B08_-_Attachment_3_PMS_Maintenance_Instruction_WI1070_Issue_2.pdf

PMS Maintenance Instruction WI 1070

Author: Graham Josland Responsibility: Service Director Issue 2 : 20 September 2016

Winsford, UK Page 1 of 20

1. Purpose

The purpose of this document is to provide instructions for the PM procedure for PMS instruments and the recording of the results of that maintenance.

2. Scope

PM of all Prima PRO, Prima PRO Ex, Prima BT, Sentinel PRO and Sentinel PRO Ex instruments.

This document will cover the majority of instrument options but there will be some hardware configurations that are not covered, in which case tests can be added, adapted or omitted as appropriate.

3. Applicability

All field service engineers carrying out maintenance of PMS Instruments. The field service engineer must be adequately trained both for the planned activities and health and safety aspects of those activities.

4. Definitions

PM Preventative maintenance / Preventive maintenance

PMS Process mass spectrometer

PPE Personal protective equipment

5. Requirements

The following steps should be completed in the order shown and results recorded in the

PMS Scheduled Maintenance Checklist F1040. All recorded data should be labelled to indicate the specific test or check to which it applies.

In some of the tests and checks below, comparisons with previously recorded data are required. If such data is not available comparisons should be made with what would be considered normal for that instrument type.

5.1. Safety

This document must be used in conjunction with the PMS PM Risk Assessment

RA2013-04(current year) and Method Statement PMS Service MS(current year), or equivalent documents.

In addition to the health and safety elements of the specific activities to be undertaken

(see 3 above), consideration must be given to other potential hazards in the on-site working environment.

a) Adhere to any safety requirements imposed by the site, including the use of PPE.

b) In addition to the above, assess the requirement for any additional precautions, such as additional PPE. This assessment should be dynamic for the duration of the visit.

c) Before opening up any gas handling parts of the equipment, ensure that external gas supplies (sample and calibration) are effectively isolated. It might also be necessary to isolate exhaust lines to prevent back flow of gases (which might be

Winsford, UK Page 2 of 20 unrelated to the instrument being serviced if the exhaust system is shared) when anything is disconnected.

Extra care must be taken if the gases are toxic, flammable, asphyxiants etc. It will be necessary to purge the pipework and inlet system with an appropriate safe gas before starting work.

d) Some activities might require isolation of the mains power to the instrument.

Precautions should be taken to avoid accidental switching on of power, especially when relying on an external power isolator. The user must operate any external isolation device, and the formal site tag out / lockout procedure must be followed.

e) If dust is disturbed during any part of the PM activity, particularly if using compressed air clean any part of the system, use eye protection and take appropriate precautions to avoid inhalation of the dust.

For hazardous area systems:

f) Maintenance activities will require working on the instrument in a non-protected condition (i.e. door open). Steps must be taken to ensure that the area is non-hazardous before starting work and during the course of work. Approval must be sought from the responsible person on site and the formal site procedure followed (e.g. permit to work) before any work commences, especially if there is a need to leave the instrument unattended in this condition.

5.2. Initial Review and Pre-Checks

The purpose of this section is to collect and review information showing the initial condition, status and performance of the instrument, before commencing the maintenance activities.

Hazardous area systems with an interlocked purge (ATEX, IECEx, X-purge) should be switched to override mode at this point.

a) Note any issues reported by the instrument user at the initial meeting of the PM visit. Also check with the user that all the required communication and IO channels are working correctly.

b) Visually inspect the external condition and general installation of the instrument.

This should include general cleanliness of the instrument, obstructions to airflow for cooling (enclosure and pump) and safe access. Also check the condition and correctness of external pipework in the immediate vicinity of the instrument, looking for any bad practice that might lead to problems in the future. Remember that any of this might have changed from, or have been missed on, a previous visit.

c) Visually inspect the internal condition of the instrument. Dust might indicate that the instrument has been operated with the door open / cover removed or (for a

BT) a failure of the air filter.

Note any unauthorised modifications made to the instrument. Any such modifications might void the system warranty, invalidate any certifications or listings applicable to that system and create safety hazard - electrical, mechanical or gas related. This is especially true for hazardous area systems where modifications are generally not allowed, may create an explosion risk and

Winsford, UK Page 3 of 20 potentially invalidate any hazardous area certification. Concerns must be reported to the user in writing.

d) Before starting work on the instrument, make a backup copy of the instrument database.

e) In ‘Control Center’, start a scan (typically) of mass 28 and record the identity of the stream used for this scan. Where possible, to obtain a consistent result, a calibration gas should be used. Select a gas such as air or nitrogen that will give the closest to a ‘correct’ pressure reading.

Check the instrument Status display for any alarms or readings that might indicate a fault or pending fault (compare with previous Status readings for that instrument). Record a copy of the Status file (PDF format where possible) and verify that the copy is OK.

Switch to the other filament and repeat (this latter step can be omitted if it is known that the ion source will be replaced as part of the PM visit). Switch back to the original filament.

f) Continuing from e), record a peak shape scan image (typically mass 28). Check that the flow for this stream is indicated in GasWorks. Compare with the last known recording for that instrument and check for any significant degradation of peak shape or peak height. Check that the alignment of the peak is within acceptable limits (i.e. on the flat top of the peak).

g) Using the above selected gas stream, record scans of repeller and deflector curves and compare with scans recorded during the previous the PM visit. Check for significant changes, particularly in the position of the maximum points.

h) Where applicable, check the functionality of the SEM. Select a peak that can be measured on both Faraday and multiplier detectors (typically mass 34 in air if air can be admitted to the system, otherwise select an alternative peak of suitable intensity). Record the height of the peak on each detector. Verify that the SEM peak shape and the gain are suitable for the application (or adjust to be suitable).

i) Using a suitable zero gas (typically helium), check the signal to background ratio

(mass 32 in air/mass 32 in helium) For Sentinel systems, check also the mass 28:mass 32peak height ratio in a clean air sample. The results should be within the following limits. If not, leak check the system – the problem might need to be addressed while the system is shut down for maintenance.

Leak type Typical system pressure

(mbar)

Background ratio

(mass 32 in air*/mass 32 in helium)

70μm 3×10-6 - 6×10-6 ≥1000

50μm 1.5×10-6 - 4×10-6 ≥500

30μm 0.8×10-6 - 2×10-6 ≥200

20μm 0.5×10-6 - 2×10-6 ≥100

200μm (VPI inlet) 3×10-6 - 6×10-6 ≥500

Membrane (Sentinel) ≤2×10-6 ≥200 (if available) mass 28:mass 32 (air) ≤ 2.5

* - If air cannot be readily admitted into system, estimate the mass 32 peak height in air from another gas sample containing oxygen (or a gas of similar sensitivity)

j) Compare a recent calibration report from the instrument PC with a known good report (generally from a previous PM or commissioning visit), checking for any

Winsford, UK Page 4 of 20 significant changes in peak heights or increases in background levels (see also section i) above).

If a recent report (say, within the previous month) is not available, calibrate (if brief) or record the required peak height data by running an analysis.

k) Check that all internal/external fans are operating (including air amplifiers for Ex systems).

For PRO systems, close the door and record the cabinet temperature over a period of at least 15 minutes (this could be part of an analysis method). Check that the cabinet temperature cycles less than ±1°C, and the cycle time is less than

2 minutes. Check for any evidence of condensate at the end of the drain pipe.

This will be due to either running with the door open or using purge air with high moisture content - in either case, this should be reported to the user.

For BT systems, check that the fans switch off when the top cover is removed.

Review the information acquired in the sections above and consider whether the planned service activities are likely to address any issues. If necessary, adjust those plans.

Any site or installation related issues should be reported to the user in writing.

Immediate action might be required for safety issues or cases where damage to or impairment of the instrument might occur.

5.3. System Shutdown

Turn off the filament and ion source heater within GasWorks.

Wherever possible, shut the system down with the dry gas vent facility enabled. Use the switch on the PDU to stop the pumps. Check that the rotary pump is switched off, the vacuum gauge LED goes off and the turbo pump slows down. ‘Disconnect’ in

GasWorks and then:

• Safe area systems – switch off all circuit breakers, followed by the main isolator

(on a BT, unplug the power cable).

• Ex systems (all types) – close the enclosure door and record the enclosure pressure o Z-purge systems – press the e-stop button on the power isolation box and check that the enclosure power is cut. The circuit breakers and compressed air can then be switched off.

o ATEX/IECEx/X-purge – shut the enclosure door and switch off the purge override. Enclosure power should be maintained. Open the enclosure door and verify that power to the instrument enclosure is cut

(main contactor switches off). The circuit breakers and compressed air can then be switched off.

Remember that, unless isolated externally, the end of the incoming power cable will still be ‘live’. Communication and IO cables may also have low voltages present on them.

5.4. Maintenance Activity Schedule

The Maintenance Activity Schedule is shown in the tables below.

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Select the table for the appropriate application type and look in the column with the correct year number heading. Carry out the indicated activities, details of which are given in Appendix A.

Part numbers of items referenced in the schedule are given in Appendix B.

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Application - Group A1 Schedule2

Activity (see details in Appendix A)

1-year 2-year 3-year 4-year 5-year 6-year

🔧 🔧 🔧 🔧 🔧 A.1.a) Rotary Pump (Standard Oil)

🔎 🔎 🔎 🔎 🔎 A.1.b) Rotary Pump (Fomblin Oil)

🔎 🔎 🔎 🔎 🔎 🔎 A.2. Vacuum Lines

🔎 🔎 🔎 🔎 🔎 A.3.a) Molecular Sieve (check)3, 5 🔧 A.3.b) Molecular Sieve (replace)3, 5

🔧 🔧 🔧 🔧 🔧 🔧 A.4. Oil Mist Filter3 🔧 🔧 A.5.a) Turbomolecular Pump (service) 🔧 A.5.b) Turbomolecular Pump (replace)

🔧 🔧 A.6. Vacuum Gauge

🔎 🔎 🔎 🔎 🔎 🔎 A.7. Capillary/Leak Element (Prima only)

🔎 🔎 🔎 🔎 🔎 🔎 A.8. Membrane (Sentinel only)

🔎 🔎 🔎 🔎 A.9.a) Ion Source - Source Checks 🔧 🔧 A.9.b) Ion Source - Source Clean or Replacement

🔎 🔎 🔎 🔎 🔎 🔎 A.10. Magnet Pole Pieces/Z-Restrictor

🔧 🔧 🔧 🔧 🔧 A.11. Enclosure Cooling System

🔧 🔧 🔧 🔧 🔧 🔧 A.12. Inlet System4

🔎 🔎 🔎 🔎 🔎 🔎 A.13. Ex Systems3

🔧 🔧 🔧 🔧 🔧 🔧 A.14. Enclosure Cleaning 🔧 A.15. Mechanical Major Service

🔎 - Inspect or check as indicated in the final column. Further actions might be required depending on the outcome of the inspection/check.

🔧 - Carry out the activity indicated in the final column.

1 – Group A: includes all fermentation, human calorimetry and Sentinel applications. Consult factory for further guidance regarding the application categories if required.

2 – Repeat at the same frequency when the end of the table is reached. Activities executed out of the above sequence should be noted so that, going forward, a correct sequence can be planned.

3 – If applicable / if fitted.

4 – This document does not cover checks specific to instruments with a variable pressure inlet fitted. This will be covered elsewhere.

5 – Typically Sentinel only but may also be used on Prima systems.

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Application - Group B1

Activity (see details in Appendix A)

1-year 2-year 3-year 4-year 5-year 6-year

🔧 🔧 🔧 🔧 🔧 A.1.a) Rotary Pump (Standard Oil)

🔎 🔎 🔎 🔎 🔎 A.1.b) Rotary Pump (Fomblin Oil)

🔎 🔎 🔎 🔎 🔎 🔎 A.2. Vacuum Lines

🔎 🔎 🔎 🔎 🔎 A.3.a) Molecular Sieve (check)3, 5 🔧 A.3.b) Molecular Sieve(replace)3, 5

🔧 🔧 🔧 🔧 🔧 🔧 A.4. Oil Mist Filter3 🔧 🔧 A.5.a) Turbomolecular Pump (service)

🔧 A.5.b) Turbomolecular Pump (replace)

🔧 🔧 🔧 🔧 🔧 🔧 A.6. Vacuum Gauge

🔎 🔎 🔎 🔎 🔎 🔎 A.7. Capillary/Leak Element (Prima only)

🔧 🔧 🔧 🔧 🔧 🔧 A.9.d) Ion Source - Source Replacement

🔎 🔎 🔎 🔎 🔎 🔎 A.10. Magnet Pole Pieces/Z-Restrictor

🔧 🔧 🔧 🔧 🔧 A.11. Enclosure Cooling System

🔧 🔧 🔧 🔧 🔧 🔧 A.12. Inlet System4

🔎 🔎 🔎 🔎 🔎 🔎 A.13. Ex Systems3

🔧 🔧 🔧 🔧 🔧 🔧 A.14. Enclosure Cleaning 🔧 A.15. Mechanical Major Service

🔎 - Inspect or check as indicated in the final column. Further actions might be required depending on the outcome of the inspection/check.

1 – Group B: where the sample gas is predominately hydrocarbon, e.g. ethylene cracking. Consult factory for further guidance regarding the application categories if required.

2 – Repeat at the same frequency when the end of the table is reached. Activities executed out of the above sequence should be noted so that, going forward, a correct sequence can be planned.

3 – If applicable / if fitted.

4 – This document does not cover checks specific to instruments with a variable pressure inlet fitted. This will be covered elsewhere.

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Application – Group C1

Activity (see details in Appendix A)

1-year 2-year 3-year 4-year 5-year 6-year

🔧 🔧 🔧 🔧 🔧 A.1.a) Rotary Pump (Standard Oil)

🔎 🔎 🔎 🔎 🔎 A.1.b) Rotary Pump (Fomblin Oil)

🔎 🔎 🔎 🔎 🔎 🔎 A.2. Vacuum Lines

🔎 🔎 🔎 🔎 🔎 A.3.a) Molecular Sieve (check)3, 5 🔧 A.3.b) Molecular Sieve(replace)3, 5

🔧 🔧 🔧 🔧 🔧 🔧 A.4. Oil Mist Filter3 🔧 🔧 A.5.a) Turbomolecular Pump (service)

🔧 A.5.b) Turbomolecular Pump (replace)

🔧 🔧 🔧 🔧 🔧 🔧 A.6. Vacuum Gauge

🔎 🔎 🔎 🔎 🔎 🔎 A.7. Capillary/Leak Element (Prima only)

🔎 🔎 🔎 🔎 A.9.c) Ion Source - Source Checks 🔧 🔧 A.9.d) Ion Source - Source Replacement

🔎 🔎 🔎 🔎 🔎 🔎 A.10. Magnet Pole Pieces/Z-Restrictor

🔧 🔧 🔧 🔧 🔧 A.11. Enclosure Cooling System

🔧 🔧 🔧 🔧 🔧 🔧 A.12. Inlet System4

🔎 🔎 🔎 🔎 🔎 🔎 A.13. Ex Systems3

🔧 🔧 🔧 🔧 🔧 🔧 A.14. Enclosure Cleaning 🔧 A.15. Mechanical Major Service

🔎 - Inspect or check as indicated in the final column. Further actions might be required depending on the outcome of the inspection/check.

1 – Group C: solvent drying applications using a variable pressure inlet where the sample gas contains high concentrations of solvent vapour. Consult factory for further guidance regarding the application categories if required.

2 – Repeat at the same frequency when the end of the table is reached. Activities executed out of the above sequence should be noted so that, going forward, a correct sequence can be planned.

3 – If applicable / if fitted.

4 – This document does not cover checks specific to instruments with a variable pressure inlet fitted. This will be covered elsewhere.

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Application – Group D1

Activity (see details in Appendix A)

1-year 2-year 3-year 4-year 5-year 6-year

🔧 🔧 🔧 🔧 🔧 A.1.a) Rotary Pump (Standard Oil)

🔎 🔎 🔎 🔎 🔎 A.1.b) Rotary Pump (Fomblin Oil)

🔎 🔎 🔎 🔎 🔎 🔎 A.2. Vacuum Lines

🔎 🔎 🔎 🔎 🔎 A.3.a) Molecular Sieve (check)3, 5 🔧 A.3.b) Molecular Sieve(replace)3, 5

🔧 🔧 🔧 🔧 🔧 🔧 A.4. Oil Mist Filter3 🔧 🔧 A.5.a) Turbomolecular Pump (service)

🔧 A.5.b) Turbomolecular Pump (replace) 🔧 🔧 A.6. Vacuum Gauge

🔎 🔎 🔎 🔎 🔎 🔎 A.7. Capillary/Leak Element (Prima only)

🔎 🔎 🔎 🔎 A.9.c) Ion Source - Source Checks 🔧 🔧 A.9.d) Ion Source - Source Replacement

🔎 🔎 🔎 🔎 🔎 🔎 A.10. Magnet Pole Pieces/Z-Restrictor

🔧 🔧 🔧 🔧 🔧 A.11. Enclosure Cooling System

🔧 🔧 🔧 🔧 🔧 🔧 A.12. Inlet System4

🔎 🔎 🔎 🔎 🔎 🔎 A.13. Ex Systems3

🔧 🔧 🔧 🔧 🔧 🔧 A.14. Enclosure Cleaning 🔧 A.15. Mechanical Major Service

🔎 - Inspect or check as indicated in the final column. Further actions might be required depending on the outcome of the inspection/check.

1 – Group D: applications not listed in the other tables above, including, but not limited to, iron and steel (all), ethylene oxide (process), ammonia, methanol. Consult factory for further guidance regarding the application categories if required.

2 – Repeat at the same frequency when the end of the table is reached. Activities executed out of the above sequence should be noted so that, going forward, a correct sequence can be planned.

3 – If applicable / if fitted.

4 – This document does not cover checks specific to instruments with a variable pressure inlet fitted. This will be covered elsewhere.

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5.5. System Start up

a) Re-establish power to the instrument enclosure by switching on any external isolator, then:

• Safe area – switch on the main isolator/plug in the mains cable.

• Z-purge – turn on the compressed air supplies and check that the purge regulator is set correctly (typically 3.0 bar). Reset the e-stop button.

• ATEX/IECEx/X-purge – turn on the compressed air supplies and check that the purge regulator is set correctly (typically 3.0 bar). Check that the e-stop button is in the ‘on’ (out) position. Close the enclosure door. When pressure is sensed, the purge sequence should start and run for the time indicated on the instrument Ex label, after which the main contactor should switch on. Use a suitable timer to check that the purge time is correct (±20s). At this point, switch the purge override on.

b) Switch on the circuit breakers and ‘Connect’ in GasWorks. Start the pumping system using the PDU switch. Verify that:

• The rotary pump starts after a few seconds.

• The vacuum gauge LED does not switch on until the turbo pump reaches

80% speed.

• The turbo pump reaches 99-100%, at which point the turbo current drops to

<0.5A.

• Source (emission and high voltage) switch on only when the system pressure reaches the set-point.

c) Check that filament 1 and filament 2 are functional and give acceptable sensitivity and peak shapes, allowing for the short time since pump-down (if the ion source has been replaced enter the factory tuning parameters, otherwise use initially the previous settings).

d) Switch on all heaters at the settings required for the application and check that they function correctly: ion source, inlet probe, inlet system (1 or 2 heaters, depending on inlet type).

e) Sentinel systems – start up the sample pump and check that the sample vacuum status is indicated correctly in GasWorks.

• For Ex systems (ATEX/IECEx/X-purge), verify that, on loss of sample vacuum (e.g. line disconnected in the internal sample loop or the pump is switched off), the RMS drives immediately to port 1. Verify also that a safe, pressurised, sample gas (normally instrument air) is permanently connected to port 1, and that gas continues to flow at ≥1 l/min when the sample vacuum

(sample pump) is off. Check that the restoration of vacuum allows the RMS to operate normally again.

f) Ex systems – check the indicated cabinet pressure and compare with the previous recorded value. A reduction could indicate an enclosure leak. Check door seals and any other enclosure seals that have been disturbed (use a leak detector such as ‘Snoop’). The enclosure pressure should be at least 1 mbar above the setpoint.

Check that the purge condition is correctly indicated in GasWorks, as follows:

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• Z-purge – with the purge air flowing, open/close the enclosure door and verify that ‘Purge Status’ is correctly indicated in GasWorks.

• ATEX/IECEx/X-purge – with the enclosure pressurised, switch the purge override function on/off and check that ‘Purge Override Status’ is correctly indicated in GasWorks.

Allow the system to run for as long as possible (preferably overnight) before proceeding to the next step. During this time, sample an inexpensive gas such as air, nitrogen or a process gas, using a method that includes (as a minimum) system pressure and cabinet temperature. If possible, sample helium hourly to monitor the rate at which the mass 32 background peak height is falling.

For Ex systems, check whether the purge needs to be active during this time.

5.6. Post-Checks

a) For systems with an RMS inlet, switch off any hazardous gases and visually check the alignment of the sample head by selecting a few ports at random

(including port 1) over at least two complete revolutions.

b) If no problems are evident with the instrument and heaters are running correctly, switch on the remaining calibration and sample gases.

c) Check and optimise the instrument tuning on filament #1. Note: where a new ion source has been fitted, it is strongly recommended that the factory ion source tuning is used without modification. Record an image of the peak shape

(typically mass 28) using the same gas as was used in Section 5.2.e) above.

Check that the intensity of the peak is suitable for the application. Record images of the repeller and deflector curves, and a copy of the Status file (PDF format where possible, check after recording).

Using the filament #1 tuning, record for filament #2 the peak shape, repeller and deflector curves and a copy of the Status file (PDF format where possible, verify after recording). Following this test, select a filament (typically #1) for long term operation. Record the instrument parameters as indicated in the checklist.

d) Where applicable, check the functionality of the SEM. Record a scan of both the

Faraday and SEM peaks using the same peak as selected in Section 5.2.h). Verify that the SEM peak shape is acceptable and the gain is suitable for the application.

e) Select a plugged inlet port (i.e. zero flow) and check that the indicated raw flow is within ±1 DAC of the flow zero setting. Adjust the zero setting if required.

Select a few sample ports and check that an expected flow is indicated (use an external flow indicator, for example part of the SCS, if available). Repeat for each calibration gas.

f) Check the alignment of all peaks that are locked into the mass table, and correct if required.

g) Check the instrument backgrounds using the procedure of Section 5.2.i) above.

Verify that the background criterion is met, or is likely to be met soon (it might be that the system is still pumping down at this point – check the system pressure trend and mass 32 in helium trend).

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h) Carry out a full calibration and check the calibration report against a known good calibration report for any errors or significant differences. Also check that the maximum peak height measured in any calibration gas mixture is not too close to the maximum for the Faraday detector, i.e. not greater than 9 ×10-10A.

i) Set up the instrument to analyse the ‘mixed’ calibration gas, i.e. the simulated process gas (for some applications there may be more than one of these), and a small number of process streams. Run for as long as possible (at least 1 hour) and confirm that the results agree with those expected (including indicated flow rates).

j) Restore the system to the normal operating condition and verify that data communication is re-established.

k) Create a copy of the instrument database for backup/records (also, retain the backup recorded during Pre-Check).

l) Ex systems – verify that the instrument is left in a safe (protected) state. Purge protection must be active (where applicable purge override must be ‘off’) and all covers on Ex enclosures must be in place and tight.

m) Record serial numbers of any replaced items not already recorded in the checklist. Highlight any configuration changes (hardware or software) in the

‘Notes’ section. Inspect the service kit for completeness and make list of missing parts for reordering.

n) Inform the user of any issues requiring their attention. Ensure that the site responsible person is informed that work is complete and that any tag out / lockout and/or permit to work documentation is closed off and complete.

6. Documentation

F1040 – PMS Maintenance Checklist

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7. Flow Diagram

Section 5.3

Shutdown in preparation for service activities and check the shutdown process

Finish

Section 5.2

Pre-Check – assess initial condition of instrument

Start

Section 5.4

Carry out Scheduled Activities as indicated in the appropriate application table

Section 5.5

Start-up

Section 5.6

Post-Check – check and record final condition of instrument

Section 5.1

Safety – review before starting work

Appendix A

Details of Scheduled Activities

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Appendix A – Maintenance Activities

The activities in this appendix should be executed only when indicated in Section 5.4.

A.1. Rotary Pump

a) Standard Oil (Edwards Ultragrade 19)

Inspect the pump to confirm that the pump is a standard (not Fomblin) type.

Check the level of oil in the sight glass, look for any oil leaks and determine if any immediate action is required.

Change the oil:

• Drain the oil and if the sight glass is dirty, remove, clean and refit.

• Refill the pump to below the maximum level indicator (approximately 0.5 l).

Remove dust deposits from the air intake grille on the end of the pump motor.

Clean up any oil spills on or around the pump.

b) Fomblin Oil

Inspect the pump to confirm that the pump is a Fomblin (not standard) type.

Check the level of oil in the sight glass, look for any oil leaks and determine if any immediate action is required.

Check the condition of the oil in the sight glass. If clean, no further action is required, otherwise:

• Drain the oil and if the sight glass is dirty, remove, clean and refit.

• Particulates can be removed by filtration and the oil reused. If the oil condition is still poor, consider replacement.

• Refill the pump to below the maximum level indicator (approximately 0.5 l).

Remove dust deposits from the air intake grille on the end of the pump motor.

Clean up any oil spills on or around the pump.

A.2. Vacuum Lines

Inspect the vacuum lines between the rotary pump and turbo pump/inlet system, inside and outside the enclosure. Check for kinks, deformations, internal obstructions or degradation of the material. Replace where necessary.

A.3. Molecular Sieve

a) Inspection - check the molecular sieve material for discolouration or the presence of oil.

If contaminated, replace the sieve material - empty the molecular sieve material from the canister and dispose of correctly. Clean any traces of oil from the assembly and refill the canister with new material.

b) Replacement - empty the molecular sieve material from the canister and dispose of correctly. Clean any traces of oil from the assembly and refill the canister with new material.

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A.4. Oil Mist Filter

Remove the bowl from the oil mist filter in the pump exhaust and check that only a small amount of oil is present in the bottom (larger quantities indicate a blockage in the oil return line).

Replace the oil mist filter element.

A.5. Turbomolecular Pump

a) Replace both the turbo pump oil reservoir and 8 x ceramic rods (as per Pfeiffer instructions). Inspect the old oil reservoir – significant discolouration could indicate a need to replace the pump earlier than expected.

b) Replace the complete pump with a new or service replacement pump.

A.6. Vacuum Gauge

Clean and refurbish the cold cathode vacuum gauge. If cleaning is not possible due to the condition of the gauge head, or not practical for other reasons, replace the item.

A.7. Capillary / Leak Element

Remove the leak element and inspect under magnification. Check that the pinhole is clear and that the glass tube is clean and shows no signs of cracks or damage. If the leak element is OK it can be re-used, otherwise it should be replaced.

Also inspect the leak element seal and re-use if undamaged. If a replacement is required, use either the ‘Crossflon’ ferrule type or the o-ring type (if transitioning from ferrule to o-ring, shorter screws will be required).

If the instrument sensitivity/pressure has dropped compared to previous recorded values, or there is indication of contamination in the leak element, replace the capillary.

A.8. Membrane

If the mass 28: mass 32 peak height ratio is within specification and there has been no significant drop in sensitivity for the application VOCs, the membrane does not need any further attention. Otherwise, it should be replaced.

A.9. Ion Source

a) Source Checks (1)

Look at the data recorded during the Pre-Checks and determine if any further action is required. For example, significant increases in the source:trap current ratio, poor peak shape, analytical stability, drifting repeller or deflector profiles could indicate that filament replacement or a source clean (or replacement) is required. If filament replacement is considered appropriate, replace both filaments.

If performance is not restored or is otherwise not acceptable, clean the ion source, replacing both filaments if not done already. If cleaning is not possible or practical, replace with a factory tested source.

b) Source Clean or Replacement

Clean the ion source, replacing both filaments.

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If cleaning is not possible or practical, replace with a factory tested source.

c) Source Checks (2)

Look at the data recorded during the Pre-Checks and determine if any further action is required. For example, significant increases in the source:trap current ratio, poor peak shape, analytical stability, drifting repeller or deflector profiles could indicate that a source replacement is required. If so, replace with a factory tested source.

d) Source Replacement Only

Replace with a factory tested source.

A.10. Analyser Pole Pieces / Z-Restrictor Plate

If the peak shape and/or quadrupole lens setting indicates a possible issue, clean the pole pieces and clean or replace the z-restrictor plate.

A.11. Enclosure Cooling System

BT systems – remove and clean the air filter (depending on the nature of the dust use a vacuum cleaner, compressed air or wash with water/detergent). Clean around the fan assembly.

PRO systems – clean the air intake guard, and fan (where applicable). Clean the air conditioner condenser section (use a vacuum cleaner or compressed air) and ensure it is free from obstructions.

Ex systems – inspect the air amplifier central bore from the bottom (inlet) side. The profiled bore must have no build-up of debris or the performance will be impaired. If necessary, disassemble the air amplifiers for full cleaning.

A.12. Inlet System

a) Contamination and Safety

Before starting work, refer to Section 5.1.c).

Any solid or liquid residues encountered within the inlet system should be treated as potentially hazardous until identified and confirmed otherwise by the user.

Wherever possible, take photographs of any contaminated areas. If cleaning is to be undertaken, seek advice from the user regarding the best materials for this process.

Note: any contamination, including significant quantities of dust in filters, should be treated as a failure of sample conditioning and reported to the user.

b) RMS Inlet Systems

Remove the stator cover and inspect the common exhaust chamber, including the inner face of the cover. Identify which port(s) are responsible for any contamination and disconnect and inspect the corresponding incoming lines.

Remove the sample arm taking care to retain the seal and spring assembly. Check the condition of the seal face, noting the orientation of any wear lines. Check the condition of the 2µm sample arm filter (not fitted for Sentinel instruments) before removal and replacement.

Winsford, UK Page 17 of 20

Clean the stator face and cover (see (a) above), avoiding pressing any debris into the sample ports.

If reusing the sample arm seal, clean any wear debris from the seal before refitting in the same orientation. Significantly damaged seals should be replaced. It is advisable to replace any older o-ring style seals with the newer PTFE collar type.

Check the tension of the RMS drive belt and adjust if required.

RMS Leak Check

Note: this step is a requirement for Prima PRO Ex systems. Other systems might benefit from this test, if the external leak integrity of the system is critical and not monitored by any other means. Generally, this test is not necessary for Sentinel systems.

Warning!

• This test involves pressurizing the RMS and appropriate precautions should be taken to avoid over pressurisation. Exceeding 0.7 bar can damage the flow sensor.

• Correct fittings and blanks must be used.

• Read this section in full and ensure that all the required parts are available before commencing.

Remove the transfer line and blank the port with a 1/8” Swagelok plug. The RMS exhaust and all but one of the inlet ports must be blanked. If shutoff valves have been fitted in the sample lines these may be used if the pressure rating is appropriate. Otherwise, the individual ports must be blanked. Check that all the main RMS cover plate bolts are in place and tight.

Connect a supply of a clean gas (e.g. nitrogen or helium) to the remaining RMS port via a suitable shutoff valve. Also, fit a pressure gauge (0 to 1 bar(g)) between this valve and the RMS (or use another blanked inlet port if this is easier).

Pressurise the assembly to 0.5 bar(g). Close the isolation valve and disconnect the gas supply. Monitor the pressure. The test is passed if the pressure falls by no more than 0.05 bar in one hour. If a leak is suspected, search with a leak detector such as Snoop.

c) Solenoid (all types) and Single Point Inlet Systems

Disconnect all sample lines and exhaust line and inspect the ports and the inside of the lines for any evidence of contamination (see (a) above). Further disassembly may be undertaken if cleaning is required.

Replace the filters in the inlet ports.

A.13. Ex Systems

Remove the bowl from each of the external compressed air regulators and check that the filters are free from dust, water and oil. Any significant contamination should be treated as a fault in the compressed air supply and reported to the user.

Inspect the pneumatic pipework starting at the point where the compressed air enters the enclosure (top right corner), checking that lines are correctly connected and there are no kinks or other damage. This should include the line to the air conditioner (air amplifiers supply, white line), the internal purge air lines (blue) and all the vacuum lines (red). If

Winsford, UK Page 18 of 20 there was any evidence of contamination in the compressed air filters, the internal passages of the vacuum eductor should be inspected and, if necessary, cleaned.

A.14. Enclosure Cleaning

The exterior of the instrument enclosure should be cleaned using appropriate water based cleaners or wipes, as far as possible returning it to an ‘as new’ condition. In particular, all identification and warning labels must be readily visible.

A.15. Mechanical Major Service

a) Rotary Pump

Carry out one of the following, as indicated in the service contract (if nothing is indicated, execute part i.):

i. Service the pump as described in Section A.1.

ii. A full service of the rotary pump (dismantle, clean all parts and replace the vanes, seals, motor coupling etc with the items from a rotary pump service kit). Fill the pump with new oil, Edwards Ultragrade 19 or

Fomblin, as appropriate for the pump type.

iii. Replace the pump with a new or service exchange pump.

b) Cooling System

Carry out one of the following, as indicated in the service contract (if nothing is indicated, execute part i.):

i. Service the cooling system as described in section A.11.

ii. For PRO systems, replace the air conditioner fans (internal and, where applicable, external). The user should be advised that the air conditioner might need emptying and refilling with refrigerant. This could be done by any qualified air conditioning engineer and it is the user’s responsibility to organise this (the user should be made aware of the locations of the filling point and the label indicating the type and quantity of refrigerant).

For BT systems, replace the enclosure fan assembly and filter.

iii. Replace the air conditioner (PRO systems only).

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Appendix B - Part Numbers

This section is provided for reference only. Requirement for replacement or use of any item on this list must be determined from the instructions and schedule elsewhere in this document.

Description App. A

Ref.

Option/Comment

Qty

Req’d Part Number

Rotary pump oil A.1. Standard (hydrocarbon) oil 1 201-125-990

Fomblin oil 1 201-125-150

Vacuum lines A.2. PVC hose 13mm ID x 19mm OD 1m 201-125-239

Nylon tube 10mm OD x 8mm ID 1m 201-155-500

Molecular sieve A.3. 1 201-125-490

Oil mist filter A.4. Filter element 1 201-135-169

Turbomolecular pump A.5. Fluid reservoir and ceramic rods 1 201-125-339

HiPace 80 series pump 1 201-130-380

Vacuum gauge A.6. Cold cathode vacuum gauge 1 202-300-070

Capillary A.7. Standard microcapillary (75µm) 1 204-764-006

Low flow microcapillary (50µm) 1 204-764-009

Spare o-ring 1 201-120-400

Leak element A.7. 70µm leak element 1 203-200-846

50µm leak element 1 203-200-844

30µm leak element 1 203-200-852

20µm leak element 1 203-200-842

100µm leak element 1 203-200-843

200µm leak element 1 203-200-849

Leak element ferrule 1 201-125-283

Leak element o-ring 1 201-120-323

Screws to suit o-ring 4 201-100-664

Membrane assembly A.8. 1 203-217-522

Filament A.9. Thoria filament 2 203-135-305

Replacement ion source A.9. Ion source with thoria filaments 1 404-760-015TH

Ion source with tungsten/thoria filaments

1 404-760-015WT

Ion source with tungsten/thoria filaments, 1mm exit slit 1 404-760-400

Magnet z-restrictor A.10. 1 203-702-008

Inlet filter 2µm A.12.

6-way solenoid inlet:-

All other inlet types:-

201-110-292

RMS sample arm seal A.12. Includes seal, PTFE collar, spring 1 208-760-025

Winsford, UK Page 20 of 20

Description App. A

Ref.

Option/Comment

Qty

Req’d Part Number

Rotary pump A.15.a) Rotary pump service kit 1 201-130-116

Rotary pump RV8 1 201-130-190

Rotary pump RV8 Fomblin 1 201-130-193

Rotary pump RV8 Ex 115V/50Hz 1 201-130-222

Rotary pump RV8 Ex 115V/60Hz 1 201-130-221

Rotary pump RV8 Ex 230V/50Hz 1 201-130-220

Rotary pump RV8 Ex 230V/60Hz 1 201-130-219

Cooling system A.15.b) Air conditioner internal fan 115V 1 208-701-001

Air conditioner internal fan 230V 1 208-701-002

Air conditioner external fan 24V (not required for Ex systems)

1 202-115-210

Air conditioner 115V (excludes external fan)

1 202-310-510

Air conditioner 230V (excludes external fan)

1 202-310-515

Prima BT fan assembly (includes 3 fans, bracket and connectors)

1 208-760-030

BT air filter 1 201-135-995