIC-704-2009-01 3. Maintenance

3.2.4. Replacing the tube of the automatic discharge pump

As a guide, replace the pump tube after one year or 400 hours of operation. Note that a
deterioration of the tube may cause a failure of the pump.
(1) Turn off the power of the analyzer, and pull the tube out of the pump.
(2) Remove the bluish plastic cover from the pump by pulling the left side toward you.

Replace the tube.

If the rotor does not run, apply
silicone grease.

(3) Put the pump and the tube back in place.

3.2.5. Replacing the automatic discharge pump

(1) Open the side plate in accordance with Section 3.2.7
(2) Remove the connector.
(3) Hold the pump body (gray part), lightly push the hook located on the upper side, and pull out
the pump.

(4) Replace it with a new pump, and put it back in place.

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NIC-704-2009-01 3. Maintenance

3.2.6. Replacing and cleaning the solenoid valves (V1-V5)

(1) Open the front door, and remove the two screws. When they are removed, you can open the
front panel.

(2) The valves are installed on the back of the front panel. The following photo shows the
installation positions of the valves. (The valves V1-V5 are the same models.)

V5

V1 V2 V3 V4

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NIC-704-2009-01 3. Maintenance

(3) Detach each valve from the analyzer by removing the two screws from the bottom of the valve
and disconnecting connectors and tubes.
(4) Replace the valve with a new one.

(5) You can also remove the two screws from the bottom of each valve, disassemble each
solenoid valve, immerse its plastic parts into nitric acid (1+10), and wash them with an
ultrasonic cleaner.
* A large amount of oil adheres to the valves V1 and V4 because they are installed on the line
through which volatile components pass.

3.2.7. Solenoid valves (V6-V7)

(1) Open the front panel in accordance with Section 3.2.6, and remove the one screw and the two
tubes from the analyzer side.

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NIC-704-2009-01 3. Maintenance

(2) Open the side plate by pushing it to the left. The valves V6 and V7 are installed in the upper
part of the analyzer.

V6
V7

(3) Detach each valve from the analyzer by removing the two fixing screws from the bottom of the
valve and disconnecting three tubes and an electric connector.

(4) Remove two screws each from the upper and lower parts of the valve body.

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NIC-704-2009-01 3. Maintenance

(5) Disassemble each valve as shown in the following photo. Check the inside of each valve for
any rust or foreign matter.
* If any foreign matter gets stuck into the valve V6, the leak check 4 indicates NG.

3.2.8. Mass flow controllers (HIGH and LOW)

(1) Set the source pressure of argon and air to zero.
(2) Open the side plate of the analyzer in accordance with Section 3.2.6.
(3) The mass flow controllers are installed at the center of the analyzer.
 Left: For HIGH flow rate (1 L/min)
 Right: For LOW flow rate (100 ml/min)
(4) Remove the two set screws from the bottom of the analyzer and disconnect the two pipes and
the electric connector.

HIGH

LOW

(5) Remove them from the analyzer.

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NIC-704-2009-01 3. Maintenance

3.2.9. Adjusting the mercury lamp and reference voltage

(1) Loosen the six mounting screws, and remove the cover.
(2) Remove the connector of the lamp.

(3) Remove the two screws, and pull out the lamp to the right. Attach a new lamp so that the front
of the lamp is aligned with the lower hole of the thermostatic cap (the direction of the cell). A
red marker is put onto the front of the lamp.

(4) Wait for 20 minutes after turning on the power. Then open the Maintenance window and
Parameter tab. After entering the password (0219), open the OPTICAL ADJ tab.

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NIC-704-2009-01 3. Maintenance

(5) Click [Optical Adjust], and execute [Auto Adjust].

(6) Adjust the sensitivity in accordance with Section 3.2.20.

3.2.10. Heaters (H-1 to 3)

(1) Remove the combustion tube in accordance with Section 3.2.2.
(2) Remove the nuts, and detach the heaters from the analyzer.

(3) When attaching a new heater, widen the position for the thermocouple (area shown as the red
circle in the following photo).
* The H-1 heater wears out quickly because of repeated cycles of heating and cooling.

22
NIC-704-2009-01 3. Maintenance

(4) Fasten the nuts lightly, and attach the heaters and the combustion tube.
(5) Fully tighten the nuts.
* When you tighten the upper nut, be careful not to cause the heater wire to move down.

3.2.11. Heater (H-5)

(1) Remove the mercury collector tube in accordance with Section 3.2.1.
(2) Remove the nuts, and detach the heater from the analyzer.

(3) Fasten the nuts lightly, and attach the heater and the mercury collector tube. Set the
thermocouple into the gap of the heater wire, and check that the mercury collector tube can
be smoothly inserted and removed.
※There is no problem with this thermocouple touching heater wire.
(4) Fully tighten the nuts.

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NIC-704-2009-01 3. Maintenance

3.2.12. H5 thermocouple
(1) Open the side plate of the analyzer in accordance with
Section 3.2.6.
Remove the four screws and the connectors, and remove the
cover.
(2) Disconnect the H51 connector:
Press the hole next to each pin with a precision screwdriver
or the like, and remove the pins from the connector.
You need to remove the two pins at the center.

(3) Remove the two screws fixing the thermocouple, and pull out the thermocouple.
(4) Attach the thermocouple by reversing the removal procedure. When the thermocouple is
attached, insert the collector tube as in Section 3.2.11, and check that the collector tube can
be smoothly inserted and removed.

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NIC-704-2009-01 3. Maintenance

3.2.13. Main board

(1) Open the front door and the side plate in accordance with Section 3.2.5.
(2) Remove the tubes and the screws, and open the front panel.

(3) Remove the six mounting screws and the connectors, and detach the board from the
analyzer.

(4) Install a new main board. Put it back in place by reversing the removal procedure.

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NIC-704-2009-01 3. Maintenance

3.2.14. Activated charcoal on the outlet side

(1) Open the front door in accordance with Section 3.2.5. The activated charcoal is located at the
center of the back side.

(2) Remove the upper tubes and the mounting screws from the bottom, and detach the charcoal
case from the analyzer.

(3) To replace the activated charcoal inside the case, open the lid on the bottom of the case.

26
NIC-704-2009-01 3. Maintenance

3.2.15. Activated charcoal on the inlet side

(1) The activated charcoal cases are installed on the back of the analyzer.
(2) Remove the mounting screws and the tubes, detach them from the analyzer, and replace
them.

3.2.16. Cell
(1) Remove the L-joint from the right side of the fluorescent cell.

(2) Remove the three hexagon head screws from the right side, and remove the retaining plate.

27
NIC-704-2009-01 3. Maintenance

(3) Remove the four hexagon head screws and the retaining plate from the front side. Then take
out the fluorescent cell.

(4) Disassemble the cell as shown in the following photo. The left and right joints and the gaskets
can be cleaned with nitric acid. Carefully handle the cell body so that its films are not peeled
off, and clean the inside with alcohol.

(5) Films are put on two out of four sides of the cell. When you attach the cell, ensure that the
films are located on the front side and bottom side of the analyzer.

Top

Front: film side

Back

Bottom: film side

28
NIC-704-2009-01 3. Maintenance

3.2.17. SSRs
(1) Open the side plate in accordance with Section 3.2.7.
(2) With the side plate opened to the back of the analyzer, pull the plate upward, which allows the
side plate to be removed.

(3) Remove the six screws from the back of the analyzer. Remove the tubes connected to V7 NO
and NC, the exhaust tube, and the connectors of the mass flow controllers, V6, and V7, and
remove the back plate.

29
NIC-704-2009-01 3. Maintenance

(4) Remove each mounting screw, and replace the SSRs. Put them back in place by reversing
the removal procedure.

3.2.18. Switching power supplies

(1) Remove the side plate and the back plate in accordance with Section 3.2.15. Remove the
electric wires. The switching power supplies are fixed in place with screws from the metal
plate located on the front of the analyzer. Because the main board is mounted on the front of
the analyzer, you need to remove the main board.

30
NIC-704-2009-01 3. Maintenance

(2) Remove the upper and lower front panels and the tubes.

(3) Remove the mounting screws and the connectors of the main board, the AFS board, and the
valve relay board, and dismount them from the analyzer. Remove each mounting screw (four
screws for PS3 and two screws for the others), and replace the switching power supplies. Put
them back in place by reversing the removal procedure.

PS1

PS3
PS6 PS2 PS5 PS4

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NIC-704-2009-01 3. Maintenance

3.2.19. Calibrating the flow sensor

(1) Open the front panel in accordance with Section 3.2.5.
(2) Disconnect the Teflon tube connected to V2 COM.

(3) Disconnect the filter from the flow sensor, and directly connect the above-mentioned Teflon tube to
it. Check the Teflon tube and the Tygon tube for any kinks or bends.

(4) Select “user entry”  Parameter tab in the Maintenance window. After entering the password
(0219), open F.M ADJ tab shown in the following figure. Then click [Calcu. Factor]. The system
automatically executes calibration.

(5) If the automatic calibration fails, check the tubes for any bends and run the automatic
calibration again. If it succeeds, conduct the leak check.

32
NIC-704-2009-01 3. Maintenance

3.2.20. Adjusting the sensitivity of the optical unit

* Because this adjustment needs to be made when the analyzer is running normally, be
sure to conduct it after overhaul work, which includes everything from the replacement of
the optical unit’s mercury lamp, the sample heating tube, the mercury collector tube, the
tubes, and the joints to the cleaning of the cell.

(1) Measure 1 ng mercury of the standard solution in Low and High ranges, and check the
sensitivity.
(2) Check that the respective Integral values are in the following ranges. If they are in the
following ranges, no adjustment is necessary.
• Low: 3000±300
• High: 5700±570
(3) If any of the values are out of the ranges, change the factor(s). Open the Maintenance window
and select “user entry”  Parameter tab. After entering the password (0219), open OPTICAL ADJ
tab shown in the following figure.

(4) Change the values in Sensitivity Factor [Low] and Sensitivity Factor [High]. The default values
of the factors are 1.000.
(5) Measure 1 ng mercury of the standard solution again, and check that the values in Low and
High fields are in the above-mentioned ranges. If any of the values are out of the ranges,
change the factor(s) again.

33
NIC-704-2009-01 3. Maintenance

3.3. HT-3103A
3.3.1. Replacing the syringe
Be sure to use a genuine syringe.
* Be sure to replace the syringe after starting the software, or an error may occur at the time of
initialization.
(1) Click [Run]  [HT Start Maintenance Software] to display the Virtual screen below.

(2) Select [Settings].

(3) Select [Setup].

34
NIC-704-2009-01 3. Maintenance

(4) Select [Syringe Installation].

(5) After the following standby window appears (left), the window in the right figure appears.
Select [Manual].

(6) Actuate the following parts to make it easier to remove the syringe.
Turret
Left and right swivel motion of the turret
Plunger
Vertical motion of the plunger
Needle
Vertical motion of the syringe

(7) Open the cover of the syringe section, loosen the screws of the syringe fixture, and remove it.

35
NIC-704-2009-01 3. Maintenance

(8) Pull out the plunger fixture.

Plunger fixture

Fixing screw for

sample vial guide * If it is difficult to remove the plunger
fixture, move the syringe up or down to a
position where the fixture is easy to
remove.
Syringe fixture

Needle guide

Sample vial guide

(9) Remove the syringe, and attach a new syringe. At that time, remove the O-ring from the old
syringe, and attach it to the new syringe.

Remove and attach the

O-ring.

When you tighten the screws of the syringe fixture, be careful not
Caution to bend the syringe.
 While pushing the following two points,  After attaching the syringe, check the
tighten the screws. syringe for any bending. If the syringe is
not straight when viewed from the side,
attach the syringe again.

Syringe fixture

At 0 μL position of syringe scale

36
NIC-704-2009-01 3. Maintenance

(10) Loosen the fixing screws for vial guide, and adjust the height of the needle so that the needle
tip does not protrude from the vial guide.

(11) When the work is complete, press [Continue] to exit the Manual mode.
(12) Select the syringe volume (normally 100 μL), and press [Save] to save the setting.

(13) Plunger Zero automatically starts. When the process is complete, select [Exit] to return to the
[Setup] window.

Caution!
Check for any gap at the zero position of the syringe. If there is a gap, execute Syringe Installation
again.
* To return to PE-1000 win, press [Exit] to return to the [RUN] window, and then press key
to close the HT maintenance software. If you close the maintenance software without
returning to the [RUN] window, the sample changer does not enter the measurement mode.

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3.3.2. Adjusting the origin in the vertical direction (Touch and Plunger Zero)
Make this adjustment if there is a problem with the detection of vertical positions of the sample vial
and the effluent bottle.

(1) Select [Alignment].

* To start from the initial window [RUN], open the [Setup] window through the following
procedure:
Select [Settings]  [Setup].

(2) Select [Touch Plunger Zero].

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(3) After the following standby window appears (left), the window in the right figure appears. Set
the effluent bottle and the sample vial in the holder No. 8 and the vortex section.

Vortex section

No. 8 sample vial Effluent bottle

(4) Select the [Continue] key to start the automatic adjustment of the plunger position and the vial
height.
You can check the progress of the adjustment in the following window.

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(5) When the Oven is automatically adjusted, select the [Exit] key to return to the [Alignment]
window because the adjustment of Plunger Zero is not necessary.

* To return to PE-1000 win, press [Exit] to return to the [RUN] window, and then press key
to close the HT maintenance software. If you close the maintenance software without
returning to the [RUN] window, the sample changer does not enter the measurement mode.

3.3.3. Adjusting the sample injector position

(1) Select [Front Injector] from the [Alignment] window.
* To start from the initial window [RUN], open the [Alignment] window through the following
procedure.
Select [Settings].  Select [Setup].  Select [Alignment].

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(2) After the following standby window appears (left), the window in the right figure appears.
Choose [Do Manual] to open the setup window for injector alignment.

(3) Adjust the turret with the keys so that the septum guide can move down smoothly,

and lower the syringe to the sample injection section with the key.

If you cannot precisely align the position through the settings

of the sample changer alone, loosen the screws of the
heater unit and those of the positioning plate, and adjust the
position by shifting the injection port in the horizontal
direction.
When the adjustment is complete, bring the positioning plate
into contact with the heater unit, and fix them in place.

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(4) Press [Store] to register the injector position.

(5) Set the needle injection depth to 42 mm, and press [Save] to register.

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(6) Set the injection speed to [Medium], and press [Save] to register.

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(7) Press [Exit] to return to the [RUN] window, and press key to exit the HT maintenance
window.
* If you close the maintenance software without returning to the [RUN] window, the sample
changer does not enter the measurement mode.

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3.3.4. Adjusting the origin in the horizontal direction (Borders Mark-Out)

Make this adjustment if there is a problem with the detection of horizontal positions.

(1) Click [Run]  [HT Start Maintenance Software] to open the Virtual screen.
Select [Settings]  [Setup]  [Service].

(2) Enter 66880 as the password.

(3) Click [BMO] in the following window.

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(4) After removing the syringe, click [Continue].

(5) The system automatically checks the limit positions of the plunger, the needle, and the turret.

(6) When the process is complete, the following window appears. Remove all the sample vials,
and click [Continue].

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(7) The position of the sample vials is aligned at No. 1 and No. 15. The following window appears,
and the needle guide automatically moves toward the sample vial No. 1.

(8) Adjust the needle guide to the right and left to set it at the center of the sample vial No. 1 when
viewed from the front. Then move down the needle until the touch sensor is turned ON, and
click [Store].

(9) Make the same alignment also at the sample vial No. 15.

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(10) When the adjustments are complete at the sample vials No. 1 and No. 15, you need to align
the positions of the solvent bottles. Remove all the solvent bottles (including the effluent
bottle) as instructed in the following window, and click [Continue].

(11) You need to align the positions at the solvent bottles at B and E. Adjust the needle guide to
the right and left when viewed from the front to set it at the center. Then move down the
needle until the touch sensor is turned ON, and click [Store].

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(12) When the positions are aligned at the solvent bottles B and E, you need to align the position
of the oven. Set the sample vial into the oven.

(13) Adjust the needle guide to the right and left when viewed from the front to set it at the center of
the sample vial. Then move down the needle until the touch sensor is turned ON, and click
[Store].

(14) When the following window appears, the BMO is complete.

* After the completion of the Borders Mark-Out, be sure to attach the syringe (refer to 3.3.1.
"Replacing the syringe".), and execute the Touch and Plunger Zero.

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3.3.5. Cleaning the metal block and touch sensor

Carry out this procedure in the event of a vial detection error or a touch sensor error.

(1) Remove the HT-3103A from the PE-1.

(2) Loosen the two screws of the metal blocks, and remove the whole vial guide and the metal
blocks.

(3) Wipe the blocks and the touch sensor section with cotton paper dampened with alcohol etc.

(4) Put the parts back in place in reverse order. Position the needle with the block on the right
side. Adjust the right block so that the needle tip is positioned at the same height as the
bottom of the guide. Fix the left block at the position about 1 cm higher than the right block.

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3.3.6. Replacing the flex cable

You need to replace the cable at the same time when you replace the turret head, the plunger
motor assembly, and the turret motor assembly.

(1) Remove the HT-3103A from the PE-1, and remove the upper cover.

(2) Move the turret by hand, and remove the four fixing screws.

(3) Lift the turret assembly, and remove the three connectors.

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NIC-704-2009-01 3. Maintenance

(4) Remove the turret assembly.

(5) Carefully pull out the needle section until the cable connector can be seen.

(6) Disconnect the flex cable from the connector, and insert a new flex cable.

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NIC-704-2009-01 3. Maintenance

(7) Connect the old flex cable and the new flex cable with tape.

(8) Pull them out until the new flex cable can be seen from the turret head side.

(9) Remove the tape, disconnect the old flex cable from the connector, and insert the new flex
cable.

(10) Put the turret assembly back in place.

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3.3.7. Replacing the turret motor assembly and encoder

You need to replace them if the turret malfunctions or the turret makes an abnormal noise during
motion.

(1) Remove the turret assembly in accordance with Section 3.3.6.

(2) Remove the two screws from the motor assembly and the one screw from the encoder, and
detach them.

(3) Attach a new motor assembly. Fasten the two screws lightly.

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(4) While pushing the motor toward the outside of the turret, fix it in place with the two screws.

(5) Attach a new encoder. Fasten the screw lightly.

(6) While pushing the encoder toward the outside of the turret, tighten the screw to fix it in place.

(7) Put the turret assembly back in place. Execute the Borders Mark-Out, the Touch and Plunger
Zero, and readjust the injector position.

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3.3.8. Replacing the turret head

You need to replace the turret head if the needle malfunctions or the needle makes an abnormal
noise during motion.

(1) Remove the turret assembly in accordance with Section 3.3.6.

(2) Remove the flex cable, and remove the two screws fixing the turret head to the turret body.

(3) Remove the vial guide and the metal blocks in accordance with Section 3.3.5.
(4) Loosen the fixing screw for belt holder, and remove it.

(5) Carefully pull out the turret head until the belt blockers can be seen.

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NIC-704-2009-01 3. Maintenance

(6) Remove the screw of the left belt blocker.

(7) Remove the belt from the belt blocker.

(8) Remove the belt from the turret head.

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NIC-704-2009-01 3. Maintenance

(9) Remove the motor assembly and the encoder from the turret head in accordance with Section
3.3.7.
(10) Remove the two connectors and the three screws, and remove the turret board from the turret
head.

(11) Attach the motor assembly and the encoder to a new turret head in accordance with Section
3.3.7.
(12) Attach the turret board to the new turret head.
(13) Get the new turret head close to the turret body, and pass the belt.

(14) Pass the belt as shown in the following photo.

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NIC-704-2009-01 3. Maintenance

(15) Run the belt around the needle gear, and fix it with the left belt blocker.

(16) Connect the flex cable.

(17) While checking the positions of the flex cable and the belt, carefully push the turret head and
the sledge into the turret body.

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(18) Insert the belt holder, and fix it in place.

(19) Remove the flex cable, and fix the turret head and the turret body with the two screws.
(20) Check that the belt holder and the flex cable are arranged as shown in the following photo
when viewed from the lower side of the turret body.

(21) Put the turret assembly back in place, and execute the Touch and Plunger Zero and readjust
the injector position.

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NIC-704-2009-01 3. Maintenance

3.3.9. Replacing the plunger motor assembly

You need to replace it if the plunger malfunctions or the plunger makes an abnormal noise during
operation.

(1) Remove the turret assembly in accordance with Section 3.3.6.

(2) Remove the two screws of the turret head and remove the belt holder in accordance with
Section 3.3.8, and pull the sledge out of the turret body.

(3) From the sledge board, remove the cables of the encoder and the motor, as well as the flex
cable.

(4) Remove the two screws located on the front of the sledge.

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(5) Remove the one screw and the sliding plate from the back side of the sledge.

(6) Push up the trolley male screw (the screw for moving the plunger up and down) at least 1 cm
from the lower limit.

(7) Slowly lift the plunger motor assembly as shown in the following photo.

(8) Remove the trolley male screw from the female screw located on the other side, and remove
the old plunger motor assembly.

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(9) Insert the trolley male screw into the hole of the sledge.

(10) Screw the trolley male screw into a new plunge motor assembly.

(11) Push the plunger motor into the sledge.

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(12) Tighten the two screws located on the front of the sledge.

(13) Push the trolley male screw down to the lower limit.

(14) Attach the screw, the spring, and the sliding plate onto the back of the sledge.

(15) Put the sledge back into the turret body in accordance with Section 3.3.8, and put the turret
assembly back in place.
(16) Execute the Touch and Plunger Zero and readjust the injector position.

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3.3.10. Replacing the antifriction tape

Replace the tape if the motion of the turret is not smooth or if the antifriction tape is deteriorated.

(1) Remove the turret assembly in accordance with Section 3.3.6.

(2) Put a mark along the lower edge of the antifriction tape with a pencil or the like.

(3) Remove the antifriction tape.

(4) Attach new antifriction tape along the mark.

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3.4. Flow diagram of PE-1000

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