Varian Analytical Instruments

2700 Mitchell Drive

Walnut Creek, CA 94598 USA

CP-3800 GC
Pre-Installation Instructions

The information provided here will help you identify and prepare a suitable installation site for
your CP-3800 GC.

The Varian CP-3800 GC has been designed to operate reliably under carefully controlled
environmental conditions. It is your responsibility to provide a suitable location, power source,
and operating environment. Operating or maintaining a system in operational conditions outside
of the power and operating environment limits described below could cause failures of many
types. The repair of such failures is specifically excluded from the Warranty and Service
contract conditions.

All phases of the installation site preparation must conform to local

safety, electrical, and building codes. These codes take precedence over
CAUTION any recommendations in these instructions, and compliance to them is
the responsibility of the customer.

Contents
Space and Weight Requirements............................................................ 2
Power Requirements ............................................................................... 2
Operating Environment............................................................................ 4
Temperature/Humidity ...................................................................... 4
Particulate Matter.............................................................................. 4
Vibration............................................................................................ 4
Exhaust System................................................................................ 4
Gas Requirements................................................................................... 5
Fuel and Carrier Gases .................................................................... 5
Proper Handling of Gas Cylinders .................................................... 6
Regulator Installation ........................................................................ 6
Gas Connections .............................................................................. 6
Gas Lines.......................................................................................... 7
Gas Filters ........................................................................................ 8
Network Requirements ............................................................................ 9
Inspection ................................................................................................ 9
Unpacking and Installation .................................................................... 10
Spare Parts............................................................................................ 10
Preventive Maintenance ........................................................................ 10

03-914675-00:5 SPEC 03-914411-00 / 1:2:3:4:7 1 of 10

Space and Weight Requirements
Before arranging for delivery of the CP-3800 GC to your facility, please make sure that all
passages to the site of installation are least 91.5 cm (36 in.) wide. Allow additional room for
maneuvering the shipping container around corners and/or through doors.

Table 1 identifies the space and weight requirements of the CP-3800 GC components. The GC
is intended to sit on a workbench that is wide enough and deep enough to accommodate these
components, and sturdy enough to support their combined weight. Allow at least two inches of
space at the sides and rear of the GC to permit free air circulation. For optimum column oven
cooldown performance, six inches is required at the rear of the instrument.

Power cord, gas inlets, and the power switch are located at the rear of the Instrument. Signal
output connectors for peripheral instrumentation are located under the top cover of the GC.

Table 1 Physical Dimensions of the CP-3800 GC System Components

Height Width Depth Weight

Instrument in. cm in. cm in. cm lb. kg
CP-3800 GC 20 51 26 66 22 56 95 43
CP-8400 AutoSampler / CP-8410 AutoInjector 16 41 9 23 18 46 20 9
CP-8200 AutoSampler 20 51 6 16 16 41 24 11
Tekmar 3000 Purge and Trap 19 48 9 23 18 46 37 17
Archon Purge and Trap AutoSampler 17 43 22 55 21 53 80 36
Tekmar ALS-2016 27 69 15 38 15 38 35 16
Genesis Headspace AutoSampler 22 56 28 71 18 46 110 50
Star Chromatography Workstation 17 43 17 43 21 53 35 16
(computer with monitor, approximate values)

Power Requirements
A separate circuit is required for each CP-3800 GC. The mating socket must have adequate
amperage capacity and a reliable ground.

Note: 120V and 101V GCs are designed for single phase operation only.

A measured GROUND to NEUTRAL potential of greater than 3 volts ac or dc indicates

grounding problems that may need correction before connecting an instrument to the power
source. Any power source suspected of having noise problems should be evaluated with a
recording type power line monitor prior to being used for operating instruments.

Each CP-3800 GC requires a clean 50 or 60 Hz power source capable of providing up to:

101 Vac ± 10%, 50 or 60 Hz ± 2%, 25 Amps, 2.5 Kilowatts
120 Vac ± 10%, 60 Hz ± 2%, 20 Amps, 2.4 Kilowatts
230 Vac ± 15%, 50 Hz ± 2%, 10 Amps, 2.3 Kilowatts

Installation Category: II (per Standard IEC664)

2 of 10 CP-3800 GC Pre-installation Instructions

 In 230V, 50 Hz countries, the CP-3800 GC is supplied with a standard molded power cord with
an IEC6 C15/C16 “Class I Hot” connector. This connector plugs into the receptacle on the rear
of the GC as shown in Figure 1. This power cord can be replaced to suit local power
requirements.
Receptacle located on rear of GC.
10 Amp, 230 Vac Nominal, 50 Hz
Line 2 Line 1
(blue) (brown)

Ground (green/yellow)
Line 2
(blue)
Line 1 (brown)

Ground
(green/yellow)

Figure 1 Power Cord Wiring (230 Vac)

Power cords for North America and other 120V, 60 Hz applications are terminated in a 3-prong
plug that requires a matching 120 Vac receptacle as shown in Figure 2. Power cords for 101V,
60 Hz countries require the receptacle shown in Figure 3. Replacement or substitution of the
power plug requires strict compliance with power cord color coding as shown in Figures 2 and 3.

CAUTION
NOTE: Potential between neutral and This instrument is designed for
ground should not exceed 3 volts. single phase operation ONLY.

Neutral Line
Ground (green/yellow or green)
Neutral
(light blue or white)
Hot (brown or black)
Ground
20 Amp, 120 Vac Nominal, 60 Hz

Figure 2 Power Cord Wiring (120 Vac)

CAUTION
NOTE: Potential between neutral and This instrument is designed for
ground should not exceed 3 volts. single phase operation ONLY.

Neutral Line
Ground (green/yellow or green)
Neutral
(light blue or white)
Hot (brown or black)

Ground
25 Amp, 101 Vac Nominal, 60 Hz

Figure 3 Power Cord Wiring (101 Vac)

Operation of a CP-3800 GC near the low limit of the permissible line voltage will increase the
time required for thermal zones to reach their final setpoint temperature, and may adversely
reduce the maximum usable ramp rate for programmable thermal zones.

03-914675-00:5 3 of 10
 Care must be taken to ensure that sources of radio frequency interference (RFI) and
electromagnetic interference (EMI) are not placed on the same power line, or share the same
ground plane, since this can degrade the performance of the GC. Equipment such as motors,
solenoids, fluorescent light fixtures, and radio communication transmitters should be isolated
from the instrument and connecting cables as much as possible.

Operating Environment
You are responsible for providing an acceptable operating environment. Attention paid to the
operating environment will ensure the continued peak performance of your CP-3800 GC.

The CP-3800 GC is intended for indoor use and certified for operation up to an altitude of
2000m. Your GC should be protected from corrosive chemicals or gases and from direct
venting of air conditioners, heaters, furnaces or fans.

Calculate heat dissipation using the following formula:

Watts x 3.4129 = BTU/hr

Actual dissipation will depend on method parameters and instrument configuration.

Pollution Degree: 2 (per Standard IEC664)

Temperature/Humidity
The acceptable temperature of the operating environment is between 10° to 40 °C (50° and
104 °F). The acceptable storage temperature is between -20° to 65 °C (-4° and 149 °F).

Hot air vented from the GC column oven may contribute to room heating and to the resulting air
conditioning load. Ducting the GC column oven air out of the lab should reduce this heating
effect.

The relative humidity (RH) of the operating environment must be between 40 and 80%, with no
condensation. Operating the GC at very low humidity will result in the accumulation and
discharge of static electricity which shortens the life of electronic components. Operating the
system at high humidity will produce condensation and result in short circuits.

Varian recommends that your laboratory be equipped with a temperature/humidity monitor.

This will ensure that your laboratory is always in conformance with temperature and humidity
specifications.

Particulate Matter
Take necessary precautions to minimize particulates in the laboratory environment. A layer of
dust on the electronic components could act as an insulating blanket, and reduce heat transfer
to the surrounding air.

Vibration
Ensure that lab benches are free from vibrations, e.g., those caused by equipment in adjoining
locations.

Exhaust System
It is your responsibility to provide an adequate exhaust system. Consult local regulations for the
proper method of exhausting the fumes from your system.

4 of 10 CP-3800 GC Pre-installation Instructions

 WARNING: WARNING:
EXPLOSION HAZARD FIRE HAZARD
Do not exceed MAXIMUM inlet pressures listed on the rear panel of the instrument.

Gas Requirements
Fuel and Carrier Gases
Table 2 lists the gases commonly used with GC detectors. Table 3 lists gases that may be
required for other GC purposes. Refer to Table 4 for regulator and gas line fittings.

Table 2 Instrument Gas Requirements

Detector Inlet Pressure Purity CP-Gas Clean Filter Kits Recommended

TCD CP738408 (incl. 1 oxygen and 1 moisture
Carrier Gas to injector: He, H2, N2, Ar 80 psig / 5.5 bar 99.999% filter, 1/8” tube)
(Note: He: 3 ppm H2O; 5 ppm O2)
Makeup Gas: He, H2, N2, Ar 99.999%
Micro-TCD CP738408 (incl. 1 oxygen and 1 moisture
Carrier Gas to injector: He, H2, N2, Ar 80 psig / 5.5 bar 99.999% filter, 1/8” tube)
(Note: He: 3 ppm H2O; 5 ppm O2)
Makeup Gas: None 99.999%
ECD If carrier and makeup same:
Carrier Gas to injector: He, N2 80 psig / 5.5 bar 99.999% CP748408 (incl. 1 oxygen and 1 moisture
(Note: N2: 0.02 ppm H2O; 1 ppm O2) filter, 1/8” tube)
Makeup Gas: N2, Ar/CH4 99.999% If carrier and makeup different:
2 each CP748408 (incl. 2 oxygen and 2
moisture filters, 1/8” tube)
Note: for Ar/CH4 flush overnight at
100 mL/min
FID If carrier and makeup same:
Carrier Gas to injector: He, N2, H2 80 psig / 5.5 bar 99.999% CP736530 (incl. 1 oxygen, 1 moisture,
Detector Gas: H2 40 psig / 2.8 bar 99.999% and 2 charcoal filters, 1/8” tube)

Air 60 psig / 4.1 bar 0 grade If carrier and makeup different:

CP736530 (incl. 1 oxygen, 1 moisture,
Makeup Gas: He, N2 99.999% and 2 charcoal filters, 1/8” tube)
CP7988 (filter base)
CP17972 (charcoal filter)
TSD If carrier and makeup same:
Carrier Gas to injector: He, N2 80 psig / 5.5 bar 99.999% CP736530 (incl. 1 oxygen, 1 moisture,
Detector Gas: H2 40 psig / 2.8 bar 99.999% and 2 charcoal filters, 1/8” tube)

Air 60 psig / 4.1 bar 0 grade If carrier and makeup different:

CP736530 (incl. 1 oxygen, 1 moisture,
Makeup Gas: N2, He 99.999% and 2 charcoal filters, 1/8” tube)
CP7988 (filter base)
CP17972 (charcoal filter)
PFPD CP736530 (incl. 1 oxygen, 1 moisture, and 2
Carrier Gas to injector: He, N2, H2 80 psig / 5.5 bar 99.999% charcoal filters, 1/8” tube)
Detector Gas: H2 40 psig / 2.8 bar 99.999%
Air 60 psig / 4.1 bar 0 grade
Makeup Gas: N/A
Important Note: Obtain gases for chromatographic use from a supplier who is aware of your requirements. An analysis of
selected impurities is used to determine the purity rating for a given gas. If your supplier does not establish purity based on
an analysis of appropriate chromatographic contaminants, a purity rating of 99.999% may not be suitable for GC use. A
quality supplier of gas and the regular use of filters will minimize system contamination problems.

03-914675-00:5 5 of 10
 Table 3 Operating Gases

Purpose Recommended Gas Inlet Pressure

8200 AutoSampler Air or N2 40 - 60 psig
2.8 - 4.1 bar
Valve Actuators Air 60 psig
4.1 bar
Subambient (LCO2*) LCO2* 850-1000 psig
58.5 – 68.8 bar
Subambient LN2 LN2 20-50 psig
1.4 – 3.4 bar
*Requires an eductor tube in the tank.

Proper Handling of Gas Cylinders

Observe safe laboratory practice in the transportation, storage, and usage of gas cylinders
under high pressure.

• Never move a cylinder with a regulator installed. Make sure safety cap is in place over valve
when transporting cylinder.

• Always chain or strap cylinders in the laboratory and in storage.

• Always use cylinder condition labels to show whether tank is FULL, IN USE, or EMPTY.

• Always leave at least 100 psig (6.9 bar) residual gas in a depleted cylinder. Always store in
empty tank storage area with tank valve closed. Empty cylinders should be clearly marked
as such and dated.

• Do not expose cylinders to temperatures above 125 °F (50 °C).

Regulator Installation
Carrier gases, air, and H2 supplied from a cylinder must have a two-stage regulator having a
zero (0) to 100 psig (6.9 bar) low-pressure stage. The inlet pressure for He, N2, Ar/CH4, or other
carrier gases is normally 80 psig (5.5 bar). Air is supplied at 60 psig (4.1 bar), and H2 is usually
supplied at 40 psig (2.8 bar). H2 may be supplied from a cylinder or a hydrogen generator. If H2
is used for the carrier gas, it should be at 80 psig (5.5 bar).

Gas Connections
All instrument gases connect to 1/8-inch Swagelok® fittings on the rear of the instrument. (The
exception is liquid nitrogen, which requires 1/4-inch fittings.) All fittings are labeled for specific
gases with provision for auxiliary and cryogenic coolant supplies.

Table 4 lists the part numbers of hardware that may be required to connect gases to the
instrument.

6 of 10 CP-3800 GC Pre-installation Instructions

 Table 4 Gas Line Fittings

Description Part Number

Pressure Regulator 57-000180-00
Specify connector:
CGA 350 Connector (H2 or Ar/CH4) 16-000207-00
CGA 580 Connector (N2 or He) 16-000197-00
CGA 590 Connector (Air) 16-000196-00
LCO2 Connector (for 1079 injector or column oven) 28-207304-00
1/4" to 1/8" pipe bushing 28-202012-00
1/8" pipe to 1/8" tubing union 28-694205-00
1/8" ferrule, front 28-694027-01
1/8" ferrule, back 28-694028-01
1/8" nut 28-694029-00
1/8" tubing (25' coil) 03-918326-00
Teflon tape*, 1 roll (1/2" x 520") 88-189610-00

*For use on pipe fittings ONLY. Never use Teflon tape on Swagelok® fittings.

A 1/8-inch line with brass fittings (such as Copper Carrier Gas Kit, P/N 02-000034-00) is
required to connect the carrier gas supply cylinder to the instrument bulkhead fitting. However,
additional tubing may be required to connect the GC to the required gas supplies.

Gas Lines
Table 5 Stainless Steel and Copper Tubing

OD, in. ID, in. Length, ft (m) Part Number

Stainless Steel 1/16 0.046 10 (3) 37-000241-02
1/16 0.046 50 (15) 37-000241-01
1/8 0.093 50 (15) 37-000119-01
Copper 1/8 0.065 25 (7.6) 03-918326-00
1/4 0.190 50 (15) 37-000146-00*
Note: Fully annealed and specially heat-cleaned copper tubing is recommended for ease of
plumbing. This tubing will usually appear discolored due to the heat-cleaning process.
*Not heat cleaned

DO NOT USE UNCLEANED TUBING. Use of plastic tubing or improperly

cleaned tubing or impure gases may result in severe contamination of the GC
CAUTION
pneumatics and may void the warranty.

03-914675-00:5 7 of 10
 Use these plastic closures to keep metal tubing interiors clean during storage.

Table 6 Tubing Closures

Tubing OD, in. Part Number

1/16 28-996023-00
1/8 28-995806-00
1/4 28-995808-00

Gas Filters
Carrier gas filters should be installed to further clean high purity gases, reduce detector noise,
and protect the chromatography system from potential contamination. Carrier gas filters should
be installed where the indicator is visible. The following filters are recommended for GC
systems (see Table 2 for filter kit part numbers):

Table 7 Gas Filters / Filter Bases

Filter Description Part Number

Moisture Gas Filter „ Removes water vapor from carrier gas CP17971
„ Installed between gas tank and GC inlet
„ Molecular sieve
„ Filter should be changed when indicator shows filter is
spent
Oxygen Gas Filter „ Removes oxygen from carrier gas CP17970
„ Installed between moisture filter and GC inlet
„ Recommended with capillary columns
„ Required for ECD
„ Filter should be changed when indicator shows filter is
spent
Charcoal Gas Filter „ Removes organic contaminants from detector gas CP17972
„ Installed between gas tank and GC inlet
„ Activated charcoal
„ Filter should be changed at the same time as other
filters
Filter base for 1 filter „ Snap-on cartridge design CP7988
(1/8” tubing) „ No flushing of gas lines required
Filter base for 2 „ Snap-on cartridge design CP738407
filters (1/8” tubing) „ No flushing of gas lines required
Filter base for 4 „ Snap-on cartridge design CP736520
filters (1/8” tubing) „ No flushing of gas lines required

IMPORTANT NOTE: Filters are used to remove small amounts of contaminants from high purity gases.
They are not capable of removing all of the contaminants from low purity gases. The purity specifications
listed in Table 2 are minimum acceptable values.

8 of 10 CP-3800 GC Pre-installation Instructions

Network Requirements
If you are planning to connect your CP-3800 GC to a company network, you will need to provide
a 10Base2 connection to the back panel of the CP-3800 GC. In addition, the company network
must allow TCP/IP communications to be routed across it from the CP-3800 GC to the Star
Workstation. For basic 10Base2 Ethernet cabling information, please refer to the
“Communications” section of the CP-3800 GC Operator's Manual. Any hardware, adapters,
cables, and configuration and setup work required to convert from the company network wiring
type to 10Base2 wiring will need to be provided by you or your network administrator. This
hardware must comply with the IEEE 802.3 standard.

Inspection
When your CP-3800 GC arrives, carefully inspect the exterior of the shipping cartons for
evidence of any damage that might have occurred during shipment. Inspect the cartons for the
following:
• Water stains
• Cuts, punctures, or deep indentations
• Crushed corners or excessively abraded edges

If one or more of the above conditions are evident on any of the shipping cartons, report the
conditions to the carrier at time of receipt.

Systems are shipped either FOB Varian or FOB Destination. The manner of shipment
determines who has responsibility for filing a claim against the carrier if the system is damaged
in transit. Most systems are shipped FOB Varian, and in this instance any damages incurred in
shipment are the responsibility of the purchaser and the carrier. Contact Varian Service for
assistance with claims filing and billing for repairs if necessary. If the system is shipped FOB
Destination, contact Varian Order Processing who will file a claim against the carrier. Note,
however, that Varian will not accept liability for damage if you receive obviously damaged
materials but do not make note of the damage on the receiving documents.

If none of the conditions listed above are evident after inspecting the shipping carton, place the
shipping container on the floor near the installation site. Before proceeding, you should make
sure that the site to be used for installation has the required power and meets the space
requirements described in these instructions.

This instrument weighs approximately 95 pounds. Use proper lifting

techniques to avoid possible personal injury or damage to the
WARNING
instrument.

03-914675-00:5 9 of 10
Unpacking and Installation
Locate the Installation Section in the CP-3800 GC Getting Started Manual, P/N 03-914647-00.
This section contains the detailed information needed to install your GC. Should you experience
difficulties during installation, Varian Customer Support personnel will be available to assist you
by telephone. This assistance is provided with the purchase of your GC.

If Varian Customer Service installs your instrument, the representative will demonstrate the
fundamentals of operation and maintenance. To take full advantage of this on-site visit, please
arrange to have your system operator available during the installation. The Customer Service
Representative will run a chromatogram using a test column and sample. Be sure the
conditions are recorded on the chromatogram. Store the chromatogram for future use in
analyzing possible chromatographic problems.

At the time of installation, the customer service representative will demonstrate that your system
meets the performance specifications written into your sales contract. Please do not make
plans to analyze samples with the system until after the installation has been completed and
you have accepted the conditions of delivery.

Spare Parts
The CP-3800 GC Getting Started Manual provides a list of spare parts for routine operation.

Preventive Maintenance
Please note that it is essential that you perform regular preventive maintenance on your GC.
By performing this maintenance, you will increase the life of the system, increase system
uptime, and enjoy optimum system performance. Please refer to the Maintenance section of the
CP-3800 GC Getting Started Manual for details.

10 of 10 CP-3800 GC Pre-installation Instructions