<Int> <Ind> <Rev>

Technical Process Gas Chromatograph

Information GC1000 Mark II
Installation Manual
TI 11B03A03-03E

Contents
䉬 Notice ......................................................................................................... 2
䉬 Introduction ............................................................................................... 5
1. Overview ...................................................................................................13
1.1 System Configuration ...................................................................................... 13
1.1.1 Wiring and Piping Diagram .................................................................14
1.1.2 External Dimensions ...........................................................................18
1.2 Auxiliary Provisions ..........................................................................................26
1.3 Necessary Operation Conditions for Gases .................................................... 27
1.4 Standard Performance ......................................................................................28
1.5 Data Plate 具CENTELEC Atex directive典 ............................................................30

2. Installation, Piping, and Wiring .................................................................31

2.1 Installation .........................................................................................................31
2.1.1 Analyzer Installation ........................................................................... 31
2.1.2 Installation of Auxiliary Provisions ...................................................... 33
2.2 Piping ................................................................................................................ 37
2.2.1 General Notes on Piping Work ............................................................37
2.2.2 Types of Piping .................................................................................. 37
2.2.3 Piping Connection ............................................................................. 38
2.3 Wiring ................................................................................................................41
2.3.1 General Cautions on Wiring ............................................................... 41
2.3.2 Kinds of Wiring ....................................................................................41
2.3.3 Recommended Cables ...................................................................... 42
2.3.4 Precautions on Wiring ........................................................................ 43
2.3.5 Cable Inlet Locations ..........................................................................47
2.3.6 Connecting Power Cable and Grounding ............................................ 48
2.3.7 Connecting Process I/O Signals ........................................................ 58

◆ Revision Record .......................................................................................67

TI 11B03A03-03E
©Copyright Oct. 2001(YK)
2nd Edition Sep. 2002(YK)
Yokogawa Electric Corporation
<Toc> <Ind> <Rev> <Introduction> 2

䉬 Notice
This Manual is to provide the technical information for installing a GC1000 Mark II at
site.
When installing or checking up the installation of GC1000 Mark II, read this sentence
carefully.

● Regarding This Manual

1. This Manual should be passed on to the end user.
2. Read this manual carefully and fully understand how to operate this product before
you start operation.
3. Yokogawa makes no warranty of any kind with regard to this material, but not
limited to, implied warranties of merchantability for particular purpose.
4. All rights reserved. No part of this manual may be reproduced in any form without
Yokogawa’s written permission.
5. Great effort has been expended to ensure that the descriptions in this manual are
correct. Should you, however, come across a questionable area or note an incon-
sistency, a telephone call or letter to Yokogawa.co.,ltd. noting the questionable area
would be highly appreciated.
6. The contents of this manual are subject to change without prior notice.

● Regarding Protection, Safety, and Prohibition Against Unauthorized

Modification.
1. For the protection and safe use of the product and the system controlled by it, be
sure to follow the instructions on safety described in this manual when handling
the product. In addition, if you handle the product in contradiction to these instruc-
tions, our company does not guarantee safety.
2. The following safety symbol marks are used on the product concerned or in this
Manual :

WARNING
A WARNING sign denotes a hazard. It calls attention to procedure, practice,
condition or the like, which, if not correctly performed or adhered to, could result in
injury or death of personnel.

CAUTION
A CAUTION sign denotes a hazard. It calls attention to a procedure, practice,
condition or the like, which, if not correctly performed or adhered to, could result in
damage to or destruction of part or all of the product.

Media No. TI 11B03A03-03E 2nd Edition : Sept. 2002 (YK) TI 11B03A03-03E 2nd Edition : Sept. 30,2002-00
All Rights Reserved Copyright ©2001, Yokogawa Electric Corporation
<Toc> <Ind> <Rev> <Introduction> 3

IMPORTANT:
Indicates that operating the hardware or software in this manner may damage it or
lead to system failure.

NOTE:
Draws attention to information essential for understanding the operation and
features.

TIP:
Gives information that complements the present topic.

See Also:
Gives the reference locations for further information on the topic.

Protective ground terminal:

In order to provide protection against electrical shock in case of a fault. This sym-
bol indicates that the terminal must be connected to ground prior to operation of
equipment.

Function ground terminal:

In order to provide protection against noise. This symbol indicates that the terminal
must be connected to ground prior to operation of equipment.

Alternating current
Indicates the power switch state “ON”.

Indicates the power switch state “Stand - by”.

Indicate the power switch state “OFF”.

3. If protection / safety circuits are to be used for the product or the system controlled
by it, they should be installed outside of the product.
4. When you replace parts or consumables of the product, use those specified by our
company.
5. Do not modify the product

● Exemption from Responsibility

1. Yokogawa Electric Corporation does not make any warranties regarding the
product except those mentioned in the WARRANTY that is provided separately.
2. Yokogawa Electric Corporation assumes no liability to any party for any loss or
damage, direct or indirect, caused by the use or any unpredictable defect of the
product.

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<Toc> <Ind> <Rev> <Introduction> 4
● Regarding Software and set including Software Supplied by YOKOGAWA
1. Yokogawa makes no other warranties expressed or implied except as provided in
its warranty clause for software supplied Yokogawa.
2. Use this software with one specified computer only.
You must purchase another copy of the software for use with each additional
computer.
3. Copying this software for purposes other than backup is strictly prohibited.
4. Store the streamer or floppy disk (original medium) in a secure place.
5. Reverse engineering such as the disassembly of software is strictly prohibited.
6. No portion of the software supplied by Yokogawa may be transferred, exchanged,
or sublet or leased for use by any third party without prior permission by Yokogawa.

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<Toc> <Ind> <Rev> <Introduction> 5

䉬 Introduction
Thank you for purchasing the GC1000 Mark II process gas chromatograph.
This manual describes the installation of Model GC1000D / GC1000S / GC1000T /
GC1000E / GC1000W / GC1000C (Hereafter, it is abbreviated as GC1000 Mark II)
Process Gas Chromatograph.
Please read the following respective documents before installing and using the
GC1000 Mark II system.

● Documents Related to the GC1000 Mark II Process Gas Chromatograph

1. Instruction manuals
The product comes with the following instruction manuals.

■ Instruction manuals that do not depend upon the specifications of the

product
(1) Overview (IM 11B03A03-01E)
(2) Basic Operation and Startup (IM 11B03A03-02E)
(3) Maintenance and Inspection Manual (IM 11B03A03-04E)
(4) LCD Panel Operation Manual (IM 11B03A03-05E)
(5) Alarm Message Manual (IM 11B03A03-06E)
and Installation Manual (TI 11B03A03-03E)

■ Instruction manuals that depend upon the specifications of the product

(1) GCMT Gas Chromatograph Maintenance Terminal Software Package Operation
Guide (IM 11B03G03-03E)
(2) Capture It! Manual (IM 11B3G1-02E)

■ Instruction manuals for related products

(1) Model GCCU Computing Unit for a gas chromatograph (IM11B03S03-01E)
(2) GCCU Utility Software Manual (IM11B3S2-02E)
(3) Analyzer Server User's Manual (IM11B5B1-01E)
(4) ASMT Analyzer Server Maintenance Terminal Operation Guide
(IM11B05A03-01E)
(5) GCIU Interface Unit (IM 11B5B2-01E)
and Hub GCHUB Installation Manual (TI 11B5C1-01E)

2. Operation Data
Operation data is supplied with the operation manuals in the delivered package and
contains the following required to use the gas chromatographs.
● Process conditions and measurement range
● Instrument specifications and operating conditions
● Standard sample for calibration

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<Toc> <Ind> <Rev> <Introduction> 6
● Column system and column
● Miscellaneous data
Chromatogram, base line, repeatability, power supply voltage variation, etc.
● Analyzer flow diagram and installation
● Parts composition table
● General connection diagram
● Sampling system diagram (only if supplied by Yokogawa)

● General Precautions

WARNING
(1) In order to analyze gases, process gas chromatographs use a sample of the
process gas and utility gases.
Since these gases are typically combustible, combustion-sustaining, toxic,
odorous, resolvable, polymerizing, or corrosive, refer to the “Safety Informa-
tion” in our approval drawings and others to ensure safety thoroughly
before using these analyzers.
(2) Up to two protection systems, each of which weighs approximately 10 kg, are
installed on top of the GC1000. Therefore, the center of gravity is higher than the
center of the analyzer body.
Take great care when carrying and installing (piping- wiring) the GC1000.
The GC1000 must be carried and installed very carefully (including piping
and wiring) by more than one person (at least four people are recom-
mended).
(3) Since the GC1000 are precision instruments, take care when handling not to
jolt of knock them.
(4) Use the GC1000 within the range of your purchase specifications.
Yokogawa assumes no responsibility for problems resulting from use by the
customer outside the purchase specifications.
If the GC1000 need to be modified or repaired, please contact your nearest
Yokogawa representative. Yokogawa assumes no responsibility for results where
the customer or any third party has attempted to modify or repair these products.
(5) When touching LCD Panel switches
When touching LCD Panel switches, first, discharge Electro Static Charge of the
body. Then, touch the LCD Panel switches. If not, LCD display may be changed
by Electro Static Discharge.

IMPORTANT:
(1) Read the attached instruction manual before operating the GC1000
(2) The instruments must be installed and operated according to the installation
manual, instruction manual, approval drawings, and operation data.

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<Toc> <Ind> <Rev> <Introduction> 7
● CAUTIONS OF USING EXPLOSION-PROTECTION INSTRUMENTS
The GC1000 Process Gas Chromatographs are designed to protect against explosion.
When these analyzers are used in a hazardous area, observe the following precau-
tions.
Since the applicable standard differs depending on the specifications of the analyzer to
be used, check the specifications of your analyzer.

(1) Kinds of explosion protection

To assure explosion protection, the GC1000 Process Gas Chromatographs have a
pressurized and flameproof construction, or type X purging and explosionproof con-
struction meeting the following standards :

<GC1000D / GC1000S>
• JIS Expd IIB + H2 T1 (programmed-temperature oven 320˚C max., isothermal
oven 225˚C max., liquid-sample valve 250˚C max.)
• JIS Expd IIB + H2 T2 (programmed-temperature oven 225˚C max., isothermal
oven 225˚C max., liquid-sample valve 225˚C max.)
• JIS Expd IIB + H2 T3 (programmed-temperature oven 145˚C max., isothermal
oven 145˚C max., liquid-sample valve 145˚C max.)
• JIS Expd IIB + H2 T4 (programmed-temperature oven 95˚C max., isothermal oven
95˚C max., liquid-sample valve 95˚C max.)

<GC1000W / GC1000C>
CENELEC (ATEX directive) certified : Group II Category 2G
• EEx pd II B +H2 T1 (programmed-temperature oven 320°C max, isothermal oven
225°C max., liquid-sample valve 250°C max.)
• EEx pd II B +H2 T2 (programmed-temperature oven 225°C max, isothermal oven
225°C max., liquid-sample valve 225°C max.)
• EEx pd II B +H2 T3 (programmed-temperature oven 145°C max, isothermal oven
145°C max., liquid-sample valve 145°C max.)
• EEx pd II B +H2 T4 (programmed-temperature oven 95°C max, isothermal oven
95°C max., liquid-sample valve 95°C max.)

<GC1000T / GC1000E>
FM Type X purging and Explosionproof for CLI, DIV1, GPS B, C & D, NEMA3R
Type Y purging and Type X purging for CLI, DIV1, GPS B, C & D, NEMA3R
• T1 (programmed-temperature oven 320˚C max., isothermal oven 225˚C max.,
liquid-sample valve 250˚C max.)
• T2 (programmed-temperature oven 225˚C max., isothermal oven 225˚C max.,
liquid-sample valve 225˚C max.)
• T3 (programmed-temperature oven 145˚C max., isothermal oven 145˚C max.,
liquid-sample valve 145˚C max.)
• T4 (programmed-temperature oven 95˚C max., isothermal oven 95˚C max., liquid-
sample valve 95˚C max.)

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<Toc> <Ind> <Rev> <Introduction> 8
CSA Type X purging and Explosionproof for CLI, DIV1, GPS B, C & D, TYPE3R
Type Y purging and Type X purging for CLI, DIV1, GPS B, C & D, TYPE3R
• T1 (programmed-temperature oven 320˚C max., isothermal oven 225˚C max.,
liquid-sample valve 250˚C max.)
• T2 (programmed-temperature oven 225˚C max., isothermal oven 225˚C max.,
liquid-sample valve 225˚C max.)
• T3 (programmed-temperature oven 145˚C max., isothermal oven 145˚C max.,
liquid-sample valve 145˚C max.)
• T4 (programmed-temperature oven 95˚C max., isothermal oven 95˚C max., liquid-
sample valve 95˚C max.)

(2) Precautions for Explosionproof section (The analyzer with optional

code "FM/CSA Type Y purging" does not have the explosionproof
section.)
When handling the screws on the cover of the Protection system, note the following to
avoid damaging the screws since they cannot be repaired.
(1) The enclosure is pressurized. Before removing the cover, reduce the internal
pressure by loosening the sealing plug for wiring on the enclosure or relevant
means.
(2) When removing the cover, prevent any dirt or foreign matter from contaminating
the screw part.
(3) When installing the cover, tighten the screws by hand ; never use tools.
(4) Since the screws are coated with MOLYKOTE, do not lubricate them.

(3) Precautions when using hydrogen gas

When using hydrogen gas as the carrier gas, the FID or FPD combustion gas, to
ensure safety, install the analyzer in a location equipped with a ventilator or where there
is sufficient ventilation. Make sure there are no gas leaks from the pipe joints and
inspect for leaks.

(4) Installation site and environment

The analyzer specifications allow it to be used in hazardous areas as defined by Zone 1
IIB + H2T1, T2, T3, T4 (JIS / CENELEC) or DIV1, GPS B, C & D, T1, T2, T3, T4 (FM /
CSA). However, never install the analyzer in an area where the density of explosive gas
persists for a long time.

(5) Wiring works

Model GC1000D / GC1000S, analyzer obtains explosion proof authorization by the
complete set including metal fittings of the attachment.
When performing wiring, always use the attached sealing fittings and flameproof
packing adapter.

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<Toc> <Ind> <Rev> <Introduction> 9
(6) Maintenance and inspection
During usual maintenance and inspection, it is not necessary to check the explosion-
protected section.
Before opening the door of the explosion-protected section for maintenance and in-
spection, be sure to turn off the power. After completing maintenance and checks, close
the door completely then turn on the power after checking that the specified explosion
protection performance is guaranteed. The parts to be checked are described in the
Maintenance and Inspection Manual (IM 11B03A03 - 04E).
If any of the following damage occurs, contact a Yokogawa sales representative or the
Yokogawa sales division
(1) If the screws securing the Protection System (explosionproof construction) are
damaged
(2) If the exterior or light transmission section of the enclosures is damaged
(3) If packings are cracked or conspicuously deformed

(7) Override function (The analyzer with optional code "FM/CSA Type Y
purging" does not have this function.)

WARNING
• When the override function is used, Analyzer becomes an ignition source and the
high temperature and the high voltage part will be exposed.
• Please confirm that in the ambient atmosphere, the concentration of explosive
gases is less than the allowable limit, by using a gas detector.

To return to the normal operation, turn off “the override switch” and then close the door
as it was before turning on power.
In this analyzer, if the pressure of the pressurized / type X purged enclosure system
(oven, electronic section) drops while the power is on, the pressurized explosion pro-
tection section is activated to stop power supply. Therefore, in case of opening the door
of the oven or of the electronic section inadvertently, for maintenance, while the power
is on, the protection system is activated to cut off the power.
The “override function” intensively releases this function of protection system.
The override switch is installed in section.

(8) Replacing parts

Always use parts specified by Yokogawa when replacing parts, for replacement, refer to
the Maintenance and Inspection Manual (IM 11B03A03 - 04E).

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<Toc> <Ind> <Rev> <Introduction> 10
(9) Operation

WARNING
<CENELEC>
* Only trained persons may use this instrument in a hazardous location.
* Do not open when energized.
<FM>
For type X purging:
* This equipment contains components that operate at high temperature. The
equipment shall be deenergized for 60 minutes to permit those components to
cool before the enclosure is opened unless the area is demonstrated to be non-
hazardous at the time.
* Enclosure shall not be opened unless the area is known to be nonhazardous, or
unless all devices within have been de-energized.
* Power shall not be restored after enclosure has been opened until enclosure has
been purged for 12 minutes. (When the internal pressure is restored, the system
automatically purges over the 12 minutes, then turns on the power again.)
For explosionproof enclosure:
* Seal all conduits within 18 inches
* Open circuit before removing cover.
For type Y purging:
* Enclosure shall not be opened unless the area is known to be non-hazardous, or
unless all devices within have been de-energized. Power shall not be restored after
enclosure has been opened until enclosure has been purged for 12 minutes at
specified pressure indicated by the pressure gauge labeled “EL.BOX” in the
pressure and flow control section.
* Alarm shall be provided and connected to alarm contact output.
(a) The alarm shall generate a visual or audible signal that attracts attention
(b) The alarm shall be located at constantly attended location.
(c) Electrical alarms shall be approved for the location in which they are installed.

<CSA>
For type X purging:
* This equipment contains components that operate at high temperature. The
equipment shall be deenergized for 60 minutes to permit those components to
cool before the enclosure is opened unless the area is demonstrated to be non-
hazardous at the time.
* Enclosure shall not be opened unless the area is known to be non-hazardous, or
unless all devices within the enclosure have been de-energized. Power must not
be restored after enclosure has been opened until enclosure has been purged for
12 minutes at a flow rate of 0.05m3/min.
* Power will automatically be removed when purge pressure falls below 40 mm (1.6
in) of water column.

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<Toc> <Ind> <Rev> <Introduction> 11
For explosionproof enclosure:
* A seal shall be installed within 50 cm of the enclosure.
* Open circuit before removing cover.
For type Y purging:
* Enclosure shall not be opened unless the area is known to be non-hazardous, or
unless all devices within the enclosure have been de-energized. Power must not
be restored after enclosure has been opened until enclosure has been purged for
12 minutes at a flow rate of 0.05 m3 / minute min.
* Remove power below 40 mm (1.6in) of water column.

Take care not to generate mechanical spark when accessing to the instrument and
peripheral devices in hazardous locations.
Do not press prick the keyboard of LCD panel (operation and display section) using
such as knives and sticks.

(10) Maintenance and Repair

The instrument modification or parts replacement by other than authorized representa-
tive of Yokogawa Electric Corporation is prohibited and will void the approval of Factory
Mutual Research Corporation and CSA certification and CENELEC certification .

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<Toc> <Ind> <Rev> <Introduction> 12
● Precautions Against Electrostatic Problems
The GC1000 system uses numerous IC components. When handling cards
with IC components mounted on them for maintenance or setting changes, take
full precautions against electrostatic problems.
These precautions are summarized below.
(a) When storing or carrying cards, enclose them in a conductive bag or anti-
static bag. (Cards as shipped by Yokogawa are enclosed in a conductive bag
or antistatic bag labeled with cautions against electrostatic problems.)
(b) Whenever mounting or demounting cards into or from a product, wear a
wrist strap grounded via a 1 MΩ resistance. Connect the wrist strap to any
ground terminal near the ground wire or to any unpainted part of the
grounded frame.

Gard List strap

Sheet
List strap

1MΩ

F0001.EPS

Using a wrist strap and conductive sheet Using a Conductive Sheet

(c) When servicing cards on the bench, place them on a conductive sheet
grounded via a 1 MΩ resistance, wearing a wrist strap as in (2) above. Keep
easily-chargeable plastic materials away from the bench.
(d) Never touch components mounted on the cards, the pattern side, connec-
tors, pin components, etc. with bare hands, unless using a wrist strap and a
conductive sheet.
(e) Wrist straps and conductive sheets are available from Yokogawa Engineering
Service (YSV).

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<Toc> <Ind> <1. Overview > 13

1. Overview
A gas c hromatograph separates a gas mixtures into eac h component and seriall y
detects the components. The gas c hromatograph is a representative gas anal yzer
owing to its wide measurab le area, no interf erence , and its capability to measure the
various components at the same time .
This anal yzer can be installed up to tw o detector s. The combinations of these detector s
can be: a thermal conductivity detector (TCD), a flame ionization detector (FID) or a
flame photometric detector (FPD).
Since the method of handling the anal yzer diff ers slightl y accor ding to the detector s
installed, refer to the Instruction Man ual in accor dance with the method to be adopted.
Gas chromatograph system v aries accor ding to user's conditions. Therefore, please
note that this installing and operating the anal yzer.

1.1 System Configuration

The follo wing equipments can be utiliz ed with GC1000 Mark II anal yzer and configure
to pr ocess gas c hromatograph system:
(1)External sample pr ocessing equipment
(2)Personal computer
(3)Super visor y computer , Analogue equipment
(4)Analyzer bus system
However, the system configuration ma y diff er accor ding to the specifications.

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<Toc> <Ind> <1. Overview > 14

1.1.1 Wiring and Piping Diagram

(1) With analyzer base sampling system; With Vent Stack

Class D independent
grounding (100Ω or less)
Communlcation via personal computer
Transmission : Analysis results, Operation info., Operational conditions Communication via DCS RS-422 1200/2400/4800/
(RS-422, 19.2/38.4k bps ; for explosion protection,
Transmission : Analysis results 9600/19200bps for
an RS-422/RS-232C converter is provided) explosion protection,
Reception : Operation requests, Operational conditions change an RS-422/RS-232C
Reception : Operation requests
converter is provided.

(Note 5) Analog input (4 to 20mA DC/1 to 5V DC) Max. 4 points

Contact input (5V DC, 20mA DC or more) Max. 8 points
Analog hold output (4 to 20mA, insulation of load resistance
300Ω or less) Max. 36 points (Note 6)
Contact output (30V DC, 100mA DC) 8 points
2B SGPW Output to remote sampling stream selector valve
(Pneumatic, 350kPa) Max. 8 points

1/2B SGPW
vent stack
Keep pipe support so as Rc1/2 or
not to bend by the weight 1/2NPT
of pipe.
Dehumidifier
Vent Header
Both ends are RC 1/2
FID/FPD air

Rc1/2 Purge air

or 1/2NPT Cooling air

∗
Process1
∗ ∗1 ∗2 ∗ ∗ ∗ ∗ ∗ ∗
∗
Liquid sample 2
•
(up to two streams) •
∗ 1/2B SGPW • Instrument air
Drain pipe
∗
•
• ∗1. 350 to 900kPa
Up to 31 streams ∗
2. 400 to 700kPa
FID hydrogen

FID hydrogen

Carrier gas 1

Carrier gas 1

Carrier gas 2

Carrier gas 2
(including standard sample)

∗ Drain tank
2B SGPW Analyzer base
sampling system
(Note 1)
Drain tank is used only for using FID/FPD. (spare) (spare) (spare)
This is not used for using TCD

Note1: As an analyzer base sampling system is provided, in many cases, most applications require no external sampling
equipment.
In addition, optimum sampling systems are prepared depending on various conditions. (For details, consult
Yokogawa. Optimal sampling systems will be offered.)
Note2: For piping air purging, use stainles steel pipe of 1/2 inch or more. For another piping, see subsection 1.1.2,
"External Dimensions".
Wiring cables, piping and installation materials marked with an * should be supplied by the user.
Note3: For I/O cables, see Subsection 2.2.3, “Recommended Cables”.
Note4: Fix venting pipes properly so that the dead load of the venting pipes does not apply to the assembling vents of
this analyzer.
Note5: The specification decides the number of flameproof enclosure. No enclosure is applied for the general purpose or
Y-purge type.
Note6: There is a case of analog output by via GCCU. GCCU is a computing unit to handle various types of signal such
as A/O, analog serial output, trend output, digital output and so on. Refer to GS 11B03S03-01E for detail.
F01.EPS

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<Toc> <Ind> <1. Overview > 15
(2) With analyzer base sampling system; Without Vent Stack

Class D independent
grounding (100Ω or less)
Communlcation via personal computer
Transmission : Analysis results, Operation info., Operational conditions Communication via DCS RS-422 1200/2400/4800/
(RS-422, 19.2/38.4k bps ; for explosion protection,
Transmission : Analysis results 9600/19200bps for
an RS-422/RS-232C converter is provided) explosion protection,
Reception : Operation requests, Operational conditions change an RS-422/RS-232C
Reception : Operation requests
converter is provided.

Analog input (4 to 20mA DC/1 to 5V DC) Max. 4 points

(Note 4) Contact input (5V DC, 20mA DC or more) Max. 8 points
Analog hold output (4 to 20mA, insulation of load resistance
300Ω or less) Max. 36 points (Note 5)
Contact output (30V DC, 100mA DC) 8 points

Vent Line Output to remote sampling stream selector valve

• 1/8 inch sus pipes (Pneumatic, 350kPa) Max. 8 points
When using only FID/FPD detector.
detector vent is 1/4 inch teflon tube.

Dehumidifier
Gas sampling vent
1/8 inch sus pipes
Used for only gas sampling FID/FPD air

2B SGPW Purge air

Cooling air

∗
Process1
∗ ∗1 ∗2 ∗ ∗ ∗ ∗ ∗ ∗
∗
2
Liquid sample •
•
(up to two streams) • Instrument air

∗
•
• ∗1. 350 to 900kPa
Up to 31 streams ∗
2. 400 to 700kPa
FID hydrogen

FID hydrogen

Carrier gas 1

Carrier gas 1

Carrier gas 2

Carrier gas 2
1B SGPW or (including standard sample)
1/2B SGPW ∗
Vent stack
∗ Header Analyzer base
sampling system
(Note 1)
2B SGPW (spare) (spare) (spare)

Note1: As an analyzer base sampling system is provided, in many cases, most applications require no external sampling
equipment.
In addition, optimum sampling systems are prepared depending on various conditions. (For details, consult
Yokogawa. Optimal sampling systems will be offered.)
Note2: For piping air purging, use stainles steel pipe of 1/2 inch or more. For another piping, see subsection 1.1.2,
"External Dimensions".
Wiring cables, piping and installation materials with an * should be supplied by the user.
Note3: For I/O cables, see subsection 2.2.3, “Recommended Cables”.
Note4: The specification decides the number of flameproof enclosure. No enclosure is applied for the general purpose or
Y-purge type.
Note5: There is a case of analog output by via GCCU. GCCU is a computing unit to handle various types of signal such
as A/O, analog serial output, trend output, digital output and so on. Refer to GS 11B03S03-01E for detail.
F02.EPS

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(3) Without analyzer base sampling system; With Vent Stack

Class D independent
grounding (100Ω or less)
Communlcation via personal computer
Transmission : Analysis results, Operation info., Operational conditions Communication via DCS RS-422 1200/2400/4800/
(RS-422, 19.2/38.4k bps ; for explosion protection, Transmission : Analysis results 9600/19200bps for
an RS-422/RS-232C converter is provided) explosion protection,
Reception : Operation requests, Operational conditions change Reception : Operation requests an RS-422/RS-232C
converter is provided.

(Note 4) Analog input (4 to 20mA DC/1 to 5V DC) Max. 4 points

Contact input (5V DC, 20mA DC or more) Max. 8 points
Analog hold output (4 to 20mA, insulation of load resistance
300Ω or less) Max. 36 points (Note 5)
Contact output (30V DC, 100mA DC) 8 points

2B SGPW Output to remote sampling stream selector valve

(Pneumatic, 350kPa) Max. 8 points

1/2B SGPW
vent stack
Keep pipe support so as Rc1/2 or
not to bend by the weight 1/2NPT Sample inlet
of pipe. Sample vent
Dehumidifier
Vent Header
Both ends are RC 1/2
FID/FPD air

Rc1/2 Purge air

or 1/2NPT Cooling air

∗
Liquid sample ∗1 ∗2 ∗ ∗ ∗ ∗ ∗ ∗
(up to two streams)
∗ 1/2B SGPW Instrument air
Drain pipe ∗1. 350 to 900kPa
∗2. 400 to 700kPa
FID hydrogen

FID hydrogen

Carrier gas 1

Carrier gas 1

Carrier gas 2

Carrier gas 2
∗ Drain tank
2B SGPW
Drain tank is used only for using FID/FPD. (spare) (spare) (spare)
This is not used for using TCD

Note1: For piping air purging, use stainles steel pipe of 1/2 inch or more. For another piping, see subsection 1.1.2,
"External Dimensions".
Wiring cables, piping and installation materials marked with an * should be supplied by the user.
Note2: For I/O cables, see Subsection 2.2.3, “Recommended Cables”.
Note3: Fix venting pipes properly so that the dead load of the venting pipes does not apply to the assembling vents of
this analyzer.
Note4: The specification decides the number of flameproof enclosure. No enclosure is applied for the general purpose or
Y-purge type.
Note5: There is a case of analog output by via GCCU. GCCU is a computing unit to handle various types of signal such
as A/O, analog serial output, trend output, digital output and so on. Refer to GS 11B03S03-01E for detail.

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(4) Without analyzer base sampling system; Without Vent Stack

Class D independent
grounding (100Ω or less)
Communlcation via personal computer
Transmission : Analysis results, Operation info., Operational conditions Communication via DCS RS-422 1200/2400/4800/
(RS-422, 19.2/38.4k bps ; for explosion protection,
Transmission : Analysis results 9600/19200bps for
an RS-422/RS-232C converter is provided) explosion protection,
Reception : Operation requests, Operational conditions change an RS-422/RS-232C
Reception : Operation requests
converter is provided.

Analog input (4 to 20mA DC/1 to 5V DC) Max. 4 points

(Note 3) Contact input (5V DC, 20mA DC or more) Max. 8 points
Analog hold output (4 to 20mA, insulation of load resistance
300Ω or less) Max. 36 points (Note 4)
Contact output (30V DC, 100mA DC) 8 points

Vent Line Output to remote sampling stream selector valve

• 1/8 inch sus pipes (Pneumatic, 350kPa) Max. 8 points
When using only FID/FPD detector.
detector vent is 1/4 inch teflon tube.

Sample inlet
Sample vent
Dehumidifier

FID/FPD air

2B SGPW Purge air

Cooling air

∗ ∗1 ∗2 ∗ ∗ ∗ ∗ ∗ ∗
Liquid sample
(up to two streams) Instrument air
∗1. 350 to 900kPa
∗2. 400 to 700kPa
FID hydrogen

FID hydrogen

Carrier gas 1

Carrier gas 1

Carrier gas 2

Carrier gas 2
1B SGPW or
1/2B SGPW ∗
∗ Header
Vent stack

2B SGPW (spare) (spare) (spare)

Note1: For piping air purging, use stainles steel pipe of 1/2 inch or more. For another piping, see subsection 1.1.2,
"External Dimensions".
Wiring cables, piping and installation materials with an * should be supplied by the user.
Note2: For I/O cables, see subsection 2.2.3, “Recommended Cables”.
Note3: The specification decides the number of flameproof enclosure. No enclosure is applied for the general purpose or
Y-purge type.
Note4: There is a case of analog output by via GCCU. GCCU is a computing unit to handle various types of signal such
as A/O, analog serial output, trend output, digital output and so on. Refer to GS 11B03S03-01E for detail.

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1.1.2 External Dimensions

(1) GC1000D / GC1000S with analyzer base sampling system

Enclosure 2 (connection size G3/4)

Unit : mm
(No enclosure is attached by the specification)
Enclosure 1 (connection size G3/4)
Packing adapter or Sealing fitting
616 Connection size G3/4 355

Connection to
L

L
electronics section
Packing 100
Sealing fitting 130
ground wiring
1.6mm2 or more
Protection system (100Ω max.)

Operation and Electronics section

display section

1212
Liquid sampling valve 1012
Pressure
with vaporizer
Flow controller Standard gases, carrier gas,
and air for FID/FPD
6mm or 1/4"tube
(1642)

Air for valve driving and for

purge/cooling
• RC1/4 or 1/4NPT(F)
for GC1000S/E/W
• RC1/2 or 1/2NPT(F)
Isothermal oven, for GC1000D/T/C
programmed-temperature Analyzer base sampling system
Inlet/Outlet of sample gas,
oven
standard gas and others.
(Note 1)
630

RC1/4 or 1/4NPT(F)
Steam Inlet (Note 1)
RC1/4 or 1/4NPT(F)
Steam drain Outlet (Note 1)
RC1/4 or 1/4NPT(F)
450
305
245

Weight : Approx. 120kg

30

410 Hole for installation (Note 2)

4-φ15 F03.EPS

Space for analyzer maintenance

460
300 (616) 400

Note 1 : Due to specification, there is the

case of no use.
Note 2 : The height of M12 screw from
installation floor is 25±5mm

M12 screw
25±5
1000

(Space for analyzer maintenance)

• Installation height :
1842 + L is Total height, including wiring
fitting.
Have space for maintenance of wiring
(1316)

F04.EPS

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(2) GC1000D / GC1000S without analyzer base sampling system
Unit : mm
Enclosure 2 (connection size G3/4)
(No enclosure is attached by the specification)
Enclosure 1 (connection size G3/4)

Packing adapter or Sealing fitting

616 connection size G3/4 355
Connection to electronics
section
Protection system L

L
Packing 100
Sealing fitting 130
ground wiring
1.6mm2 or more
(100Ω max.)
Operation and
display section Electronics section

Liquid sampling valve

1212
with vaporizer

1012
Prescore Inlet/Outlet of sample gas,
Flow controller standard gases, carrier gas,

550
and air for FID/FPD
6mm or 1/4"tube
Isothermal oven,
programmed-temperature
oven

50
Air for valve driving and for
50

4-φ10 hole purge/cooling

20
Fitting hole • RC1/4 or 1/4NPT(F)
710 375 for GC1000S/E/W
• RC1/2 or 1/2NPT(F)
770 for GC1000D/T/C

Weight : Approx. 100kg

F05.EPS

Space for analyzer maintenance

460
300 (616) 400
1000

(Space for analyzer maintenance) • Installation height :

For the best installation, provide ample
clearance on the top of the wiring fitting
to meet the wire-lead requirements.

(1316)
F06.EPS

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(3) GC1000T / GC1000E with analyzer base sampling system

Enclosure 2 (connection size 3/4NPT) Unit : mm

(No enclosure is attached by the specification)
Enclosure 1 (connection size 3/4NPT)
(No enclosure is attached by the specification)

616 connection size 3/4NPT 355

Connection to
electronics section

ground wiring
1.6mm2 or more
Protection system (100Ω max.)

Operation and Electonics section

display section

1212
1012
Liquid sampling valve
Pressure
with vaporizer
Flow control section Standard gases, carrier gas,
and air for FID/FPD
6mm or 1/4"tube
(1642)

Air for valve driving and for

purge/cooling
• RC1/4 or 1/4NPT(F)
for GC1000S/E/W
• RC1/2 or 1/2NPT(F)
Isothermal oven, for GC1000D/T/C
programmed-temperature Analyzer base sampling system
Inlet/Outlet of sample gas,
oven
standard gas and others.
(Note 1)
630

RC1/4 or 1/4NPT(F)
Steam Inlet (Note 1)
RC1/4 or 1/4NPT(F)
Steam drain Outlet (Note 1)
RC1/4 or 1/4NPT(F)
450
305
245

Weight : Approx. 120kg

30

410 Hole for installation (Note 2)

4-φ15 F07.EPS

Space for analyzer maintenance

460
300 (616) 400
100

Note 1 : Due to specification, there is the

case of no use.
Note 2 : The height of M12 screw from
installation floor is 25±5mm

M12 screw
1000

25±5

(Space for analyzer maintenance)

• Installation height :
1842 + L is Total height, including wiring
fitting.
Have space for maintenance of wiring
(1316)

F08.EPS

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(4) GC1000T / GC1000E without analyzer base sampling system

Enclosure 2 (connection size 3/4NPT) Unit : mm

(No enclosure is attached by the specification)
Enclosure 1 (connection size 3/4NPT)
(No enclosure is attached by the specification)

616 connection size 3/4NPT 355

Connection to
electronics section
Protection system

ground wiring
1.6mm2 or more
(100Ω max.)
Operation and
display section Electronics section

Liquid sampling valve

1212
with vaporizer

1012
Prescore Inlet/Outlet of sample gas,
Flow control section standard gases, carrier gas,

550
and air for FID/FPD
6mm or 1/4"tube
Isothermal oven,
programmed-temperature
oven

50
Air for valve driving and for
50

4-φ10 hole purge/cooling

20
Fitting hole • RC1/4 or 1/4NPT(F)
710 375 for GC1000S/E/W
• RC1/2 or 1/2NPT(F)
770 for GC1000D/T/C

Weight : Approx. 100kg

F09.EPS

Space for analyzer maintenance

460
300 (616) 400
20
1000

• Installation height :
(Space for analyzer maintenance)
For the best installation, provide ample
clearance on the top of the wiring fitting
to meet the wire-lead requirements.

(1316)

F10.EPS

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(5) GC1000W / GC1000C with analyzer base sampling system
Enclosure 2 (connection size M25×1.5 : Note 1) Unit : mm
(No enclosure is attached by the specification.)
Connector : Note 1 Enclosure 1 (connection size M25×1.5 : Note 1)
connection size M25×1.5, 3/4NPT PG21 or G3/4

616 355

32±5
Connection to
electronics section

ground wiring
1.6mm2 or more
Protection system (100Ω max.)

Operation and Electronics section

display section

1212
1012
Liquid sampling valve
Pressure
with vaporizer
Flow control section Standard gases, carrier gas,
and air for FID/FPD
6mm or 1/4"tube
(1642)

Air for valve driving and for

purge/cooling
• RC1/4 or 1/4NPT(F)
for GC1000S/E/W
• RC1/2 or 1/2NPT(F)
Isothermal oven, for GC1000D/T/C
programmed-temperature Analyzer base sampling system
Inlet/Outlet of sample gas,
oven
standard gas and others.
(Note 1)
630

RC1/4 or 1/4NPT(F)
Steam Inlet (Note 1)
RC1/4 or 1/4NPT(F)
Steam drain Outlet (Note 1)
RC1/4 or 1/4NPT(F)
450
305

Weight : Approx. 120kg

245

Note 1 : Connectors are installed when the following

screw size is used
3/4 NPT
30

410 Hole for installation (Note 2) PG21

4-φ15 G3/4
F11.EPS

Space for analyzer maintenance

460
300 (616) 400
100

Note 1 : Due to specification, there is the

case of no use.
Note 2 : The height of M12 screw from
installation floor is 25±5mm

M12 screw
1000

25±5

(Space for analyzer maintenance)

• Installation height :
1842 + L is Total height, including wiring
fitting.
Have space for maintenance of wiring
(1316)

F12.EPS

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(6) GC1000W / GC1000C without analyzer base sampling system
Enclosure 2 (connection size M25×1.5 : Note 1)
Unit : mm
(No enclosure is attached by the specification.)
Connector : Note 1 Enclosure 1 (connection size M25×1.5 : Note 1)
connection size M25×1.5, 3/4NPT PG21 or G3/4

616 355
Connection to

32±5
electronics section
Protection system

ground wiring
1.6mm2 or more
(100Ω max.)
Operation and
display section Electronics section

Liquid sampling valve

1212
with vaporizer

1012
Prescore Inlet/Outlet of sample gas,
Flow control section standard gases, carrier gas,

550
and air for FID/FPD
6mm or 1/4"tube
Isothermal oven,
programmed-temperature
oven

50
Air for valve driving and for
50

4-φ10 hole purge/cooling

20
Fitting hole • RC1/4 or 1/4NPT(F)
710 375 for GC1000S/E/W
• RC1/2 or 1/2NPT(F)
770 for GC1000D/T/C
Weight : Approx. 100kg

Note 1 : Connectors are installed when the following

screw size is used
3/4 NPT
PG21
G3/4
F13.EPS

Space for analyzer maintenance

460
300 (616) 400
20
1000

• Installation height :
(Space for analyzer maintenance)
For the best installation, provide ample
clearance on the top of the wiring fitting
to meet the wire-lead requirements.

(1316)

F14.EPS

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(7) Utility connections
Unit: mm
31
1/4-inch or 6mm pipe connections
16

27

AIR OUT 1 23
AIR OUT 2

AIR OUT 3

AIR OUT 4

AIR OUT 5

AIR OUT 6

AIR OUT 7
(A.T.M. BALANCE)
AIR OUT 8
(A.T.M. BALANCE) 322
SAMPLE 1 IN
SAMPLE 1 VENT

SAMPLE 2 IN

SAMPLE 2 VENT

CARRIER 1

CARRIER 2

BURNER FUEL

BURNER AIR
40

PURGE AIR

Rc1/4 or NPT1/4

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(8) Gas piping connections (Analyzer base sampling system)
Unit: mm

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1.2 Auxiliary Provisions

(1) Cylinders (carrier gas, standard gases, etc.)
These c ylinder s are filled with suc h as a carrier gas, standar d gases, and FID / FPD
hydr ogen gas. The maxim um filling pressure is limited to 15MP a {150 kgf / cm 2} consid-
ering the strength of the c ylinder s.

(2) Regulator for cylinder

This v alve reduces a c ylinder pressure to saf e degree to handle easil y.The valve is
directl y mounted to the c ylinder .

(3) Stop valve

This v alve inter cepts the lines f or the sample gas, the v alve driving, air and so on. It is
operated man ually.

(4) Dehumidifier
Any moisture in the carrier gas attac k the columns. Theref ore, in the case of the carrier
gas contains moisture abo ve the de w point of – 60 ºC, it is recommended to use a
desiccant, suc h as a molecular sie ve, to pre vent deterioration of the columns.

(5) Vent stacks

These are pipes to disc harge sample b ypass vent, sample vent, backflush vent,
foreflush vent, reference gas vent, measurement gas vent, and other s to the atmo-
sphere collectivel y. Induce the e xhaust gas to area where the gas is sufficientl y dis-
persed and rarefied bef ore disc harging.

(6) Regulator for sample

This v alve reduces the sample pressure to a specified degree if the sample pressure is
high. If it is necessar y to v aporiz e a liquid sample , use a regulator with a steam -
heated v aporiz er.

(7) Air and Hydrogen for FID / FPD

The Air and Hydr ogen for FID / FPD are al ways necessar y for an anal yzer with FID /
FPD. Generall y, a cylinder gas ha ving f ew impurities is used f or both of them. Instru-
ment air can also be used f or comb ustion air . However, the de w point m ust be – 60 ºC
or less in 5 ppm or less of or ganic component (the FID / FPD h ydr ogen also m ust
satisfy this condition).

(8) Pipings
The pipes f or the sample inlet, carrier gas inlet, and standar d gas inlet ; the air f or v alve
driving and air f or FID / FPD ; the FID / FPD h ydr ogen ; steam ; the sampling b ypass ;
and the diver se vents are pr ovided.

(9) Joints
The joints are used to connect pipes.

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1.3 Necessary Operation Conditions for Gases

The follo wing gases are required f or the anal yzer :

(1) Sample gas (liquid)

This is a gas (liquid) subject to anal ysis fr om the pr ocess line .

(2) Carrier gas

Prepare a gas c ylinder f or the carrier gas.
It is recommended that a spare c ylinder be prepared considering the con venience in
replacement.
If two diff erent carrier gases are used, prepare tw o gas c ylinder s respectivel y.

The gas m ust satisfy the f ollo wing conditions

• the purity m ust be 99.99% or more
• the or ganic components m ust be 5 ppm or less
• the de w point m ust be – 60 ºC or less.

(3) Standard gas

This gas is used f or calibration. Prepare a gas c ylinder inc luding measurement compo-
nent. Since up to three diff erent standar d gases can be used f or automatic calibration,
prepare a gas c ylinder suitab le for the gas.

(4) FID / FPD combustion hydrogen gas

This h ydr ogen gas is necessar y when either FID or FPD is used as a detector . Prepare
pure h ydr ogen gas in a c ylinder .
In this case also, it is recommended that a spare c ylinder be prepared considering the
convenience in replacement.

The gas m ust satisfy the f ollo wing conditions

• the purity m ust be 99.99% or more
• the or ganic components m ust be 5 ppm or less
• the de w point m ust be – 60 ºC or less.

(5) Air for valve driving and purging

This air is used f or driving v alves and as pur ging air . Prepare the air suppl y at 350kPa
or more , and 0.15m 3/min or more (f or GC1000D / GC1000T / GC1000W) or 0.1m 3/min
or more (f or GC1000S / GC1000E / GC1000C). Flow rate adjustment is not necessar y
because it is being adjusted at the time of shipping. When the air is supplied, fix ed flo w
rate is obtained automaticall y.When using cooling de vice , prepare the air suppl y at
500kPa or more , and 0.45m 3/min or more , and air de w point less than – 20 ˚C.

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(6) FID / FPD combustion air
This air is used to comb ustion h ydr ogen gas in an FID or FPD . Prepare c lean air ha ving
few impurities.
A pressure of 400kP a or more is necessar y.

The air m ust satisfy the f ollo wing conditions

• the purity m ust be 99.99% or more
• the or ganic components m ust be 5 ppm or less
• the de w point m ust be – 60 ˚C or less.

(7) Steam
This is required when a sample is steam - heated. Prepare a steam supply at the
pressure listed in “Operation Data. ”

1.4 Standard Performance

(1) Safety Standard
Complying Standard : EN61010-1 (for GC1000W/C)
: ISA(IEC1010), CSA1010 (for GC1000T/E)
Altitude at installation side: Max. 2000 m abo ve sea le vel
• Installation categor y based on IEC 1010: II (See Note)
• Pollution le vel based on IEC 1010: 2(See Note)
NOTE:
• The “Installation categor y” implies the regulation f or impulse withstand v olta ge. It is also called the
“Over volta ge categor y”.“II” applies to electrical equipment.
• “Pollution le vel” describes the degree to whic h a solid, liquid or gas whic h deteriorates dielectric
strength is adhering. “2” applies to a normal indoor atmosphere .

(2) Emission
Compl ying Standar d; EN55011-Group 1 Class A (f or GC1000W/C)
Test Item Frequency Range Basic Standard
Mains terminal disturbance voltage 0.15 MHz - 30 MHz
EN55011-Group 1 Class A
Electromagnetic radiation disturbance 30 MHz - 1 GHz

Signal Cab le requirement: Use shielded cab le

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(3) Immunity
Specification under imm unity cir cumstances
Temporar y output-c hang e of 10% is regular rang e under imm unity cir cumstances.

Compl ying Standar d: EN61326: 1997 +AM1: 1998 (for GC1000W/C)

No. Test item Test specification Basic Standard Performance

criteria
1 Electro Static Discharge 4 kV (contact) IEC61000-4-2: 1995 C
8 kV (air)
2 Radio-frequency electromagnetic field 80 to 1000 MHz IEC61000-4-3: 1995 B
Amplitude modulated 10 V/m (unmodulated)
80% AM (1 kHz)
3 Radio-frequency electromagnetic field 1.4 to 2 GHz IEC61000-4-3: 1995 A
Amplitude modulated 10 V/m (unmodulated) Amendment 1: 1998
80% AM (1 kHz)
4 Fast transients common mode 2 kV IEC61000-4-4: 1995 A
5/50 Tr/Th ns
5 kHz REP.
5 Radio-frequency 0.15 to 80 MHz IEC61000-4-6: 1996 A
common mode 3 V (unmodulated)
Amplitude modulated 80% AM (1 kHz)
Source impedance
150 ⍀
6 Surge 1 kV (Line to Line) IEC61000-4-5: 1995 A
2 kV (Line to Ground)
7 Voltage Dips/Short interruption 0.5 cycle, IEC61000-4-11: 1994 A
each polarity/100%

Note: Definition of perf ormance criteria

Performance criterion A: During testing, normal perf ormance within the specification limits.
Performance criterion B: During testing, temporar y degradation, or loss of function or perf ormance
whic h is self-reco vering
Performance criterion C: During testing, temporar y degradation, or loss of function or perf ormance
whic h requires operator inter vention or system reset occur s.

Signal Cab le requirement: Use shielded cab le

(4) Harmonics Current Emission

Compl ying Standar d: EN61000-3-2: 1995 (for GC1000W/C)

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1.5 Data Plate 具CENTELEC Atex directive典

具GC1000W典
Electronic section Isothermal oven Column oven
PROCESS PRESSURIZED ENCLOSURE
GAS CHROMATOGRAPH Internal free volume approx approx approx
MODEL GC1000 81,000 cm3 27,000 cm3 11,000 cm3
SUFFIX Note1
Minimum purging flow
rate at outlet of the 0.035 m3/min 0.035 m3/min 0.035 m3/min
pressurized enclosure
Minimum purging duration 14 min 14 min 14 min
SUPPLY V AC–
Minimum overpressure of
392 Pa 392 Pa 392 Pa
KW 50/60Hz pressurized enclosure
Tamb
-10 TO 50ºC Maximum overpressure
980 Pa 980 Pa 980 Pa
STYLE of pressurized enclosure
NO.
*1) KGC Maximum leakage flow rate
0.1 m3/min 0.1 m3/min 0.1 m3/min
from pressurized enclosure
Containment system
0344 22G Category of internal release Limited release Limited release
is not provided
Minimum flow rate of
KEMA 98ATEX4675 protective gas at inlet of the 0.04 m3/min 0.04 m3/min 0.04 m3/min
pressurized enclosure
WARNING Maximum inlet pressure to Containment system
451 kPa 451 kPa
Tokyo 180-8750 DO NOT OPEN WHEN ENERGIZED. the containment system is not provided
Made in Japan Maximum flow rate of Containment
flammable gas into the system is not 300 cm3/min 300 cm3/min
containment system provided

EEx pd2B+H2T4 or T3 or T2 or T1 具GC1000C典

Electronic section Isothermal oven

MODEL : Specified model code. Internal free volume approx approx

SUFFIX 81,000 cm3 49,000 cm3
Note1
STYLE : Specified style code. Minimum purging flow
Tamb : Ambient temperature. rate at outlet of the 0.035 m3/min 0.035 m3/min
pressurized enclosure
KGC : JOB number.
Minimum purging duration 14 min 14 min
0344 : CE-Marking
Minimum overpressure of
The identification number of the notified body. 392 Pa 392 Pa
pressurized enclosure
22G : Group 2, Category 2, Gas atmosphere.
Maximum overpressure of
980 Pa 980 Pa
KEMA 98ATEX4675 : Certificate number. pressurized enclosure

EEx pd2B+H2 : Type of protection and temperature class. Maximum leakage flow rate
0.1 m3/min 0.1 m3/min
T4 or T3 or T2 or 1 from pressurized enclosure

: Name and address of manufacturer. Containment system

Category of internal release Limited release
Tokyo 180-8750 is not provided
Made in Japan
Minimum flow rate of
*1 : The year of production. protective gas at inlet of the 0.04 m3/min 0.04 m3/min
(For example: 2002.7) pressurized enclosure
Maximum inlet pressure to Containment system
451 kPa
the containment system is not provided
Maximum flow rate of Containment
flammable gas into the system is not 300 cm3/min
containment system provided
Note: In the case of “with EPC”, approx 84,000 cm3

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2. Installation, Piping, and Wiring

If the pr ocess gas c hromatograph is to be installed in a hazar dous location, do the
wiring accor ding to the applicab le explosion - pr oof requirements.

2.1 Installation
2.1.1 Analyzer Installation
There are tw o types : Floor mounting and wall mounting. Install the c hromatograph
accor ding to the pr ocedure determined f or eac h type .

(1) Installation site

Install the anal yzer where the f ollo wing conditions are met:
(a)Specified en vir onmental conditions (atmospheric gases) are satisfied if used in a
hazardous area.
(b) Less vibration
(c) Not subject to rainfall or direct sunlight
(d) No corr osive gas or f ew dust

(2) Analyzer house

• If the anal yzer is installed outdoor s, it is recommended that the anal yzer be
housed in a special house to pr otect it fr om rain and directsunlight and to facilitate
inspection and maintenance . Figure 2.1 sho ws an e xample of an anal yzer house .
• The house should be designed to pr ovided space f or standar d gas c ylinder s
because the eff ects of the ambient temperature on standar d gas can be better
contr olled indoor s than outdoor s, preventing deg eneration of the gas.
• It is also desirab le for maintenance that the house be ab le to accommodate an
external sampling system if suc h a system is specified e xcept when leaka ge of a
toxic or flammab le standar d gas is to be a voided.
• The floor area sho wn in Figure 2.1 is the minim um requirement f or the house .
• Keep an area f or the house taking into consideration the types of items to be
accommodated and the space required f or maintenance .
• Leave a space of at least 400 mm to the right of the anal yzer for connecting v ari-
ous pipes.
• Provide ventilation openings in the upper por tion (near the ceiling) and lo wer
por tion (near the floor) of a side wall of the house .
• Provide a windo w to let in natural light to facilitate inspection and maintenance .
Electric lights, if pr ovided, will permit maintenance after dark.
• Carrier gas c ylinder s, if installed outdoor s, should be pr otected fr om exposure to
direct sunlight and rainfall b y eaves extending fr om the house .

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Figure 2.1 Example of Analyzer house

(3) Unpacking
The Model GC1000 Mark II weighs about 120 kg. Unpac k it near the installation site .
Use a transpor tation mac hine to mo ve it. It is at the position where the center of gra vity
of GC1000 Mark II is high. Handle it carefull y so that it does not fall.

CAUTION
Take great care when carr ying and installing (piping, wiring) the GC1000 Mark II. The
GC1000 Mark II m ust be carried and installed ver y carefull y (inc luding piping and
wiring) b y more than one per son (at least f our people are recommended).

(4) Installation
To securel y install the anal yzer on the floor , use anc hor bolts.
To securel y install the anal yzer on a wall, use n uts and bolts.

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2.1.2 Installation of Auxiliary Provisions

(1) Cylinders
The cylinder s should be located near the anal yzer or the e xternal sampling system f or
the con venience of connecting piping to those units. Provide a place f or installation
where the c ylinder s are not in direct sunlight (i.e ., under a r oof or ea ves) and where the
ambient temperature is 0 to 40 ˚C to install the c ylinder s. The place should be well -
ventilated so that leaking gases, if any, do not accum ulate .
Conform to regulations f or high - pressure gases.

(2) Other items

(a) Dehumidifier
Provide a dehumidifier near the anal yzer between the carrier gas c ylinder s and the
analyzer.
(b) Sample - gas pressure regulator
Provide sample - gas pressure regulator s as near the sampling point as possib le
between the sampling point and the anal yzer or the e xternal sampling system.
(c) Vent stac k, Drain tank
• With Vent Stack
Connect the top end of vent stac k to the section f or exhaust. Extend the vent stac k
outside the house using a pipe 1/2 inc h in diameter . Make pr ovisions to pre vent
rain fr om g etting in the top end of the vent stac k.
When using TCD detector , plug the lo wer end of vent stac k.
When using FID or FPD detector , provide a drain tank about 2 inc hes in siz e near
the anal yzer, where the venting lines of the anal yzer gathered, because water
occur s.
When a vent stac k is used, hold the vent stac k joint with a wrenc h so that the vent
stack does not r otate during piping installation. (See Figure 2.2)
• WithoutVent Stack
Provide a header about 2 inc hes in siz e near the anal yzer, where the venting lines
of the anal yzer are gathered. Extend the vent stac k outside the house using a pipe
1/2 inc h in diameter . Make pr ovisions to pre vent rain fr om g etting in the top end of
the vent stac k. (See Figure 2.3)

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Figure 2.2 To lock/unlock screw of Vent Stack

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Figure 2.3 Example of Vent Stack Installation

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Note 1: Drain tank is used only for using FID/FPD. Piping after removing the handle for transmission of left side on analyzer.
And piping incline so as not to stop drain in pipe. . .
Note 2: Piping and installation materials marked with an * should be supplied by the user.
Note 3: Provide the top end of vent stack to rain - protected construction.
Figure 2.4 Example of Vent Stack Construction

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2.2 Piping
2.2.1 General Notes on Piping Work
(1) Do not remo ve the b lind plugs, provided at the anal yzer piping connections to
prevent deterioration of the columns, until immediatel y before star ting piping w ork.
(2) Use an anti - corr osion material f or the pipes and pipe fittings.
(3) Avoid using pipes with too lar ge a diameter f or the sample inlet piping, for the
purpose of reducing dead time . However, use a little lar ger pipe f or the e xhaust line
so as not to appl y back pressure to the venting lines.
(4) Use pipes and pipe fittings free of interior contamination fr om grease , oil or other
substances. Before connecting those pipes, completel y air - pur ge their interior s.
(5) Carefully connect the pipes so that there is no leakage from the pipe connections
suc h as the joints.
(6) Use filter s or other appr opriate pipe fittings to pre vent dust, moisture , or other
foreign matter fr om g etting inside the anal yzer.

2.2.2 Types of Piping

The types of piping are sho wn belo w. Note, however, that the types of piping and
quantities of individual pipes required v ary with the specifications suc h as the anal yzer
type and detector type (TCD , FID, or FPD). Refer to the flo w sheets in the attac hed
“Operation Data” when implementing piping.
Pressure Connections
(1)External air pressure output 1 to 8 (AIR OUT 1 to 8)
(2)Sample-gas inlet pipe (SAMPLE 1, 2 IN)
(3)Sample-gas vent (SAMPLE 1, 2 VENT)
(4)Carrier -gas inlet pipe (CARRIER 1, 2)
(5)Comb ustib le-hydr ogen gas pipe (B URNER FUEL)
(6)Comb ustib le air pipe (B URNER AIR)
(7)Purge air pipe (PURGE AIR)
Vent connections
(1)FID vent (FID 1, 2)
(2)TCD measurement-gas vent (TCD 1, 2)
(3)TCD reference-gas venting (REF . 1, 2)
(4)Split vent (SPLIT 1, 2)
(5)Backflush venting (B. F. 1, 2)
(6)Foreflush venting (F . F. 1-1, 1-2, 2-1, 2-2)
Analyzer Base Sampling Pipes
(1)Sample inlet pipe (STREAM #1 to #12)
(2)Reference-gas inlet pipe (ST ANDARD #1, #2, #3)
(3)Steam pipe (STEAM IN)
(4)Sample b ypass vent pipe (SAMPLE B/P VENT)
(5)Sample vent pipe (SAMPLE VENT 1, 2)
(6)Condensate drain pipe (CONDENSA TE OUT)
(7)Steam drain pipe

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2.2.3 Piping Connection

For tie - in connection, refer to “Operation Data. ”
(1) Sample inlet pipes
• These are pipes to lead samples fr om pr ocess lines or fr om an external sampling
system into anal yzer STREAMS #1 to #12.
• The anal yzer can anal yze up to 31 point samples. However, since the n umber of
piping connections that can be pr ovided in an anal yzer is limited, an external
sampling system is emplo yed, whic h has a stream s witc hing function, if there are
very man y samples. In this case , a sample inlet pipe is used to lead eac h sample
into the anal yzer.
• When more than one pipe is pr ovided, implement piping ref erring to the attac hed
“Operation Data” so that the specified sample can flo w into the anal yzer from the
designated inlet por t since STREAM and No. are marked at the piping por t.
• Use piping of I.D . 4 mm or O .D. 1 / 4 inc h stainless steel treated f or oil - inhibition.
• When piping to anal yzer base sampling and to pressure flo w contr ol section, use
piping of ID1/8 inc h stainless steel treated f or oil - inhibition.
(2) Standard gas inlet pipes
These are used to implement piping between the outlets of pressure regulator s for
standar d gas c ylinder and STANDARD #1 to #3 por ts of the anal yzer. When a f ew
diff erent standar d gases are used, provide separate pipes f or eac h gas to lead them
into the anal yzer.
Use piping of I.D . 4 mm or O .D. 1 / 4 inc h stainless steel treated f or oil - inhibition.
(3) Carrier gas inlet pipes
• These are pipes to intr oduce the carrier gas to the anal yzer and the y are used to
implement piping between the outlets of carrier gas c ylinderpressure regulator s
and CARRIER IN por ts of the anal yzer.
• When tw o diff erent carrier gases are used, provide separate pipes f or eac h gas to
lead them into the anal yzer.
• The follo wing is recommended. Putting the 2 gas c ylinder s in this wa y, there is no
contamination of air .

To GC1000 Mark II

(Spare)
Figure 2.5

• When this piping is to be implemented, completel y check that the insides of the
pipes and pipe fittings are not contaminated.
• Do the piping so that there is no leaka ge. Specificall y when h ydr ogen gas is used,
make sure there is no leaka ge because that is also required f or explosionpr oof .

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• If the carrier gas contains moisture abo ve the de w point of –60˚C, it is recom-
mended that a desiccant, suc h as a molecular sie ve, be used to remo ve as m uch
moisture as possib le to pre vent deterioration of the columns.
• Use piping of O .D. 1 / 8 inc h stainless steel treated f or oil - inhibition.

CAUTION
Do not use solvents containing impurities suc h as non - v olatile components to c lean
the inside of the pipes. Otherwise , this will contaminate the inside of the pipes disallo w-
ing correct anal ysis. (To correct suc h a condition, replacement of the par ts in the ana-
lyzer may be required.) If it is necessar y to use a solvent f or c leaning, use highl y pure
acetone .

(4) Valve actuating and purge - air pipes

• These are the pipes f or suppl ying air to the anal yzer for actuating sampling and
backflush v alves and f or pur ging the inside of the electr onics section and the o ven.
Usuall y an air pressure of 350 kP a or more is required. Thus, use g eneral instru-
ment air as the air suppl y and do the piping to the anal yzer PURGE AIR por t
thr ough a pressure regulator fr om the air suppl y.
• Use piping of O .D. 1 / 2 inc h stainless steel treated f or oil - inhibition.
(5) Combustion air pipeor
f FID or FPD
This is necessar y onl y for using the detector FID or FPD .
• It is required that the FID / FPD air do not contain suc h impurities as this will ha ve
an adverse eff ect on the anal yzed results. Use an air suppl y meeting the abo ve
condition and do the piping between this suppl y and the anal yzer BURNER AIR
por t.
• Use piping of O .D. 1/8 inc h stainless steel treated f or out - inhibition.
(6) Combustion hydrogen gas pipeor
f FID or FPD
This is necessar y onl y for using the detector FID / FPD .
• Do the piping between the outlet of the pressure regulator of a h ydr ogen gas
cylinder and the anal yzer BURNER FUEL por t.
• Use piping of O .D. 1 / 8 inc h stainless steel treated f or oil - inhibition.
(7) Steam pipe
This is needed when it is to be heated the sample with steam.
• Do the piping between a steam suppl y that can pr ovide the required pressure (see
Operation Data) and the anal yzer STEAM IN por t.
(8) Venting pipes
• These are used f or sample b ypass venting, sample venting, backflush venting,
foreflush venting, reference gas venting, etc. With Vent Stac k, the piping f or Vent
Stack is completed pre viousl y.Without Vent Stac k, implement pipings f or them as
shor t as possib le to the vent stac k.
• Use lar ge pipes f or venting to minimiz e pressure losses.
• Usuall y connect the venting to about a 2 - inc h header with I.D . 4 mm or O .D. 1 / 4
inc h pipes f or the shor t distance fr om the anal yzer.

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(9) Steam drain pipe
This is used to drain the condensate of the steam that heats the sample .
• Do the piping fr om the steam trap of the anal yzer and also fr om the condensate
drain piping por t (CONDENSATE OUT), if pr ovided, to the drain pit at a sloping
angle .
(10) Pipes for external valves
These are used f or piping between the anal yzer valve actuating pneumatic outlet and
the external sampling system to actuate the stream selection and atmospheric pres-
sure balancing v alves pr ovided in the e xternal sampling system.
Make piping pr operl y accor ding to piping dia gram.
Use piping of O .D. 1 / 8 inc h stainless steel.

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2.3 Wiring
2.3.1 General Cautions on Wiring
(1) Cautions on wiring for protection system
• There ma y be 0 to 2 enc losures f or Protection System depending on customer's
specifications.
a. Specifications f or no enc losure :
• Model GC1000/E / GC100T Y-pur ging
b. Specifications f or one enc losure :
• Model GC1000S / GC1000E / GC1000C
• No analog input
c. Specifications f or tw o enc losures :
Models GC1000 Mark II without the abo ve specifications
• If JIS explosionpr oof wiring connections are required, always use the sealing fittings
or pac king adapter supplied.

(2) Other general cautions

(a) Lay the signal wiring and electrical wiring in separate conduit pipes or ducts,
respectivel y.
(b) Make independent gr ounding ha ving a gr ounding resistance of 100 ohm or less.

2.3.2 Kinds of Wiring

The follo wing kinds of wiring are required f or GC1000 Mark II. The wiring required
varies with the specifications.
Refer to Subsection 2.3.3, 2.3.4, 2.3.5.
(A, B, C)Electrical wiring for heater, power circuit, and rgounding circuit
(D) Contact output
Error alarms, timing signal, status signal, and ann unciator
(E) Analog input (4 to 20 mA)
(H) Contact input
Operation star t / stop, mode - selection request, etc.
(I) Communication wir
ing
RS - 422, analyzer bus, and field b us
(J) Analog output (4 to 20 mA)
Analog hold output
(K) Grounding
(L) Analyzer bus

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2.3.3 Recommended Cables

Table 2.1

Wiring Wiring Inlet

Cables Wiring Cable O.D. and Length Cable Shield
Connections Cables Used
8 to15.9mmTwo enclosures Not required
dia. for (A) Heater power line 3.5mm2 to 5.5mm2 max.
flameproof (B) Electrical circuitry 1.25mm2 to 5.5mm2 max.
packing power line
Protection Two adapter One enclosure
System inlets for (C) Power line 1.25mm2 to 5.5mm2 max.
each (D) Contact output line 0.75mm2 to 1.5mm2 max. Required
enclosure (8 points max.) cable length 1km max.
(E) Analog input line 0.75mm2 to 1.5mm2 max. Required
(4 points max.) cable length 1km max.
(A) Heater power line 3.5mm2 to 5.5mm2 max. Not required
(B) Electrical circuitry 1.25mm2 to 5.5mm2 max.
power line
(C) Power line 1.25mm2 to 5.5mm2 max.
(H) Contact input line 0.75mm2 to 1.5mm2 max. Required
(8 points max.) cable length 1km max.
Electronics Four 10 to 15.9mm ( I ) Serial communications 0.75mm2 to 1.5mm2 max. Required
section inlets dia, for line cable length 1km max.
packing twisted pair cable
adapter (J) Analog output line 0.5mm2 to 1.5mm2 max. Required
(36 points max.) cable length 1km max.
(K) Grounding wire 5.5mm2 or more; Not required
grounding resistance up to
100Ω
(L) Analyzer bus line For use twisted pair cable Required
(max of 2 point) 0.2mm2 to 1.5mm2 max.
300m or less
Note 1: Wiring to Protection System
<JIS>
It is available to use either sealing fitting or flameproof packing adapter. I.D. of the metal conduit for sealing fitting is
22mm. Cable size is of ø 8 to ø15.9mm for flameproof packing adapter. Select packing seal according to cable size
(See Table 2.3).
<FM/CSA>
It is only available to use sealing fitting.
<CENELEC>
It is only available to use flameploof packing adapter.
Note 2: Wiring to electronics section
<JIS>
It is available to use which sealing fitting or flameproof packing adapter. I.D. of the metal conduit for sealing fitting is
22mm. Cable size is of ø 10 to ø 15.9mm for flameploof packing adapter. Select packing seal according to cable size
(See Table 2.4).
<FM/CSA>
It is only available to use sealing fitting.
<CENELEC>
It is only available to use flameploof packing adapter.
Note 3: When shield is required, provide the shield to connecting side. (In GC1000, no shield terminal is supplied as standard.)
Note 4: Use “MKKDSN” Series terminals (manufactured by Phoenix Contact K.K.) for the contact output line (D), analog
input line (E), contact input line (H), serial communications line (I), analog output line (J), and detector output line (K).
For these wiring connections, use AI Series crimp-on terminals also manufactured by the company. Four types of
crimp-on terminals are used to meet wire diameters (see the table below).
Please peel off the cover of wire by 5 mm if you do not use the terminal and contact with the terminal.
Table 2.2 “MKKDSN” Series terminals
Wire Diameter Outside Diameter Terminal Type
0.5 mm2 Less than 2.6mm2 AI 0.5-6WH
0.75 mm2 Less than 2.8mm2 AI 0.75-6GY
1 mm2 Less than 3.0mm2 AI 1-6RD
1.5 mm2 Less than 3.4mm2 AI 1.5-6BK

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2.3.4 Precautions on Wiring

<JIS>
In case when e xplosion-pr oof application, the follo wing wiring pr ocedure m ust be taken.

(1) Leading cables into the protection System

Sealing fitting or flamepr oof pac king adapter s whic h are inc luded in the accessar y kit
must be used.
In case of flamepr oof pac king adapter , select a appr opriate pac king seal whic h has a
hole siz e matc hing with the cab le diameter fr om the accessor y kit (See Table 2.3).
In case of sealing fitting, the follo wing dimension should be confirmed because of the
flamepr oof construction (See Figure 2.6).

(2) Leading cables into Electronics selection

Sealing fitting or pac king adapter m ust be used.
In case of pac king adapter , the pac king adapter s is connected with the Anal yzer. All
packing adapter contain pac king seals without a cab le hole (f or sealing in case no cab le
enter s the Terminal Section). Select a appr opriate pac king seal whic h has a hole siz e
matc hing with the cab le diameter fr om the accessor y kit and replace the pac king seal
(See Table 2.4).
In case of sealing fitting, sealing fittings are inc luded in accessor y kit.
If the cab le entr y is not sealed, the Electr onics cir cuit section is not pressuriz e, and
operation can not be allo wed.
Unit: mm

Figure 2.6 Replacement Parts : K9401LR

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Table 2.3 Packing seal for Protection System
Packing Mark Packing I.D. Cable O.D.
9ø ø9.0 ø8.0 to ø9.0
10ø ø10.0 ø9.1 to ø10.0
11ø ø11.0 ø10.1 to ø11.0
12ø ø12.0 ø11.1 to ø12.0
13ø ø13.0 ø12.1 to ø13.0
14ø ø14.0 ø13.1 to ø14.0
15ø ø15.0 ø14.1 to ø15.0
16ø ø16.0 ø15.1 to ø15.9

Table 2.4 Packing seal for Terminal section

Packing Mark Packing I.D. Cable O.D.
24-12ø ø12.0 ø10.0 to ø12.0
24-14ø ø14.0 ø12.1 to ø14.0
24-16ø ø16.0 ø14.1 to ø15.9

<CENELEC>

WARNING
• All wiring shall compl y with local installation requirements and local electrical code .
• The cab le entr y devises shall be of a cer tified flamepr oof type , suitab le for the
conditions of use .

Electrical connection
The type of electrical connection is stamped near the electrical connection por t accor d-
ing to f ollo wing codes.
(Code)
• 3/4NPT female :N
• PG21 female :D
• G3/4 female :G
• ISO M25 x 1.5 feemale : none (Code is not stamped.)

<FM>
• All wiring shall compl y with National Electric Code ANSI/NFP A 70 and Local
Electric Codes.
• In hazar dous location, wiring f or explosionpr oof enc losure and type x pur ged
enclosure to be in conduit as sho wn in the Figure 2.7.
• In hazardous location, wiring f or type Y pur ged enc losure to be in conduit as
sho wn in Figure 2.8.

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Nonhazardous Nonhazardous
Location Location
Equipment Equipment

Nonhazardous Locations
Hazardous Locations

Sealing Fitting

18 inches
(457mm) maximum

Conduit
GC1000 as close as possible not
Explosionproof more than 18 inches(457mm)
Enclosure

GC1000
Type X Purging

Figure 2.7

Nonhazardous
Location
Equipment

Nonhazardous Locations

Hazardous Locations

Sealing Fitting

Conduit
as close as possible not
more than 18 inches(457mm)

GC1000
Type Y Purging

Figure 2.8

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<CSA>
• All wiring shall compl y with Canadian Electric Code P art I and Local Electric
Codes.
• In hazardous location, wiring f or explosionpr oof enc losure and type X pur ged
enclosure to be in conduit as sho wn in the Figure 2.9.
• In hazardous location, wiring f or type Y pur ged enc losure to be in conduit as
sho wn in the Figure 2.10.

Nonhazardous Nonhazardous
Location Location
Equipment Equipment

Nonhazardous Locations
Hazardous Locations

Sealing Fitting

50cm
maximum

Conduit
GC1000 as close as possible
Explosionproof not more than 50 cm
Enclosure

GC1000
Type X Purging

Figure 2.9

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Nonhazardous
Location
Equipment

Nonhazardous Locations
Hazardous Locations

Sealing Fitting

Conduit as close as possible

not more than 50 cm

GC1000
Type Y Purging

Figure 2.10

2.3.5 Cable Inlet Locations

1. Analyzer with two enclosures of Protection system 2. Analyzer with one enclosure of Protection system

Figure 2.11

Note 1: Up to 4 of the cables H, I, J, K and L can be led out of a pressurized vessel.

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2.3.6 Connecting Power Cable and Grounding

CAUTION
• Wire the po wer suppl y cab le keeping the distance of 1 cm or more fr om other
signal wires.
• Power suppl y cab le must conf orm to UL or CSA.
• Do wiring after y ou do pr otective gr ounding securel y.

(1) Cable termination

Use solderless lugs f or all po wer cab les (See Figure 2.12).

(2) Solderless (crimp-on) lug specifications

The solderless lug to use m ust ha ve the dimensions given in Table 2.5 accor ding to the
nominal cr oss sectional area of the po wer cab le for whic h the lug is to be used.
Table 2.5 Solderless Lug Dimensions

Hole Lug Insulation

Remarks (Note)
Nominal Screw outside Lug length covering
cross diameter inside (Example of applicable
used(mm) diameter (mm)
sectional (mm) (mm) diameter solderless Lug)
area (mm)
* 1 AMP 170785-1
4 4~5 9.8 or less 25~29 5.8 or less
5.5 mm2 JST 5.5-4
AMP 170781-1
1.25mm2 4 4.3 or more 8.7 or less About 21 5.8 or less
JST V1.25-4
AMP 170782-1
2.0mm2 4 4.3 or more 8.7 or less About 21 5.8 or less
JST V2-4

*1: Solderless lugs vary in outside diameter depending on the type of the equipment for which
the power cable is used.
Note
AMP: Japan AMP Co., Ltd.
JST: JST Co., Ltd. (Insulator s 0.8 mm 2 or more in siz e are optionall y availab le.)

Figure 2.12 Solderless Lug

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WARNING
<CENELEC>
The cab le entr y devices and the b lanking elements shall be of a cer tified
flamepr oof type , suitab le for the conditions of use and correctl y installed.
For external ear thing of bonding connection a cab le lug shall be used so that the
conductor is secured against loosening and twisting and that contact pressure is
permanentl y maintained.

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(A) (B) GC1000D / GC1000T Type Xpurging (There are two enclosures of
Protection System)
Refer to Table 2.1

Figure 2.13

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(A) (B) GC1000S / GC1000E Type Xpurging (In the case of two enclosures
of Protection System)
Refer to Table 2.1

Figure 2.14

It branc hes off with terminal [Heater po wer suppl y line and Electric cir cuit po wer line].
Wire for branc h is installed in the terminal at the time of shipping. Be sure to tighten it
when y ou wire it f or the po wer suppl y line . Remove wire f or branc h, and wire it when
Heater po wer suppl y line and Electric po wer suppl y line are made another po wer
supply system.

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(C) GC1000S / GC1000E Type X purging (In the case of one enclosure of
Protection System)
Refer to Table 2.1

Figure 2.15

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(A)(B) GC1000W (There are two enclosures of Protection System)
Refer to Table 2.1
Use specified f errite core as sho wn in the f ollo wing figure .

Figure 2.16

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(A)(B) GC1000C (In the case of two enclosures of Protection System)
Refer to Table 2.1
Use specified f errite core as sho wn in the f ollo wing figure .

Figure 2.17

It branc hes off with terminal [Heater po wer suppl y line and Electr onic cir cuit po wer line].
Wire for branc h is installed in the terminal at the time of shipping. Be sure to tighten it
when y ou wire it f or the po wer suppl y line . Remove wire f or branc h, and wire it when
Heater po wer suppl y line and Electr onic cir cuit po wer suppl y line are made another
power suppl y system.

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(C) GC1000C (In the case of one enclosure of Protection System)
Refer to Table 2.1
Use specified f errite core as sho wn in the f ollo wing figure .

Figure 2.18

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(A) (B) GC1000T Type Y Purging

L N G L N G

Electric Heater
Circuit Power Power

Figure 2.19

(C) GC1000E Type Y Purging

L N G L N G

Electric Heater
Circuit Power Power

Figure 2.20

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(K) Grounding Wire
GC 1000 requires the f ollo wing types of gr ound wiring.
Refer to Table 2.1

Earth terminal

Rear Panel

Ground

Figure 2.21

CAUTION
• For pr otective gr ounding of terminal connector -type de vices, connect to the
terminal.
• For gr ounding of de vices with function gr ounding terminals, connect to the
terminal.

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2.3.7 Connecting Process I/O Signals

(1) General
• Be sure to separate the po wer and signal cab les. Avoid running them in parallel as
much as possib le.
• For analog input, use twisted pair cab les with a common shield, with a twist pitc h
of 50 mm or less, to pr otect a gainst induced noise .The shield needs to be
grounded at a point as c lose to the transmitter as possib le.
Use twisted pair cab les f or digital signals as well.
• Stranded cab les are superior to single-conductor cab les in the f ollo wing respects :
• Since the y are more fle xib le, stranded cab les are easier to w ork with in a
cur ved pit or cramped space .
• Stranded cab les pr ovide better contact with solderless lugs, with less c hang e
over time .
• Secure the cab les to keep their weight fr om being applied to the terminals.
• Be sure to tighten the scre w of the terminal.

(2) Signal Cable Termination

• Cable termination
Use solderless lugs f or all the pr ocess I/O signals that are wired b y terminal connec-
tion.

CAUTION
• Always use solderless lugs with insulated co vering.
• Always use solderless lugs and crimp-on tool man ufactured b y the same man ufac-
turer .
• The crimp-on tool m ust be matc hed to the wire thic kness.

• Solderless lug specifications

The specifications of the solderless lug to use are determined b y the nominal cr oss
sectional area of the po wer cab le for whic h the lug is to be used, the lug scre w, di-
mensions and so on.
Use “MKKDSN” Series terminals (man ufactured b y Phoenix Contact K.K.) f or the
contact output line (D), analog input line (E), contact input line (H), serial comm unica-
tions line (I), and analog output line (J).
For these wiring connections, use AI Series crimp-on terminals also man ufactured b y
the compan y. Four types of crimp-on terminals are used to meet wire diameter s (see
Table 2.6).
Please peel off the co ver of wire b y 5 mm if y ou do not use the terminal and contact
with the terminal. 5 mm is the maker recommendation v alues.
Use the f ollo wing solder less lug onl y for anal yzer bus line (L) (For use twisted pair)

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Table 2.6 Solderless Lug Dimensions
Screw Hole Lug Lug Dimension Color of
Nominal cross outside length Applicable Example of Example of
used diameter diameter “C” insulating wire size applicable applicable
sectional area (mm) (mm) (mm) (mm) (mm) material solderless lug crimp-on tool
4.3 or 8.7 or About 7.0 or 0.25 to AMP 170781-1 AMP 47386
1.25mm2 4 more less 21 more Red
1.65 mm2 JST V1.25-4 JST YAD-1
4.3 or 8.7 or About 7.1 or 1.0 to AMP 170782-1 AMP 47387
2.0mm2 4 less 21 more Blue
more 2.6 mm2 JST V2-4 JST YAT-1

Note
AMP: Japan AMP Co., Ltd.
JST: JST Co., Ltd. (Insulator s 0.8 mm 2 or more in siz e are optionall y availab le.)

CAUTION
• All de vices, suc h as the signal line , relay terminal, relay, power suppl y, etc. to be
connected to contact input and contact output m ust conf orm to IEC1010 or CSA 1010
or CSA 950.
• Do wiring after y ou do pr otective gr ounding securel y.

Figure 2.22 Solderless Lug

(3) Terminal connection of shielded signal cables for GC1000W/C

The shielded wire of eac h interface cab le is connected with the internal gr ound bar of
GC1000.
The attac hed f errite core is connected with eac h shielded cab le.

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(D) GC1000W / GC1000C (In the case of two enclosures of Protection System)
Use specified f errite core as sho wn in the f ollo wing figure .

Figure 2.23

(D) GC1000C (In the case of one enclosure of Protection System)

Use specified f errite core as sho wn in the f ollo wing figure .

Figure 2.24

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(E) GC1000W / GC1000C (In the case of two enclosures of Protection System)
Use specified f errite core as sho wn in the f ollo wing figure .

Figure 2.25

(H)(J) GC1000W / GC1000C

Use specified f errite core as sho wn in the f ollo wing figure .

Figure 2.26

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(I)(L) GC1000W / GC1000C
Use specified f errite core as sho wn in the f ollo wing figure .

Figure 2.27

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(4) Terminal in Electronics Section (Standard equipment)
(a) GC1000D/GC1000S, GC1000W/GC1000C, GC1000T/GC1000E Type X
purging

+ 29 1 +
D/I 3 + 15
- 30 D/I 2
- 16
2 - D/I 1
+ 31 3 +
D/I 6 + 17
- 32 D/I 5
- 18
4 - D/I 4
33 5 +
+ 19
34 D/I 8
- 20
6 - D/I 7
RDA 35 7 RDA
RDA 21
RS-422 RDB 36 8 RDB RS-422
(DCS) SDA RS-422 RDB 22
37 (GCCU) 9 SDA (PC)
SDA 23
SDB 38 10 SDB
SDB 24
39 11
25
40 12
26
P.MONITOR + 41 13 + P.MONITOR
P.MONITOR + 27
(DC12V) - 42 (DC12V) -28
14 - (DC12V)
Figure 2.28

(b) GC1000T/GC1000E Type Y purging

+ 53 1 +
D/I 3 + 27
- 54 D/I 2
- 28
2 - D/I 1
+ 55 3 +
D/I 6 + 29
- 56 D/I 5
- 30
4 - D/I 4
57 5 +
+ 31
58 D/I 8
- 32
6 - D/I 7
RDA 59 7 RDA
RDA 33
RS-422 RDB 60 8 RDB RS-422
(DCS) SDA RS-422 RDB 34
61 (GCCU) 9 SDA (PC)
SDA 35
SDB 62 10 SDB
SDB 36
63 11
37
64 12
38
NC65 13 NC
NC 39
D/O 3 COM 66 14 COM D/O 1
D/O 2 COM 40
NO 67 15 NO
NO 31
NC 68 16 NC
NC 42
D/O 6 COM 69 17 COM D/O 4
D/O 5 COM 43
NO 70 18 NO
NO 44
NC 71 19 NC
ANNUN- NC 45
CIATOR COM 72 D/O 8 COM 46
20 COM D/O 7
NO 73 21 NO
NO 47
74 22
48
+ 75 23 +
A/I 3 + 49 A/I 1
- 76 A/I 2
- 50
24 -
77 25 +
51 A/I 4
78
52
26 -
Figure 2.29

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(D) Contact Output Terminals
(1) GC1000D/GC1000S, GC1000W/GC1000C, GC1000T/GC1000E Type X
purging (Protection system)
Terminal Number
Normally close (NC) Contact output 1 1 15 Contact output 5 NC
Common (COM) Contact output 1 2 16 Contact output 5 COM
Normally open (NO) Contact output 1 3 17 Contact output 5 NO
NC Contact output 2 4 18 Contact output 6 NC
COM Contact output 2 5 19 Contact output 6 COM
NO Contact output 2 6 20 Contact output 6 NO
NC Contact output 3 7 21 Contact output 7 NC
COM Contact output 3 8 22 Contact output 7 COM
NO Contact output 3 9 23 Contact output 7 NO
NC Contact output 4 10 24 Contact output 8 NC
COM Contact output 4 11 25 Contact output 8 COM
NO Contact output 4 12 26 Contact output 8 NO
Annunciator 13 27
Annunciator 14 28 Annunciator NO
Figure 2.30

(2) GC1000T/GC1000E Type Y purging (Electronics Section)

Refer to Figure 2.29
Terminal
Number Terminal Number
NC Contact output 1 65 NC Contact output 2 39 13 Contact output 1 Normally close (NC)
COM Contact output 1 66 COM Contact output 2 40 14 Contact output 1 Common (COM)
NO Contact output 1 67 NO Contact output 2 41 15 Contact output 1 Normally open (NO)
NC Contact output 2 68 NC Contact output 5 42 16 Contact output 4 NC
COM Contact output 2 69 COM Contact output 5 43 17 Contact output 4 COM
NO Contact output 2 70 NO Contact output 5 44 18 Contact output 4 NO
Annunciator 71 NC Contact output 8 45 19 Contact output 7 NC
Annunciator 72 COM Contact output 8 46 20 Contact output 7 COM
Annunciator 73 NO Contact output 8 47 21 Contact output 7 NO
Figure 2.31

(E) Analog Input Terminals (Option)

(1) GC1000D/GC1000S, GC1000W/GC1000C, GC1000T/GC1000E Type X
purging (Protection system)

Terminal
Number
29 Analog input 1 +
30 Analog input 1 -
31 Analog input 2 +
32 Analog input 2 -
33 Analog input 3 +
34 Analog input 3 -
35 Analog input 4 +
36 Analog input 4 -
Figure 2.32

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(2) GC1000T/GC1000E Type Y purging (Electronics Section)
Refer to Figure 2.29

Terminal
Number Terminal Number
+ Analog input 3 75 + Analog input 2 49 23 Analog input 1 +
- Analog input 3 76 - Analog input 2 50 24 Analog input 1 -
25 Analog input 4 +
26 Analog input 4 -
Figure 2.33

(H) Contact Input Terminals (Electronics Section)

Refer to Figure 2.28 and 2.29

Terminal
Number Terminal Number
+ Contact input 3 (53) 29 + Contact input 2 (27) 15 1 (1) Contact input 1 +
- Contact input 3 (54) 30 - Contact input 2 (28) 16 2 (2) Contact input 1 -
+ Contact input 6 (55) 31 + Contact input 5 (29) 17 3 (3) Contact input 4 +
- Contact input 6 (56) 32 - Contact input 5 (30) 18 4 (4) Contact input 4 -
+ Contact input 8 (31) 19 5 (5) Contact input 7 +
- Contact input 8 (32) 20 6 (6) Contact input 7 -

( ) : For GC1000T/GC1000E Type Y Purging

Figure 2.34

(I) Communication Terminals (Electronics Section)(Option)

• RS-422 (DCS, Personal Computer , GCCU)
Refer to Figure 2.28 amd 2.29

Terminal
Number Terminal Number
Send data A (GCCU) (59) 35 Send data A (DCS) (33) 21 7 (7) Send data A (personal computer)
Send data B (GCCU) (60) 36 Send data B (DCS) (34) 22 8 (8) Send data B (personal computer)
Receive data A (GCCU) (61) 37 Receive data A (DCS) (35) 23 9 (9) Receive data A (personal computer)
Receive data B (GCCU) (62) 38 Receive data B (DCS) (36) 24 10(10) Receive data B (personal computer)

Power off signal +(GCCU) 41 Power off signal + (DCS) 27 13 Power off signal + (personal computer)
Power off signal - (GCCU) 42 Power off signal - (DCS) 28 14 Power off signal - (personal computer)

( ) : For GC1000T/GC1000E Type Y Purging

Figure 2.35

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(J) Analog Output Terminals (Right Side of Electronics Section)(Option)

Terminal Number
Analog output 19 + + + Analog output 1 +
19 1 -
Analog output 19 - - Analog output 1 -
Analog output 20 + + + Analog output 2 +
20 2 -
Analog output 20 - - Analog output 2 -
Analog output 21 + + + Analog output 3 +
21 3 -
Analog output 21 - - Analog output 3 -
Analog output 22 + + + Analog output 4 +
22 4 -
Analog output 22 - - Analog output 4 -
Analog output 23 + + + Analog output 5 +
23 5 -
Analog output 23 - - Analog output 5 -
Analog output 24 + + + Analog output 6 +
24 6 -
Analog output 24 - - Analog output 6 -
Analog output 25 + + + Analog output 7 +
25 7 -
Analog output 25 - - Analog output 7 -
Analog output 26 + + + Analog output 8 +
26 8 -
Analog output 26 - - Analog output 8 -
Analog output 27 + + + Analog output 9 +
27 9 -
Analog output 27 - - Analog output 9 -
Analog output 28 + + + Analog output 10 +
28 10 -
Analog output 28 - - Analog output 10 -
Analog output 29 + + + Analog output 11 +
29 11 -
Analog output 29 - - Analog output 11 -
Analog output 30 + + + Analog output 12 +
30 12 -
Analog output 30 - - Analog output 12 -
Analog output 31 + + + Analog output 13 +
31 13 -
Analog output 31 - - Analog output 13 -
Analog output 32 + + + Analog output 14 +
32 14 -
Analog output 32 - - Analog output 14 -
Analog output 33 + + + Analog output 15 +
33 15 -
Analog output 33 - - Analog output 15 -
Analog output 34 + + + Analog output 16 +
34 16 -
Analog output 34 - - Analog output 16 -
Analog output 35 + + + Analog output 17 +
35 17 -
Analog output 35 - - Analog output 17 -
Analog output 36 + + + Analog output 18 +
36 18 -
Analog output 36 - - Analog output 18 -
Figure 2.36

(L) Analyzer bus terminal (Hub board in Electronics Section)(Option)

• For use twisted pair cab le

Terminal Number
- Analyzer bus A 1 5 Analyzer bus B -
+ Analyzer bus A 2 6 Analyzer bus B +
- Power off signal (A) 3 7 Power off signal (B) -
+ Power off signal (A) 4 8 Power off signal (B) +
Figure 2.37

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<Ind> <Toc> 67

䉬 Revision Record
● Manual No. : TI 11B03A03-03E
● Title : Process Gas Chromatograph GC1000 Mark II Installation Manual

Oct. 2001 / 1st Edition

Sep. 2002 / 2nd Edition

TI 11B03A03-03E 1st Edition : Oct. 31,2001-00

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