FS95 Furnace Autosampler

Service Manual
9499 400 20131
000620
Issue 2

2001 Unicam Limited, Registration No. 441506,

Thermo Elemental, SOLAAR House, PO Box 207, St Andrews Road, Cambridge CB4 1YF, UK
Telephone +44 (0)1223 347400, Fax +44 (0)1223 347403, http://www.thermoelemental.com

A Thermo Electron business

CONTENTS

FS95 FURNACE AUTOSAMPLER

SERVICE MANUAL
CONTENTS
Page

Section 1 System Description

1.1 System Dimensions

. . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5

Section 2 Cricuit Diagrams

2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2 Detailed Circuit Description . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.1 Motor Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.2 Solenoid Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.3 Opto-sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.3 Modification/Rework Record . . . . . . . . . . . . . . . . . . . . . . 2.2

Section 3 Printed Circuit Board Layout

Section 4 Mechanical Drawings
Section 5 Parts Lists
5.1 FS95 Service Kit Part Numbers (9423 450 20015) . . . . . . . . . . . 5.1
5.1 FS95 User Spares Kit (9423 450 20004) . . . . . . . . . . . . . . . . 5.3

Section 6 Assembly Instructions

6.1 Sub-Assemblies

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

6.2 Autosampler Functional Testing . . . . . . . . . . . . . . . . . . . . 6.11

6.2.1 Bottle Leak Test
6.2.2 System Leak Test

. . . . . . . . . . . . . . . . . . . . . . . . . 6.11
. . . . . . . . . . . . . . . . . . . . . . . . 6.12

6.3 Final Assembly and Packing . . . . . . . . . . . . . . . . . . . . . . 6.12

FS95 Furnace Autosampler, Service Manual, Issue 2 (06/00)

Contents i

SECTION 1

SYSTEM DESCRIPTION

SECTION 1 FS95 SYSTEM DESCRIPTION

1.1

System Dimensions

FS95
Weight:
Bottle capacity:
Sample cup capacity
Reagent cup capacity
Syringe volume
Syringe incremental volume
Gas pressure

7.3 kg approx.
1.0 litre
2.0 ml
60 off
24.5 ml
6 off
100l (Side Port)
0.042l per motor step (0.001"/step)
4.0 1.0 p.s.i.

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1.1

SYSTEM DESCRIPTION

1.2

SECTION 1

Introduction
The FS95 will accommodate up to 60 samples in the large carousel. Carousel
changeover allows up to 120 samples per element run. Six large reagent pots
enable up to six matrix modifiers to be employed. Using the cup reducing ring,
smaller sample cups can be used to reduce modifier consump- tion. The sample
is collected and dispensed via an inert PTFE capillary with rapidly interchangeable
tips. Viscous and Normal modes of injection ensure that samples are handled
appropriately and an enhanced wash program eliminates contamination. The
syringe is visible and easily accessible for routine maintenance. A large 1 litre
capacity wash vessel for long unattended analysis is complemented by an
on-board waste vessel, removing the need for inconvenient waste collection on the
laboratory floor.
All facilities are programmed from the AA Data Station software and sampling
facilities such as matrix modification (wet or dry mixing), standards addition, dilution,
reconcentration and automatic recalibration functions are provided. If a sample
falls outside the calibration range the system automatically and intelligently
calculates the most appropriate dilution factor required to bring the sample back
within range. Autosampler loading guides indicate the optimum carousel layout.

The FS95 is an autosampler designed for use with either the SOLAAR GF95
or GF95Z Graphite Furnace Atomisers.

The furnace autosampler fully automates the sample injection procedure into
the graphite furnace optimising productivity and quality of analytical results.

The furnace autosampler

1.2

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SECTION 1

1.3

SYSTEM DESCRIPTION

Installation

Pre-installation
Install an H.C.L. (H.C.L page)
Install and set-up the graphite furnace system (Setting up the GF95
Furnace System page)
Lift the autosampler by supporting the main body with both hands.
Locate the mounting shafts into the two support holes on the right hand side of
the sample compartment and push fully home.
Connect the Autosampler interface cable to the connector socket on the side
panel of the furnace power supply labelled AUTOSAMPLER and secure the two
screws (Systems components and interconnections page).
Connect the gas supply line from the autosampler to the outlet labelled GAS
SUPPLY adjacent to the interface cable socket on the furnace power supply.

Wash Solution
Prior to any analysis ensure that the Wash Bottle is replenished with wash
solution.
Unscrew the wash bottle from the bottle cap attached to the Autosampler
base, fill with the appropriate wash solution and replace the bottle on the
Autosampler.
Ensure that the inert gas pressure is set to 1.1 bar (15 psi).

Waste Bottle
Under standard operation the waste solution is collected in a Waste Bottle
fitted on the underneath of the Autosampler.
Prior to any analysis ensure that the Waste Bottle has been emptied.

Note: The Wash and Waste Bottles should not be interchanged . Refer
to labels displayed on the bottle to confirm bottle identity.

Floor Standing Drain Assembly

For use of a larger capacity waste collection vessel (stand alone) first
remove the on board waste bottle. Extend the flexible tygon waste tubing
using the spare length supplied with the Autosampler connecting the two
pieces with the connector supplied. Position the free end of the waste tubing
in a suitable waste collection vessel placed on the floor.

Capillary Tip
Install a capillary tip onto the end of the Autosampler arm
Gain access to the end of the Autosampler arm by carefully lifting the arm
in a vertical orientation by hand.

Note: Do not move the arm horizontally by hand since this may damage the arm
motor drive mechanism.

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1.3

SYSTEM DESCRIPTION

1.4

Carousel
Fill the carousel with the sample and reagent solutions specified in the
Autosampler Loading Guide generated for the intended analysis sequence
(Sequence pull down menu - ASLG).
Sample solutions
Use either standard sample cups
(2 ml, polypropylene or PTFE)
or reduced volume sample cups
(<1.5 ml, polypropylene)
Reagent solutions
Use either standard reagent cups
(25 ml, polypropylene)
or for situations with low reagent availability use a
standard sample cup fitted into a reagent cup position
using a cup reducing ring. The cup reducing ring can be
also used to cover a standard reagent cup to reduce
evaporation losses and risk of contamination.
Fit the cover to the Autosampler carousel over the carousel handle and
insert the whole assembly into the recess in the top face of Autosampler
body. To remove the carousel reverse the operation.

Alignment

1.4

SECTION 1

Switch on the furnace power supply. This operation will initialise the furnace
autosampler ready for operation.Using the software control move the
Autosampler capillary tip into the alignment position immediately above the
graphite furnace ready for the manual alignment procedure. (Actions pull
down menu - Align capillary)
Once in the active alignment position the capillary tip position can be
adjusted relative to the cuvette hole using the two adjustment screws on the
Autosampler body, refer to the FS95 Furnace Autosampler diagram and the
Capillary Tip Alignment diagram.
Adjustment screw (A) moves the capillary tip in a diagonal path from the
front right hand side to the back left of the furnace assembly.
Adjustment screw (B) moves the capillary tip in a diagonal path from the
front left hand side to the back right hand side of the furnace assembly.
Make adjustments to the position of the capillary relative to the cuvette
hole until the capillary tip passes cleanly through the cuvette hole. Unless
supported the arm mechanism will allow the capillary to drop to its currently
selected injection depth.
Take a dental mirror supplied with the furnace atomiser and hold it against
the right hand window of the sample compartment. Alternatively view the
inside of the cuvette using the GFTV accessory if available.
Adjust the height of the capillary tip relative to the floor of cuvette, platform
or probe using Adjustment screw (C).
Clockwise Adjustment
Reduces Injection Depth
Anti-clockwise Adjustment
Increases Injection Depth
The optimum depth of the capillary is dependent on the sample volume and
type; it will require final checking and adjustment when the instrument is
operating and a sample is dispensed and viewed in the dental mirror or on
GFTV (Refer to the Optimum Capillary Depth Setting Diagram). Tighten the
lock nut once the optimum depth has been set.
Following any manual capillary alignment procedure return the Autosampler
capillary to the non active wash position (Actions pull down menu - Park
Autosampler).

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SECTION 1

SYSTEM DESCRIPTION

Autosampler capillary tip alignment

Optimisation of capillary tip depth setting

1.5

Operation

Before starting any analysis the syringe requires priming with wash solution.
To prime the syringe perform a Purge Autosampler action - Actions pull down
menu. Following this priming sequence if air bubbles are visible in the syringe
it is necessary to carry out a syringe purge operation.
Return the Autosampler Capillary to the non active wash position (Actions
pull down menu - Park Autosampler).
Access the Autosampler syringe by removing the syringe housing door flap.
Carefully pull on the syringe handling strap to remove the syringe from its
mount.

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1.5

SYSTEM DESCRIPTION

SECTION 1

Autosampler capillary tip assembly

Autosampler syringe assembly

1.6

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SECTION 1

SYSTEM DESCRIPTION

Withdraw the plunger of the syringe.

Hold the syringe above a waste receptacle and from the software perform a
Purge Autosampler action - Actions pull down menu. Wash solution will flow
through the syringe body to waste.
Whilst wash solution flows out of the syringe body replace the plunger into
the syringe.
Return the syringe back into its mount.

Perform a Purge Autosampler action - Actions pull down menu. Check for
absence of bubbles.

The syringe is self priming therefore on each subsequent wash action the
syringe will be automatically primed with wash solution.

Refer to the ON-Line Help section of the SOLAAR data station software for
all further operating instructions.

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1.7

SYSTEM DESCRIPTION

SECTION 1

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1.8

FS95 Furnace Autosampler, Service Manual, Issue 2 (06/00)

SECTION 2

CIRCUIT DIAGRAMS

SECTION 2 CIRCUIT DIAGRAMS

FS95 Furnace Autosampler PCB Assy. N4155

2.1

Overview
The FS95 furnace autosampler is powered and controlled from the GF95 furnace
PSU. The autosampler is connected to the furnace control PCB via a 25 way
screened cable. The cable is plugged directly into the autosampler PCB and is
attached to the autosampler casting by a cable gland (i.e. it is a "flying lead").
This PCB contains the autosampler motor drive circuits, wash solenoid drive and
interconnections for the autosampler sensors. The "arm vertical index sensor" is
fitted to the PCB, the other sensors are routed via this PCB to the GF95 furnace
PSU control PCB.

2.2

Detailed Circuit Description

2.2.1

Motor Drives

There are four stepper motors in the autosampler:

Arm horizontal motor (M1)
Arm vertical motor (M2)
Tray motor (M3)
Syringe motor (M4)
Drive signals for the motors are output from IC19 on the furnace control PCB.
There are two signals provided by the control PCB for each motor (one for each
coil). The four drive lines for the bifilar stepper motors are generated by the octal
inverting buffers IC1 and IC2 on the autosampler PCB (each coil uses a drive
signal, and the inverse of that signal). The outputs of the buffers are fed to octal
transistor arrays IC3 and IC4 which drive the motors. Flyback diodes are included
in the transistor array packages. The arm and tray motors are 12V motors and
are driven directly from the 12VM supply. The syringe motor is a 5V motor and is
driven via the current limiting resistors R1 to R4.
2.2.2

Solenoid Drive

The wash solenoid is controlled from the GF95 furnace control PCB. The "wash
solenoid" signal activates the relay RL1, which connects the solenoid coil across
the 12VM supply. D1 acts as a flyback diode for the solenoid coil back emf.
2.2.3

Opto-sensors

Inter connection is provided for the following opto-sensors:

Arm horizontal
Tray
Syringe

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2.1

CIRCUIT DIAGRAMS

SECTION 2

The sensor outputs are fed back to the GF95 furnace control PCB via the
autosampler cable.
Opto-sensor OS1 (arm vertical) is mounted on the underside of the autosampler
PCB.

2.3.

2.2

Modification/Rework Record

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SECTION 2

FS95 Furnace Autosampler, Service Manual, Issue 2 (06/00)

CIRCUIT DIAGRAMS

2.3

CIRCUIT DIAGRAMS

2.4

SECTION 2

FS95 Furnace Autosampler, Service Manual, Issue 2 (06/00)

SECTION 3

PRINTED CIRCUIT BOARD LAYOUT

SECTION 3 PRINTED CIRCUIT BOARD LAYOUT

FS95 Furnace Autosampler, Service Manual, Issue 2 (06/00)

3.1

PRINTED CIRCUIT BOARD LAYOUT

SECTION 3

THIS PAGE HAS BEEN LEFT INTENTIONALLY BLANK

3.2

FS95 Furnace Autosampler, Service Manual, Issue 2 (06/00)

SECTION 4

MECHANICAL DRAWINGS

SECTION 4 MECHANICAL DRAWINGS

FS95 Furnace Autosamper, Service manual, Issue 2 (06/00)

4.1

MECHANICAL DRAWINGS

4.2

SECTION 4

FS95 Furnace Autosamper, Service manual, Issue 2 (06/00)

SECTION 5

PARTS LISTS

SECTION 5 PARTS LISTS

5.1

FS95 Service Kit Part Numbers (9423 450 20015)

ITEM

PART NUMBER

DESCRIPTION

942339381221

CONE REPAIR KIT

10

401316686641

CAROUSEL COVER - FEET

21

401317277831

ARM ROTATION MOTOR/EXTENSION

22

401317284532

ARM HEIGHT MTR CABLEFORM

23

401317284562

ARM ROTATION SENSOR CABLEFORM

31

252263404005

RETAIN RING ST BLK SIZE 2,3

41

401316687153

ARM COVER

44

401316687342

TRUNNION NUT

45

401317277841

HUB WITH BUSHES

46

401316687423

OPTO SWITCH ADJUSTER BLOCK

47

401316687522

SAMPLE ARM SKIRT

48

401316687532

CAPILLARY DEPTH STOP SCREW

49

401317284631

ARM END STOP LEVER ASSY

50

401317284652

RISE AND FALL LEVER ASSY

51

401317284662

ARM ADJUSTER SCREW ASSY

52

401317284683

TRANSFER ARM ASSY

55

401316687692

TORSION SPRING

56

401322845071

SPRING EXTENSION 7 OD X 16,1

57

401322845171

SPRING EXTENSION 6.1 OD X 19.05 ST STL

58

401322845321

SCREW GRUB M4 X 8 SPECIAL

62

401316686581

KNURLED THUMB NUT

71

401316687481

FRAME BOBBIN

72

401316687491

FRAME SLEEVE

73

401317284592

PROBE MTR & SENSOR CABLEFORM

85

401322841701

1 CIRCLIP

86

401322845061

PIN GROOVED - SPRING ANCHR. 3 X 25

93

401322845051

FOOT ROUND INSERT 0.75 IN OD LDPE

100

401317284701

HOUSING ADJUSTER SCREW ASSY

101

420117941552

PCB ASSEMBLY

103

420117203301

CABLEFORM - AUTOSAMPLER INTERFACE

105

401322845131

SPRING EXTENSION 11 OD X 24.5 FL

FS95 Furnace Autosampler, Service Manual, Issue 2 (06/00)

5.1

PARTS LISTS

5.2

SECTION 5

ITEM

PART NUMBER

DESCRIPTION

106

401317277851

SYRINGE ACCESS COVER ASSY

111

401317284552

SYRINGE MTR CABLEFORM

112

401317284582

SYRINGE SENSOR CABLEFORM

118

401316687612

MOVING BLOCK PIN

122

401316687141

SYRINGE RETENSION SPRING

124

401316687223

SYRINGE HOUSING

125

401316687612

SYRINGE MOVING BLOCK

126

401316687273

SYRINGE APERTURE CLAMP

127

401322845021

SYRINGE (SIDE PORTED)

128

251366613203

DOWEL PIN

129

242201516206

TWIST LOK 350

131

401317284523

ARM/TURNTABLE ROTATE MTR CABLEFORM

132

401317284572

TURNTABLE SENSOR CABLEFORM

149

401316687194

CAROUSEL COVER

150

942339383261

AUTOSAMPLER CAROUSEL AND TRAY

151

401317284675

CAROUSEL DRIVE TABLE

161

401316687243

BOTTLE MOUNTING BLOCK - WASH

162

401316687252

BOTTLE MOUNTING BLOCK - WASTE

163

401317284513

SOLENOID CABLEFORM

164

401317290831

BOTTLE SET FS95 (SPARES)

166

401316687623

TUBE - WASH TO SOLENOID

167

401316687632

TUBE - SOLENOID TO SYRINGE

168

401322836641

PTFE SAMPLING NEEDLE

181

081303198006

VINYL TUB 1/4 1/DX3/8 0/D TRL

182

081310595055

PTFE TUB 2,5MM0/DX0,5MM W/T

183

081310898073

TYGON TUB 1/8IDX3/160D

217

401316687353

WASH FUNNEL

218

401316687511

CAPILLARY COLLET

246

401322845031

SEAL O RING 0496-24 VITON

248

401322845141

SEAL CONE INVERTED PTFE (1.01 TUBE)

249

292200714088

COUPLING SKT 5X1

250

292201498031

CON PA 1/8 UNF

251

401316694811

DRAIN TUBE

253

131350059701

SILICONE GREASE H240/16

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SECTION 5

5.2

PARTS LISTS

FS95 User Spares Kit (9423 450 20004)

ITEM

PART NUMBER

DESCRIPTION

4013 228 36641

PTFE SAMPLING NEEDLE

4013 228 45021

SYRINGE (SIDE PORTED)

4013 228 45141

SEAL CONE INVERTED PTFE (1.01 TUBE)

4013 166 87651

FS90+ CAPILLARY TIP (BOX OF TEN)

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5.3

PARTS LISTS

SECTION 5

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5.4

FS95 Furnace Autosampler, Service Manual, Issue 2 (06/00)

SECTION 6

ASSEMBLY INSTRUCTIONS

SECTION 6 ASSEMBLY INSTRUCTIONS

6.1

Sub-Assemblies
Clean the Motor Shaft Extension (4013 166 87203) and the shaft of the Arm
Rotation Motor #3 (4013 172 84523) with Acetone (1313 500 00101) and
roughen the surface of the motor shaft with a file in a circular motion around the
shaft, such that the marks form rings around the shaft rather than lines along it.
Apply Loctite 638 adhesive (4013 228 47161). Fit the Arm Rotation Motor to the
Assembly Jig (???) and push the Motor Shaft Extension onto the motor shaft,
aligning the cross hole in the motor shaft extension with the hole in the jig, using
the pin attached to the jig. It is essential to use this jig as it controls the
height of the motor shaft extension with respect to the motor.
Place the Autosampler Housing upside down on the support Jig .

Knock the Pin Grooved Spring Anchor 3 x 25 (4013 228 45061) into the hole
shown.

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6.1

ASSEMBLY INSTRUCTIONS

SECTION 6

Using the Bench Press Jig (???) press one Large DU Bearing (4013 228
45041) into each side of the Autosampler Housing where shown.

Fit the Turntable Rotation Motor #5 (4013 172 84523) to the Autosampler
Housing using two M3 x 8 Taptite Screws (2511 001 05021) where shown.

Fit the Turntable Sensor #8 (4013 172 84572) using two M3 x 8 Taptite Screws
(2511 001 05021) where shown.

6.2

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SECTION 6

ASSEMBLY INSTRUCTIONS

Cut a 300mm length of the Vynil Tubing 1/4 1/D X 3/8 0/D (0813 031 98006). Fit
the Wash Funnel (4013 166 87353) into the recess in the top of the Autosampler
Housing, the point on the bottom of the funnel should protrude through to the
underside of the casting. Push the vynil tubing onto the wash funnel where it
protrudes, this is all that retains the wash funnel so ensure the tubing is pushed
fully on.
Fit the Lid of the Bottle Modified - Waste (4013 166 872262) onto the Bottle
Mounting Block Waste (4013 166 87252), ensuring that the lid is pushed over
the raised area as this will retain the lid on the mounting block.
Push the free end of the waste tube (the other end is attached to the funnel)
through the large hole in the mounting block such that it protrudes by
approximtaley 2".
Fit the mounting block onto the Autosampler Housing using one M4 x 12 Screw
(2522 177 29083) screwed through the Housing into the mounting block.

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6.3

ASSEMBLY INSTRUCTIONS

SECTION 6

Fit the Lid of the Bottle Modified - Wash (4013 166 87601) onto the Bottle
Mounting Block Wash (4013 166 87243), ensuring that the lid is pushed over
the raised area as this will retain the lid on the mounting block.
Fit the Seal ORing 0496-24 VITON (4013 228 45031) onto the Bottle Mounting
Block Wash.
Screw the Con Pa 1/8 UNF (2922 014 98031) into the top of the Bottle Mounting
Block Wash and gently tighten with a spanner.

Fit the Tube Wash to Solenoid (4013 166 87623) (Yellow/Brown ends) to the
Bottle Mounting Block Wash. Ensure that the tube is sufficiently straight to
reach the bottom of the bottle when it is fitted (straighten the tube if necessary)
and also that the tube is fully secured in the block. Tighten carefully using a
spanner.
Connect the brown connector of the Tube Solenoid to Syringe (4013 166
876312) (brown/black) to the Solenoid (4013 172 84513) and carefully tighten
using a spanner.
Fit the Solenoid to the Autosampler Housing, ensuring the arrow on the solenoid
is aligned with the arrow on the casting. Retain with 2 Pan Screw 4-40X1/4 (2522
086 04025), screwed through the housing into the solenoid.
Fit the Mounting Block Wash to the underside of the Autosampler Housing
using a Pan Screw Stl St M4 x 12 (2522 177 29083), screwed through the
Housing into the Mounting Block.
Fit the free end of the Tube Wash to Solenoid to the IN port of the solenoid.
The solenoid IN port is identified by an arrow on the solenoid showing the flow
direction.
Fit the Syringe Sensor #9 (4013 172 84582) onto the Syringe Housing (4013
166 87223) using 2 M3 x 8 Taptite Screws (2511 001 05021).
Carefully knock the Dowel Pin ST 3X8 (2513 666 13203) into the hole in the end
of the Syringe Housing where shown.

6.4

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SECTION 6

ASSEMBLY INSTRUCTIONS

Carefully knock the Moving Block Pin (4013 166 87612) into the Syringe
Moving Block (4013 166 87231) using a small hammer and the Jig (???).
Screw the Syringe Moving Block fully onto the leadscrew of the Syringe Motor
#6 (4013 172 84552).
Note: It is important that the shaft of the motor is fully extended as shown in the
diagram; if it is not turn the shaft in the appropriate direction until it is.
Pass the Syringe Motor Bracket (4013 166 87212) over the leadscrew of the
motor. Fit the Syringe Motor and Moving Block into the Syringe Housing, aligning
the Moving Block Pin with the slot in the Housing.
Ensure the Motor is correctly aligned and that the wire exit is positioned as
shown. Then clamp the bracket against the Syringe Housing using 2 off M3 x 8
Taptite Screws (2511 001 05021).

Fit the Syringe Housing to the Autosampler Housing with 3 off Screw Taptite M4
x 8 (4013 228 45121).
Fit the Syringe Retension Spring (4013 166 87141) over the locating pin and
secure with 1 Screw Taptite M4 x 8 (4013 228 45121) as shown.

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6.5

ASSEMBLY INSTRUCTIONS

SECTION 6

Cut an angle on one end of a 450mm length of PTFE Tubing 2,5mm0/DX0,5mm

(0813 105 95055) and pass it through the Syringe Housing from the sensor side,
then trim it flush with the front face using a knife.
Pass the other end of the End Stop Adjuster slot in the casting and position the
conduit as shown in the diagram.

Fit the tube from the Solenoid to the side port of the Syringe (4013 228 45021).
Dampen the needle of the Syringe (this is the plunger that goes inside the glass
body of the syringe) by dipping it in de-ionised water.
Fit a Twist-Lok Clip (2422 015 16206) to the Syringe, ensuring it is positioned
near the middle of the Syringe.
Fit the Syringe into the Syringe Housing.
Pass the Arm Adjuster Screw (4013 172 84662) through the Autosampler
Housing from the top and retain it with a Retaining Ring (2522 634 04005).
Screw the Trunnion Nut (4013 166 87342) onto the Arm Adjuster Screw.
Fit a second Retaining Ring (2522 634 04005) at the top of the Arm Adjuster
Screw.
Locate the Trunnion Nut into the fingers of the Arm End Stop Lever (4013 166
84631) and place the other end in the seat on the casting.

6.6

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SECTION 6

ASSEMBLY INSTRUCTIONS

Hook one end of Spring Extension 7 OD x 16,1(4013 228 45071) through the
hole in the Arm End Stop Lever and attach the other end to the Pin Spr Dowel St
2x16 (2513 658 18104).
With the spring still attached, position the Pin in the retaining slot in the
Autosampler Housing as shown.
This is retained by the Arm Rotation Motor #3 (4013 172 84562) which sits over
the pin retaining slot. Retain the Motor using 2 M3 x 8 Taptite Screws (2511 001
05021). Ensure the motor is positioned such that the wires exit as shown in the
diagram.

Fit the Arm Height Motor #4 (4013 1172 84532) using 2 M3 x 8 Taptite Screws
(2511 001 05021), ensuring the cable exits towards the center of the Autosampler
Housing and the spindle is pushed fully down.
Push 2 Medium DU Bushes (4013 228 41651) into the Transfer Arm Hub
(4013 166 87373) using the Bench Press Jig (8113 102 14941).
Push 2 Small DU Bushes (4013 228 45081) into the Transfer Arm Hub using the
Bench Press Jig (8113 102 14931).

Place the Torsion Spring (4013 166 87692) over the Arm Rotation Motor.
Fit the Sample Transfer Arm to the Arm Rotation Motor, positioning it correctly
with respect to the sensor and the spring.

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ASSEMBLY INSTRUCTIONS

SECTION 6

Align the slot in the Arm Hub with the hole in the Motor Shaft Extension and fit a Pin
Grooved 3 x 16 (4013 228 45101) through the Hub and the Extension Shaft as
shown. Secure the Pin in position using a Grub Screw M3 x 4 (2522 043 02037)
with a small amount of Loctite 241 threadlock (1304 500 42503) applied to its thread.

Attach the Arm Rotation Sensor #7 (4013 172 84562) to the Opto-Switch
Adjuster Block (4013 166 87423) using 2 M3 x 8 Taptite Screws (2511 001
05021).
Pass the connector end of the Arm Rotation Sensor cableform through the Arm
End Stop aperture in the Autosampler Housing (the one nearest the centre).
Fit the Opto-Switch Adjuster Block to the Autosampler Housing with 1 M3 x 8
Taptite Screws (2511 001 05021). This is fitted from the underside of the
Housing and screws into the Block.
Apply High Vacumn Grease () to the Rise And Fall lever where the spindle of the
Arm Height Motor makes contact. Also apply Grease to the underside of the Arm
Hub where the pips of the arm make contact when lifting the Arm Hub.
Fit the Furnace A/S PCB (4013 179 41551) using Screw Taptite M4 x 8 (4013
228 45121).

6.8

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SECTION 6

ASSEMBLY INSTRUCTIONS

Plug all the connectors into their sockets on the PCB. Route the wiring as shown.

Change both Jumper settings to 2-3.

Cut 250mm of PTFE Tubing 2,5mm0/DX0,5mm (0813 105 95055). Trim one
end to give an angle. Feed this end into the hole in the Transfer Arm Assy (4013
172 84683) as shown. Continue to push in the tubing until it emerges from the
side hole at the other end of the Arm and then trim it off flush.

Whilst holding the Transfer Arm Assy in position in the Hub push a Dowel Pin Stl
(2513 666 14143) through the Hub and secure the Pin in place by fitting a Grub
Screw M3 x 4 (2522 043 02037) with Loctite 241 threadlock (1304 500 42503)
applied to its threads.
Fit the Carousel drive Table (4013 172 84675) to the Turntable Motor shaft
using a Grub Screw HEX ST BLK M4X6 (2522 043 02048) with Loctite 241
threadlock (1304 500 422503) applied to the threads.
Ensure the carousel is not fitted.
Locate the Alignment Jig (??) on the drive table boss and the wash funnel.
Connect the data lead to the arm alignment jig.
Plug the alignment jig power supply into the mains.
The sample arm should be in its lowest position.
Move the sample arm anti-clockwise to align the centre of the collet with the line
marked on the jig.

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ASSEMBLY INSTRUCTIONS

SECTION 6

It is essential that the arm is unrestrained and biased anti-clockwise by the

torsion spring.
To ensure this, always position the arm over the line by moving it anti-clockwise,
if it goes past the line move the arm right back to the wash position and try again.
Slacken off the opto-sensor locking screw. This is positioned on the underside of
the autosampler.
If the underside cover is fitted this screw can still be reached through the
clearance hole provided in the cover.
Fit the opto-sensor block tommy bar into the rear of the upper opto-sensor screw
hole.
Rotate the opto-sensor block fully clockwise.
Slowly rotate the opto-sensor block anti-clockwise until the red LED on the arm
setting jig lights.
Whilst holding the opto-sensor block in this position fully tighten the locking screw.
Lift the arm from the jig and slowly rotate it clockwise by hand towards the wash
position.
Slowly rotate the arm anti-clockwise back towards the index until the LED on the
arm setting jig lights.
The centre of the sample arm collet should be aligned with the line on the jig.
If the line on the jig is not central to the collet the arm is NOT setup correctly, and
the process will need to be repeated until successful.
Remove the alignment jig.
Pass the Arm Cover (4013 166 87153) over the Transfer Arm Assy.
Pass the Arm Skirt (4013 166 87522) over the Transfer Arm Assy such that it
sits on the Arm Cover.
Find the Conduit tubing where it emerges from the aperture in the Autosampler
Housing and feed it through the hole in the Arm Cover (cutting an angle on the
end of the tubing may help). Leave a comfortable amount of slack in the
Autosampler Housing and then trim it such that it protrudes slightly.
Fit the Arm Cover in position using 2 Stainless Screws M3 x 6 (2522 177 29058).
Screw the Knurled Thumb Nut (4013 166 86581) onto the Depth Stop Screw
(4013 166 87532).
Screw the Depth stop screw into the Transfer Arm Assy.

6.10

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SECTION 6

ASSEMBLY INSTRUCTIONS

Fit the PTFE Sampling Needle (4013 228 36641) to the end port of the Syringe.
Feed the Sampling Needle through the conduit where it is mounted in the Syringe
Housing, through to where it emerges just above the Arm Cover.
Then feed the Sampling Needle back into the conduit in the Transfer Arm. Push it
through until it emerges from the hole in the side of the Arm. Then re-feed the
Sampling Needle into the Arm on the other side of the hole and push it through
until it emerges at the other end of the Transfer arm.
Fit the Seal Cone Inverted (4013 228 45141) onto the Sampling Needle. This is
easier if an angle is first cut on the end of the Sampling Needle. When the Needle
has been pulled through the Cone, trim the Sampling Needle flush with the face
of the Cone using a razor and the Jig (??). Be careful not to damage the face of
the Cone as this is a sealing surface.
Fit the Capillary Collet (4013 166 87512) to the end of the Transfer Arm Assy.
Attach a Coupling Skt 5x1 (2922 007 14088) to a 1.45M length of Tygon
Tubing 1/8IDX3/160D (0813 108 98073).
Attach the free end of the Tygon tubing to the barbed connector in the Bottle
Mounting Block Wash.
Screw the bottles on to their mounts.
Push the Carousel Hub Key (4013 166 87592) into the Carousel Hub (4013
166 87184).
Press the Carousel tray (4013 166 87162) onto the Carousel Hub using the
Fitting Tool (??).
Press Carousel Disc (4013 166 87171) onto the top of the Hub using the Fitting
tool (??), ensuring that the guide for the drive pin in the Carousel Tray is aligned
with the hole for the drive pin in the Carousel.
Place the assembled Carousel on the Drive Table.
Place the Plastic Cover (4013 166 87194) on the Carousel such that it locates
on the Autosampler Housing correctly.

6.2

Autosampler Functional Testing

6.2.1

Bottle Leak Test

Ensure the wash bottle lid is securely tightened.

Note: If required this test can be performed earlier, during the assembly process,
to avoid dismantling in cases of failure.
Set the pressure to 6 psi and open the gas valve to the autosampler.
Allow 15 seconds for the bottle to pressurise and settle.
Close the gas valve and note the pressure reading.
Wait 1 minute and note the pressure reading.
Check the two readings to see that the pressure has not dropped by more than
0.5 psi.
If the pressure drop is less than 0.5 psi then the autosampler has passed the
bottle leak test and the reading should be noted on the result sheet.

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ASSEMBLY INSTRUCTIONS

6.2.2

SECTION 6

System Leak Test

Block the capillary tip to create a gas tight seal.

Set the pressure to 6 psi and open the gas valve to the autosampler.
Allow 15 seconds for the bottle to pressurise and settle.
Close the gas valve and note the pressure reading.
Wait 5 minutes and note the pressure reading.
Check the two readings to see that the pressure has not dropped by more than
0.5 psi.
If the pressure drop is less than 0.5 psi then the autosampler has passed the
system leak test and the reading should be noted on the result sheet.

6.3

Final Assembly and Packing

Remove the Carousel, Bottles and GF95 FS95 I/F Lead (disconnect the other
end of the Lead from the PSU).
Fit a 55mm length of 12" wide Black PVC Tape (1222 100 06131) to the
Underside Cover (4013 166 92922) in the position shown.

Stick two strips of Self-adhesive Magnetic Tape (1213 100 98322) on the
Underside Cover in the positions shown.

Fit the Underside Cover to the Autosampler Housing using 5 Screws Taptite M4
x 8 (4013 228 45121).
Fit the Syringe Window (4013 166 87273) to the Autosampler Housing such that
it clamps the edges of the Underside Cover to the Housing, using 2 Screws
Taptite M4 x 8 (4013 228 45121).
Push the Foot Round Black (4013 228 45051) into the end of the cranked leg
of the Mounting Frame (4013 172 84695).
Screw a Frame Extension (4013 166 87501) onto the Mounting Frame. Then
screw the Frame Sleeve (4013 166 87491) onto the end of the Frame Extension.

6.12

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SECTION 6

ASSEMBLY INSTRUCTIONS

Press the Frame Bobbin (4013 166 87481) onto the Mounting Frame flange.
Fit the Autosampler Housing onto the Mounting Frame.
Pass the Housing Adjuster Screw (4013 172 84701) through the slot in the
Autosampler Housing and screw it into the Mounting Frame.
Fit a Circlip (4013 228 41701) into the groove in the Housing Adjuster Screw.
Attach one end of the Spring Extension 11 OD X 24.5 FL (4013 228 45131)
onto the pin in the Autosampler housing and the other end over the pin in the
Mounting Frame.
Fit an elastic band over the Transfer Arm and around the leg of the Mounting
Frame to ensure that the arm is in the Wash Cup and restrained for transit.
Attach the Waste Label (part of:4013 172 84622) to the Waste Bottle using the
Alignment Fixture (8113 102 14991) and then re-fit the bottle.
Attach the Wash Label (part of:4013 172 84622) to the Wash Bottle using the
Alignment Fixture (8113 102 14991) and then re-fit the bottle.
Attach the FS95 Label (part of:4013 172 84622) to the front of the Autosampler
Housing using the Alignment Fixture (8113 102 14991).

Attach the Pre-Printed Unicam Serial No. Label to the Underside Cover.
Fit the D Shaped Label (part of:4013 172 84622) over the top of the hole in the
Autosampler Housing where it sits on the Mounting Frame. This hides the top of
the Mounting Frame shaft and also helps prevent it corroding.
Carefully undo the FS95 Parts Sent With (4013 172 77821) and add the
Alignment Guide Label (part of:4013 172 84622). Tick the appropriate box on
the ticksheet and reseal the Parts Sent With.
Place the Autosampler into the Pack; it should sit on one moulded insert and a
second moulded insert then goes on top.
Place the Parts Sent With into the recess in the top moulded insert and seal the
top of the cardboard box with tape.
Place a printed box label on the outside of the pack stating the serial number and
part number. Check that the part number corresponds with the part number of the
Autosampler.

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SECTION 6

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6.14

FS95 Furnace Autosampler, Service Manual, Issue 2 (06/00)