Varian B.V.

Herculesweg 8
4330 EA Middelburg
The Netherlands

49X-GC Micro-GC

Service manual
North/South America Europe Australia/East Asia
2700 Mitchell Drive P.O. Box 8033 679 Springvale Road
Walnut Creek 4330 EA Middelburg Mulgrave, Victoria
94598 California, USA The Netherlands 3171
Tel: ++(1)9259392400 Tel: ++(31)118671000 Australia
Fax: ++(1)9259452360 or Fax: ++(31)118623193 Tel: ++(61)395607133
++(1)9259452344 Fax: ++(61)395607950
49X-GC Micro-GC

© 2002-2009 Varian, Inc. All Rights Reserved Printed in the Netherlands CP501268490 Rev: 1 January 2010

Manual Contents

INFORMATION..............................................................................................................................................................5
INDICATIONS................................................................................................................................................................ 6
CAUTIONS......................................................................................................................................................................7
WARNINGS.....................................................................................................................................................................9
TOOLS REQUIRED..........................................................................................................................................................1
BASIC................................................................................................................................................................................1
SPECIALIZED..................................................................................................................................................................... 2
FLUKE PRESSURE VACUUM MODULE.................................................................................................................................3
COVERS.............................................................................................................................................................................4
BEFORE YOU START..........................................................................................................................................................4
REMOVING THE RIGHT SIDE COVER..................................................................................................................................5
REMOVING THE TOP COVER..............................................................................................................................................5
REMOVING THE UPPER REAR PANEL................................................................................................................................. 5
REMOVING THE LOWER REAR PANEL................................................................................................................................5
REMOVING THE FRONT PANEL..........................................................................................................................................6
REMOVING AND REPLACING PROCEDURES........................................................................................................7
REMOVING THE MAIN BOARD...........................................................................................................................................7
REMOVING THE INTERCONNECTION BOARD......................................................................................................................7
REMOVING THE TCD CONTROLLER..................................................................................................................................8
REPLACING THE PRESSURE SENSOR.................................................................................................................................. 9
REPLACE PRESSURE SENSOR O-RING................................................................................................................................9
REMOVING THE COLUMN UNIT.......................................................................................................................................10
REMOVING THE HEATED SAMPLE LINE...........................................................................................................................11
ILLUSTRATED PARTS BREAKDOWN.......................................................................................................................1
SERVICE FIELD KIT...........................................................................................................................................................1
HOUSING FRONT VIEW......................................................................................................................................................1
HOUSING BACK VIEW.......................................................................................................................................................2
ANALYTICAL MODULE UNIT (UNHEATED STRAIGHT).......................................................................................................3
ANALYTICAL MODULE UNIT (HEATED STRAIGHT)............................................................................................................5
ANALYTICAL MODULE UNIT (UNHEATED BACKFLUSH)...................................................................................................7
ANALYTICAL MODULE UNIT (HEATED BACKFLUSH)........................................................................................................8
ANALYTICAL CHANNEL UNIT (UNHEATED STRAIGHT).....................................................................................................9
ANALYTICAL CHANNEL UNIT (HEATED STRAIGHT)........................................................................................................11
ANALYTICAL CHANNEL UNIT (UNHEATED BACKFLUSH)................................................................................................13
ANALYTICAL CHANNEL UNIT (HEATED BACKFLUSH).................................................................................................... 13
ANALYTICAL MODULE....................................................................................................................................................14
Inside view Analytical module....................................................................................................................................14
Inside view Analytical backflush module...................................................................................................................15
MANIFOLD AND TCD CONTROLLER KIT, STRAIGHT.......................................................................................................16
MANIFOLD AND TCD CONTROLLER KIT, BACKFLUSH....................................................................................................16
EGC AND MANIFOLD ELECTRONICS...............................................................................................................................17
EGC/MANIFOLD TO COLUMN MODULE CONNECTION.....................................................................................................18
PUMP MANIFOLD ASSEMBLY...........................................................................................................................................19
UPGRADE SECOND PUMP MANIFOLD ASSEMBLY (CP74020680)....................................................................................20
SAMPLE-IN CONNECTORS...............................................................................................................................................22
UPGRADE FROM HEATED TO UNHEATED SAMPLE INJECTION (KIT PN CP740827).........................................................23
CARRIER GAS TUBES.......................................................................................................................................................24
CARRIER GAS KIT IS P/N CP740828...............................................................................................................................24
DUAL CARRIER GAS CONNECTION (UPGRADE KIT PN CP490201).................................................................................25
HEATED SAMPLE LINE.....................................................................................................................................................26
MICROGASIFIER BRACKET............................................................................................................................................. 27
MICROGASIFIER..............................................................................................................................................................28

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GASIFIER PRESSURE REGULATOR....................................................................................................................................29
Adjustment procedure.................................................................................................................................................29
ELECTRONIC BOARDS................................................................................................................................................30
INTERCONNECTION BOARD 2-CH....................................................................................................................................30
INTERCONNECTION BOARD 4-CH....................................................................................................................................30
MAIN BOARD...................................................................................................................................................................31
COOLING FAN (MAIN BOARD).........................................................................................................................................31
COMPUTER......................................................................................................................................................................31
ETHERNET AND COMMUNICATION PORT CARD...............................................................................................................32
ANALYTICAL MODULE INTERFACE..................................................................................................................................32
TCD CONTROLLER..........................................................................................................................................................33
POWER SUPPLY................................................................................................................................................................33
TCD CABLE ASSEMBLY..................................................................................................................................................34
PRESSURE SENSOR ASSEMBLY.........................................................................................................................................34
HEATER/SENSOR FOR INJECTOR......................................................................................................................................34
COLUMN HEATER............................................................................................................................................................34
FIELDCASE.....................................................................................................................................................................35
CABLE OVERVIEW...........................................................................................................................................................36
FIELDCASE SWITCHER.....................................................................................................................................................37
CABLE ASSEMBLY POWER-2........................................................................................................................................... 38
CABLE ASSEMBLY POWER-1........................................................................................................................................... 38
CABLE ASSEMBLY BATTERY 1........................................................................................................................................39
CABLE ASSEMBLY BATTERY 2........................................................................................................................................39
COOLING FAN (FIELDCASE)............................................................................................................................................39
BATTERY PACK...............................................................................................................................................................39
CARRIER GAS REFILL ASSEMBLY.................................................................................................................................... 40
ACCESORY BRACKET.................................................................................................................................................41
EXPLODED VIEW ACCESSORY BRACKET........................................................................................................................ 41
MICROGASIFIER..............................................................................................................................................................42
GENIE FILTER..................................................................................................................................................................42
GAS SYRINGE ANALYSIS...........................................................................................................................................43
SEPTUM INJECTION PORT................................................................................................................................................ 43
RELIEF VALVE ADJUSTED AT 10PSI (0,7BAR)................................................................................................................44
PNEUMATIC DIAGRAMS............................................................................................................................................45
PNEUMATIC DIAGRAM OVERVIEW...................................................................................................................................45
PNEUMATIC DIAGRAM STRAIGHT IDLE..........................................................................................................................46
PNEUMATIC DIAGRAM STRAIGHT IDLE CONTINUOUS FLOW.................................................................................. 47
PNEUMATIC DIAGRAM STRAIGHT SAMPLING.............................................................................................................. 48
PNEUMATIC DIAGRAM STRAIGHT EQUILIBRATION....................................................................................................49
PNEUMATIC DIAGRAM STRAIGHT PRESSURISATION..................................................................................................50
PNEUMATIC DIAGRAM STRAIGHT INJECTION..............................................................................................................51
PNEUMATIC DIAGRAM STRAIGHT RUN..........................................................................................................................52
PNEUMATIC DIAGRAM BACKFLUSH.................................................................................................................................53
PNEUMATIC DIAGRAM BACKFLUSH, FOREFLUSH MODE...........................................................................................54
PNEUMATIC DIAGRAM BACKFLUSH, BACKFLUSH MODE..........................................................................................55
FLUSH CYCLE..................................................................................................................................................................56
WIRING AND ELECTRONIC INFORMATION........................................................................................................57
EGC AND MANIFOLD KIT...............................................................................................................................................57
Straight manifold........................................................................................................................................................57
Backflush manifold.....................................................................................................................................................57
Valve Connector.........................................................................................................................................................58
Pump connections (single)........................................................................................................................................58
Pump connections (dual)............................................................................................................................................58
2 CHANNEL INTERCONNECTION BOARD............................................................................................................59
BLOCKDIAGRAM............................................................................................................................................................. 59
LAY-OUT.........................................................................................................................................................................60

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49X-GC Micro-GC
SCHEMATICS 1 OF 3..................................................................................................................................................61
SCHEMATICS 2 OF 3..................................................................................................................................................62
SCHEMATICS 3 OF 3..................................................................................................................................................63
4 CHANNEL INTERCONNECTION BOARD............................................................................................................64
BLOCKDIAGRAM............................................................................................................................................................. 64
LAY-OUT.........................................................................................................................................................................65
SCHEMATICS................................................................................................................................................................... 65
MAIN BOARD..................................................................................................................................................................66
LAY-OUT.........................................................................................................................................................................67
SCHEMATICS 1 OF 5........................................................................................................................................................68
SCHEMATICS 2 OF 5........................................................................................................................................................69
SCHEMATICS 3 OF 5........................................................................................................................................................70
SCHEMATICS 4 OF 5........................................................................................................................................................71
SCHEMATICS 5 OF 5........................................................................................................................................................72
ANALYTICAL MODULE INTERFACE......................................................................................................................73
LAY OUT.........................................................................................................................................................................73
SCHEMATICS................................................................................................................................................................... 74
TCD CONTROLLER......................................................................................................................................................75
LAY OUT.........................................................................................................................................................................76
PRESSURE SENSOR ASSEMBLY...............................................................................................................................77
LAY OUT.........................................................................................................................................................................77
SCHEMATICS................................................................................................................................................................... 77
POWER SUPPLY............................................................................................................................................................78

FIELDCASE SWITCHER REVISION 3......................................................................................................................79

LAY OUT REVISION 3......................................................................................................................................................80
SCHEMATICS 1 OF 2 REVISION 3.....................................................................................................................................81
SCHEMATICS 2 OF 2 REVISION 3.....................................................................................................................................82
FIELDCASE CABLE ASSEMBLY POWER-1............................................................................................................83

FIELD CASE CABLE ASSEMBLY POWER-2...........................................................................................................84

FIELD CASE CABLE ASSEMBLY BATTERY 1.......................................................................................................85

FIELD CASE CABLE ASSEMBLY BATTERY 2.......................................................................................................85

TUBING OVERVIEW.....................................................................................................................................................86
BACKFLUSH.....................................................................................................................................................................86
REFERENCE VENT 2CH (ONE CARRIER GAS)...................................................................................................................87
REFERENCE VENT 2CH (TWO CARRIER GAS)..................................................................................................................88
REFERENCE VENT 4CH TWO CARRIER GAS.....................................................................................................................89
SAMPLE VENT..................................................................................................................................................................90
COLUMN VENT................................................................................................................................................................91
TWO PUMP SEPARATE SAMPLE-IN...................................................................................................................................92
SENSITIVITY RANGE SETTINGS..............................................................................................................................93
AUTO RANGE...................................................................................................................................................................93
HOW TO ASSIGN A IP ADDRESS ON THE MICRO-GC........................................................................................96

GALAXIE CDS WORKSTATION................................................................................................................................97

HOW TO SET THE IP ADDRESS IN GALAXIE WORKSTATION USING BOOTP...................................................................97
HOW TO SET THE IP ADDRESS IN GALAXIE WORKSTATION USING RS232...................................................................101
GALAXIE IP ADDRESS PERSISTENT PROBLEMS............................................................................................................104
OVERVIEW RELEASED SERVICE BULLETINS..................................................................................................105

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49X-GC Micro-GC
NEW VARIAN MICRO-GC DRIVER FOR GALAXIE RELEASED.......................................................................................105
OVERVIEW PIB OF SERVICE INTERESTS...........................................................................................................106
INTRODUCTION OF VARIAN'S NEW 490-GC SERIES MICRO-GC..................................................................................106
490-GC CONFIGURATOR...............................................................................................................................................106
INFORMATION............................................................................................................................................. 5
INDICATIONS............................................................................................................................................... 5
CAUTIONS................................................................................................................................................... 6
WARNINGS.................................................................................................................................................. 8
TOOLS REQUIRED...................................................................................................................................... 1
BASIC............................................................................................................................................................. 1
SPECIALIZED................................................................................................................................................... 2
FLUKE PRESSURE VACUUM MODULE................................................................................................................. 3
COVERS....................................................................................................................................................... 4
BEFORE YOU START........................................................................................................................................ 4
REMOVING THE RIGHT SIDE COVER.................................................................................................................. 5
REMOVING THE TOP COVER............................................................................................................................. 5
REMOVING THE UPPER REAR PANEL................................................................................................................. 5
REMOVING THE LOWER REAR PANEL................................................................................................................ 5
REMOVING THE FRONT PANEL.......................................................................................................................... 6
REMOVING AND REPLACING PROCEDURES........................................................................................................ 7
REMOVING THE MAIN BOARD............................................................................................................................ 7
REMOVING THE INTERCONNECTION BOARD....................................................................................................... 7
REMOVING THE TCD CONTROLLER.................................................................................................................. 8
REPLACING THE PRESSURE SENSOR................................................................................................................ 9
REPLACE PRESSURE SENSOR O-RING.............................................................................................................. 9
REMOVING THE COLUMN UNIT........................................................................................................................ 10
REMOVING THE HEATED SAMPLE LINE............................................................................................................ 11
ILLUSTRATED PARTS BREAKDOWN........................................................................................................ 1
SERVICE FIELD KIT......................................................................................................................................... 1
HOUSING FRONT VIEW.................................................................................................................................... 1
HOUSING BACK VIEW...................................................................................................................................... 2
ANALYTICAL MODULE UNIT (UNHEATED STRAIGHT)............................................................................................ 3
ANALYTICAL MODULE UNIT (HEATED STRAIGHT)................................................................................................ 5
ANALYTICAL MODULE UNIT (UNHEATED BACKFLUSH)......................................................................................... 7
ANALYTICAL MODULE UNIT (HEATED BACKFLUSH)............................................................................................. 8
ANALYTICAL CHANNEL UNIT (UNHEATED STRAIGHT).......................................................................................... 9
ANALYTICAL CHANNEL UNIT (HEATED STRAIGHT)............................................................................................ 11
ANALYTICAL CHANNEL UNIT (UNHEATED BACKFLUSH)..................................................................................... 13
ANALYTICAL CHANNEL UNIT (HEATED BACKFLUSH).......................................................................................... 13
ANALYTICAL MODULE..................................................................................................................................... 14
INSIDE VIEW ANALYTICAL MODULE.................................................................................................................. 14
INSIDE VIEW ANALYTICAL BACKFLUSH MODULE................................................................................................ 15
MANIFOLD AND TCD CONTROLLER KIT, STRAIGHT........................................................................................... 16
MANIFOLD AND TCD CONTROLLER KIT, BACKFLUSH........................................................................................ 16
EGC AND MANIFOLD ELECTRONICS............................................................................................................... 17
EGC/MANIFOLD TO COLUMN MODULE CONNECTION........................................................................................ 18
PUMP MANIFOLD ASSEMBLY........................................................................................................................... 19
UPGRADE SECOND PUMP MANIFOLD ASSEMBLY (CP74020680)...................................................................... 20
SAMPLE-IN CONNECTORS............................................................................................................................. 22
UPGRADE FROM HEATED TO UNHEATED SAMPLE INJECTION (KIT PN CP740827)............................................. 23
CARRIER GAS TUBES..................................................................................................................................... 24
CARRIER GAS KIT IS P/N CP740828.............................................................................................................. 24
DUAL CARRIER GAS CONNECTION (UPGRADE KIT PN CP490201).................................................................... 25
HEATED SAMPLE LINE.................................................................................................................................... 26
MICROGASIFIER BRACKET............................................................................................................................. 27
MICROGASIFIER............................................................................................................................................ 28
GASIFIER PRESSURE REGULATOR................................................................................................................... 29
ADJUSTMENT PROCEDURE............................................................................................................................. 29
ELECTRONIC BOARDS............................................................................................................................. 30
INTERCONNECTION BOARD 2-CH................................................................................................................... 30
INTERCONNECTION BOARD 4-CH................................................................................................................... 30
MAIN BOARD................................................................................................................................................. 31
COOLING FAN (MAIN BOARD)......................................................................................................................... 31
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49X-GC Micro-GC
COMPUTER................................................................................................................................................... 31
ETHERNET AND COMMUNICATION PORT CARD................................................................................................. 32
ANALYTICAL MODULE INTERFACE.................................................................................................................... 32
TCD CONTROLLER........................................................................................................................................ 33
POWER SUPPLY............................................................................................................................................ 33
TCD CABLE ASSEMBLY................................................................................................................................. 34
PRESSURE SENSOR ASSEMBLY...................................................................................................................... 34
HEATER/SENSOR FOR INJECTOR.................................................................................................................... 34
COLUMN HEATER.......................................................................................................................................... 34
FIELDCASE................................................................................................................................................ 35
CABLE OVERVIEW.......................................................................................................................................... 36
CABLE OVERVIEW.......................................................................................................................................... 37
FIELDCASE SWITCHER................................................................................................................................... 37
CABLE ASSEMBLY POWER-2........................................................................................................................... 38
CABLE ASSEMBLY POWER-1........................................................................................................................... 38
CABLE ASSEMBLY BATTERY 1........................................................................................................................ 39
CABLE ASSEMBLY BATTERY 2........................................................................................................................ 39
COOLING FAN (FIELDCASE)............................................................................................................................ 39
BATTERY PACK............................................................................................................................................. 39
CARRIER GAS REFILL ASSEMBLY.................................................................................................................... 40
ACCESORY BRACKET.............................................................................................................................. 41
EXPLODED VIEW ACCESSORY BRACKET......................................................................................................... 41
MICROGASIFIER............................................................................................................................................ 42
GENIE FILTER................................................................................................................................................ 42
GAS SYRINGE ANALYSIS......................................................................................................................... 43
SEPTUM INJECTION PORT............................................................................................................................... 43
RELIEF VALVE ADJUSTED AT 10PSI (0,7BAR)................................................................................................. 44
PNEUMATIC DIAGRAMS........................................................................................................................... 45
PNEUMATIC DIAGRAM OVERVIEW.................................................................................................................... 45
PNEUMATIC DIAGRAM STRAIGHT IDLE............................................................................................................ 46
PNEUMATIC DIAGRAM STRAIGHT IDLE CONTINUOUS FLOW........................................................................ 47
PNEUMATIC DIAGRAM STRAIGHT SAMPLING................................................................................................. 48
PNEUMATIC DIAGRAM STRAIGHT EQUILIBRATION........................................................................................ 49
PNEUMATIC DIAGRAM STRAIGHT PRESSURISATION.................................................................................... 50
PNEUMATIC DIAGRAM STRAIGHT INJECTION................................................................................................. 51
PNEUMATIC DIAGRAM STRAIGHT RUN............................................................................................................ 52
PNEUMATIC DIAGRAM BACKFLUSH.................................................................................................................. 53
PNEUMATIC DIAGRAM BACKFLUSH, FOREFLUSH MODE............................................................................... 54
PNEUMATIC DIAGRAM BACKFLUSH, BACKFLUSH MODE............................................................................... 55
FLUSH CYCLE................................................................................................................................................ 56
WIRING AND ELECTRONIC INFORMATION............................................................................................ 57
EGC AND MANIFOLD KIT............................................................................................................................... 57
STRAIGHT MANIFOLD..................................................................................................................................... 57
BACKFLUSH MANIFOLD................................................................................................................................... 57
VALVE CONNECTOR...................................................................................................................................... 58
PUMP CONNECTIONS (SINGLE)...................................................................................................................... 58
PUMP CONNECTIONS (DUAL).......................................................................................................................... 58
2 CHANNEL INTERCONNECTION BOARD.......................................................................................................... 59
BLOCKDIAGRAM............................................................................................................................................ 59
LAY-OUT....................................................................................................................................................... 60
SCHEMATICS.................................................................................................................... 1 OF 3
.................................................................................................................................................................... 61
SCHEMATICS.................................................................................................................... 2 OF 3
.................................................................................................................................................................... 62
SCHEMATICS.................................................................................................................... 3 OF 3
.................................................................................................................................................................... 63
4 CHANNEL INTERCONNECTION BOARD.......................................................................................................... 64
BLOCKDIAGRAM............................................................................................................................................ 64
LAY-OUT....................................................................................................................................................... 65
SCHEMATICS................................................................................................................................................. 65
MAIN BOARD................................................................................................................................................. 66
LAY-OUT....................................................................................................................................................... 67
SCHEMATICS 1 OF 5...................................................................................................................................... 68
SCHEMATICS 2 OF 5...................................................................................................................................... 69
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49X-GC Micro-GC
SCHEMATICS 3 OF 5...................................................................................................................................... 70
SCHEMATICS 4 OF 5...................................................................................................................................... 71
SCHEMATICS 5 OF 5...................................................................................................................................... 72
ANALYTICAL MODULE INTERFACE.................................................................................................................... 73
LAY OUT....................................................................................................................................................... 73
SCHEMATICS................................................................................................................................................. 74
TCD CONTROLLER........................................................................................................................................ 75
LAY OUT....................................................................................................................................................... 76
PRESSURE SENSOR ASSEMBLY...................................................................................................................... 77
LAY OUT....................................................................................................................................................... 77
SCHEMATICS................................................................................................................................................. 77
POWER SUPPLY............................................................................................................................................ 78
FIELDCASE CHARGER/SWITCHER REVISION 2.................................................................................................. 79
BLOCKDIAGRAM............................................................................................................................................ 79
LAY OUT REVISION 2..................................................................................................................................... 80
SCHEMATICS 1 OF 4 REVISION 2.................................................................................................................... 81
SCHEMATICS 2 OF 4 REVISION 2.................................................................................................................... 82
SCHEMATICS 3 OF 4 REVISION 2.................................................................................................................... 83
SCHEMATICS 4 OF 4 REVISION 2.................................................................................................................... 84
FIELDCASE SWITCHER REVISION 3................................................................................................................. 85
BLOCKDIAGRAM............................................................................................................................................ 85
SCHEMATICS 1 OF 2 REVISION 3.................................................................................................................... 86
SCHEMATICS 2 OF 2 REVISION 3.................................................................................................................... 87
FIELDCASE CABLE ASSEMBLY POWER-1......................................................................................................... 88
FIELD CASE CABLE ASSEMBLY POWER-2........................................................................................................ 89
FIELD CASE CABLE ASSEMBLY BATTERY 1...................................................................................................... 90
FIELD CASE CABLE ASSEMBLY BATTERY 2...................................................................................................... 90
TUBING OVERVIEW........................................................................................................................................ 91
BACKFLUSH.................................................................................................................................................. 91
REFERENCE VENT 2CH (ONE CARRIER GAS)................................................................................................... 92
REFERENCE VENT 2CH (TWO CARRIER GAS).................................................................................................. 93
REFERENCE VENT 4CH TWO CARRIER GAS.................................................................................................... 94
SAMPLE VENT............................................................................................................................................... 95
COLUMN VENT.............................................................................................................................................. 96
TWO PUMP SEPARATE SAMPLE-IN................................................................................................................... 97
SENSITIVITY RANGE SETTINGS....................................................................................................................... 99
AUTO RANGE................................................................................................................................................ 99
HOW TO ASSIGN A IP ADDRESS ON THE MICRO-GC...................................................................................... 102
GALAXIE CDS WORKSTATION...................................................................................................................... 103
HOW TO SET THE IP ADDRESS IN GALAXIE WORKSTATION USING BOOTP...................................................... 103
HOW TO SET THE IP ADDRESS IN GALAXIE WORKSTATION USING RS232....................................................... 107
GALAXIE IP ADDRESS PERSISTENT PROBLEMS............................................................................................ 110
OVERVIEW RELEASED SERVICE BULLETINS................................................................................................... 111
NEW VARIAN MICRO-GC DRIVER FOR GALAXIE RELEASED........................................................................... 111
OVERVIEW PIB OF SERVICE INTERESTS....................................................................................................... 112
INTRODUCTION OF VARIAN'S NEW 490-GC SERIES MICRO-GC..................................................................... 112
490-GC Configurator................................................................................................................................. 112

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49X-GC Micro-GC

Before servicing the various components of the 49X-GC Micro-GC observe the
following safety precautions.

INFORMATION

In accordance to Varian commitment to customer service and safety, this instrument and its
accompanying documentation complies with the CE (NEN 5509) specifications and the
safety requirements for electrical equipment for measurement, control, and laboratory use
(CEI/IEC 1010-1)

To prevent any injury to the user or any damage to the instrument it is essential that you
read the information in this chapter.

If this manual is not in your mother language and if you have problems understanding the
text, we advise you to contact your Varian office for assistance. Varian cannot accept
responsibility for any damage or injury caused by misunderstanding of the information in this
manual.

INDICATIONS

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49X-GC Micro-GC
This manual contains warnings and precautionary statements that can prevent personal
injury, instrument damage and loss of data if properly followed. Statements of this nature are
called to your attention by the following symbols:

The CAUTION calls attention to procedure, practice, CAUTION or the like, which, if not correctly performed
or adhered to, could result in inadequate functioning of the instrument.

The WARNING calls attention to a procedure, WARNING practice, or the like, which, if not correctly
performed or adhered to, could result in personal injury or damage to the product.

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49X-GC Micro-GC

Specific symbols, drawing attention to safety hazards have been applied on appropriate
places on the instrument. The following symbols can be encountered:

Instruction manual symbol. Indicates that the user should refer to the
manual before operating the equipment.

Indicates dangerous voltage. (terminals fed from the interior by voltage

exceeding 1000 V must be so marked.)

Protective conductor terminal. For protection against electrical shock in

case of a fault. Used with field wiring terminals to indicate the terminal,
which must be connected to ground before operating equipment.

Radioactive hazard. Indicates that the instrument contains radioactive

components, which may cause personal injury when handled incorrectly.

Skin puncture. Indicates sharp or suddenly moving parts such as injection

needles that may cause injury.

Hot surface.
Indicates parts that may cause burns when touched.

Cryogenic frostbite. Contains extremely cold material (such as liquid

nitrogen,
carbon dioxide) that may cause injury when handled carelessly.

Static discharge warning. Item contains parts or information that can be

damaged by electrostatic discharge. Take care for proper grounding before
handling.

Do not touch. Touching this item may result in damage to the instrument or
personal injury.

CAUTIONS

1. An experienced Varian service engineer will normally carry out the installation of this instrument.
Any damage to the system that occurs during unpacking when it is not carried out in the
presence of a Varian service engineer will result in the rejection of a warranty claim.

2. This instrument should be placed in a suitable location with sufficient ventilation to remove gases
and vapors. Space around the instrument must be sufficient to enable cooling of the instrument.

3. Before plugging the instrument in or turning the power on, always make sure that the voltage
and fuses are set appropriately for your local power source.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 10

49X-GC Micro-GC
4. Do not turn on the instrument if there is a possibility of any kind of electrical damage. Instead,
disconnect the power cord and contact your Varian office.

5. The supplied power cord must be inserted into a power outlet with a protective earth ground
connection. When using an extension cord, make sure that the cord is also properly grounded.

6. Do not change the external or internal grounding connections as this could endanger you and/or
damage the instrument.

7. The instrument is properly grounded when shipped. You do not need to make any changes to
the electrical connections or to the instrument chassis to ensure safe operation.

8. When working with this instrument, follow the regulations for GLP (Good Laboratory Practice).
Take cares to wear safety glasses and appropriate clothing.

9. Do not place containers with flammable liquids on this instrument. Spillage of the liquid over hot
parts may cause fire.

10. This instrument may use flammable or explosive gases e.g. hydrogen under pressure. Be sure
to be familiarized with and to follow accurately the operation procedures prescribed for those
gases before operating the instrument.

11. Never try to repair or replace any component that is not described in this manual without the
assistance of a Varian service engineer. Unauthorized repairs or modifications will result in
rejection of warranty claims.

12. Always disconnect the AC power cord before attempting any type of maintenance.

13. Use proper tools when working on the instrument to prevent danger for you and/or damage to
the instrument.

14. The customer should not attempt to replace the battery or fuses in this instrument.

15. Damage can result if the instrument is stored under unfavorable conditions for prolonged periods
(e.g. subject to heat, water, etc.).

16. Do not shut off column flow when the oven temperature is high or may damage the column.

17. This unit has been designed and tested in accordance with recognized safety standards and
designed for use indoors.

18. If the instrument is used in a manner not specified by the manufacturer, the protection provided
by the instrument may be impaired.

19. Substituting parts or performing any unauthorized modification to the instrument may result in a
safety hazard.

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49X-GC Micro-GC

WARNINGS

The following general safety warnings must be observed during all phases of operation,
service, and repair of the 49X-GC Micro-GC. Failure to comply with these precautions or
with specific warnings elsewhere in this manual violates safety standards of design,
manufacture, and the intended use of the instrument.
Varian, Inc. assumes no liability for failure to comply with these requirements

 Allow the injectors, detectors and oven to cool down before an installation.

 Remove the Power connector before installation, service, and repair.

 Removing the 49X-GC Micro-GC covers should be performed only be service-trained

personnel who are aware of all involved hazards.

Whenever possible, disconnect the 49X-GC Micro-GC from its power source before working
on or near voltage carrying components of the 49X-GC Micro-GC.

When the power to the 49X-GC Micro-GC is turned on, low voltages exist on these
additional components:

 All electronic boards.

 All internal wires and cables connected to these boards.

 To protect against electrostatic discharge, use a static control wrist strap connected to a
ground. If you do not use static protection, you may damage the electronics of a board.

USE A MASS SPECIFIC LEAKDETECTOR OR A HAND HELD

LEAK DETECTOR TO INSPECT THE UNIT FOR LEAKS.
DO NOT USE LIQUID SNOOP OR SIMILAR PRODUCT TO INSPECT FOR LEAKS AS
THIS MAY CONTAMINATE YOUR UNIT!

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49X-GC Micro-GC

TOOLS REQUIRED

The following tools are required to perform the service procedures described in this
manual.

Basic

 Electrostatic discharge (ESD) protective wrist strap Part number: CP737948

 Philips screwdrivers
 Hex key 3 mm.
 Open end wrenches: 7 and 8 mm
 Socket wrench 7 mm
 Torx tools (T-10 and T20)

Hex key Torx T-10 CP69026

Hex key Torx T-20 CP69027

Hex key with T-grip Torx T-10 CP69029

Hex key with T-grip Torx T-20 CP69030

Screwdriver Torx T-10 CP69023

Screwdriver Torx T-20 CP69024

 Gas Leak Detector, 110 VAC,CP87610

220 VAC,CP80610
240 VAC,CP83610

 Replacement battery, ALD229RB

 FP- 407 flow meter

http://www.applied-instruments.com/fp-meter.html

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49X-GC Micro-GC

Specialized

 Tube remover for snap-in connectors (CP741218)

 Dual carrier gas tool (CP741219)

 Digital voltmeter

 Service tool (software), available on Service DVD (CP505000)

 Fluke pressure vacuum module.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 2

49X-GC Micro-GC
Fluke pressure vacuum module

During trouble shooting the Micro-GC it is recommended to use the Fluke vacuum module.
The Fluke vacuum module can be used for leakage testing on the sample inlet or directly on the modules.
All Micro-GC’s configured with a sample pump can be used.

Fluke PV350 ordering information can be found on the following website:

http://us.fluke.com/usen/home/default.htm

The following parts are needed to connect the PV350 to the Micro-GC sample inlet or module:

Description: Part number: Qty:

External Sample filter kit CP736729 1X
1/16” union SS SWSS1006 1x
¼” Nut SS SWSS4021 1x
¼” front ferrule SWSS4031 1x (package of 10)
¼” back ferrule SWSS4041 1x (package of 10)
Adaptor CP733384 1x
Teflon tape

How to use this Pressure Vacuum module:

 Connect the PV350 to the Micro-GC Sample Inlet, using the above-described parts, depending of
the instrument configuration.
 Use the peek finger tight for unheated instruments and the 1/16” nut for the heated instruments to
connect the PV350 to the sample line.
 Set the method according the final test results, run time 70 sec.
 Start the GC and read the vacuum on the multimeter while the pump is running.

Specifications: -15KpA ,  0.2kPA change per minute is allowed.

When these specifications are not meet, check the O-rings and/or the connector of the sample line (heated)
or the vespel ferrule/nut connection (unheated) for leaks.

When no leaks are found on the sample in connector, then leak test the channels separate to define which
module is leaking.

Field experience indicates that most of the time the problem is inside the module, replacing the module is the
only option.

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49X-GC Micro-GC

COVERS
All covers should be handled with the necessary care to prevent damaging.

Top panel
Upper right side panel

Frame panel left

Frame panel right

Lower right side panel

For part numbers, follow this link

Main frame panel

Upper rear panel

Lower-rear panel link

Before you start

Before removing the Micro-GC covers, allow (if present) injector, sample line (if present), and oven to cool
down before removing the covers.
The metal surfaces of the Micro-GC can be very hot and could burn your skin.
Turn off the power to the Micro-GC and disconnect the power cord at their source.
Disconnect and remove all sample line(s) and carrier gas supply line(s).

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49X-GC Micro-GC

Removing the right side cover

1. Follow-up the WARNING remarks given in “before you start”.

2. Open the sides cover and remove the two (2) Torx T-20 screws.
3. Carefully lift the side covers up and remove them.
4. Reassemble is the reverse of removal.

Removing the top cover

1. Follow-up the WARNING remarks given in “before you start”.

2. Remove the right side cover.
3. Remove the two (2) Torx T-20 screws holding the top cover.
4. Slide the top cover towards you and remove it.
5. Reassemble is the reverse of removal.

Removing the upper rear panel

1. Follow-up the WARNING remarks given in “before you start”.

2. Remove the right side cover.
3. Remove the three (3) Torx T-20 screws
holding the upper rear panel.
4. Slide upper rear panel up and remove it.
5. Reassemble is the reverse of removal.

Removing the lower rear panel

1. Follow-up the WARNING remarks given in “before you start”.

2. Remove the right side cover and upper rear panel.
3. Remove the three (3) Torx T-20 screws holding the lower rear panel.
4. Remove the panel.
5. Reassemble is the reverse of removal.

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49X-GC Micro-GC
Removing the front panel

1. Follow-up the WARNING remarks given in “before you start”.

2. Remove the right side cover and upper rear panel.
3. Remove the pump assembly connector and the sample inlet nut.
4. Remove the two (2) Torx T-20 screws holding the front panel.
5. Remove the front panel by lifting it up.
6. Reassemble is the reverse of removal.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 6

49X-GC Micro-GC

Removing and replacing procedures

Removing the main board

Before performing this procedure be sure to wear an ESD strap

grounded to the Micro-GC chassis.

1. Follow-up the WARNING remarks given in “before you start”.

2. Remove the right side cover and upper rear panel and front panel.
3. Remove the two (2) Torx T-10 screws holding the main board.
4. The main board can now be removed.
5. Reassemble is the reverse of removal.

Board information, follow this link

Removing the interconnection board

n, follow this link for 2-CH and here for 4-CH.

Before performing this procedure be sure to wear an ESD strap

grounded to the Micro-GC chassis.

1. Follow-up the WARNING remarks given in “before you start”.

2. Remove the right side cover and upper rear panel and front panel.
3. Remove all analytical channels.
4. Remove the cool-fan connector.
5. Remove the two (2) Torx T-10 screws.
6. Slide the main panel assembly towards the arrow and lift it up.
7. Remove the five (5) Torx T-10 screws holding the board and the two (2) at the power
connector side.
8. The interconnection board can now be removed.
9. Reassemble is the reverse of removal.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 7

49X-GC Micro-GC

Removing the TCD controller

Before performing this procedure be sure to wear an ESD strap

grounded to the Micro-GC chassis.

1. Follow-up the WARNING remarks given in “before you start”.

2. Remove the right side cover and upper rear panel.
3. Remove the analytical channel unit.
4. Remove the valve connector.
5. Turn the analytical channel up side down and remove the two (2) Torx T-10 screws holding
the TCD controller.
6. Slide the TCD controller out of his case.
7. Remove the pressure sensor connector.
8. Reassemble is the reverse of removal.

Board information, follow this link

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49X-GC Micro-GC

Replacing the pressure sensor

Before performing this procedure be sure to wear an ESD strap

grounded to the Micro-GC chassis.

1. Follow-up the WARNING remarks given in “before you start”.

2. Remove the right side cover and upper rear panel.
3. Remove the analytical channel unit.
4. Remove the TCD controller board.
5. Loosen the two (2) Torx T-20 screws.
6. Gently pull the pressure sensor out.
7. Reassemble is the reverse of removal.

Check after reassemble for leaks around the pressure sensor, if leaking replace the pressure sensor O-ring.

Replace pressure sensor O-ring

Before performing this procedure be sure to wear an ESD strap

grounded to the Micro-GC chassis.

1. Follow-up the WARNING remarks given in “before you start”.

2. Remove the right side cover and upper rear panel.
3. Remove the analytical channel unit.
4. Remove the TCD controller board.
5. Remove the two (2) Torx T-20 screws and pressure sensor bracket.
6. Gently pull the pressure sensor out.
7. Loosen (do not remove) with a 3mm Hex-key the Hex-nut.
8. Continue on next page.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 9

49X-GC Micro-GC

9. Carefully slide the EGC manifold block away from the column module.

Pressure sensor O-ring

Part number? Click here.

10. Reassemble is the reverse of removal.

Check before assemble all O-rings for damage, situated on the manifold block, replace if necessary (click
here for part numbers).
Check for leaks after reassemble.

Never put any grease on the O-rings!

Removing the Column unit

Before performing this procedure make sure to wear an ESD strap, grounded to the Micro-GC chassis.

1. Follow-up the WARNING remarks given in “before you start”.

2. Remove the right side cover and upper rear panel.
3. Remove the analytical channel unit.
4. Turn the analytical channel upside down and remove the two Torx T-20 screws.
5. Loosen (do not remove) with a 3mm Hex-key the Hex-nut.

6. Continue on next page.

7. Carefully slide the column unit away from the EGC manifold block.
8. Reassemble is the reverse of removal.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 10

49X-GC Micro-GC

Check before assemble all O-rings for damage, situated on the manifold block, replace if necessary (click
here for partnumbers).
Check for leaks after reassemble.

Never put any crease on the O-rings!

Removing the Heated sample line

1. Follow-up the WARNING remarks given in “before you start”.

2. Remove the right side cover and upper rear panel.
3. Remove the top and side insulation.

4. Carefully remove the sample inlet oven box.

5. Loosen only one turn (do not remove!) the two Torx T-10 screws.

Part numbers?
Follow this link.

6. Turn the heated sample inlet connector 90°counter clockwise (arrow direction) and remove
him.
7. Remove the Torx T-10 screw.
8. Lift the heated sample line bracket up and remove it.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 11

49X-GC Micro-GC

9. The sample heater manifold is now visible.

10. Reassemble is the reverse of removal.

Pay during reassembly extra attention to the O-ring(s), replace if necessary.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 12

49X-GC Micro-GC

ILLUSTRATED PARTS BREAKDOWN

Service Field Kit

General maintenance can be done with all necessary parts, part number CP741528
Kit contents click here.

Housing Front view

CP742908
CP742910 Top panel 2-CH Frame panel right
CP742901 Top panel 4-CH

CP742911 Upper right side panel 2-CH

CP742903 Upper right side panel 4-CH
CP742909
Frame panel left

CP742912 Lower right side panel 2-CH

CP742904 Lower right side panel 4-CH

CP742913 Frame bottom 2-CH CP739980 x 4

CP742906 Frame bottom 4-CH Foot bottom

Varian, Inc. 49X-GC Micro-GC Service manual Page: 1

49X-GC Micro-GC

Housing Back view

CP742672 Top panel 2-CH Breakout
CP742673 Top panel 4-CH Breakout
CP86757
Screw M4 x 8 Torx

CP742902
Upper rear panel

CP742914 Main frame panel 2-CH

CP742905 Main frame panel 4-CH

CP742900
Lower-rear panel

CP420640 x 4 Luer female

CP420100 Luer male
CP420200 Luer locking nut Power connector, see for
more details.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 2

49X-GC Micro-GC

Analytical module unit (Unheated straight)

491001330S Micro-GC Module, HayeSep A, 25 cm, Standard Injector.

Field Replacement. Column installed: HayeSep A porous polymer 0.7 mm ID, 25 cm.

491001340S Micro-GC Module, HayeSep A for Nat.Gas, 40 cm, Standard injector.

Field Replacement. Column installed: HayeSep A specially tested for Natural gas.

491001350S Micro-GC Module, MS 5A PLOT, 4 m, Standard Injector.

Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 4 m.

491001360S Micro-GC Module, MS 5A PLOT, 10 m, Standard Injector.

Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 10 m.

491001370S Micro-GC Module, MS 5A PLOT, 20 m, Standard Injector.

Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 20 m.

491001380S Micro-GC Module, CP-Sil 5 CB, 4 m, Standard Injector.

Field Replacement. Column installed: CP-Sil 5 CB 0.15 mm ID, 4 m.

491001390S Micro-GC Module, CP-Sil 5 CB for Nat.Gas, 4 m, Standard Injector.

Field Replacement. Column installed: CP-Sil 5 CB specially tested for Natural gas.

491001400S Micro-GC Module, CP-Sil 5 CB, 6 m, Standard Injector.

Field Replacement. Column installed: CP-Sil 5 CB, 0.15 mm ID, 6 m.

491001410S Micro-GC Module, CP-Sil 5 CB, 8 m, Standard Injector.

Field Replacement. Column installed: CP-Sil 5 CB, 0.15 mm ID, 8 m.

492005770S Micro-GC Module, CP-Sil 5 CB, 10 m, Standard Injector.

Field Replacement. Column installed: CP-Sil 5 CB, 0.15 mm ID, 10 m.

491004810S Micro-GC Module, CP-Sil 19 CB, 6 m, Standard Injector.

Field Replacement. Column installed: CP-Sil 19 CB, 0.15 mm ID, 6 m.

491004820S Micro-GC Module, CP-Sil 19 CB for THT, Standard Injector.

Field Replacement. Column installed: CP-Sil 19 CB specially tested for THT.

491004830S Micro-GC Module, CP-Sil 13 CB for TBM, Standard Injector.

Field Replacement. Column installed: CP-Sil 13 CB specially tested for TBM.

491001420S Micro-GC Module, CP-Wax 52 CB, 4 m, Standard Injector.

Field Replacement. Column installed: CP-Wax 52 CB 0.32 mm ID, 4 m.

491001430S Micro-GC Module, PoraPLOT Q, 10 m, Standard Injector.

Field Replacement. Column installed: PoraPLOT Q 0.25 mm ID, 10 m.

491001540S Micro-GC Module, Poraplot Q, 4m Standard Injector.

Field Replacement. Column installed: PoraPLOT Q 0.25 mm ID, 4 m.

491001440S Micro-GC Module, Alumina PLOT, 10 m, Standard Injector.

Field Replacement. Column installed: Alumina KCl PLOT 0.25 mm ID, 10 m.

491001450S Micro-GC Module, CP-Cox, 1 m, Standard Injector.

Field Replacement. Column installed: CP-Cox, 0.7 mm ID, 1 m.

491001460S Micro-GC Module, PoraPLOT U, 10 m, Standard Injector.

Field Replacement. Column installed: PoraPLOT U, 0.25 mm ID, 10 m.

Micro-GC Module, Mol. Sieve 5A PLOT, 4 m, Standard Injector, RTS Option.

491011350S Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 4 m. Including Retention Time
Stability Option.

Micro-GC Module, Mol. Sieve 5A PLOT, 10 m, Standard Injector, RTS Option.

491011360S Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 10 m. Including Retention Time
Stability Option.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 3

49X-GC Micro-GC

Micro-GC Module, Mol. Sieve 5A PLOT, 20 m, Standard Injector, RTS Option.

491011370S Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 20 m. Including Retention Time
Stability Option.

Micro-GC Module, Alumina PLOT, 10 m, Standard Injector, RTS Option.

491011440S Field Replacement. Column installed: Alumina KCl PLOT 0.25 mm ID, 10 m. Including Retention Time Stability
Option.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 4

49X-GC Micro-GC

Analytical module unit (Heated straight)

492001330S Micro-GC Module, HayeSep A, 25 cm, Heated Injector.

Field Replacement. Column installed: HayeSep A porous polymer 0.7 mm ID, 25 cm.

492001340S Micro-GC Module, HayeSep A for Nat.Gas, 40 cm, Heated Injector.

Field Replacement. Column installed: HayeSep A specially tested for Natural gas.

492001350S Micro-GC Module, Molecular Sieve 5A PLOT,4 m, Heated Injector.

Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 4 m.

492001360S Micro-GC Module, Molecular Sieve 5A PLOT, 10 m, Heated Injector.

Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 10 m.

492001370S Micro-GC Module, Molecular Sieve 5A PLOT, 20 m, Heated Injector.

Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 20 m.

492001380S Micro-GC Module, CP-Sil 5 CB, 4 m, Heated Injector.

Field Replacement. Column installed: CP-Sil 5 CB 0.15 mm ID, 4m.

492001390S Micro-GC Module, CP-Sil 5 CB for Natural Gas, 4 m, Heated Injector

Field Replacement. Column installed: CP-Sil 5 CB specially tested for Natural gas.

492001400S Micro-GC Module, CP-Sil 5 CB, 6 m, Heated Injector.

Field Replacement. Column installed: CP-Sil 5 CB, 0.15 mm ID, 6 m.

492001410S Micro-GC Module, CP-Sil 5 CB, 8 m, Heated Injector.

Field Replacement. Column installed: CP-Sil 5 CB, 0.15 mm ID, 8 m.

492005770S Micro-GC Module, CP-Sil 5 CB, 10 m, Heated Injector.

Field Replacement. Column installed: CP-Sil 5 CB, 0.15 mm ID, 10 m.

492005750S Micro-GC Module, CP-Sil 5 CB, 15 m, Heated Injector.

Field replacement. Column installed: CP-Sil 5 CB, 0.15 mm ID, 15 m.

492004810S Micro-GC Module, CP-Sil 19 CB, 6 m, Heated Injector.

Field Replacement. Column installed: CP-Sil 19 CB, 0.15 mm ID, 6 m.

492004820S Micro-GC Module, CP-Sil 19 CB for THT, Heated Injector.

Field Replacement. Column installed: CP-Sil 19 CB specially tested for THT.

492004830S Micro-GC Module, CP-Sil 13 CB for TBM, Heated Injector.

Field Replacement. Column installed: CP-Sil 13 CB specially tested for TBM.

492001420S Micro-GC Module, CP-Wax 52 CB, 4 m, Heated Injector.

Field Replacement. Column installed: CP-Wax 52 CB 0.32 mm ID, 4m.

492001430S Micro-GC Module, PoraPLOT Q, 10 m, Heated Injector.

Field Replacement. Column installed: PoraPLOT Q 0.25 mm ID, 10 m.

492003130S Micro-GC Module, PoraBond Q, 10m, Heated Injector.

Field Replacement. Column installed: PoraBond Q, 10 m.

492001540S Micro-GC Module, PoraPlot Q, 4 m, Heated Injector.

Field Replacement. Column installed: PoraPLOT Q 0.25 mm ID, 4 m.
Micro-GC Module, Alumina PLOT, 10 m, Heated Injector.
492001440S
Field Replacement. Column installed: Alumina KCl PLOT 0.25 mm ID, 10 m .

492001450S Micro-GC Module, CP-Cox, 1 m, Heated Injector.

Field Replacement. Column installed: CP-Cox, 0.7 mm ID, 1 m.

492001460S Micro-GC Module, PoraPLOT U, 10 m, Heated Injector.

Field Replacement. Column installed: PoraPLOT U, 0.25 mm ID, 10 m.

492001470S Micro-GC Module, MES in Natural Gas, 15 m, Heated Injector.

Field Replacement. Column installed: MES in Natural Gas.

492103130S Micro-GC Module, PoraBOND, 10 m Heated Injector for use with DMD.
Field Replacement. Column installed: PoraBOND Q 0.25mm ID, 10m

492101410S Micro-GC Module, CP-Sil 5 CB, 8 m Heated Injector for use with DMD.
Field Replacement. Column installed: CP-Sil5 CB 0.15mm ID, 8m

492011350S Micro-GC Module, Mol. Sieve 5A PLOT, 4 m, Heated Injector, RTS Option.
Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 4 m.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 5

49X-GC Micro-GC

Micro-GC Module, Mol. Sieve 5A PLOT, 10 m, Heated Injector. RTS Option.

492011360S Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 10 m. Including Retention Time
Stability Option.

Micro-GC Module, Mol. Sieve 5A PLOT, 20 m, Heated Injector. RTS Option.

492011370S Field Replacement. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 20 m. Including Retention Time
Stability Option.

Micro-GC Module, Alumina PLOT, 10 m, Heated Injector. RTS Option.

492011440S Field Replacement. Column installed: Alumina KCl PLOT 0.25 mm ID, 10 m. Including Retention Time Stability
Option.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 6

49X-GC Micro-GC

Analytical module unit (Unheated Backflush)

493001360S Micro-GC Module, MS 5A PLOT, 10 m, Standard Injector, Backflush.

Field Replacement. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 10 m.

493001370S Micro-GC Module, MS 5A PLOT, 20 m, Standard Injector, Backflush.

Field Replacement. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 20 m.

493001430S Micro-GC Module, PoraPLOT Q, 10 m, Standard Injector, Backflush.

Field Replacement. Column installed: PoraPLOT Q PLOT, 0.25 mm ID, 10 m.

493001440S Micro-GC Module, Alumina PLOT, 10m, Std Injector, Backflush.

Field Replacement. Column installed: Alumina KCl PLOT, 0.25 mm ID, 10 m.

493001460S Micro-GC Module, PoraPLOT U, 10 m, Standard Injector, Backflush.

Field Replacement. Column installed: PoraPLOT U PLOT, 0.25 mm ID, 10 m.

493001450S Micro-GC Module, CP-Cox, 1 m, Standard Injector, Backflush.

Field Replacement. Column installed: CP-Cox, micro-packed 1 mm, 1m.

Micro-GC Module, MS 5A PLOT, 10 m, Standard Injector, Backflush, RTS Option.

493011360S Field Replacement. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 10 m. Including Retention Time
Stability Option.

Micro-GC Module, MS 5A PLOT, 20 m, Standard Injector, Backflush, RTS Option.

493011370S Field Replacement. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 20 m. Including Retention Time
Stability Option.

Micro-GC Module, Alumina PLOT, 10 m, Standard Injector, Backflush, RTS Option.

493011440S Field Replacement. Column installed: Alumina KCl PLOT, 0.25 mm ID, 10 m. Including Retention Time Stability
Option.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 7

49X-GC Micro-GC

Analytical module unit (Heated Backflush)

494001360S Micro-GC Module, MS 5A PLOT, 10 m, Heated Injector, Backflush.

Field Replacement. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 10 m.

494001370S Micro-GC Module, MS 5A PLOT, 20 m, Heated Injector, Backflush.

Field Replacement. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 20 m.

494001430S Micro-GC Module, PoraPLOT Q, 10 m, Heated Injector, Backflush.

Field Replacement. Column installed: PoraPLOT Q PLOT, 0.25 mm ID, 10 m.

494001440S Micro-GC Module, Alumina PLOT, 10m, Heated Injector, Backflush.

Field Replacement. Column installed: Alumina KCl PLOT, 0.25 mm ID, 10 m.

494001460S Micro-GC Module, PoraPLOT U, 10 m, Heated Injector, Backflush.

Field Replacement. Column installed: PoraPLOT U PLOT, 0.25 mm ID, 10 m.

494005920S Micro-GC Module, SilicaPLOT, 10 m, Heated Injector, Backflush.

Field Replacement. Column installed: SilicaPLOT, 0.25 mm ID, 10 m.

494001340S Micro-GC Module, HayeSep A, 40 cm, Heated Inj, Backflush.

Field Replacement. Column installed: HayeSep A poreus polymer, 40 cm.

494001380S Micro-GC Module, CP-Sil 5 CB, 4 m, Heated Inj, Backflush.

Field Replacement. Column installed: CP-Sil 5 CB, 0.15 mm ID, 4 m.

494001450S Micro-GC Module, CP-Cox 1 m, Heated Inj, Backflush.

Field Replacement. Column installed: CP-Cox, micro-packed 1 mm, 1m.

Micro-GC Module, MS 5A PLOT, 10 m, Heated Injector, Backflush, RTS Option.

494011360S Field Replacement. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 10 m. Including Retention Time
Stability Option.

Micro-GC Module, MS 5A PLOT, 20 m, Heated Injector, Backflush, RTS Option.

494011370S Field Replacement. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 20 m. Including Retention Time
Stability Option.

Micro-GC Module, Alumina PLOT, 10m, Heated Injector, Backflush, RTS Option.
494011440S Field Replacement. Column installed: Alumina KCl PLOT, 0.25 mm ID, 10 m. Including Retention Time Stability
Option.

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49X-GC Micro-GC

Analytical channel unit (Unheated Straight)

491001330F Micro-GC Channel, HayeSep A, 25 cm, Standard Injector.

Field Installed. Column installed: HayeSep A porous polymer 0.7 mm ID, 25 cm.

491001340F Micro-GC Channel, HayeSep A for Nat. Gas, 40 cm, Standard Injector.
Field Installed. Column installed: HayeSep A specially tested for natural gas.

491001350F Micro-GC Channel, MS 5A PLOT, 4 m, Standard Injector.

Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 4 m.

491001360F Micro-GC Channel, MS 5A PLOT, 10 m, Standard Injector.

Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 10 m.

491001370F Micro-GC Channel, MS 5A PLOT, 20 m, Standard Injector.

Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 20 m.

491001380F Micro-GC Channel, CP-Sil 5 CB, 4 m, Standard Injector.

Field Installed. Column installed: CP-Sil 5 CB 0.15 mm ID, 4 m.

491001390F Micro-GC Channel, CP-Sil 5 CB for Nat.Gas, 4 m, Standard Injector.

Field Installed. Column installed: CP-Sil 5 CB specially tested for Natural gas.
Micro-GC Channel, CP-Sil 5 CB, 6 m, Standard Injector.
491001400F
Field Installed. Column installed: CP-Sil 5 CB, 0.15 mm ID, 6 m.

491001410F Micro-GC Channel, CP-Sil 5 CB, 8 m, Standard Injector.

Field Installed. Column installed: CP-Sil 5 CB, 0.15 mm ID, 8 m.

491004810F Micro-GC Channel, CP-Sil 19 CB, 6 m, Standard Injector.

Field Installed. Column installed: CP-Sil 19 CB, 0.15 mm ID, 6 m.
Micro-GC Channel, CP-Sil 19 CB for THT, Standard Injector.
491004820F
Field Installed. Column installed: CP-Sil 19 CB specially tested for THT.

491004830F Micro-GC Channel, CP-Sil 13 CB for TBM, Standard Injector.

Field Installed. Column installed: CP-Sil 13 CB specially tested for TBM.
Micro-GC Channel, CP-Wax 52 CB, 4 m, Standard Injector.
491001420F
Field Installed. Column installed: CP-Wax 52 CB 0.32 mm ID, 4 m.

491001430F Micro-GC Channel, PoraPLOT Q, 10 m, Standard Injector.

Field Installed. Column installed: PoraPLOT Q 0.25 mm ID, 10 m.
Micro-GC Channel, PoraPLOT Q, 4m Standard Injector.
491001540F
Field Installed. Column installed: PoraPLOT Q 0.25 mm ID, 4 m.

491001440F Micro-GC Channel, Alumina PLOT, 10 m, Standard Injector.

Field Installed. Column installed: Alumina KCL PLOT 0.25 mm ID, 10 m.
Micro-GC Channel, CP-Cox, 1 m, Standard Injector.
491001450F
Field Installed. Column installed: CP-Cox, 0.7 mm ID, 1 m.
Micro-GC Channel, PoraPLOT U, 10 m, Standard Injector.
491001460F
Field Installed. Column installed: PoraPLOT U, 0.25 mm ID, 10 m.

Micro-GC Channel, Mol. Sieve 5A PLOT, 4 m, Standard Injector, RTS Option.

491011350F Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 4 m. Including Retention Time Stability
Option.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 9

49X-GC Micro-GC

Micro-GC Channel, Mol. Sieve 5A PLOT, 10 m, Standard Injector, RTS Option.

491011360F Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 10 m. Including Retention Time
Stability Option.

Micro-GC Channel, Mol. Sieve 5A PLOT, 20 m, Standard Injector, RTS Option.

491011370F Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 20 m. Including Retention Time
Stability Option.

Micro-GC Channel, Alumina PLOT, 10 m, Standard Injector, RTS Option.

491011440F Field Installed. Column installed: Alumina KCL PLOT 0.25 mm ID, 10 m. Including Retention Time Stability
Option.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 10

49X-GC Micro-GC

Analytical channel unit (Heated Straight)

492001330F Micro-GC Channel, HayeSep A, 25 cm, Heated Injector.

Field Installed. Column installed: HayeSep A porous polymer 0.7 mm ID, 25 cm.

492001340F Micro-GC Channel, HayeSep A for Nat Gas, 40 cm, Heated Injector.
Field Installed. Column installed: HayeSep A specially tested for Natural gas.

492001350F Micro-GC Channel, Mol. Sieve 5A PLOT, 4 m, Heated Injector.

Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 4 m.

492001360F Micro-GC Channel, MS 5A PLOT, 10 m, Heated Injector.

Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 10 m.
Micro-GC Channel, MS 5A PLOT, 20 m, Heated Injector.
492001370F
Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 20 m.
Micro-GC Channel, CP-Sil 5 CB, 4 m, Heated Injector.
492001380F
Field Installed. Column installed: CP-Sil 5 CB 0.15 mm ID, 4m.

492001390F Micro-GC Channel, CP-Sil 5 CB for Nat. Gas, 4 m, Heated Injector.

Field Installed. Column installed: CP-Sil 5 CB specially tested for Natural gas.

492001400F Micro-GC Channel, CP-Sil 5 CB, 6 m, Heated Injector.

Field Installed. Column installed: CP-Sil 5 CB, 0.15 mm ID, 6 m.

492001410F Micro-GC Channel, CP-Sil 5 CB, 8 m, Heated Injector.

Field Installed. Column installed: CP-Sil 5 CB, 0.15 mm ID, 8 m.

492005770F Micro-GC Channel, CP-Sil 5 CB, 10 m, Heated Injector.

Field Installed. Column installed: CP-Sil 5 CB, 0.15 mm ID, 10 m.

492005750F Micro-GC Channel, CP-Sil 5 CB, 15 m, Heated Injector.

Field Installed. Column installed: CP-Sil 5 CB, 0.15 mm ID, 15 m.

492004810F Micro-GC Channel, CP-Sil 19 CB, 6 m, Heated Injector.

Field Installed. Column installed: CP-Sil 19 CB, 0.15 mm ID, 6 m.

492004820F Micro-GC Channel, CP-Sil 19 CB for THT, Heated Injector.

Field Installed. Column installed: CP-Sil 19 CB specially tested for THT.

492004830F Micro-GC Channel, CP-Sil 13 CB for TBM, Heated Injector.

Field Installed. Column installed: CP-Sil 13 CB specially tested for TBM.

492001420F Micro-GC Channel, CP-Wax 52 CB, 4 m, Heated Injector.

Field Installed. Column installed: CP-Wax 52 CB 0.32 mm ID, 4m.

492001430F Micro-GC Channel, PoraPLOT Q, 10 m, Heated Injector.

Field Installed. Column installed: PoraPLOT Q 0.25 mm ID, 10 m.

492003130F Micro-GC Channel, PoraBond Q, 10m, Heated Injector.

Field installed. Column installed: PoraBond Q, 10 m.

492001540F Micro-GC Channel, PoraPlot Q, 4 m, Heated Injector.

Field Installed. Column installed: PoraPLOT Q 0.25 mm ID, 4 m.

492001440F Micro-GC Channel, Alumina PLOT, 10 m, Heated Injector.

Field Installed. Column installed: Alumina KCl PLOT 0.25 mm ID, 10 m.

492001450F Micro-GC Channel, CP-Cox, 1 m, Heated Injector.

Field Installed. Column installed: CP-Cox, 0.7 mm ID, 1 m.

492001460F Micro-GC Channel, PoraPLOT U, 10 m, Heated Injector.

Field Installed. Column installed: PoraPLOT U, 0.25 mm ID, 10 m.

492001470F Micro-GC Channel, MES in Nat. Gas, 15 m Heated Injector.

Field Installed. Column installed: MES in Natural Gas, 15 m.

492103130F Micro-GC Channel, PoraBOND, 10 m Heated Injector for use with DMD.
Field Installed. Column installed: PoraBOND Q 0.25mm ID, 10m

492101410F Micro-GC Channel, CP-Sil 5 CB, 8 m Heated Injector for use with DMD.
Field Installed. Column installed: CP-Sil5 CB 0.15mm ID, 8m

Micro-GC Channel, Mol. Sieve 5A PLOT, 4 m, Heated Injector, RTS Option.

492011350F Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 4 m. Including Retention Time Stability
Option.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 11

49X-GC Micro-GC

Micro-GC Channel, Mol. Sieve 5A PLOT, 10 m, Heated Injector. RTS Option.

492011360F Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 10 m. Including Retention Time
Stability Option.

Micro-GC Channel, Mol. Sieve 5A PLOT, 20 m, Heated Injector. RTS Option.

492011370F Field Installed. Column installed: Molecular Sieve 5A PLOT 0.25 mm ID, 20 m. Including Retention Time
Stability Option.

Micro-GC Channel, Alumina PLOT, 10 m, Heated Injector. RTS Option.

492011440F Field Installed. Column installed: Alumina KCl PLOT 0.25 mm ID, 10 m. Including Retention Time Stability
Option.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 12

49X-GC Micro-GC

Analytical channel unit (Unheated Backflush)

493001360F Micro-GC Channel, MS 5A PLOT, 10 m, Std Injector, Backflush.

Field Installed. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 10 m.

493001370F Micro-GC Channel, MS 5A PLOT, 20 m, Std Injector, Backflush.

Field Installed. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 20 m.

493001430F Micro-GC Channel, PPQ, 10 m, Standard Injector, Backflush.

Field Installed. Column installed: PoraPLOT Q PLOT, 0.25 mm ID, 10 m.

493001440F Micro-GC Channel, Alumina PLOT, 10m, Std Injector, Backflush.

Field Installed. Column installed:: Alumina KCl PLOT, 0.25 mm ID, 10 m.

493001460F Micro-GC Channel, PPU, 10 m, Standard Injector, Backflush.

Field Installed. Column installed: PoraPLOT U PLOT, 0.25 mm ID, 10 m.

493001450F Micro-GC Channel, CP-COX, 1 m, Standard Injector, Backflush.

Field Installed. Column installed: CP-COX, micro-packed 1 mm, 1m.

Micro-GC Channel, MS 5A PLOT, 10 m, Standard Injector, Backflush, RTS Option.

493011360F Field Installed. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 10 m. Including Retention Time
Stability Option.

Micro-GC Channel, MS 5A PLOT, 20 m, Standard Injector, Backflush, RTS Option.

493011370F Field Installed. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 20 m. Including Retention Time
Stability Option.

Micro-GC Channel, Alumina PLOT, 10 m, Standard Injector, Backflush, RTS Option.

493011440F Field Installed. Column installed: Alumina KCl PLOT, 0.25 mm ID, 10 m. Including Retention Time Stability
Option.

Analytical channel unit (Heated Backflush)

494001360F Micro-GC Channel, MS 5A PLOT, 10 m, Heated Injector, Backflush.

Field Installed. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 10 m.

494001370F Micro-GC Channel, MS 5A PLOT, 20 m, Heated Injector, Backflush.

Field Installed. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 20 m.

494001430F Micro-GC Channel, PoraPLOT Q, 10 m, Heated Injector, Backflush.

Field Installed. Column installed: PoraPLOT Q PLOT, 0.25 mm ID, 10 m.

494001440F Micro-GC Channel, Alumina PLOT, 10m, Heated Inj, Backflush.

Field Installed. Column installed: Alumina KCl PLOT, 0.25 mm ID, 10 m.

494001460F Micro-GC Channel, PoraPLOT U, 10 m, Heated Injector, Backflush.

Field Installed. Column installed: PoraPLOT U PLOT, 0.25 mm ID, 10 m.

494005920F Micro-GC Channel, SilicaPLOT, 10 m, Heated Injector, Backflush.

Field Installed. Column installed: SilicaPLOT, 0.25 mm ID, 10 m.

494001340F Micro-GC Channel, HayeSep A, 40 cm, Heated Inj, Backflush.

Field Installed. Column installed: HayeSep A poreus polymer, 40 cm.

494001380F Micro-GC Channel, CP-Sil 5 CB, 4 m, Heated Inj, Backflush.

Field Installed. Column installed: CP-Sil 5 CB, 0.15 mm ID, 4 m.

494001450F Micro-GC Channel, CP-Cox, 1 m, Heated Inj, Backflush.

Field Installed. Column installed: CP-Cox, micro-packed 1 mm, 1m.

Micro-GC Channel, MS 5A PLOT, 10 m, Heated Injector, Backflush, RTS Option.

494011360F Field Installed. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 10 m. Including Retention Time
Stability Option.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 13

49X-GC Micro-GC

Micro-GC Channel, MS 5A PLOT, 20 m, Heated Injector, Backflush, RTS Option.

494011370F Field Installed. Column installed: Molecular Sieve 5A PLOT, 0.25 mm ID, 20 m. Including Retention Time
Stability Option.

Micro-GC Channel, Alumina PLOT, 10m, Heated Injector, Backflush, RTS Option.
494011440F Field Installed. Column installed: Alumina KCl PLOT, 0.25 mm ID, 10 m. Including Retention Time Stability
Option.

Analytical module

Inside view Analytical module

No part numbers are given for parts inside the analytical module due to service policy.

Detector

Column

TCD vent
block
Injector

Sample line Heater/sensor for Column heater

heated injector

Varian, Inc. 49X-GC Micro-GC Service manual Page: 14

49X-GC Micro-GC

Inside view Analytical backflush module

Not all part numbers are given for parts inside the analytical module due to service policy.

Detector
Pre-Column

Column

Valco ® zero dead

volume Tee
Injector

Analytical
column

Column heater

Heater/sensor for heated

injector

Analytical module interface

TCD cable assembly

Varian, Inc. 49X-GC Micro-GC Service manual Page: 15

49X-GC Micro-GC

Manifold and TCD controller kit, straight

CP73998580
CP73998580
EGC and manifold kit, straight
EGC and manifold kit, straight

CP73990780 x 2 CP740595 x 2
Clippard 2/2 valve Quick release connector

CP742145 x 2
Solenoid valve NO

CP742259 x 2
Solenoid valve NC
Wiring details, follow this link

Manifold and TCD controller kit, backflush

CP74003580 (standard)
CP74003580 (standard)
EGC and manifold kit, backflush
EGC and manifold kit, backflush

CP74139780 (Special for PPQ)

CP74139780 (Special for PPQ)
EGC and manifold kit, backflush
EGC and manifold kit, backflush

Backflush only
CP74078580
Solenoid valve NO BF

Wiring details, follow this link

Varian, Inc. 49X-GC Micro-GC Service manual Page: 16

49X-GC Micro-GC

EGC and Manifold electronics

O-ring replacement procedure

O-ring replacement procedure

CP739941 CP740028
PCB assembly pressure sensor O-ring 3.3 x 2.4 Viton
More detail, follow link

CP740046
O-ring 1.8 x 1.2 Viton

Varian, Inc. 49X-GC Micro-GC Service manual Page: 17

49X-GC Micro-GC

EGC/Manifold to column module connection

CP740586
Screw DIN-912 M4x10 SV 12.9

CP739939
Connection plate mod. & manifold

Varian, Inc. 49X-GC Micro-GC Service manual Page: 18

49X-GC Micro-GC

Pump manifold assembly

CP740206
CP740206
Pump manifold assembly
Pump manifold assembly

2815892301
CP74043090 All tubing
NMP015L Sample pump Clear polyurethane tubing

CP740595 x 4
Quick release connector

CP420940 x 2
Barbed red. connector

CP420020A x 15 mm x 2
Pur tubing 1/8”

CP847212 x 2
Screw M2 x 8

CP40129080
Solenoid valve NO

CP740350 CP740536 5140878300 CP158331 x 4

Vibration isolator Flanged nut M4 Connector 20-pole Contact

For wiring details follow this link

For wiring details follow this link

Varian, Inc. 49X-GC Micro-GC Service manual Page: 19

49X-GC Micro-GC

Upgrade second Pump manifold assembly (CP74020680)

1) Install the vibration isolators in the bottom plate.

CP740350 (2x)
Vibration isolator

2) Connect the wires from the second pump to the connector.

Pump + pin 4 red pump + pin 5 red

(single) - pin 14 black (Dual) - pin 15 black

Solenoid + pin 9 red Solenoid + pin 10 red

(single) - pin 19 black (Dual) - pin 20 black

3) Install the pump assy and fixed them with the flanged nuts.

CP740536 (2x)
Flanged nut M4

4) Connect the pump assy connector to the mainboard.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 20

49X-GC Micro-GC

5) Connect the tubing for the second pump assy.

6) Check with the Service tool the performance of the second pump assy.
This tool is available on the Service DVD P/N CP505000.
How to check?
Select Diagnostics
Select Valve test
Select Solenoid test (check pump assy)
Select pump solenoid On/Off

Varian, Inc. 49X-GC Micro-GC Service manual Page: 21

49X-GC Micro-GC

Sample-IN Connectors

CP740570
Unheated sample-In Connector assembly.
Frit is mounted in de connector

CP736335
Unheated Vespel dual hole ferrule

SG072671
Unheated Vespel single hole ferrule

CP490210
Heated sample line connector assembly (set of 5)
Frit is mounted in de connector

Varian, Inc. 49X-GC Micro-GC Service manual Page: 22

49X-GC Micro-GC

Upgrade from Heated to Unheated sample injection (kit pn CP740827)

CP740570
Unheated sample inlet
SWSS2021
1/8” Nut

CP739952
Bracket

CP740204
Nut M8

CP86757
Torx M4x8

CP736335 CR213208
Dual hole ferrule Single hole ferrule

Varian, Inc. 49X-GC Micro-GC Service manual Page: 23

49X-GC Micro-GC

Carrier gas tubes

CP739940 CP739947 Carrier tube 2-channel

Screw carrier tube CP739948 Carrier tube 4-channel, single
CP739949 carrier
Connection piece

CP480403 Stop

CP740029 x 3
All O-rings viton 4x1

CP740210
Nut for Stop carrier tube

CP740209
Stop carrier tube

Carrier gas kit is P/N CP740828

CP740209
Stop carrier tube

CP740210
Nut for Stop carrier tube

CP740029
Viton O-ring x2

Varian, Inc. 49X-GC Micro-GC Service manual Page: 24

49X-GC Micro-GC

Dual Carrier gas connection (Upgrade kit pn CP490201)

Special tool for Carriergas connector,

see specialized tools

CP740043
Male connector 1/16xM4

CP740029
Viton O-ring

CP740204
Nut M8

CP740585
Bulkhead Union

VLZN1
Valco nut 1/16”

Varian, Inc. 49X-GC Micro-GC Service manual Page: 25

49X-GC Micro-GC

Heated sample line

CP490210
CP74035180 Heated sample line
Heater sample line connector assembly (set of
5)

Heated sample
line box

information, follow this link.

CP740029
O-ring 4x1 Viton

VLZN5
Valco nut 1/32

CP740347 Sample-in manifold 1 to 2 VLZF510

CP740344 Sample-in manifold 1 to 4 Valco ferrule 1/32

VLZFB10
Valco brass ferrule 1/32

CP22474
Valco plug 1/32"

Varian, Inc. 49X-GC Micro-GC Service manual Page: 26

49X-GC Micro-GC

MicroGasifier Bracket

Remove the 2 Torx screws from the Rear housing and use these screws to install the MicroGasifier.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 27

49X-GC Micro-GC
MicroGasifier

CP738565 x 2
Insulation 2 and 3

CP739801
Insulation 1

Factory setting on 6
CP72274
Silicon foam

CP23050
Finger tight fitting peek

CP8662680
Heater and pressure CP739831 x2
assembly Bulkhead union

CP401097
Needle valve

CP401097
Needle valve

Male connector
1/16"x 1/16"
P/N: CP4478

CP4008 Sealed with red paint?

All tubing 1/16" x 1.0 mm Yes, pressure regulator adjusted.
No, adjust pressure regulator.
See Gasifier_pressure_regulator

Varian, Inc. 49X-GC Micro-GC Service manual Page: 28

49X-GC Micro-GC

Gasifier pressure regulator

The Gasifier pressure regulator/evaporator is factory adjusted and sealed with red paint.
If the red paint is damaged or not present, readjust the pressure regulator.

Locking nut Red paint

Adjustment procedure

1. Remove the locking nut on the GO-regulator.

2. Loosen the adjustment screw.
3. Build up the installation confirm the picture
beside.
4. Put 20 Bar Nitrogen on the input of the GO-
regulator.
5. Adjust the pressure regulator screw until the
output pressure is 100 kPa at a flow of
30mL/min.
6. Put 100 Bar Nitrogen on the input of the GO-
regulator.
7. The outlet pressure must be between 20 and
100 kPa.
8. Place the locking nut back.
9. Seal the locking nut with red paint.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 29

49X-GC Micro-GC

ELECTRONIC BOARDS
Interconnection board 2-CH
CP740012
Interconnection board 2-CH

For more board details follow this link

Interconnection board 4-CH

CP740020
Interconnection board 4-CH

link

Varian, Inc. 49X-GC Micro-GC Service manual Page: 30

49X-GC Micro-GC

Main board

CP740573 CP740509 CP740010

Combo card MPU card Main board

CP740812
Battery

link

Cooling Fan (main board)

CP74055780
Fan 12V 40x40x10

Computer

CP740509
Dimm PC, programmed

Varian, Inc. 49X-GC Micro-GC Service manual Page: 31

49X-GC Micro-GC

Ethernet and Communication port card

CP740573
Ethernet and Communication
port card

Analytical module interface

PCB assembly analytical

module interface

This board is situated in

the Analytical module
and is therefore not
serviceable.

For more board details, follow this link

Varian, Inc. 49X-GC Micro-GC Service manual Page: 32

49X-GC Micro-GC

TCD controller

CP740011
TCD controller

This board is a part of manifold

and TCD controller kit

For more board details, follow this link

Power supply

CP740159
Power supply (without power cable)

For more power supply details, follow this link

Varian, Inc. 49X-GC Micro-GC Service manual Page: 33

49X-GC Micro-GC

This cable is situated in

TCD Cable assembly the Analytical module
and is therefore not
Cable assembly serviceable.
TCD

Used in the analytical module

Pressure sensor assembly

CP739941
Pressure sensor assembly

For more board details, follow this link

Heater/sensor for injector

Heater / Sensor assembly for injector

This part is situated in

the Analytical module
and is therefore not
serviceable.

Column heater
Heater / sensor for column

This part is situated in

the Analytical module
and is therefore not
serviceable.

Varian, Inc. 49X-GC Micro-GC Service manual Page: 34

 49X-GC Micro-GC

FIELDCASE

CP74055680 CP740212
Fan 12 VDC PCB assembly 49X-GC Switcher
For more board details, follow this link

CP740279
Cable
assembly
Power-1
Link
CP740281
Cable
assembly
Power-2
Link
CP41010080
Pressure reducer CP473750
CP4387 Check valve
CP740282
Male connector Cable
CP472313 assembly
Elbow Male battery-1
Link
CP740283
CP740217 Cable
Clamp assembly
battery-2
Link

CP407200 CP4250 CP740328 CP740533 x 4

Carrier gas cyclinder Tubing brass Battery pack Knob selfadhesie

Varian, Inc. 49X-GC Micro-GC Service manual Page: 35

49X-GC Micro-GC

CP736967
Front pressure gauge

CP82629
CP736880 Anti Loss ring
Union assembly with
filter

CP12696
Valve PH 2-way

CP740334
Grip black steel

CP740218
Slide latch

Varian, Inc. 49X-GC Micro-GC Service manual Page: 36

49X-GC Micro-GC

Cable overview

Varian, Inc. 49X-GC Micro-GC Service manual Page: 37

49X-GC Micro-GC

CP740212
PCB assembly 49X-GC Switcher
Fieldcase switcher

link

Varian, Inc. 49X-GC Micro-GC Service manual Page: 38

49X-GC Micro-GC

Cable assembly power-2

CP740281
Cable assembly Power2 49X-GC Portable

For more cable details, follow this link

Cable assembly power-1

CP740279
Cable assembly Power1 49X-GC
Portable

For more cable details, follow this link

Varian, Inc. 49X-GC Micro-GC Service manual Page: 39

49X-GC Micro-GC

Cable assembly Battery 1

CP740282
Cable assembly Battery-1

For more cable details, follow this link

Cable assembly Battery 2

CP740283
Cable assembly Battery-2

For more cable details, follow this link

Cooling Fan (fieldcase)

CP74055680
Fan 12VDC 60 x 60 x 25

Battery pack

CP740328
Battery pack

Varian, Inc. 49X-GC Micro-GC Service manual Page: 40

49X-GC Micro-GC

Carrier gas refill assembly

CP737162
Refill assembly
Supplied without container

CP404051
Pressure gauge CP401126
Valve 1/4"male

CP401127
Relief valve 1800 Psi

CP737160 CP473732Connector BS3 (GB)

Refill tubing P/N: CP473734Connector DIN6 (BRD)
CP473735Connector CGA580 (USA IT)
CP473731Connector Euro
CP738015Connector France

Varian, Inc. 49X-GC Micro-GC Service manual Page: 41

49X-GC Micro-GC

ACCESORY BRACKET

Exploded view Accessory Bracket

CP742363
Top panel

CP742364
Side panel
CP742364
Side panel

CP742361
Front panel

CP742362
Rear panel

Varian, Inc. 49X-GC Micro-GC Service manual

Page:42
 49X-GC Micro-GC

MicroGasifier

CP739831
Bulkhead union
CP401097
Needle valve

CP8662680
GO-regulator

See MicroGasifier for more details

Genie filter
392590006
Geniefilter 170 Standard

Rotameter 392590002
Geniefilter 170 BTU

392590004
Replacement filter 170
Standard (pkg of 5)

392590003
Replacement filter 170
BTU (pkg of 5)
Geniefilter 170 BTU

Varian, Inc. 49X-GC Micro-GC Service manual

Page:43
49X-GC Micro-GC

GAS SYRINGE ANALYSIS

Septum injection port

CP958929
Septum injector assy

CP914892 CP914893
Septa low bleed Support ZF2SI

CP4401
1/16 SS Nut
SG072655
Vespel ferrule 1/16*0.8
Varian, Inc. 49X-GC Micro-GC Service manual
Page:44
49X-GC Micro-GC

Relief valve adjusted at 10PSI (0,7Bar)

CP914756
Relief valve

Varian, Inc. 49X-GC Micro-GC Service manual

Page:45
49X-GC Micro-GC

PNEUMATIC DIAGRAMS
Pneumatic diagrams for the 49X-GC Micro-GC, Straight, Backflush and Continuous flow.
After power up the system starts with the Flush cycle in order to flush the entrapped air from the manifold, click here for more details.

Pneumatic diagram overview

Varian, Inc. 49X-GC Micro-GC Service manual Page:46

49X-GC Micro-GC

Pneumatic diagram straight IDLE

Temperature and pressure set, solenoid valves and sample pump are off.

Varian, Inc. 49X-GC Micro-GC Service manual Page:47

49X-GC Micro-GC

Pneumatic diagram straight IDLE CONTINUOUS FLOW

Solenoid valve VLV2 activated, sample pump bypassed.

Varian, Inc. 49X-GC Micro-GC Service manual Page:48

49X-GC Micro-GC

Pneumatic diagram straight SAMPLING

Solenoid valve VLV2 activated, Pump and valve (pump) activated

Duration: parameter Sample time (pump active) in seconds.

Varian, Inc. 49X-GC Micro-GC Service manual Page:49

49X-GC Micro-GC

Pneumatic diagram straight EQUILIBRATION

All solenoid valves and pump are reset, sample gas will be settled.

Varian, Inc. 49X-GC Micro-GC Service manual Page:50

49X-GC Micro-GC

Pneumatic diagram straight PRESSURISATION

Solenoid valve VLV3 activated, sample pressure will be the same as the column head pressure.

Varian, Inc. 49X-GC Micro-GC Service manual Page:51

49X-GC Micro-GC

Pneumatic diagram straight INJECTION

Solenoid valve VLV1 and VLV3 are activated.

Duration: parameter Injection time in milliseconds.

Varian, Inc. 49X-GC Micro-GC Service manual Page:52

49X-GC Micro-GC

Pneumatic diagram straight RUN

All solenoids deactivated.

Duration: parameter run time in seconds.

Varian, Inc. 49X-GC Micro-GC Service manual Page:53

49X-GC Micro-GC

Pneumatic diagram backflush

Varian, Inc. 49X-GC Micro-GC Service manual Page:54

49X-GC Micro-GC

Pneumatic diagram backflush, FOREFLUSH MODE

Varian, Inc. 49X-GC Micro-GC Service manual Page:55

49X-GC Micro-GC

Pneumatic diagram backflush, BACKFLUSH MODE

Varian, Inc. 49X-GC Micro-GC Service manual Page:56

49X-GC Micro-GC

Flush cycle

The flush-cycle is a 2-minute cycle in which the various valves are activated and deactivated in order to flush the entrapped air from the manifold and valves but
especially from the internal carrier gas line. Schematically the Flush cycle actions are presented in the diagram on this page.

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WIRING AND ELECTRONIC INFORMATION

EGC and Manifold kit

All valves except VLV 4 and 7 works at 13.5 Vdc

Straight manifold

Backflush manifold

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Valve Connector

Pump connections (single)

Pump (single):
+ Pin 4 red
- Pin 14 black

Solenoid (single):
+ Pin 9 red
- Pin 19 black

11 10
20

Pump connections (dual)

Pump (single):
+ Pin 4 red
- Pin 14 black

1 Pump (dual)
+ Pin 5 red
- Pin 15 black

Solenoid (single):
+ Pin 9 red
- Pin 19 black

Solenoid (dual)
+ Pin 10 red
- Pin 20 black

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2 Channel Interconnection Board

Blockdiagram

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Lay-out

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Schematics 1 of 3

NOTE: Only the most important schematics are included

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Schematics 2 of 3

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Schematics 3 of 3

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4 Channel Interconnection Board

Blockdiagram

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Lay-out

Schematics

The schematic of the 4 Channel interconnection board are identical as the 2 Channel, only there are 4 Channel connections instead of 2 Channel connections.

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Main board

Main board Date PCB revision Changes

Revision
23 December August
15 3.20 490-GC compatible
201001

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Lay-out

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Schematics 1 of 5

NOTE: Only the most important schematics are included

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Schematics 2 of 5

NOTE: Only the most important schematics are included

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Schematics 3 of 5

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Schematics 4 of 5

NOTE: Only the most important schematics are included

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Schematics 5 of 5

NOTE: Only the most important schematics are included

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Analytical module interface

Lay out

Analytical Date PCB revision Changes

module
Revision
Temperature readings become instable, after connecting a “metal”
06 15 May 2003 4.00 sample loop (ground loop). R2 has been removed

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Schematics

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TCD controller
TCD Date PCB Changes
controller revision
Revision
05 1 November 2001 4.00 PCB layout changed, due to less noise TCD during heater on

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Lay out

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Pressure sensor assembly

Lay out

Schematics

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Power supply

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Fieldcase charger/switcher Revision 32

Blockdiagram

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Lay out Revision 32

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Schematics 1 of 4 Revision 2

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Schematics 2 of 4 Revision 2

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Schematics 3 of 4 Revision 2

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Schematics 4 of 4 Revision 2

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Fieldcase Switcher Revision 3

Blockdiagram

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Schematics 1 of 2 Revision 3

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Schematics 2 of 2 Revision 3

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Fieldcase cable assembly Power-1

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Field case cable assembly Power-2

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Field case cable assembly Battery 1

Field case cable assembly Battery 2

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Tubing overview

Backflush

CP420553
TUBING, POLY, 1/16"X1/8" YELLOW

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Reference vent 2CH (one carrier gas)

One carrier gas

CP420552
TUBING, POLY, 1/16"X1/8" BLUE

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Reference vent 2CH (two carrier gas)

CP420552
TUBING, POLY, 1/16"X1/8" BLUE

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Reference vent 4CH two carrier gas

CP420552
TUBING, POLY, 1/16"X1/8" BLUE

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Sample vent

2815892301
TUBING, POLYURETH, 1/16"x1/8"x25', CLEAR

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Column vent

CP420551
TUBING, POLY, 1/16"X1/8" RED

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Two pump separate sample-in

2815892301
TUBING, POLYURETH, 1/16"x1/8"x25', CLEAR

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Sensitivity Range settings

Auto range

If the analog signal from the TCD is for instance 10mV, the PGA (programmable gain amplifier) will
give a maximum amplification, resulting in a value (V) for the ADC (analog digital converter), through
the MPU this value will be divided by the maximum amplification of the PGA, so the out coming
digital signal to the WorkStation will be the same as the incoming analog signal.

Example: 10mV (TCD signal) x 250 (maximum PGA for that peak) = 2500mV (2.5V) 2500mV/250 =
10mV signal to WS.

When using the low, (PGA range 0.25) medium (PGA range 16) high (PGA range 256) or extra high
(PGA range 1024) it’s using then fixed PGA settings.

Note: The maximum for the PGA is 2.5V!

Example: 10mV (TCD signal) x 1024 (fixed PGA for extra high) =10200mV (Max=2500mV)
2500mV/1024 = 2.5mV signal to WorkStation.

Higher concentration then 2.5V ADC will be cut off to 2.5V; this will give then the topped peaks.

The digital out signal send to the WorkStation, will be converted to areas.
These areas are calculated by 10nVs.
Calculation (peak width ½ heights in seconds) multiplied by (nV peak height in nV).

Height in microVolt
nV

Peak width ½ height

seconds

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Auto range

Extra High

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Conclusion

When using the auto range, the optimum settings are used by the PGA and ADC, this will give the
best results for high and low concentrations of your sample.
The main benefit of this auto range is that low and high concentrations are measured in
ONE run.

When using the fixed setting, low, medium, high and extra high will give the same results as for the
auto range mode, with exception when very high concentration are in the sample this will not be
analyzed correctly and needs a second run to analyze in a different range mode

Solution

Always measure the sample in auto range mode.

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How to assign a IP address on the Micro-GC

1. How to set the IP address in Galaxie workstation using BOOTP

2. How to set the IP address in Galaxie workstation using RS232

3. Galaxie IP address persistent problems

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Galaxie CDS Workstation

How to set the IP address in Galaxie workstation using BOOTP

1) Select the network card of your computer and write down the IP address of the card.
2) IP address network card : 10.2.128.1
3) Subnet mask and Gateway are already set by the customer, you don’t need to change this or write this
down.
4) Open the Galaxie configuration manager and select the BOOTP configuration.

5) Select BootP configuration

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6) Select

7) Press the BOOTP button of the 49X-GC and switch the MicroGC on with this button pressed until the
LED display blinks on Power led and Ready led, this is the BOOTP mode.

8) When the MACK address appears select the address and press the validate button.

9) Fill in the IP address and the host name or description and press apply

10) Create a new system 49X-GC in the configuration.

11) Press the magnetize glass and select the instrument and press OK.

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12) Press

13) Select network settings in order to make the IP address persistent.

14) Press Download Ethernet Parameters

15) Send Ethernet parameters to instrument. YES

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16) Reboot the instrument.

17) After rebooting the instrument and instrument is ready.

18) Reactivate the new IP settings.

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How to set the IP address in Galaxie workstation using RS232

1) Select communication in the configuration and select Serial communication.

2) The message that appears has NO influence on the IP address setting, only on
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DATA Handling.

3) Select network settings in order to make the IP address persistent.

4) Press Download Ethernet Parameters

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5) Send Ethernet parameters to instrument. YES

6) Reboot the instrument.

7) After rebooting the instrument and instrument is ready.

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8) Reactivate the new IP settings.

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Galaxie IP address persistent problems

Galaxie workstation

Making the network setting persistent you need to click “download ethernet parameters”

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Overview released Service Bulletins

Service bulletin Date Title

number

DS-S-2009-25 November 9,2009 New Varian Micro-GC Driver for Galaxie Released

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Overview PIB of Service interests

PIB number Date Title

GC-P-2009-06 November 4, 2009 Introduction of Varian's New 490-GC Series Micro-GC

GC-F-2009-11 November 10,2009 490-GC Configurator

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