Service_manual_GSS

Service Manual
GSS/LPG combination module

for compEAct S/N, multi EA 5000, Combustion Module
Manufacturer Analytik Jena AG
Konrad-Zuse-Str.1
07745 Jena  Germany
Phone + 49 3641 77 70
Fax + 49 3641 77 92 79
Email info@analytik-jena.de
Service Contact your supplier's service:
Analytik Jena AG
Konrad-Zuse-Str. 1
07745 Jena  Germany
Phone + 49 3641 77 7407
Fax + 49 3641 77 7449
Email service@analytik-jena.de
Service Metrohm AG Metrohm AG

Combustion Module only CH-9100 Herisau  Switzerland
(or your nearest Metrohm representative)
Phone + 41 71 353 85 85
Fax + 41 71 353 89 01
Email info@metrohm.com
General information http://www.analytik-jena.com

http://www.metrohm.com
Copyrights and Microsoft and Windows are registered trademarks of Microsoft Corp. The identification
Trademarks with ® or TM is omitted in this manual.
Edition 02.19
Implementation of the Analytik Jena AG

Technical Documentation
© Copyright 2019, Analytik Jena AG

GSS/LPG combination module Contents
Contents
1 General information ........................................................................................................ 5
2 Gas supply ....................................................................................................................... 10

2.1 Flow diagrams........................................................................................................... 10
2.2 Pneumatic block assembly ........................................................................................ 11
2.3 Adjustment of the gas block...................................................................................... 12
2.3.1 Adjust the pressure regulator (internal pressure) ..................................................... 12
2.3.2 Adjust the pressure switch (internal pressure) ......................................................... 13
2.3.3 Adjust the carrier gas flow (Ar) in LPG Mode ........................................................... 14
2.3.4 Adjustment the carrier gas flow (Ar) in GSS Mode ................................................... 15
2.3.5 Exchange the gas block ............................................................................................. 16
3 Controller module .......................................................................................................... 17

3.1 Block diagram controller ........................................................................................... 17
3.2 Firmware controller .................................................................................................. 18
3.2.1 Firmware controller (for devices up to serial number N76-239) .............................. 18
3.2.2 Firmware controller (from serial number N76-240 and higher) .............................. 19
3.3 Signal termination for RS 485 bus (compEAct) ........................................................ 20
3.4 Check of the GSS/LPG combination module with service program ........................... 21
3.4.1 Service program commands ...................................................................................... 22
3.5 Communication and type check ................................................................................ 23
3.6 Heating/Cooling........................................................................................................ 24
3.6.1 Check of the temperature values............................................................................... 25
3.7 Firmware update for the LPG/GSS controller pcb ..................................................... 25
3.7.1 Firmware update (up to S/N N76-239) .................................................................... 25
3.7.2 Firmware update (S/N N76-240 and higher) ........................................................... 29
3.8 Exchange of the controller pcb.................................................................................. 32
3.9 Exchange of firmware controller pcb with service upgrade kit.................................. 33
3.10 Exchange of heating unit (expansion chamber) ....................................................... 33
4 Dosing valve assembly................................................................................................... 35

4.1 Pneumatic valve assembly ........................................................................................ 35
4.2 Adjustment of the dosing valve ................................................................................ 37
4.3 Exchange of dosing valve assembly .......................................................................... 38
5 Maintenance ................................................................................................................... 41
5.1 GSS/LPG rotor cleaning and/or exchange ................................................................ 41
6 Leak test .......................................................................................................................... 43

6.1 Leak test with sample gas and sniffer ....................................................................... 43
6.2 Leak test with Argon ................................................................................................. 44
7 Troubleshooting ............................................................................................................. 46
8 Recommended Tools ..................................................................................................... 48
3
Figures GSS/LPG combination module
Figures
Figure 1 Front view of GSS/LPG combination module ....................................................... 5
Figure 2 Connections and interfaces (rear side).................................................................. 6
Figure 3 Sample supply to Combustion Module .................................................................. 6
Figure 4 Sample supply to multi EA 5000 (in horizontal mode) ....................................... 7
Figure 5 Communication schema ......................................................................................... 7
Figure 6 GSS/LPG combination module, left side panel removed ..................................... 8
Figure 7 GSS/LPG combination module, right side panel removed ................................... 9
Figure 8 Functional principle of GSS/LPG combination module ..................................... 10
Figure 9 Flow diagram of GSS/LPG combination module ............................................... 10
Figure 10 Flow schema of pneumatic block ........................................................................ 11
Figure 11 Pneumatic block ................................................................................................... 11
Figure 12 Measuring the internal pressure......................................................................... 12
Figure 13 Pressure switch (seen from the left) and screw on the pressure switch (seen
from the right) ..................................................................................................... 13
Figure 14 Adjusting the pressure sensor ............................................................................. 14
Figure 15 Measuring the Ar carrier gas flow ...................................................................... 15
Figure 16 Removing the gas block....................................................................................... 16
Figure 17 Block diagram controller ..................................................................................... 17
Figure 18 Firmware controller (old model) ........................................................................ 18
Figure 19 Firmware controller (present model) ................................................................. 19
Figure 20 Check of GSS/LPG combination module with service program ........................ 21
Figure 21 Service program, Device choice menu ................................................................ 21
Figure 22 Service program, LPG/GSS menu (with command V = show version) ............. 22
Figure 23 Pcb with temperature sensor and heating element .......................................... 24
Figure 24 Measuring points 1 to 5 on the pcb.................................................................... 24
Figure 25 Cable connection for firmware update ............................................................... 26
Figure 26 Jumper for firmware update on the pcb ............................................................. 26
Figure 27 File <Siow.exe> .................................................................................................... 27
Figure 28 Menu Configuration ▸ Set port options.............................................................. 27
Figure 29 Programing mode of program <Siow> ............................................................... 28
Figure 30 menu command: File ▸ Download Software ...................................................... 28
Figure 31 Selecting the hex.file ........................................................................................... 28
Figure 32 Download status .................................................................................................. 29
Figure 33 Cable connection for firmware update ............................................................... 29
Figure 34 Firmware update with terminal program........................................................... 30
Figure 35 Firmware update: COM Port selection ............................................................... 30
Figure 36 Firmware update: select the fw file .................................................................... 31
Figure 37 Test of firmware version ..................................................................................... 32
Figure 38 Screws and gas hoses at the heating unit .......................................................... 34
Figure 39 Dosing valve unit, complete with drive .............................................................. 35
Figure 40 Dosing valve unit.................................................................................................. 35
Figure 41 Single parts of dosing valve unit ......................................................................... 36
Figure 42 Drive shaft ............................................................................................................ 36
Figure 43 Coupler.................................................................................................................. 37
Figure 44 Adjustment of dosing valve unit ......................................................................... 37
Figure 45 Opening of the dosing valve with special wrench (tool set) ............................. 41
Figure 46 Orientation of rotor ............................................................................................. 42
Figure 47 Leak test with sniffer at gas fittings ................................................................... 44
Figure 48 Leak test with sniffer at dosing valve assembly................................................. 44
4
GSS/LPG combination module General information
1 General information
The GSS/LPG combination module is an optional module, which allows the supply of
liquefied pressurized gases (LPG) or of pressurized gases (GSS) into the combustion unit
of the Combustion Module, the compEAct S/N or multi EA 5000. The transfer of the
sample into the combustion unit will be done by using the carrier gas Argon. The speed of
transfer will be controlled by a microcontroller inside the GSS/LPG combination module to
ensure a complete combustion.
Figure 1 Front view of GSS/LPG combination module

1 GSS connection mount 9 Purging gas connection to LPG/GSS sample cylinder
2 GSS filtration unit 10 Needle valve for GSS flow adjustment
3 GSS sample cylinder connection 11 Service flap
4 GSS manometer 12 Needle valve for LPG flow adjustment
5 GSS pressure reducer 13 Filtration unit for LPG connection
6 Purge unit (purging gas metering valve) 14 Bubble container
7 LPG sample cylinder connection 15 LPG manometer
8 LPG sample cylinder support 16 Sample cylinder mount
5
General information GSS/LPG combination module
Figure 2 Connections and interfaces (rear side)

1 Communication interface to the combustion unit 7 Inspection opening for RS 485 signal termination
(via RS 232 bus) (compEAct)
2 Argon connection (pneumatic block) 8 Communication interface (in) via RS 485 bus
3 Argon connection (purge) (compEAct)
4 Gas outlet "waste" for connection to an extractor 9 Mains connection
5 Gas outlet "sample out" for transferring the sample 10 Fuse holder
gas to the combustion unit 11 Mains(device)switch
6 Communication interface (out) via RS 485 bus
(compEAct)
Figure 3 Sample supply to Combustion Module
6
Figure 4 Sample supply to multi EA 5000 (in horizontal mode)
Figure 5 Communication schema
Note: For all service activities and adjustments inside the GSS/LPG combination module,
it is required to remove both side panels from the module. Make sure to disconnect the
ground connectors from the side panels.
7
General information GSS/LPG combination module
Figure 6 GSS/LPG combination module, left side panel removed

1 Expansion chamber with heating unit 3 Gas block
2 Pneumatic drive (of dosing valve assembly) 4 Wide range power module
8
Figure 7 GSS/LPG combination module, right side panel removed

1 Mains input module 4 Pneumatic drive
2 Wide range power module 5 Dosing valve assembly
3 Firmware controller 6 Cooling unit
9
Gas supply GSS/LPG combination module
2 Gas supply
With its bas block, the GSS/LPG combination module supplies a fixed flow (55 ml/min) of
carrier gas (Ar) to transfer the sample gas to the combustion unit. The samples are dosed
by moving a pneumatic drive. This process will be controlled by the gas block as well. For
correct operation of the pneumatic drive (dosing valve), it is required to set the internal
pressure to 3.5 bar.
2.1 Flow diagrams
Figure 8 Functional principle of GSS/LPG combination module
Figure 9 Flow diagram of GSS/LPG combination module
10
GSS/LPG combination module Gas supply
2.2 Pneumatic block assembly
Figure 10 Flow schema of pneumatic block
Figure 11 Pneumatic block
1 Switching valve V3a (select: GSS/LPG) 6 Pressure switch (2.0 bar)

2 Connector hose no. 20 7 Connector hose no. 8
3 Connector hose no. 6 8 Connector hose no. 7
4 Needle valve for flow adjustment 9 V2a (Drive)
Ar (55 ml/min) 10 V2b (Drive)
5 Valve V1 (Argon on) 11 Pressure regulator (3.5 bar)
11
2.3 Adjustment of the gas block
2.3.1 Adjust the pressure regulator (internal pressure)
1. Provide all gas connections (gas supply for operation to the GSS/LPG combination
module).
2. Remove hose no. 8 from the gas block and connect a manometer (0 to 6.0 bar) to this
connector of gas box (see Figure 12).
3. Turn on the GSS/LPG combination module and start the service program.
 Choose the device LPG/GSS; start the communication.
 Open Ar-valve V1 with command . On the controller pcb, check whether
LED "V1" is on.
4. Switch valve V3a and V3b to LPG mode with command .
On the controller pcb: LED "V3" off.
5. Press three times the button [SWITCH DOSE-VALVE].
6. Pull the knob of the pressure regulator (11 in Figure 11 p. 11) out and turn it
clockwise or counter-clockwise to increase or decrease the internal pressure until it
reaches the nominal value of 3.5 bar.
7. Remove the manometer and reconnect hose no. 8 to the gas block.
Figure 12 Measuring the internal pressure
12
2.3.2 Adjust the pressure switch (internal pressure)
module).
2. Close the gas supply of the GSS/LPG combination module at the external pressure
regulator.
3. Remove hose no. 8 from the gas block and connect a manometer (0 to 6.0 bar) to this
connector of gas box (see Figure 14).
4. Connect a voltmeter with the electrical pins of pressure switch (see Figure 14).
6. Choose the device LPG/GSS; start the communication.
7. Open Ar-valve V1 with command . On the controller pcb, check whether LED
"V1" is on.
8. Set the inlet pressure into the module from 0 to 4.5 bar to determine the trigger point
of the pressure switch (nominal pressure 1.7 to 2.0 bar). Observe the pressure and
electric voltage at the manometer and voltmeter.
 5 V = pressure to low (<2.0 bar)
 0 V = pressure OK (≥2.0 bar)
9. With a hex wrench (1.5 mm), turn the screw on the pressure switch (see Figure 13)
clockwise or counterclockwise to increase or decrease the trigger-point.
10. Remove the manometer and voltmeter and reconnect hose no. 8 to the gas block.
Figure 13 Pressure switch (seen from the left) and screw on the pressure switch (seen from the right)
13
Figure 14 Adjusting the pressure sensor
2.3.3 Adjust the carrier gas flow (Ar) in LPG Mode
module).
2. Connect an external volumetric flow meter to the gas outlet "sample out" (see 5 in
Figure 2 and Figure 15).
5. Open Ar-valve V1 with command . On the controller pcb: LED "V1" on.
6. Switch valves V3a and V3b to LPG mode with command .
On the controller pcb: LED "V3" off.
7. Press three times the button [SWITCH DOSE-VALVE].
8. Check the Ar carrier gas flow with the external volumetric flow meter.
9. Adjust the Ar carrier gas flow by turning the needle valve (5 in Figure 11 p. 11):
nominal flow: 55 ml/min, measured gas flow: 40 to 70 ml/min.
10. Close Ar-valve V1 with command . On the controller pcb: LED "V1" off.
14
Figure 15 Measuring the Ar carrier gas flow
2.3.4 Adjustment the carrier gas flow (Ar) in GSS Mode
module).
2. Connect an external volumetric flow meter to the gas outlet "sample out" (see 5 in
Figure 2 and Figure 15).
6. Switch valves V3a and V3b to GSS mode with command .
On the controller pcb: LED "V3" on.
7. Press three times the button SWITCH DOSE-VALVE.
8. Check the Ar carrier gas flow with the external volumetric flow meter.
9. Adjust the Ar carrier gas flow by turning the needle valve (5 in Figure 11 p. 11).
Nominal flow: 55 ml/min, measured gas flow: 40 to 70 ml/min.
10. Close Ar-valve V1 with command . On the controller pcb: LED "V1" off.
15
2.3.5 Exchange the gas block
1. Turn off the GSS/LPG combination module.

2. Remove the gas supply (inlet) into the GSS/LPG combination module.
3. Remove all hoses from the gas block.
4. Loosen the three screws (see Figure 16) and remove the gas block.
5. Install the new gas block in the reverse order.
6. Check the adjustments of gas block (see sections 2.3.1 to 2.3.4).
Figure 16 Removing the gas block
16
GSS/LPG combination module Controller module
3 Controller module
3.1 Block diagram controller
The controller pcb controls all electrical and pneumatic functions while the process of
LPG/Gas sampling. A wide range power module (110 to 240 VAC) provides 24 VDC for
the controller pcb.
The controller pcb communicates with the firmware controller inside the combustion unit,
multi EA 5000/multi X 2500 via RS 232 interface.
The analyzer compEAct N/S/SMPO communicates with the LPG 2.0 controller pcb via
RS 485 interface.
Figure 17 Block diagram controller
17
Controller module GSS/LPG combination module
3.2 Firmware controller
3.2.1 Firmware controller (for devices up to serial number N76-239)
Figure 18 Firmware controller (old model)
LED Operating status

LED D8 Displays device status, flashes if device is ready for operation
LED V1 Displays status of valve V1 for Argon supply
LED V2a, 2b Control valves V2a and V2b, LEDs flash during dosing
LED V3 Controls switching valves 3a to 3c, off in LPG mode, on in GSS mode
LED heater on Displays status of heating unit of expansion chamber
LED Ar pressure control LED on = Argon pressure too low
LED cooling on Displays status of cooling unit of dosing valve assembly
18
To configure the GSS/LPG combination module for the current gas box with valve 2a and
2b remove the jumper from pin1/2 and set a jumper to pin 9/10.
The LEDs on the controller pcb display the operating status of the different valves and
temperature control.
The heating unit will be supplied by 24 VDC, the temperature sensor monitors a power of
10 mV/°C. Example: 80 °C = 800 mV. The cooling unit needs a voltage of 5 VDC for cooling
and 24 VDC for the temperature sensor. It also monitors 10 mV/°C.
3.2.2 Firmware controller (from serial number N76-240 and higher)
Figure 19 Firmware controller (present model)
19
To configure the GSS/LPG combination module remove the jumper "set LPG" on the
controller pcb.
The LEDs on the controller pcb display the operating status of the different valves and
temperature control.
LED Operating status

LED V1 Displays status of valve V1 for Argon supply
LED V2a, 2b Control valves V2a and V2b, LEDs flash during dosing
LED V3 Controls switching valves 3a to 3c, off in LPG mode, on in GSS mode
LED heater on Displays status of heating unit of expansion chamber
LED Ar pressure control LED on = Argon pressure too low
LED cooling on Displays status of cooling unit of dosing valve assembly
The heating unit will be supplied with 24 VDC, the temperature sensor monitors a power
of 10 mV/°C. Example: 80 °C = 800 mV. The cooling unit needs a voltage of 5 VDC for
cooling and 12 VDC for the temperature sensor. It also monitors 10 mV/°C.
3.3 Signal termination for RS 485 bus (compEAct)
The signal termination of RS 485 bus must be set through the inspection opening (2)
between the RS 485 interface connections "in" (1) and "out" (3).
The two switches must be set as follows:
 The LPG 2.0 module is the last device on the RS 485 bus ▸ upper position
(ON = terminated).
 After the LPG 2.0 module follow further devices on the RS 485 bus ▸ lower position
(OFF = not terminated).
20
3.4 Check of the GSS/LPG combination module with service program
1. Connect the module with the service program.
Figure 20 Check of GSS/LPG combination module with service program
2. In the DEVICE CHOICE menu choose the device LPG/GSS.

3. Start the communication.
Figure 21 Service program, Device choice menu
21
Figure 22 Service program, LPG/GSS menu (with command V = show version)
3.4.1 Service program commands
Command Description
V show Version
* LPG Vx y.y CTaa HTbb / Vx NPy.y.yCTaa HTbb
x=1 LPG, x=2 GSS, x=3 LPG/GSS,Vx=version
y.y = Version
aa = cooling temperature
bb = heating temperature
U xy - Valve on/off
x=1 Ar-Valve
x=2 dosing valve
x=3 switch valve GSS
x=4 activate / deactivate heating and cooling
y=0 off
y=1 on
y=2 switch (only for dosing valve)
G xxx Start dosing LPG xxx = dosing volume(µl)
g xxx Start dosing GSS xxx = dosing volume(µl)
E Stop dosing
K xxx - set sample-loop LPG (µl)
L xxx - set sample-loop GSS (µl)
M xxx - set dose-time (1/10 sec)
T xxx - set heat-temperature (°C)
22
Command Description
k Show configuration
* K xxx yyy zzz
xxx = sample-loop LPG(µl)
yyy = sample loop GSS(µl)
zzz = dose time(1/10 sec)
S Show State
s Show state(Service)
*Sxyz
*sxyzab
x=0 ready, x=2 no Ar-pressure,
x=4 heattemp. Out of range, x=8 cooling out of
range
x=16 Tempsensor heating out of work, x=32
Tempsensor cooling out of work
y=0 Ar-valve off, y=1 Ar-valve on
z=0 switching valve GSS off, z=1 switching valve
GSS on
a=current cooling-temp.
b=current heating-temp.
3.5 Communication and type check
1. Connect the service program with a RS 232 cable to the GSS/LPG combination
module.
3. Read out the firmware version with command <V>.
Answer (up to S/N N76-239) <LPG V3NP 3.2 CTxxHTxx> (or higher version)
Answer (S/N N76-240 and higher) <LPG V3NP 1.1.13 CTxxHTxx> (or higher version)
4. Display: device type / internal software version / cooling set temperature / heater set
temperature:
LPG V3NP 3.2 CT15 HT80

LPG V3NP 1.1.13 CT15 HT80
1=LPG or Software version cooling set heater set
3=LPG/GSS temperature temperature
5. Determine whether the device type is LPG/GSS.

If the wrong device coding is displayed, remove the jumper ("1/2" or "set LPG") to
correct the configuration on the firmware controller (see Figure 18 and Figure 19).
23
3.6 Heating/Cooling
The device test program performs a heater and cooling check.

The heater target temperature (80 °C) must be reached within approx. 15 minutes after
entering the commands (see section 3.6.1) and must then be controlled. The LED "heater
on" then flashes irregularly. At the rear side of the expansion chamber is a thermal switch,
which should interrupt the heating voltage (24 VDC) in case of a firmware crash and heat
it up to a temperature of 85 °C.
After the module has been switched on, the cooling set temperature is automatically set
according to the ambient temperature (see table). The cooling set temperature must be
reached within approx. 30 minutes.
Measured ambient temperature [°C] Cooling set temperature [°C]

< 21 10
< 28 15
< 33 20
Figure 23 Pcb with temperature sensor and heating element

1 24 V
2 Temp (10 mV/°C)
3 GND
4 24 V (Heater)
5 GND switched (Heater)
Figure 24 Measuring points 1 to 5 on the pcb
The heating unit will be supplied by 24 VDC, the temperature sensor monitors a power of
10 mV/°C. Example: 80 °C = 800 mV.
24
3.6.1 Check of the temperature values
1. Read out the nominal temperatures with command <V>:

Answer: <LPG V3NP x.x.x CT15HT80> (depending on ambient: CT10/15/20)
2. In the service program: activate the temperature control with command .
On the controller pcb, check LED "heater on" and LED "cooling on".
3. After 30 minutes check the evaluated temperature values with <s>:
Answer: s 2 0 0 15.0 80.0
4. Do not switch off the heating as it is required for an accurate flow measurement.
5. Use the command <s> for a continuous temperature check.
Output: XYZab
Meaning of the parameters (Y and Z for information only):
X Y Z a b
=0 =0 V1 (Ar) off =0 V3a to V3c off Current cooling Current heater
Ready for operation (LPG loop active) temperature [°C] temperature [°C]
=2 =1 V1 (Ar) on =1 V3a to V3c on

No primary pressure (GSS loop active)
=4
heater temperature
out of range
=8
cooling temperature
out of range
3.7 Firmware update for the LPG/GSS controller pcb
3.7.1 Firmware update (up to S/N N76-239)
The GSS/LPG combination module can be updated as described below:

1. Switch off the module.
2. Remove the side panels.
3. Remove/detach the connection cable between the module and the sampler/analyzer
and connect it directly to the PC.
25
Figure 25 Cable connection for firmware update
4. Set the jumper to the programming position (see Figure below and Figure 18 p. 18).
Figure 26 Jumper for firmware update on the pcb
5. Start the file (program) <Siow.exe> for the firmware update.
26
Figure 27 File <Siow.exe>
6. Select the port with the menu command CONFIGURATION ▸ SET PORT OPTIONS.
Figure 28 Menu Configuration ▸ Set port options
7. Open the programming mode by switching on the GSS/LPG combination module

whilst pressing the keys [PORT] and [START].
Message in the program <Siow>: Please select *.hex file.
27
Figure 29 Programing mode of program <Siow>
8. Select the menu command FILE ▸ DOWNLOAD SOFTWARE ▸ hex.file.
Figure 30 menu command: File ▸ Download Software
Figure 31 Selecting the hex.file
28
Figure 32 Download status
9. Wait until the firmware update is complete. The following message will occur:
PROGRAMMING COMPLETE.
10. Switch off the GSS/LPG combination module.
11. Remove the jumper from the programming position (see Figure 18 and Figure 26).
12. Reconnect the connection cable between the GSS/LPG combination module and the
sampler/analyzer.
13. The firmware version can be read out/checked in the multiWin program or by using
the device test program.
14. Please perform the leakage test with sniffer (see section 6.1 p. 43).
15. Adjust the transfer (carrier) gas flow rate (nominal gas flow sample out:
55±3 ml/min, measured gas flow 40 to 70 ml/min).
16. Perform a final check with measurement of a standard/sample.
3.7.2 Firmware update (S/N N76-240 and higher)
The firmware of the GSS/LPG combination module can be updated as described below:
1. Switch off the module.
2. Remove/detach the connection cable between the module and the sampler/analyzer
and connect it directly to the PC.
Figure 33 Cable connection for firmware update
3. Start the terminal program <Serviceterminal.exe> for the firmware update.

4. Select the menu command CONFIGURATION ▸ UPDATE LPG.
29
Figure 34 Firmware update with terminal program
5. Select the used COM interface for update.
Figure 35 Firmware update: COM Port selection
6. Start the update.

7. Select the firmware file for update.
30
Figure 36 Firmware update: select the fw file
8. Switch on the GSS/LPG combination module.
9. The transfer of the firmware file starts, the progress of the update will be displayed..
10. After the successful firmware update, switch off the GSS/LPG combination module.
31
11. The version of the installed firmware can be read out via the service program
<geraetetest.exe> with command <V>.
Figure 37 Test of firmware version
12. Please perform the leakage test with sniffer (see section 6.1 p. 43).
13. Adjust the transfer (carrier) gas flow rate (nominal gas flow sample out:
55±15 ml/min, measured gas flow 40 to 70ml/min).
14. Perform a final check with measurement of a standard/sample.
3.8 Exchange of the controller pcb
1. Switch off the GSS/LPG combination module and unplug the module from the mains.
3. Remove of all cables from the controller pcb.
4. Loosen the 4 screws from the pcb and exchange the controller pcb.
5. Reconnect all cables.
6. Set the controller pcb to LPG/GSS; there is no jumper.
7. Check the communication, the type of module and firmware version.
8. Check the carrier gas flow rate (nominal gas flow sample out: 55±15 ml/min,
measured gas flow 40 to 70ml/min).
9. Please perform the leak test (see section 6 p. 43).
32
3.9 Exchange of firmware controller pcb with service upgrade kit
For upgrade of the firmware controller pcb (up to S/N N76-239) to the current version of
firmware controller pcb (S/N N76-240 and higher), exchange the complete service kit,
which contains these items:
 Controller pcb  4 pc screws
 4 pc bolts  Fan with tachometer function
Please follow the instructions below:
1. Switch off the LPG/GSS combination module and unplug the module from the mains.
3. Unplug all connectors from the firmware controller.
4. Loosen the 4 screws and remove the firmware controller pcb.
5. Remove the 4 bolts from the housing.
6. Mount the new bolts (4x).
7. Install the new controller pcb.
NOTICE! Use only the new screws without lock washer!
8. Loosen the screws from the fan and remove the fan.
9. Mount the new fan.
10. Plug all cables to the related connectors.
11. Plug the cable of fan with tachometer function (white) to the connector fan state.
12. Set the controller pcb to LPG/GSS (there is no jumper).
13. Check the firmware controller pcb with the service program for the type of module and
firmware version.
14. Check the carrier gas flow rate (nominal gas flow sample out: 55±15 ml/min,
measured gas flow 40 to 70 ml/min).
3.10 Exchange of heating unit (expansion chamber)
1. Switch off the GSS/LPG combination module and unplug it from the mains.
3. Remove the cable of the heating unit from the controller pcb (see Figure 18 and
Figure 19).
4. Loosen screw "A" (see Figure 38).
5. Remove the cover and the gas hoses behind the cover (see arrow in Figure 38).
6. Remove the heating unit by loosening screw "B".
7. Mount the new heating unit in the reverse order.
8. Check the heating function (status, see section 3.6 p. 24)
33
9. Check the carrier gas flow rate (nominal gas flow sample out: 55±3 ml/min, measured
gas flow 40 to 70 ml/min).
Figure 38 Screws and gas hoses at the heating unit
34
GSS/LPG combination module Dosing valve assembly
4 Dosing valve assembly
4.1 Pneumatic valve assembly
Figure 39 Dosing valve unit, complete with drive
Figure 40 Dosing valve unit
35
Dosing valve assembly GSS/LPG combination module
Figure 41 Single parts of dosing valve unit
Figure 42 Drive shaft
36
Figure 43 Coupler
4.2 Adjustment of the dosing valve
1. Provide all gas connections for operating the GSS/LPG combination module.
2. Connect an external volumetric flow meter to the gas outlet "sample out".
4. Turn the dosing valve with the red handle of the actuator clockwise to its mechanical
end position (see blue arrow in Figure 44).
Figure 44 Adjustment of dosing valve unit
37

8. Switch valve V3a and V3b to LPG mode with command .
On the controller pcb, check whether LED "V3" is off.
9. Check the Ar carrier gas flow with the external volumetric flow meter (nominal flow
55±15 ml/min, measured gas flow: 40 to 70 ml/min).
10. Turn the red handle counter-clockwise to the mechanical end position.
11. Check the Ar carrier gas flow again.
If the flow isn’t 55 ml/min in one of the end positions, loosen the screw for the wrong
end-position until there is a distance of 1 mm from the end position of dosing valve to
the actuator. Secure the screw with the locknut in the new end position.
12. Perform a final check in LPG-mode by activating the DOSING function 10 times.
Meanwhile, monitor the Ar carrier gas flow in both positions.
13. Switch valve V3a and V3b to GSS mode with command .
On the controller pcb: LED "V3" on.
14. Perform a final check in GSS-mode by activating the DOSING function 10 times.
Meanwhile, monitor the Ar carrier gas flow in both positions.
4.3 Exchange of dosing valve assembly
WARNING
A leak in the dosing valve assembly can cause an explosion!
The dosing valve assembly may only be replaced by specially trained Metrohm
personnel. Otherwise, only a factory repair is permitted.
Always perform the leak test after exchanging the dosing valve assembly.
1. Switch off the GSS/LPG combination module and

unplug it from the mains.
3. Remove both interface cables from the pcb.
4. Use pliers to remove the cable ties securing the
cables to the housing.
38
5. Disconnect the following gas hoses from the gas

block:
 On the right side of the gas block:
hose 7 and hose 8.
 On the left side of the gas block: hose 6.
Use pliers to remove the cable ties securing the gas
hoses to the housing.
6. Remove gas hose 9:

 Unscrew the hose connector from the gas outlet
"sample out" on the inner back of the device.
 Remove the cover from the heating unit.

 Remove hose 9 from its hose guide under the
cover.
 Use pliers to remove the cable ties securing hose
9 to the housing.
7. Interrupt the gas connection to the dosing valve at

the T-connector.
39
8. Unscrew the filtration unit from LPG sample cylinder

support on the front side of the device.
9. Remove the 4 screws "A".
10. Loosen the 4 screws "B" that fix the dosing valve
assembly on the right and left side to the housing.
Therefore, turn the screws only 2 turns.
11. Remove the whole dosing valve assembly.

12. Mount the new dosing valve unit in reverse order.
13. Reconnect the gas hoses and electrical connections.
14. Check/Adjust the dosing valve (see section 4.2
p. 37).
15. Perform the leak test (see section 6 p. 43).
40
GSS/LPG combination module Maintenance
5 Maintenance
5.1 GSS/LPG rotor cleaning and/or exchange
Clean the GSS/LPG rotor if any of the following problems occur:
 Measurement value fluctuations

 No measured value for LPG or GSS branch
 Blind values without sample dosing
If the rotor surface has grooves, change the rotor. One rotor change is possible; the spare
parts are included in the scope of delivery. After that, change the entire dosing valve
assembly.
1. Open the service flap on the front side of the module with the service wrench (11 in
Figure 1 p. 5).
Figure 45 Opening of the dosing valve with special wrench (tool set)
2. Unscrew the preload assembly from the valve body with service wrench and brass tool
as shown in Figure 45.
NOTICE! Don’t turn the socket adjustment screw, it’s factory-adjusted.
3. In the software, press two times dosing to loosen the rotor from the valve body.
4. Pull out the rotor off the valve body using a magnet in pencil shape.
5. Note the orientation of the rotor (see ID-letter in Figure 46).
41
Maintenance GSS/LPG combination module
Figure 46 Orientation of rotor
6. Check the valve body and the rotor for scratches on their surfaces. Clean both with
some ethanol using a soft cotton swab.
7. Put the rotor carefully back into the valve body. Place it in the correct position (see ID-
letter).
8. Screw the preload assembly to the valve body. Press DOSING after each half turn of
screwing to ensure a centered position of the rotor.
9. After fixing the preload assembly hand-tight, close the service panel.
10. For the final check, perform a flow value carrier gas measurement in LPG-mode and in
GSS-mode (see section 2.3.3 p. 14 and 2.3.4 p. 15).
11. Perform the leak test with sniffer to ensure gas tightness (see section 6.1 p. 43).
For exchange the rotor, refer to Technical Note 201 by VICI:
http://www.vici.com/support/tn/tn201.pdf.
42
GSS/LPG combination module Leak test
6 Leak test
6.1 Leak test with sample gas and sniffer
In GSS mode 1. Switch on the sniffer.

2. Switch valve V3a and V3b to GSS mode using the component test or device test
program with command . On the controller pcb: LED "V3" on.
3. Close the needle valve NV2 (Flow GSS, see 10 in Figure 1 p. 5).
4. Mount the sample gas cup to the GSS connection and open it at the top.
5. Using the sniffer, check all pressure reducers, manometers, T-pieces, needle valve
connections in the area of the dosing valve for gas tightness.
6. If there is no leak, open the needle valve slightly (as if performing a measurement)
and check all connections between the needle valve and the bulkhead screw
connection at the rear panel.
7. Close the sample cup GSS connection (at the top).
8. Release the rest of the sample gas by opening the needle valve slightly
WARNING! Place a waste hose in an explosion-proof exhaust vent.
9. Wait until the pressure drops to 0 bar.
In LPG mode 1. Switch on the sniffer.

2. Switch valve V3a and V3b to LPG mode using the component test or device test
program with command . On the controller pcb: LED "V3" off.
3. Close the needle valve NV1 (Flow LPG, see 10 in Figure 1 p. 5).
4. Mount the sample gas cup to the LPG connection and open it at the top.
5. Using the sniffer, check all pressure reducers, manometers, T-pieces, needle valve
connections in the area of the dosing valve for gas tightness.
6. If there is no leak, open the needle valve slightly (as if performing a measurement)
and check all connections between the needle valve and the bulkhead screw
connection at the rear panel.
7. Close the sample cup LPG connection (at the top).
8. Release the rest of the sample gas by opening the needle valve slightly
WARNING! Place a waste hose in an explosion-proof exhaust vent.
9. Wait until the pressure drops to 0 bar.
43
Leak test GSS/LPG combination module
Figure 47 Leak test with sniffer at gas fittings
Figure 48 Leak test with sniffer at dosing valve assembly
6.2 Leak test with Argon
In GSS mode 1. Provide all gas connections for operating the GSS/LPG combination module. Set the Ar
inlet pressure to 5.0 bar.
2. Bypass the bubble vessel (14 in Figure 1 p. 5) from hose 17 to hose 15 with a GL14-
adapter (part of service kit for tightness test).
3. Close the gas outlet "waste" on the rear side (4 in Figure 2 p. 6) with a blind plug (Part
of the service kit).
4. Couple the purging gas connection with the LPG sample cylinder connection (7 and 9
in Figure 1).
5. Switch on the GSS/LPG combination module.
6. Start the service program.
44
GSS/LPG combination module Leak test
 Open Ar-valve with command . LED on respective valve connector is on, on
the controller pcb: LED "V1" on.
 Switch valve V3a and V3b with command into the GSS mode.
The controller pcb displays: "LED V3" on.
7. Open the purging gas metering valve on the front side (6 in Figure 1).
8. Close the external gas supply and observe the pressure at the LPG manometer during
the next 15 minutes.
The pressure must not drop during this time. Pressures of 4.8 to 5.0 bar are okay.
9. After this test: Close the purging gas metering valve (front side).
10. Remove the purging gas connection from the LPG sample cylinder connection.
In LPG mode 1. Provide all gas connections. Ar inlet pressure: 5.0 bar.
2. Bypass the bubble vessel (14 in Figure 1 p. 5) from hose 13 to hose 15 with a GL14-
adapter (part of service kit tightness test).
3. Close the gas outlet "waste" on the rear side (4 in Figure 2 p. 6) with a blind plug of
the service kit.
4. Couple the purging gas connection with the LPG sample cylinder connection (3 and 4
in Figure 1).
5. Switch on the LPG/GSS Module.
6. Start the service program:
 Open Ar-valve with command 
LED on respective valve 1 is on, controller pcb: LED V1 on.
 Switch valve V3a and V3b with command into the LPG mode.
The controller pcb displays: "LED V3" off.
7. Open the purging gas metering valve (front side).
8. Close the external gas supply and observe the pressure at the LPG manometer within
the next 15 minutes.
The pressure shouldn’t drop down during this time. A pressure from 4.8 to 5.0 bar is
OK.
9. Close the purging gas metering valve (front side).
10. Remove the blind plug from the waste outlet.
11. Remove the GL14-adapter from hose 17 to hose 15 and reconnect the bubble vessel.
45
Troubleshooting GSS/LPG combination module
7 Troubleshooting
Error Troubleshooting
Evaluation unit displays: temperature out The heater or cooling unit have not reached the target temperature –
of range Temperature must be ok approx. 15 minutes after the start.
 Check LEDs "heater on"/"cooling on" on the controller pcb; the LEDs flash
if the target temperature has been reached (control behavior).
 Check the heater board of the expansion chamber of the heating
resistor, position of LM35 T-sensor.
 Check the LM35 T-sensor in the dosing valve – position at the heat sink.
 Check LED "D8" (for old pcb models). Is controller ready for operation?
Evaluation unit displays: pressure fault Check LED "Ar pressure control" on the controller pcb. If it is red:
 Check gas connection.
 Check LED "V2", has V2 been triggered.
 Check LED "D8" (for old pcb models). Is controller ready for operation?
Measurement value fluctuations  Check external filter.
 Check Ar gas flow, nominal value: 55±15 ml/min
 Clean the valve rotor.
 Check the cooling function of the valve assembly.
 Check the heating function of the expansion chamber.
 Check the valve end positions.
No measured value for LPG branch  Check the Ar gas flow, nominal value: 55±15 ml/min
 Check and clean the valve rotor. 1 rotor change is possible (included in
the scope of delivery). After that, change the entire assembly.
 Check the pneumatic drive.
 Check whether cannulas are blocked.
 Check LED 1, check whether the pneumatic drive rotates.
No measured value for the GSS branch  Check the Ar gas flow, nominal value: 55±15 ml/min
 Check and clean the valve rotor, 1 rotor change is possible (included in
the scope of delivery). After that, change the entire assembly.
 Check the pneumatic drive.
 Check whether cannulas are blocked.
 Check whether the sample loop is blocked.
 Check LED "V3": it must be lit – the valves have switched to GSS, check
whether the method has been loaded.
 Check LED "V2", check whether the pneumatic drives rotates.
Blind values without sample dosing Check for internal valve leakage, for grooves on the rotor circumference or a
short circuit between sample and waste ports (wear).
1 rotor change is possible (included in the scope of delivery). After that,
change the entire assembly.
Ar flow rates in waste and sample loop  The dosing valve is mal-adjusted. Change the entire assembly.
differ significantly.  Check whether a cannula is blocked.
 Check if there is a leak in a branch.
LPG measured values approx. twice or half The wrong rotor is entered in the software.
as high as expected Check with device test program, "k" command.
46
GSS/LPG combination module Troubleshooting
Error Troubleshooting
Response: the first digit is 1 or 2.
Change: "K_X" command, X=1 or 2.
Noise when the dosing valve is activated or  Slight clacking, metallic noises may occur and are normal.
deactivated  Loud clacking noises indicate that the drive shaft is broken or the dosing
valve is maladjusted.
Change the entire assembly.
The occurrence is rather unlikely with the pneumatic drive.
47
Recommended Tools GSS/LPG combination module
8 Recommended Tools
AJ- order no. Tool

800-001-00009 Thermometer RS1313
702-823.145 Temperature sensor Type K (diameter < 1.5 mm; length > 25 cm)
800-001-00004 Flow meter GFM17 (calibrated for Ar) 500 ml/min
800-001-00002 Flow meter GFM17 (calibrated for O2) 1000 ml/min
800-003-00008 Manometer 0 to 6.0 bar

/ Service program <geaetetest.exe>
702-890.030 Gas detector "sniffer"
702-889.445 Tool set LPG/GSS complete (different special wrenches)
702-889.820 Service kit tightness test
48

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Service Manual

GSS/LPG combination module

Service Contact your supplier's service:

Service Metrohm AG Metrohm AG

General information http://www.analytik-jena.com

Implementation of the Analytik Jena AG

© Copyright 2019, Analytik Jena AG

2 Gas supply ....................................................................................................................... 10

3 Controller module .......................................................................................................... 17

4 Dosing valve assembly................................................................................................... 35

6 Leak test .......................................................................................................................... 43

8 Recommended Tools ..................................................................................................... 48

Figure 1 Front view of GSS/LPG combination module

Figure 2 Connections and interfaces (rear side)

Figure 3 Sample supply to Combustion Module

Figure 4 Sample supply to multi EA 5000 (in horizontal mode)

Figure 5 Communication schema

Figure 6 GSS/LPG combination module, left side panel removed

Figure 7 GSS/LPG combination module, right side panel removed

2.1 Flow diagrams

Figure 8 Functional principle of GSS/LPG combination module

Figure 9 Flow diagram of GSS/LPG combination module

2.2 Pneumatic block assembly

Figure 10 Flow schema of pneumatic block

Figure 11 Pneumatic block

1 Switching valve V3a (select: GSS/LPG) 6 Pressure switch (2.0 bar)

2.3 Adjustment of the gas block

2.3.1 Adjust the pressure regulator (internal pressure)

Figure 12 Measuring the internal pressure

2.3.2 Adjust the pressure switch (internal pressure)

Figure 14 Adjusting the pressure sensor

2.3.3 Adjust the carrier gas flow (Ar) in LPG Mode

Figure 15 Measuring the Ar carrier gas flow

2.3.4 Adjustment the carrier gas flow (Ar) in GSS Mode

2.3.5 Exchange the gas block

1. Turn off the GSS/LPG combination module.

Figure 16 Removing the gas block

3.1 Block diagram controller

Figure 17 Block diagram controller

3.2 Firmware controller

3.2.1 Firmware controller (for devices up to serial number N76-239)

Figure 18 Firmware controller (old model)

LED Operating status

3.2.2 Firmware controller (from serial number N76-240 and higher)

Figure 19 Firmware controller (present model)

LED Operating status

3.3 Signal termination for RS 485 bus (compEAct)

3.4 Check of the GSS/LPG combination module with service program

1. Connect the module with the service program.

Figure 20 Check of GSS/LPG combination module with service program

2. In the DEVICE CHOICE menu choose the device LPG/GSS.

Figure 21 Service program, Device choice menu

Figure 22 Service program, LPG/GSS menu (with command V = show version)

3.4.1 Service program commands

3.5 Communication and type check

LPG V3NP 3.2 CT15 HT80

5. Determine whether the device type is LPG/GSS.

The device test program performs a heater and cooling check.

Measured ambient temperature [°C] Cooling set temperature [°C]

Figure 23 Pcb with temperature sensor and heating element

Figure 24 Measuring points 1 to 5 on the pcb

3.6.1 Check of the temperature values

1. Read out the nominal temperatures with command <V>:

=2 =1 V1 (Ar) on =1 V3a to V3c on