Option Box Service Manual Assembling Procedure: Shimadzu Corporation Analytical & Measuring Instrument Division

465-00100-52
Option Box Service Manual

Assembling Procedure
Shimadzu Corporation
Analytical & Measuring Instrument Division
Page 1
Product Guarantee
Thank you for purchasing this product. Shimadzu guarantees this product in the way described below.
1. Guarantee Period
This product is guaranteed for a period of one year from the date of installation.
2. Scope of Guarantee
If a fault that can be attributed to Shimadzu occurs during the guarantee period, we will perform repair
or part replacement as appropriate without charge.
3. Items Beyond the Scope of This Guarantee

Faults that occur in any of the following cases are beyond the scope of this guarantee, even if they occur
within the guarantee period.
1) A fault occurs as a result of incorrect handling.
2) A fault occurs as a result of repairs or modifications performed by parties other than Shimadzu or
companies designated by Shimadzu.
3) A fault occurs due to factors unrelated to the equipment itself.
4) The equipment has been used in a severe environment, for example, subject to high temperatures,
high humidity levels, corrosive gases, or vibrations.
5) A fault occurs as a result of a fire or a natural disaster, such as an earthquake.
6) The equipment has been moved or transported since initial installation.
7) A fault occurs in a consumable item or a part dependant on a consumable item.
Disclaimer
(1) The copyright of this document is the property of Shimadzu Corporation. The unauthorized
reproduction or copying of this document or any part of it is not permitted.
(2) In the interests of product improvement, the contents of this document may be changed without
notice.
(3) Although every effort has been taken to ensure that the contents of this document are accurate, if an
error or omission is discovered, it may not be possible to correct the relevant part immediately.
(4) The supply period for parts required to repair this product is the 10-year period following the
termination of manufacture. It may not be possible to respond to requests for repair parts after this
period has elapsed. The supply period for parts other than genuine Shimadzu parts, however, is as
specified by the original manufacturer.
Due to product improvement, the parts described and the diagrams given in this document may differ
from the actual equipment. Also, not all the parts referred to in this document are handled as repair parts.
Copyright © 2008 Shimadzu Corporation
Page 2
Introduction
Purpose of This Manual
This service manual is intended for use by service engineers approved by Shimadzu Corporation, and
describes the maintenance methods used for the Option Box fixed on the GC-2014/2010-series gas
chromatograph. Maintenance may only be performed by service engineers who have received training
for this instrument.
There may be cases where information on subjects also covered in the instruction manual has been
omitted. Refer to the instruction manual if necessary.
Disclaimer
Due to product improvement, the parts described and the diagrams given in this document may differ
from the actual equipment. Also, not all the parts referred to in this document are handled as repair parts.
Notation Used for Precautionary Information

The precautionary information provided in this service manual is labeled in the following way to
indicate the degree of danger, potential damage, and urgency.
DANGER
Indicates a hazardous situation which, if not avoided, could result in death or in serious or
moderate injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in minor injury or
property damage.
Here, "minor injury" indicates an injury that would not require hospitalization or long-term
outpatient care. "Property damage" indicates damage to the product itself and to objects
around the product, such as housing and household items.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in damage to the
product or other property damage.
NOTE
Indicates information provided to facilitate efficient operation of the equipment or
clarify the subject matter.
Page 3
Table of Contents
Section 1
Full Size Option Box for Air Actuator
Chapter 1: Installing the Option box on GC
1.1 Confirm the packing items
1.2 Assembling the option box
1.3 Fixing the aluminum plate
1.4 Fixing the solenoid valve
1.5 Fixing the pressure balance (P.B) valve
1.6 Fixing the joint for sample IN and OUT
1.7 The pipe-1/16M connection
1.8 Connecting the air branch joint
1.9 Connecting the T-joint
Chapter 2: Installing the valve and air actuator

2.1 Fix the clamp CR-2 on Aluminum plate with two screws
2.2 Insert the valve into the clamp and tighten up with the hex-wrench
2.3 Ensure the valve mounting alignment
2.4 Join the Air actuator and the valve stand-off shaft
2.5 Alignment of 10-port valve
2.6 Air actuator alignment for 10-port valve
2.7 Confirming the valve direction
2.7.1 Example for 10-port valve
2.7.2 View of assembling both 6- and 10-port valves
Chapter 3: Installing the heater block

3.1 Insert the Aluminum sheet
3.2 Fixing the sample loop
3.3 Fixing the heater and Pt sensor assembly cable
3.4 View of the heater and Pt sensor assembly cable to AUX temperature board
Chapter 4: Installing the AUX temperature board

4.1 Fix the AUX temperature board on the specified location
Chapter 5: Installing the PRG-2010

5.1 Install the PRG-2010 controller board on the specified location
5.2 Fix the power supply of PRG-2010 at the specified location
5.3 Fix the PRG power supply at back space of GC
5.4 Connect the valve and P.B cable at PRG event control out put
Page 4
Chapter 6: Connection of air tube
6.1 Connect the air supply tubing at each solenoid valve and actuator with T-joint
6.2 Connect the air supply tubing to actuator IN and OUT
Chapter 7: View of the completed assembly

7.1 View of the final assembly
7.2 View of the covered option box on GC-2014
Full Size Option Box for Electric Actuator

1.4 Fixing the pressure balance valve and the sample IN & OUT port joint
Chapter 2: Installing the valve and electric actuator

2.4 Join the Electric actuator and the valve stand-off shaft
2.6 View of assembling 10-port valve

Chapter 4: Installing the heater and Pt sensor assembly cable

4.1 Fix the heater and Pt sensor assembly


6.4 Connect the valve and P.B cable at PRG event control out put.
Page 5
Chapter 7: Connection cables
7.1 Connect cables between Electric actuator and control module

Section 2
Half Size Option Box for Air Actuator
Chapter 1: Installing the option box on GC
1.5 Fixing the pressure balance valve
1.6 Connect the Branch-joint for air supply
Chapter 2: Installing the valve

2.1 Fix the valve clamp ring (CR-2) on the aluminum plate and alumina tube
2.4 Join the actuator and the valve stand-off shaft
2.6 Air actuator direction for 10-port valve
2.7.2 View of the assembling for 6-port valve

Chapter 4: Install the AUX temperature board

Chapter 5: Install the Event cable

5.1 Connect Event cable to “Event Option” connector
Page 6
Chapter 7: View of the completed assembling

7.2 View of the half size option box on GC-2010
Half Size Option Box for Electric Actuator

Chapter 2: Installing the valve and Electric actuator






Page 7
Section 1
Full Size Option Box for Air Actuator
WARNING
High Voltage
Before connecting the power cable directly to the terminal block in the switchboard, be sure to turn OFF
the GC power and switchboard switch.
Be sure to supply power from a power supply incorporating a circuit breaker.
Do not place heavy objects on the power cable.
Make sure that AC power meets the specifications of voltage, current capacity and earth ground.

Refer to the packing items list for full size option box in Valve GC system with option box Service
manual.
Assemble the option box referring to the procedure below.
View of the full size option box fixed on the left side panel on GC-2010
GC-2010
Temporarily fix the option box on the left
side panel with screws.
Page 8
GC-2014

View of an “Aluminum plate upper” fixed on the right side panel of the option box.
Fix an Aluminum plate upper on the right

side plate of the option box with four
screws.
View of an “Aluminum plate upper and lower” fixed together on the right side panel of the option
box.
Fix an Aluminum plate lower on the right

screws.
Page 9
Fix two solenoid valves together using the special two screws.
Solenoid valve
Fix another two solenoid valves in case of fixing four valves.
Solenoid valve
1.5 Fixing the pressure balance (P.B) valve

Fix the pressure balance valves with two screws.
Pressure Balance (P.B) valve
OUT
USB3-6-2-J-DC24V
IN
Page 10
1.6 Fixing the joint for sample IN and OUT
Fix the joint (EZBRU21) in sample IN and OUT port on the front.
Sample Inlet Sample Outlet

port port

Connect the pipe-1/16M between the sample IN port on the front panel and P.B IN.
And connect the other pipe-1/16M between P.B OUT port and sample IN position on the valve.
Pipe 1/16M, connect it between P.B

Valve (IN) and Sample Inlet port.
NOTE: P.B fixing position has been
changed as in position below.
1.8 Connecting the air branch joint

Connect the Branch-joint for air supply at “AIR” on the GC back panel.
Branch-joint for air supply
Page 11
1.9 Connecting the T-joint.
Connect the air supply tubing at each solenoid valve with a T-joint.
T-joint


Clamp CR-2 for

valve fixing.
Insert Aluminum tube through the GC oven.

The connection pipe will pass through inside
the aluminum tube.
Once the Heater block is inserted between

the clamp and valve neck, it is easy to keep
the proper alignment
of the valve. Then fix the Heater block on
the valve body.
Page 12
Port number 1(6-port)

should be in upward location.
2.4 Join the Air actuator and the valve stand-off shaft.
Tighten up the clamp (CR-3) with the hex-wrench.
Confirm: The direction of the air supply

connector on the actuator is shown in its
proper alignment for a 6-port valve.
Tight CR-3 by Hex-wrench

The alignment of a 10-port valve is shown as follows.

should be in upward
location.
Page 13
2.6 Air actuator alignment for 10-port valve


[Important confirmation]
Ensure the direction of the actuator rod alignment manually before supplying air in the actuator.
Standby position
Turn ON position
Page 14
2.7.2 View of assembling both 6- and 10-port valves

Insert the Aluminum sheet between the valve and heater block in order to keep the heat transfer from
heater block to valve head.
Note: it’s very important to keep the thermal transfer to Valve head and tighten the Valve fixing well.
Aluminum sheet

Fix the sample loop at the port number 3 and 6 in the case of a 6-port valve.
Refer to the pipe connection below.
Page 15
Fix the heater and Pt sensor assembly into the specified hole of the heater block.
Carefully handle the heater and

Pt sensor assembly since the
Pt sensor can be easily broken.
The heater and Pt sensor

assembly cable

Heater and Pt
sensor connector
For example: Connect the heater and Pt sensor cable to the AUX-3 connector.
It is controlled by the “Add.Heater” tab on the GC-Solution real time window.
Page 16
Fix the
Remove the screw
Board-A
Fix two
poles
Fix the
Board-B
Power supply DC-24V

for PRG-2010
Page 17
Fix the PRG power supply at back space of GC in case of an installed dual TCD.
Example
Event-1(valve-1)
Event-2(valve-2)
Event-3(Valve-3)
Event-4(Valve-4)
Event-5(P.B)
Page 18
6.1 Connect the air supply tubing at each solenoid valve and actuator with a T-joint

In case of standby position,

air will be supplied from solenoid port (A)
to actuator port (A).
The port (B) will release air.
In case of turn ON position,

air will be supplied from solenoid port (B)
B to actuator port (B).

A The port (A) will release air.
Page 19

7.2 View of the covered option box on GC-2014.
Page 20
Full Size Option Box for Electric Actuator
WARNING
High Voltage

Refer to the packing items list for full size option box in Valve GC system with option box Service
manual.
GC-2010
GC-2014
Page 21
View of an “Aluminum plate upper” fixed on the right side panel of the option box.
Fix an Aluminum plate upper on the right

screws.
View of an “Aluminum plate upper and lower” fixed together on the right side panel of the option
box.

screws.
1.4 Fixing the pressure balance valve and the sample IN & OUT port joint
Fix the pressure balance valve (USB3-6-2-J-DC24V) with two screws and
the sample IN & OUT port joint (EZBRU21) on the front panel.
Sample IN
and OUT port
OUT
IN
Page 22
---- Same way of Air actuator section above.----
Chapter 2: Installing the valve and electric actuator.


Clamp CR-2 for

valve fixing.

the aluminum tube.
Once the Heater block in inserted between

the clamp and valve neck, it is easy to
keep the proper alignment of the valve.
Then fix the Heater block on the valve
body.

should be in upward location.
Page 23
Electric actuator alignment.


should be in upward
location.
Page 24
Chapter 3: Installing the heater block.
Note: it’s very important to keep the thermal transfer to Valve head and tighten the Valve fixing well.
Aluminum sheet

Fix the sample loop at the port number 3 and 6 in the case of a 6-port valve.
Page 25
And then connect it to the AUX temperature board.

Chapter 5: Installing the AUX temperature board.

Heater and Pt
sensor connector
assembly cable
For example: Connect the heater and Pt sensor cable to the AUX-3 connector.
Page 26
Fix the
Remove the screw
Board-A
Fix two
poles
Fix the
Board-C
Power supply DC-24V

for PRG-2010
Page 27
Fix the PRG power supply at back space of GC in case of an installed dual TCD.
Example
Event-93(valve-1)
Event-94(Valve-2)
Example
Event-9(valve-1)
Event-10(P.B)
Page 28
Chapter 7: Connection cables
Also connect other cable between the control module and power supply DC-24V.
Fixing the power supply DC-24V in Power Box below.
Page 29
View of the covered option box on GC-2014.
Page 30
Section 2
Half Size Option Box for Air Actuator
WARNING
High Voltage

Refer to the packing items list for half size option box in Valve GC system with option box Service
manual.
View of the half size option box fixed on the left side GC panel on GC.
Temporarily fix the option box on the left side

plate of GC with screws.
Page 31
View of an “Aluminum plate upper”.
Fixed on the right side panel of the option box.

screws.

Fix a solenoid valve and event cable terminal on the bottom.
Event cable
terminal.
Solenoid valve
Fix an Event terminal plate on the bottom

with screws.
Page 32
The pipe-1/16M connection.
Other pipe-1/16M connect to P.B OUT port and sample IN on the valve.
Fix the joint (EZBRU21) to

Sample Outlet port
Sample Inlet port
Pressure Balance (P.B) valve (USB3-6-2-J-DC24V)
1.6 Connect the Branch-joint for air supply

Connect the Branch-joint for air supply at “AIR” on the GC back panel.
Branch-joint for air supply
Page 33
Clamp for valve fixing.
Alumina tube

the aluminum tube.
Once the Heater block in inserted between the

clamp and valve neck, it is easy to keep the
proper alignment of the valve.
And then fix the Heater block on the valve
Heater block body.

should be in upward direction.
Page 34
2.4 Join the actuator and the valve stand-off shaft
And then tighten up the clamp (CR-3) with the hex-wrench.


In case you have an additional 10-port valve.

should be in upward
location.
2.6 Air actuator direction for 10-port valve
Tighten up by Hex-wrench
Page 35
NOTE:
Ensure the rotation of the actuator manually before supplying air in the actuator.
Disconnect the air supply tube in order to ensure the rotation of the actuator rod alignment.
2.7.1 Example for 10-port valve.
Standby position
Turn ON position
2.7.2 View of the assembling for 6-port valve
Page 36
NOTE:
It is very important to keep the thermal transfer to Valve head and tighten the Valve fixing well.
Aluminum sheet

Fix the sample loop at the port number 3 and 6 in case of a 6-port valve.
Page 37
Fix the heater and Pt sensor assembly.


cable assembly
Chapter 4: Install the AUX temperature board

Heater and Pt
sensor connector
Example: Connect the heater and Pt sensor cable to AUX-3 connector.

Page 38
“Event Option”
connector.
Event cable
Confirm the connection

B between the solenoid valve and
Event terminal.

6.1 Connect the air supply tubing to actuator IN and OUT.
In case of standby position,

the air will be supplied from solenoid port (A)
to actuator port (A).
The port (B) will release the air.
In case of turn ON position,

the air will be supplied from solenoid port (B)
B
A to actuator port (B).
The port (A) will release the air.
Page 39
Air actuator
Heater block
Housing cover
Heater & Pt sensor Assembly
Solenoid valve Pressure balance valve
Page 40
Half Size Option Box for Electric Actuator
WARNING
High Voltage

Refer to the packing items list for half size option box in Valve GC system with option box Service
manual.
View of the half size option box fixed on the left side GC panel on GC.
Temporarily fix the option box on the left side

plate of GC with screws.
Page 41
View of an “Aluminum plate upper”.
Fixed on the right side panel of the option box.
Fix an Aluminum plate lower

on the right side plate of the option box
with four screws.

Fix a solenoid valve and event cable terminal on the bottom.
Fix an Event terminal plate

on the bottom with screws.
Event cable
terminal.

The pipe-1/16M connection.
Fix the joint (EZBRU21) to

Sample Outlet port
Sample Inlet port
Pressure Balance (P.B) valve (USB3-6-2-J-DC24V)
Page 42
Chapter 2: Installing the valve and Electric actuator
Clamp for valve fixing.
Alumina tube

the aluminum tube.
2.2 Insert the valve into the clamp and tighten up with the hex-wrench.
Once the Heater block is inserted between the

clamp and valve neck, it is easy to keep the
proper alignment of the valve.
And then fix the Heater block on the valve
Heater block body.

should be in upward direction.
Page 43
Electric actuator alignment.


should be in upward
location.
2.6 View of assembling 10 port valve
Page 44
NOTE:
It is very important to keep the thermal transfer to Valve head and tighten the Valve fixing well.
Aluminum sheet

Fix the sample loop at the port number 3 and 6 in case of a 6-port valve.
Page 45
And then connect it to the AUX temperature board.


5.1 Fix the AUX temperature board on the specified location.
Heater and Pt
sensor connector
Example: Connect the heater and Pt sensor cable to the AUX-3 connector.
Page 46
“Event Option”
connector.
Event cable

Also connect the other cable between the control module and power supply DC-24V.
Page 47
Heater block
Housing cover
7.2 View of the half size option box on GC-2010.
Page 48

Option Box Service Manual Assembling Procedure: Shimadzu Corporation Analytical & Measuring Instrument Division

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465-00100-52

Option Box Service Manual

Analytical & Measuring Instrument Division

3. Items Beyond the Scope of This Guarantee

Copyright © 2008 Shimadzu Corporation

Notation Used for Precautionary Information

Chapter 2: Installing the valve and air actuator

Chapter 3: Installing the heater block

Chapter 4: Installing the AUX temperature board

Chapter 5: Installing the PRG-2010

Chapter 7: View of the completed assembly

Full Size Option Box for Electric Actuator

Chapter 2: Installing the valve and electric actuator

Chapter 3: Installing the heater block

Chapter 4: Installing the heater and Pt sensor assembly cable

Chapter 5: Installing the AUX temperature board

Chapter 6: Installing the PRG-2010

Chapter 8: View of the completed assembly

Chapter 2: Installing the valve

Chapter 3: Installing the heater block

Chapter 4: Install the AUX temperature board

Chapter 5: Install the Event cable

Chapter 7: View of the completed assembling

Half Size Option Box for Electric Actuator

Chapter 2: Installing the valve and Electric actuator

Chapter 3: Installing the heater block

Chapter 4: Installing the heater and Pt sensor assembly cable

Chapter 5: Installing the AUX temperature board

Chapter 6: Install the Event cable

Chapter 7: View of the completed assembly

Chapter 1: Installing the Option box on GC

1.1 Confirm the packing items

1.3 Fixing the aluminum plate

Fix an Aluminum plate upper on the right

Fix an Aluminum plate lower on the right

Fix another two solenoid valves in case of fixing four valves.

1.5 Fixing the pressure balance (P.B) valve

Pressure Balance (P.B) valve

Sample Inlet Sample Outlet

1.7 The pipe-1/16M connection

Pipe 1/16M, connect it between P.B

1.8 Connecting the air branch joint

Branch-joint for air supply

Chapter 2: Installing the valve and air actuator

NOTE: P.B fixing position has been

Clamp CR-2 for

Insert Aluminum tube through the GC oven.

Once the Heater block is inserted between

Port number 1(6-port)

Confirm: The direction of the air supply

Tight CR-3 by Hex-wrench

Port number 1(10-port)

Confirm: The direction of the air supply

2.7 Confirming the valve direction

2.7.1 Example for 10-port valve

Chapter 3: Installing the heater block

3.2 Fixing the sample loop

Carefully handle the heater and

The heater and Pt sensor