Siemens Maxum II Manual

PD Maxum II Maintenance Manual Manual 10/2015 2000596-001 Analyzer Overview 1 System Functions 2 General Maintenance and Troubleshooting 3 Component Descriptions and Maintenance Procedures 4 Specifications 5 Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION indicates that minor personal injury can result if proper precautions are not taken. NOTICE indicates that property damage can result if proper precautions are not taken. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed. Trademarks All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Division Process Industries and Drives Postfach 48 48 90026 NÜRNBERG GERMANY Order number: 2000596-001 Ⓟ 10/2015 Subject to change Copyright © Siemens AG 2007 - 2015. All rights reserved Table of contents 1 2 3 Analyzer Overview........................................................................................................................................7 1.1 Introduction..............................................................................................................................7 1.2 Parts of the Maxum II...............................................................................................................8 1.3 Isothermal Oven.......................................................................................................................9 1.4 Switching and Sampling Valves.............................................................................................10 1.5 Operator Controls...................................................................................................................11 System Functions.......................................................................................................................................13 2.1 Chromatography Overview....................................................................................................13 2.2 Intended Use and Personnel Qualifications...........................................................................14 2.3 Functions................................................................................................................................15 2.4 Analyzer Operation................................................................................................................19 2.5 Data Communication..............................................................................................................23 General Maintenance and Troubleshooting...............................................................................................25 3.1 General Analyzer Shutdown Procedure.................................................................................25 3.2 General Analyzer Startup Procedure.....................................................................................25 3.3 Troubleshooting.....................................................................................................................27 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11 3.4.12 3.4.13 3.4.14 3.4.15 3.4.16 3.4.17 3.4.18 3.4.19 3.4.20 3.4.21 Alarm Codes, Descriptions, and Suggested Actions..............................................................29 Alarms 5.2 301 - 324.............................................................................................................29 Alarms 5.2 330 through 359 SNE Communication................................................................31 Alarms 5.2 360 - 399..............................................................................................................33 Alarms 5.2 400 - 562..............................................................................................................35 Alarms 5.2 671 - 699..............................................................................................................38 Alarms 5.2 700 - 736..............................................................................................................40 Alarms 5.2 801 - 999..............................................................................................................42 Alarms 5.2 1002 - 1096..........................................................................................................43 Alarms 5.2 1617 - 1697 Pecm Errors.....................................................................................49 Alarms 5.2 1917 - 2005 DPM TCD........................................................................................51 Alarms 5.2 2217 - 2306 DPM FID..........................................................................................54 Alarms 5.2 2500 - 2577 Access Bus Driver Errors.................................................................58 Alarms 5.2 2817 - 2904 DPM Temperature...........................................................................63 Alarms 5.2 3117 - 3204 EPC.................................................................................................65 Alarms 5.2 3401 - 3454 TFTP................................................................................................66 Alarms 5.2 3500 - 3528 Advance...........................................................................................67 Alarms 5.2 3718 - 3804 SNE I/O............................................................................................68 Alarms 5.2 4001 - 4124 EZChrom.........................................................................................71 Alarms 5.2 4217 - 4320 CAN Bridge......................................................................................73 Alarms 5.2 4525 - 5220 Advance TC.....................................................................................75 Alarms 5.2 10000 - 11536 MicroSAM....................................................................................77 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 3 Table of contents 4 4 Component Descriptions and Maintenance Procedures............................................................................79 4.1 4.1.1 4.1.1.1 4.1.1.2 4.1.2 4.1.2.1 4.1.2.2 4.1.2.3 4.1.2.4 4.1.3 4.1.3.1 4.1.3.2 4.1.3.3 4.1.3.4 4.1.3.5 4.1.3.6 4.1.3.7 4.1.4 4.1.4.1 4.1.4.2 4.1.4.3 4.1.4.4 4.1.4.5 4.1.5 4.1.5.1 4.1.5.2 4.1.5.3 4.1.5.4 4.1.5.5 4.1.5.6 4.1.5.7 4.1.6 4.1.7 4.1.8 4.1.8.1 4.1.8.2 4.1.9 4.1.9.1 4.1.9.2 4.1.10 4.1.10.1 4.1.10.2 4.1.10.3 Electronic Enclosure Components.........................................................................................79 Power Supplies......................................................................................................................79 Power System Module...........................................................................................................79 Replacement Procedure........................................................................................................81 Power Entry and Control Module...........................................................................................84 PECM Overview.....................................................................................................................84 Feature Additions...................................................................................................................85 PECM Functions....................................................................................................................86 Replacement Procedure........................................................................................................93 System Controller Version 2.1 (SYSCON2.1)........................................................................97 Description.............................................................................................................................97 Mechanical.............................................................................................................................98 SYSCON2.1 Components......................................................................................................99 Maintenance Overview.........................................................................................................112 Service Procedures..............................................................................................................113 Replacing the Lithium Battery on the SYSCON Module Introduction..................................117 Procedure.............................................................................................................................117 Analog and Digital I/O..........................................................................................................118 Overview..............................................................................................................................118 I/O Card Common Features.................................................................................................119 Digital I/O Card.....................................................................................................................122 Analog I/O Board..................................................................................................................123 Analog and Digital I/O Board................................................................................................124 Detector Personality Modules..............................................................................................125 DPM Types..........................................................................................................................125 Base3 Detector Personality Module (DPM).........................................................................125 Replacing a Base3DPM.......................................................................................................130 Intrinsically-Safe Thermal Conductivity DPM (IS-TCD3)......................................................132 Replacing an IS-TCD DPM..................................................................................................134 Temperature Control Personality Module............................................................................135 Replacing a TC-PM..............................................................................................................136 Sensor Near Electronics (SNE) Software............................................................................137 Solid State Relay Module.....................................................................................................138 Solenoid Valves...................................................................................................................140 Solenoid Valve Control Module (SVCM)..............................................................................140 Replacing a Solenoid Valve.................................................................................................144 Electronic Pressure Control Module.....................................................................................145 EPC Module Description......................................................................................................145 Replacing an EPC Module...................................................................................................148 Color Touchscreen...............................................................................................................149 Description...........................................................................................................................149 Maintenance Overview.........................................................................................................150 Replacement Procedures.....................................................................................................150 4.2 4.2.1 4.2.2 4.2.2.1 4.2.2.2 4.2.2.3 4.2.2.4 Oven Components...............................................................................................................156 Using Valco and Swagelok Fittings......................................................................................156 Model 50 Valve....................................................................................................................157 Model 50 Valve....................................................................................................................157 Basic Maintenance: Model 50 Valve Introduction................................................................157 Preventing Port to Port Leaks..............................................................................................158 Maintenance Considerations................................................................................................158 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Table of contents 4.2.2.5 4.2.2.6 4.2.3 4.2.3.1 4.2.3.2 4.2.3.3 4.2.3.4 4.2.3.5 4.2.4 4.2.4.1 4.2.4.2 4.2.5 4.2.5.1 4.2.5.2 4.2.5.3 4.2.5.4 4.2.5.5 4.2.5.6 4.2.5.7 4.2.5.8 4.2.5.9 4.2.5.10 4.2.5.11 4.2.6 4.2.6.1 4.2.6.2 4.2.6.3 4.2.6.4 4.2.6.5 4.2.6.6 4.2.6.7 4.2.6.8 4.2.7 4.2.7.1 Figure...................................................................................................................................159 Model 50 Valve Maintenance Procedure.............................................................................160 Liquid Injection Valve...........................................................................................................162 Description...........................................................................................................................162 Maintenance Overview.........................................................................................................166 Liquid Injection Valve Component Locations.......................................................................167 Troubleshooting...................................................................................................................168 Service Procedures..............................................................................................................169 Model 20 Valve....................................................................................................................173 Basic Maintenance...............................................................................................................173 Disassembly and Cleaning...................................................................................................178 Model 20 HT Valve...............................................................................................................186 M20HT Description..............................................................................................................186 M20HT Intended Users........................................................................................................187 M20HT Safety and Certification Information........................................................................187 M20HT Procedure - Overview..............................................................................................187 M20HT Procedure - Maintenance Facility............................................................................187 M20HT Procedure - Figures.................................................................................................188 M20HT Procedure - Cleaning of Parts.................................................................................191 M20HT Procedure - Valve Cap Disassembly.......................................................................191 M20HT Procedure - Actuator Disassembly..........................................................................192 M20HT Procedure - Actuator Re-assembly.........................................................................193 M20HT Procedure - Valve Cap Re-assembly......................................................................197 Model 11 Valve....................................................................................................................198 M11 Description...................................................................................................................198 M11 Intended Users.............................................................................................................200 M11 Safety and Certification Information.............................................................................200 Diagnostic Procedures.........................................................................................................200 M11 Procedure - Maintenance Facility.................................................................................201 M11 Procedure - Figures.....................................................................................................202 Mini-Maintenance Procedures (Valve Cap and Fittings)......................................................205 Maxi-Maintenance Procedures (Valve Body).......................................................................208 Live T Switch........................................................................................................................211 Live T Switch........................................................................................................................211 4.3 4.3.1 4.3.2 4.3.2.1 4.3.2.2 4.3.2.3 4.3.2.4 4.3.3 4.3.3.1 4.3.3.2 4.3.3.3 4.3.3.4 4.3.4 4.3.4.1 4.3.4.2 4.3.4.3 4.3.4.4 4.3.4.5 Detectors..............................................................................................................................212 Detector Introduction............................................................................................................212 Thermal Conductivity Detector.............................................................................................213 Thermal Conductivity Detector (TCD)..................................................................................213 Replace TCD Thermistor Beads/Filaments Introduction......................................................213 Figures.................................................................................................................................214 Procedure to Replace Beads/Filaments...............................................................................215 Flame Ionization Detector....................................................................................................216 Flame Ionization Detector (FID)...........................................................................................216 Replacing the FID Mesh Filter..............................................................................................216 Replacing the FID Quartz Jet...............................................................................................220 Replacing the FID Igniter.....................................................................................................222 Flame Photometric Detector................................................................................................234 Flame Photometric Detector (FPD)......................................................................................234 Upgrade Description............................................................................................................238 Intended Users.....................................................................................................................239 Safety and Certification Information.....................................................................................239 Procedure - Upgrade FPDI to FPDII....................................................................................239 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 5 Table of contents 4.3.5 4.3.5.1 4.3.6 4.3.6.1 5 Pulse Discharge Detector....................................................................................................241 Valco Pulsed Discharge Detector (PDD).............................................................................241 Methanator...........................................................................................................................241 Methanator...........................................................................................................................241 Specifications...........................................................................................................................................245 5.1 Maxum II Specifications.......................................................................................................245 Index.........................................................................................................................................................249 6 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Analyzer Overview 1.1 1 Introduction The Maxum edition II system, also called the “Maxum II”, represents a significant advance in process chromatography. The Maxum II combines the best of the Siemens Advance Maxum and PGC 302 gas chromatographs into a single platform analyzer. From oven and electronic components to software and communication networks, the system is modular. Pre-configured application modules are available for many common measurements. A Maxum II system offers a wide range of detector modules including Thermal Conductivity, Flame Ionization, Flame Photometric, and the Pulsed Discharge Detector (which can operate in Helium Ionization, Photoionization, and Electron Capture modes). All detector modules are available for both air bath and airless ovens. The Maxum II oven is designed so it can be divided into two independently heated isothermal ovens for parallel chromatography applications. The Maxum II Maintenance Panel provides maintenance personnel with access to all maintenance functions and data. In addition, the Maintenance Panel displays both real time and archived chromatograms. A PC-based network workstation runs the Gas Chromatograph Portal software. Analyzer Specific Documents Included with each analyzer is a custom documentation-drawing package. This package provides drawings and information pertinent only to a specific analyzer. Contents of this package are application-dependent and vary for each analyzer. Typical drawings included are: ● System Block and Utility Requirements ● ● System Outline and Dimensional Drawings ● ● Sampling System - Plumbing and Spare Parts List ● ● Sampling System Dimensional Diagram ● ● Sampling Probe ● ● Electronic Enclosure Section - Internal ● Layout Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Applicable Wiring Diagrams Oven Plumbing Diagram - Sensor Near Electronics Recommended Spare Parts - Analyzer Manufacturing Test Charts Stream Composition Data Database 7 Analyzer Overview 1.2 Parts of the Maxum II 1.2 Parts of the Maxum II Overview The Maxum II Gas Chromatagraph is completely enclosed in an air-purgable, metal cabinet with hinged doors. Mounted above the isothermal oven is the electronics enclosure and regulator panel. The analyzer may be mounted on a wall, in a rack or on a floor stand. Regulator Panel Electronics Enclosure Color Touchscreen Detector Compartment Isothermal Oven Figure 1-1 8 Maxum II External Component Locations Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Analyzer Overview 1.3 Isothermal Oven Electronics Enclosure The Electronics Enclosure houses all the electronics and pneumatic modules required for performing all temperature, valve control and analysis functions. The Electronics Enclosure modules are interconnected using simple cable connections made to each module. All modules can be easily removed and replaced. The Maxum II software recognizes each Maxum II’s application, hardware components and network configurations. International Power Supply System Controller (SYSCON) For Communications, Human Interface and Database Management. Solid State Relay Module 8-Channel Electronic Pressure Control. Up To 4 Modules. 2 Channels Each For Control Of Carrier Gas Pressure Power Entry Control Module (PECM) Detector Personality Module (DPM) for Detector Data Acquisition Figure 1-2 Electronics Enclosure Component Locations Regulator Panel The regulator panel contains space for seven gauges and regulators. The base Maxum II comes with two standard regulators and an electronics enclosure fast purge. See the custom documentation drawing package that was shipped with the analyzer to see which gauges and regulators are mounted on the analyzer. 1.3 Isothermal Oven The Maxum ll has a wide variety of isothermal oven configurations. Both air bath and airless ovens are available. All air bath configurations are available with Vortex cooling for subambient temperature operation. A program temperature oven option is available for Maxum II applications where isothermal, multi-dimensional chromatography is not practical. Typically the program temperature Maxum II is used for Motor Gasoline (ASTM 3710) & Simulated Distillation (ASTM 2887) applications. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 9 Analyzer Overview 1.4 Switching and Sampling Valves Oven Configurations Split Airless Oven Single Air Bath Oven Fully independent dual ovens with separate oven doors. The oven uses cartridge heaters in each side to heat the oven enclosure and its components. Large, spacious compartment for complex applications and for ease of maintenance. Programmed Temperature Air Bath Oven Provides a programmed temperature gradient for applica‐ tions requiring this. 1.4 Dual Air Bath Split Oven Split Oven Configuration: Offers two temperature zones for one or more applications. Switching and Sampling Valves Application Model Description Vapor Samples Model 50 10-port non-plunger diaphragm. Contains no moving parts. It will operate over 10 million cycles on clean samples and can operate on carrier gas or other bottled inert gas with negligible consumption. It does the work of two Model 11 valves and is half the size. Vapor or Liquid Sam‐ ples Model 11 and Model 11 LDV 6-port diaphragm–plunger valve high reliability and life. Used as a liquid or vapor sample valve, column switching valve or a column back flush valve. Process lines, columns and valve-to-valve tubes can be connected directly to the caps of the Model 11 LDV (Low Dead Volume) version of the valve. 10 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Analyzer Overview 1.5 Operator Controls Vapor or High Pres‐ sure Liquid Samples Model 20 The air-pressure actuated, diaphragm valve provides uniform sample volume, low internal volume, high pressure up to 1500 psi, 10350 kPa, fast switching (millisec‐ onds), reliability, and durability. It functions equally well as a liquid or vapor sample valve, column switching valve, or column back flush valve. Liquid Sample LIV The liquid injection valve can be used to automatically inject a constant quantity of liquid sample followed by fast, complete vaporization. Small gas quantities can also be injected using the valve. Vapor Valveless The device has no parts to fail or wear out and exhibits essentially zero dead volume Live Column for fast column switching and sample injection with capillary columns. Switching 1.5 Operator Controls Color Touchscreen The color touchscreen displays all maintenance functions and data in a graphical display. In addition it eliminates the need for a chart recorder because it can also display both real-time and stored chromatograms. The stored chromatograms include voltages and cycle times for future comparison as well as zoom and pan features. Operational and routine maintenance tasks for the analyer can be performed from the color touchscreen interactive display screens and menus. System security is assured with multiple levels of password protection for all analyzer-operating functions. A color touchscreen emulator (also called a Human Machine Interface, or HMI, emulator) is available from the Maxum Gas Chromatograph Portal (GCP) software. This emulator allows a user to perform color touchscreen tasks without being located at the unit. Workstation The Maxum II uses a PC based network workstation for programming and data processing. Analyzers can be programmed and monitored from a single location, and, like the color touchscreen, the workstation includes graphical displays for operation, maintenance, and diagnostics. It also supports PC printers to print chromatograms and alarm logs in order to meet record keeping requirements. The Maxum II workstation software, Gas Chromatograph Portal (GCP), is designed for PCs with Microsoft® Windows operating systems. PC workstations can be connected through existing LANs for wide access to monitoring or maintenance tasks. The graphical interface recognizes and displays all network hardware. The system monitors the alarm status of all analyzers connected to the network to centralize system maintenance. More information can be found in the Release Notes file supplied with the GCP Software. Chromatography Software EZChrom© industry specific software is incorporated in the GCP software. This is a laboratory quality application builder developed by Scientific Software, Inc. and includes custom features for the Maxum II. Using EZChrom, it is possible to set up methods and component peak identification. More information can be found in the Release Notes file supplied with the EZChrom software (under the Maxum EZChrom directory). Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 11 Analyzer Overview 1.5 Operator Controls EZChrom allows a user to choose the best peak gating and basing methods automatically. It is also possible to: ● Re-process captured chromatograms with different methods ● Measure unknown component peaks automatically ● Record multiple detector measurements simultaneously. 12 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 System Functions 2.1 2 Chromatography Overview Gas Chromatograph Terminology The following are new terms that are used in this manual. Application refers to the supporting hardware and software required to perform the analysis. Supporting hardware consists of hardware channels: detector channel, Solenoid Valve Control Module channel, Electronic Pressure Control channel, Temperature Controller. Streams are defined to applications. If there are 3 or 4 simultaneous streams, they are defined as a single group called a Method. Applications can run only one Method at a time. Two applications can run if there are two cycle clocks in the Maxum II. Method is the part of the application that contains the parameters for controlling the hardware. Methods control the hardware associated with an Application. The method tells the hardware what to do, and include all cycle clock timed events. Methods are defined to streams. That is, several stream sequences can make up one Method. Methods also control the integration and calculations of the chromatogram. There is one cycle clock per method. Applet refers to pre-engineered chromatographic segments of common applications, which have been optimized and standardized. Applet Module refers to a complete assembly including Model 50 valve(s), detector and interconnecting tubing all mounted as a single module. The module includes columns and restrictors Parallel Chromatography With the Maxum II hardware and software, it is possible to take a complex single-train chromatograph analysis and break it into multiple simple trains. Each simple train is then run simultaneously – in parallel. Not only does this procedure simplify the overall analysis, but also it is performed faster and more reliably. Redundant Measurements Using parallel chromatography can reduce calibration requirements by running two identical modules in parallel on the same stream to obtain redundant measurements. As long as the results remain the same within a predefined error limit, the analysis is known to be accurate. Deviations outside the error limit can trigger notification or activate analyzer calibration. Overall, the Maxum II calibration requirements are significantly lower because of the parallel measurement configurations and standard modular applications. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 13 System Functions 2.2 Intended Use and Personnel Qualifications Figure 2-1 2.2 Example Applet Intended Use and Personnel Qualifications Intended Use of the Analyzer The Maxum edition II gas chromatograph is primarily used in all branches of the fine chemicals, refining and hydrocarbon processing industries. It performs chemical composition analysis of gases and liquids that are present in all phases of production. The Maxum II is built for installation in harsh environments either directly or nearby in at-line process measurement laboratories. Its application flexibility allows it to analyze samples of feedstock, partially processed streams, final products and process byproducts including wastes and environmental hazards. This product is intended to be used only in conjunction with other devices and components which have been recommended and approved by Siemens. Appropriate safety standards were used in the development, manufacture, testing, and documentation of the Maxum II. Under normal operation, this product is safe for use providing that all safety and handling guidelines are observed with respect to configuration, assembly, approved use, and maintenance. This device has been designed such that safe isolation is guaranteed between high and low voltage circuits. Low voltages which are connected must also be generated using safe isolation. If any part of the Maxum II is opened, certain parts of the device are accessible which may carry dangerous voltages. Therefore, only suitably qualified personnel may work on this device as indicated below in the section titled Qualified Personnel. Personnel Qualifications Only suitably qualified personnel may operate or perform maintenance on the Maxum II. For the purposes of safety, qualified personnel are defined as follows: ● Those who have been appropriately trained for the tasks which they are performing (for example, commissioning, maintenance, or operation). ● Those who have been appropriately trained in the operation of automation technology equipment and are sufficiently acquainted with Maxum II documentation. 14 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 System Functions 2.3 Functions ● Those who are familiar with the safety concepts of automation technology and are sufficiently acquainted with Maxum II documentation. ● Those who are authorized to energize, ground and tag circuits and devices in accordance with established safety practices may perform the tasks for which they are trained. WARNING Operation or Maintenance is performed in the presence of dangerous voltages and potentially hazardous materials, and must be performed by qualified Personnel. Operation or Maintenance of the Maxum II by unqualified personnel or failure to observe the warnings in this manual or on the device may lead to severe personal injury and/or extensive property damage. 2.3 Functions Overview This section provides an operational overview of the real-time functional tasks of the Maxum II. ● Startup Tasks ● – Applying Power – Valid Database – Oven Temperature – Cycle Control Flag ● Timed Event Scheduling ● – Time-Of-Day Clock – Schedule of Events • Frequency Events Analysis Cycle Clock – Accessing SYSCON – Analysis Cycle Clock – SYSCON Cycle Clock – Valve Events Manual Operations via User Interface Startup Tasks On start-up, when primary AC power is applied to the analyzer, the analyzer first processes whatever electronic self-tests and diagnostics are required such as PROM, RAM, A/D, and communication ports. This processing occurs within 5 seconds. System-related initial messages are generated and output to the network ports. Appropriate initial messages are then displayed on the Maintenance Panel and completed within 20 to 25 seconds. If the analyzer cycle clock is in RUN or CAL mode, an appropriate alarm may be generated during this internal test and the following startup period. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 15 System Functions 2.3 Functions Self Test After the self-test, the following conditions occur: ● Installed hardware is initialized. ● Interrupts are enabled. ● Oven temperatures and carrier pressure default set points are output. ● Analog input system(s), associated with detector inputs, are initialized and begin scanning. The SYSCON verifies that a valid database is resident, then ouputs the appropriate temperature and carrier set points. If a valid database is not verified, default set points are left in place. Oven Temperature The analyzer monitors the oven temperature to ensure that it has stabilized at the set point before automatically proceeding. Depending on how long primary AC power has been off, this may take from 2 seconds to 45 minutes. Cycle Control Flag Cycle Control Flags can be used to run optional diagnostic cycles to validate analytical hardware including solenoid valves, detectors, or carrier regulators. This option is typically based on a custom application being initiated by a power-fail alarm. Cycle Ccontrol Flags indicate if any analyzer cycle clocks are to be in RUN mode. If they are not, the analyzer remains in the HOLD mode until operator intervention. If the cycle clock is in RUN mode, based on having been in RUN mode prior to powering down, then RUN mode starts in progress without waiting for intervention. Program Event Scheduling The Time of Day (TOD) clock schedules events on a second, minute, hourly, daily or weekly basis. The clock is maintained on the CAC3 board of the SYSCON2 (or on the main control board of the original SYSCON) and schedules events from the residing SYSCON database. The TOD clock has one-second resolution that is maintained and generated by a hardware device that maintains accurate time independent of analyzer power. This allows a power recovery event to determine duration of power down state. Certain events are scheduled on a frequency basis, which are independent of the TOD or analysis cycle clocks. The frequency clock has a resolution of 1 second, which is used to schedule repetitive events, such as reading DI and AI signals for alarm purposes. Scheduling of frequency events can be set to 5 seconds or greater. They occur regardless of whether the analyzer is in Run or Hold. Description A schedule event can be for instrument calibration and special calibrations. Special calibrations include daily or shift averages, report logging to a printer or Host computer. When these tasks are scheduled by the TOD clock, they are put into queue. This allows them to be performed at the next appropriate time. Typically, this is after completion of current analysis cycle. 16 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 System Functions 2.3 Functions If a calibration is scheduled, it is put in queue. The calibration then initiates after completion of the current cycle, and when the appropriate time has passed for the calibration blend to flow through the sampling valve. If shift average reports are to be calculated and printed, the report should include all cycles, which started, or sampled, during the specified shift. To have data available for calculation, a wait period may occur for completion of the current sample analysis. Analysis Cycle Clock The Analysis Cycle Clock (ACC) is another clock that provides the timebase for all events associated with the actual chromatograph analysis cycle. SYSCON cycle clocks can be configured to provide timed event resolutions of 0.1 second, 0.01 second, 0.01 minute, or 0.001 minute. This is the Sensor Near Electronics software module (SNE) Event Table Scan Rate, which is independent of detector scan rates. All SYSCON cycle clocks and associated SNE MUST BE of the same second or minute time units. This clock works in conjunction with the Stream Sequence Table and associated sample stream enable and skip flags. This controls sampling order and analysis of process streams connected to the analyzer. Accessing SYSCON The clock cycle RUN mode is controlled by the SYSCON upon command from SNE. When a clock cycle is started, the associated SNEs, for that method, initiate a mirror of the cycle clock. The SNE clock is the true basis of timed events relating to the Gas Chromatograph oven valve timing, detector digitization and peak integration. SNE Cycle Clock The SNE cycle clock is used to schedule the following events. ● Analysis valve timing ● Detector balances ● Temperature set points start and stop for PTGC ● Cycle Reset ● Pressure set point timing for pressure programming ● Analysis result calculations and reporting Note Scheduled solenoid valve events cause Solenoid Valve Control Module (SVCM) hardware to be activated within 5 milliseconds of stated cycle time. Any scheduled pressure set-point adjustments are transferred to the actual Electronic Pressure Control Module (EPCM) hardware within 5 milliseconds. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 17 System Functions 2.3 Functions Manual Operations Manually controlled functions can be initiated through the color touchscreen. A manuallycontrolled event can occur asynchronously with any event and control some of the analyzer operations. Controlled items include: ● Activation of solenoid valves ● Balancing detectors ● Changing a pressure or temperature set pointInitiating a calculation ● Initiating a calculation 18 ● Report logging event ● Change the cycle time of an event ● Initiate a calibration Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 System Functions 2.4 Analyzer Operation 2.4 Analyzer Operation This section provides an overview of the operation of the Maxum II analyzer. The operational block diagram shows how a sample is processed within the analyzer. The SNE functions are performed in software in new systems; older systems still have hardware versions. Electronics Enclosure I2C Network GCP Electronic Pressure Control Module SYSCON Solenoid Valve Control Module SNE Software Moule Temperature Control DPM (A/D) DPM (A/D) Oven Heater Control DPM (A/D) Detector Compartment (Mezannine) FPD FID Feedthroughs Atmosphere Vents I2C from SYSCON TCD Sample Conditioning Sample In Columns Columns Columns Sample Valve Oven Regulated Carrier Gas Figure 2-2 Operational Block Diagram Power On The Power Entry Control Module (PECM), in response to commands on internal bus, accepts system primary power and provides switching and control of AC power for oven heaters and other AC powered devices. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 19 System Functions 2.4 Analyzer Operation Sample Conditioning Before being piped to the analyzer, the sample from the process is sent to a sample conditioner system. The sample conditioner ensures that the process sample is compatible with the requirements of the analyzer. That is, it assures that the phase, pressure, temperature and flow rate to the analyzer are suitable, that the sample is filtered, that condensates are removed and other treatments are carried out. The resultant conditioned sample is typically piped via 1/8-inch stainless steel tubing to the sample valve(s) located in the oven of the Maxum II. Sample Valve The type of sample valve used in a Maxum II is application dependent. Five primary types of sample valves are available. ● The first is the 10-port Model 50 valve that is designed for vapor sample only. ● The second is the Model 11 valve for vapor or liquid samples. ● Third is the Model 20 valve for liquid high-pressure samples. ● The fourth type is the set of Valco valves that are designed for high temperatures and very low sample volumes. ● The fifth is the independently-heated Siemens Liquid Injection Valve. The sample valve(s) and any column valves are controlled by a Solenoid Valve Control Module located in the Maxum II’s electronic enclosure section. There can be up to three SVCMs installed in an electronics enclosure (EC). Solenoid Valve Control Module The Solenoid Valve Control Module (SVCM) provides pneumatic on/off control for both sampling and oven systems functions. The SVCM manifolds are connected as a group of four 4-way and four 3-way solenoids. The (SVCM) receives commands from the I2C bus. Solenoid commands are received from the SNE software module. Solenoid relay status is read back to the SNE software module to indicate whether a selected solenoid is to be deactivated or activated. Timing is controlled by SNE software module timing. There is no timebase in the SVCM. Commands from I2C bus control the deactivation or activation of solenoid valves. If fault or warning conditions have occurred, pressure control and SVCM status information is returned to the SYSCON database. Columns Samples are injected by the sample valves into the chromatograph columns where the samples are separated into individual components. Many different types of columns may be used including 1/16-inch micro-packed, 1/8-inch packed and fused silica or metal capillaries. The columns used are dependent on the requirements of the application. 20 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 System Functions 2.4 Analyzer Operation Column Valves In most applications, there are multiple columns in use that are typically switched by column valves located in between them. These column valves are not shown in the illustration, but like the sample valves described above they are also controlled by the Solenoid Valve Control Module and SNE software module. Electronic Pressure Control The carrier gas pressure that is used to push the sample through the columns is controlled by an Electronic Pressure Control Module(s) (EPCM) or in some applications by mechanical regulators. The EPCM is mounted on manifolds located on the EC right-side wall. The EPCM pneumatics are digitally controlled by the Sensor Near Electronics (SNE) software module. Up to four EPCMs can be mounted in an EC. Each EPCM contains two channels, and each channel can use a different gas at a different pressure. EPCMs are also used to control the fuels for some of the detector modules. Each Electronic Pressure Control Module (EPCM) communicates the actual pressure back to the SNE software module. Information may then be displayed on the Maintenance Panel. Oven Heaters For the columns and detectors to work correctly, they must usually be operated at elevated temperatures. The Maxum II uses electrical heater(s) to elevate the temperature. These heaters (not shown in block diagram) are connected to relays in the Electronic Enclosure section and, like the valves and the Electronic Pressure Control Module(s), are controlled by the SNE software module. Detector The sample eluted from the columns is transported to the associated detector that senses the presence of the sample and converts it to an electrical signal. Depending upon the application, the Maxum II can include up to three detector modules. Each detector module can have multiple detector sensor elements. Several detector module types are available including Thermistor, Filament, Flame Ionization, Flame Photometric, and Pulsed Discharge. The resulting electrical signal from the detector is then connected to the Detector Personality Module (DPM) located in the EC. Sensor Near Electronics (SNE) Software Module The detector signal(s) is routed to the Detector Personality Module (DPM). The DPM (unique for each detector type) amplifies the analog signal and converts it to a digital signal. The digital signal output from the DPM is processed by the SNE software module. The DPM is interfaced to installed peripherals connected to the I2C bus through a set of digital and analog I/O signal commands. All accessible I/O's are uniquely addressable through the module type, enclosure ID, SNE, location ID and module channel number. In earlier analyzers, the SNE control and processing functions were performed by a separate processor board, called the SNE controller (SNECON) mounted in the DPM cage assembly and connected to the SYSCON by an Ethernet cable. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 21 System Functions 2.4 Analyzer Operation System Controller (SYSCON) The System Controller (SYSCON) resides in a pullout drop-down assembly located in the EC and controls all external communications and internal communication. The SYSCON houses the primary processor, plug-in I/O boards (for external signal control), communication interfaces, and an interface to the maintenance panel display. All internal communication between modules and SYSCON is via the internal I2C signal bus. The original SYSCON consists of a single controller board. The newest version of SYSCON, called SYSCON2, is a base SIB (SYSCON Interface Board) with an attached CAC3 (Communication and Control board). The SYSCON combines all data results and performs additional high level data processing and calculations. The SYSCON connects to a color touchscreen display, strip chart recorder, other analyzers, printers, the Advance Communication System (ACS), or other connected networks. The SYSCON is the analyzer control system in addition to containing the application database. The application database also contains analytical hardware database definitions that are used to perform the following functions: ● Obtain desired sampling measurements ● I/O and SNE schedule of timing events ● Sequence of sampling streams 22 ● Calculations of reported values ● Formatting of results and location and outputting results ● How to report or correct error conditions Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 System Functions 2.5 Data Communication 2.5 Data Communication Internal Communication An I2C Internal Bus provides communication between the SYSCON, SVCM, EPC, PECM and to the I/O bus. External communication is through an Ethernet link. The interface for each type of module is described in the Component Descriptions and Maintenance Procedures section. Color Touch Display I2C RS232 RS485 CAN I2C Sampling System I2C I/O Boards SYSCON (SIB3) PECM Controller Board Ethernet I2C EPCs I2C CAC3 SVCMs GCP GCP Ethernet Switch (optional) Analyzers Ethernet I2C Software SNE DPM 1 Figure 2-3 I2C Software SNE DPM 2 I2C Software SNE DPM 3 Data Communication Paths Module Addressing The Maxum II modules located in the electronic enclosure section have their own physical address and communicate via the I2C Internal Bus, shown in the diagram below. Address information is contained in the SYSCON database and identifies modules by their location. Each DPM is associated with a software SNE module that appears in the list as a separate device. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 23 System Functions 2.5 Data Communication Identification Number All modules within the Maxum II electronic enclosure have a unique identification number as related to the software SNE module which controls them. The identification relationship between the SNE and the modules it controls is referred to as the SNE ID String. 11 : 1 - 1 . 1 - 1 . 1 . 129 Channel Number Channel Type PIC Index Module Number (Location ID) Sub Module Type & Description Module Type SNE ID Figure 2-4 Identification Number Address information is located in the analyzer local I/O Table. The I/O points are identified by module type, mounting location within the electronic enclosure and channel number. This allows module addressing from either the SYSCON database, SNE Tables or from Advance Database. 24 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.1 3 General Analyzer Shutdown Procedure Back Up the Database If a current database has not been saved, first save a database to a remote device to provide a potential method of reloading when a a CAC3 has been replaced or an earlier database needs to be restored to the analyzer. Generally, a database reload will not be needed, though in some cases this may be required. 1. Put the Maxum II in Hold and wait for the cycle to complete. This will provide the quickest restart of the application when power is restored. 2. Once the cycle is completed and the Maxum II is holding, then remove power from the unit. WARNING Voltage dangerous to life exists. Failure to follow appropriate safety procedures may result in severe injury or death. Before beginning to work inside the electronics enclosure, the power must be externally removed from the GC. AC power comes directly into the electronics enclosure, so power must be removed and secured/tagged to prevent inadvertent application while work is being performed. 3.2 General Analyzer Startup Procedure Before Starting the Analyzer WARNING Voltage dangerous to life exists. Severe injury or death can result if precautions are not observed. When the Electronic Enclosure door is open, voltage dangerous to life exists. These procedures will involve operation of the unit with the electronics door open, which will require a “hot work permit” in some locations to ensure that there are no hazards for the personnel working in the area. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 25 General Maintenance and Troubleshooting 3.2 General Analyzer Startup Procedure Before proceeding with these procedures, make sure the unit is installed correctly in accordance with these instructions and local and national codes. See the custom documentation package for particular Maxum II details and procedures for the particular unit. 1. Ensure that the AC (Mains) power is off to the Maxum II. 2. Open the electronic enclosure door and inspect all connections. 3. If appropriate permits have been obtained to meet area classification requirements necessary to operate with the door open, then apply power to the unit. No intervention should be necessary for the unit to begin to operate after a few minutes. If normal operation is not achieved, refer to the section on troubleshooting to resolve the issue. The Troubleshooting section defines the normal LED operating modes for this assembly. Close the electronics door and secure it per the applicable safety codes. 4. If the area classification does not permit the unit to be operated with the door open, then close the door, secure it per the applicable safety codes, and apply power to the unit. Correct operation can be determined through the interface on the door or a remote interface if one is not included in the door of the electronics enclosure. 5. Follow the procedure for restart of the specific unit. Accessing the Bootloader to Set Network Address This procedure is needed when a CAC3 is replaced, when the memory backup battery is removed, or when the CAC is removed from the SIB3. To prepare, disconnect the analyzer from the network by unlugging the Ethernet cable. From the color touchscreen in the door of the analyzer, use this set of steps to set the IP addresses for a SYSCON2.1. This allows the GCP software to communicate with the device so that a database may be loaded. 1. Push the reset button through the opening on the SYSCON cage. This provides access to the bootloader. 2. Press the Home key when the message “To enter the bootloader menu, press the Home key now…” appears. 3. Press the 5 key to select the “Configuration” menu. 4. Press the 4 key to select “Choose Device Mode”. 5. Press the 2 key to select “Standalone SysCon”. 6. The SYSCON reboots into standalone mode. 7. Press the Home key to re-enter the boot loader 8. Press the 5 key to select the “Configuration” menu again. 9. Press the 2 key to select “Primary Ethernet IP Configuration”. 10.The question “Do you want to change this configuration?” appears: Press the 9 key to select “Yes”. 11.Press the 0 key to disable DHCP. 12.Press the 9 key to change the IP address. 13.Enter the desired IP address. Press the “Home” key to return to the menu. 14.Press the 9 key to change the subnet mask. 26 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.3 Troubleshooting 15.Enter the correct subnet mask. Press the “Home” key to return to the menu. 16.Press the 9 key to change the Default Gateway address. 17.Enter the Default Gateway address. Press the “Home” key to return to the menu. 18.Press the 0 key to select “No” to the question “Change the DNS?” 19.Press any key to continue. 20.Press the Back key to return to the bootloader menu. 21.Press the 9 key to reset the device. The external Ethernet cable may now be reconnected to the network, and the analyzer should be visible in the GCP Network list. 3.3 Troubleshooting PECM Status LEDs The PECM3 should start automatically once power is applied. If the unit is not operational after applying power, then review the information below to aid in correcting the problem. The most common issue with replacing the PECM3 is cables, wiring connections, and jumpers. Check all of the cable connections to ensure that they are seated and connected properly. The alarm system can also provide direct information on alarms for an error. Review the alarms to see if they provide an indication of the problem. Each alarm has a written description that may provide an indication of the problem area. RIGHT Heater status Heater 2 Air Pressure Heater 2 Power Activate PECM-CTRL PCB The LEDs on the PECM board can help with LEFT Heater Status troubleshooting problems. There are two Heater 1 Air Pressure sets of LEDs: one on each side of the front Heater 1 Power Activate board as shown in the diagram to the right. Heater 1 Temp Limit The bottom set of three LEDs is the same as used on other boards (described below.) The Heater 1 Overtemp left set is for the PECM software. (The other LEDs are not used for PECM1 replacement.) The corrective action to take for each of the Normal LED indications is noted below with a correc‐PECM Status Fault tive action reference number on the diagram Warning at the right. The normal state indication is shown in the diagram below. Heater 2 Temp Limit Heater 2 Overtemp Normal Fault Warning Temperature Controller Status PECM LEDs Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 27 General Maintenance and Troubleshooting 3.3 Troubleshooting 28 State 6 - Fault condition; data invalid State 5 - Warning condition; data good temporarily State 4 - Normal operation State 3 - Address assignment State 2 - Self test State 1 - Power off State 1 1. If all units in this state, then power to the analyzer and/ or board is not active 2. Reset the device or cycle power 3. Check power connections to board (AC and 24VDC) 4. Replace unit State 2 1. Reset the device or cycle analyzer power 2. Replace unit State 3 1. Reset the device or cycle analyzer power 2. If all modules are in State 3, then SNECON is not communicating (check cabling and connections) 3. Replace unit State 4 Normal Operation State 5 1. Reset the device or cycle power 2. Check communication cable connections State 6 PECM LED Interpretation 1. Reset the device or cycle power 2. Check communication cable connections 3. Check for missing Temp Limit setpoint boards 4. Check for shorted or open RTDs 5. Replace the unit 6. Replace other connected units Normal Fault Warning Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.1 Alarms 5.2 301 - 324 GCP 5.2 Alarm Descriptions 301 - 324 The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # Text Description ? External Message: send failure %3 A message was received by the device Reset Gateway or SYSCON. from itself; or source of message can't be identified; or Gateway is too busy or com‐ munication was disrupted between the GC and the message handler. 302 ? External Message: server lost System Error Contact Customer Support. 303 + External Message: Rec'd invalid communication from unit %3 Message was received from Advance DataHiway unit that had previously broadcast with no slots or slot is out of range. Reset Advance DataHiway unit. 304 + External Message: Orphan An Advance DataHiway external message received from %3 PANDSP message was received with no matching PANKEY; or an ATTACH was received with no matching RATCH; or an internal timeout was generated for nonexistent message. Ignore or reset SYSCON. 305 ? External Message: Invalid Message Length for %3 Check database set up for these mes‐ sages. 306 + External Message: Send in‐ 3Message from GC is directed to an Ad‐ Check Advance DataHiway unit. valid communication to unit vance DataHiway unit that has no slots, % an invalid range of slots, or no UID has ever been received. 307 ? External Message: Dupli‐ cate anlz_id %3 detected ; setting to zero An Advance DataHiway ZIP message Check other units on network. was received from another Advance Da‐ taHiway unit, or another GC has broad‐ cast with the same analyzer num‐ ber.Check other units on network. 308 ? External Message: Dupli‐ cate UNIT %3 detected; setting loop/unit to zero An Advance DataHiway SLEEP mes‐ sage has been received. Another Ad‐ vance DataHiway unit has broadcast with the same loop/unit. Check other units on Advance DataHi‐ way and correct loop/unit of GC. 309 ? External Message: RUD:Unit does not re‐ spond; loop/unit %3 Occurs when Advance DataHiway loop/ unit does not respond to a RUD message - originates from I/O, Host, or Printer ta‐ ble in GC. Remove extraneous references to nonexistent units.　Check Advance Data‐ Hiway connection. 301 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Advance DataHiway Results, print, HAE, or Service Panel messages received from GC that have no length. Action 29 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description Action 310 # ? External Message: Unit not known for %3 GC is trying to communicate with an un‐ known unit on the Advance DataHiway. Wait 10 minutes to see if this condition will correct itself. If it does not, verify that the Gateway is communicating with the GC. 311 ? External Message: Error Bad Advance DataHiway Host Activation Check MaxBasic programs for invalid for Activation of EVT on %3 Event message was sent by GC to mes‐ setting of attributes on the analyzer ta‐ sage handler. ble. 312 ? External Message: Send error for %3 Send failure for UDP outgoing message sequences. This is a general failure that indicates a network fault. 313 ? External Message: Invalid TOR sequence on % An Advance DataHiway SEND message was received from external unit when there are no results to send. Check result transmit, # of results. 314 ? External Message: Anlz: %3 & Anlz: %4 have loop/ unit conflict Two Advance GCs have duplicate Ad‐ vance DataHiway addresses (loop,unit). Check for duplicate loop,unit addresses on the two analyzers and correct the duplication. 315 ? External Message: Anlz id exceeds allowable limit for ADH FUNCT 88 Advance DataHiway Alarm message received from HCI-H; 　or GC attempted a broadcast with an ana‐ lyzer_id greater than 255. Check analyzer ID. 316 ? External Message: Host: Anlz 1 to 50 config conflict FUNCT 89 Advance DataHiway Alarm message received from HCI-H. Check # results and # streams against HCI-H limitations. 317 ? External Message: Host: for anlz 51-254 stream>1 or # of components>9 FUNCT 90 Advance DataHiway Alarm message received from HCI-H. Check # results and # streams against HCI-H limitations. 318 ? External Message: Host: in‐ Advance DataHiway H card is sending valid data received from alarm back to GC. anlz Check trtval in result table. 319 ? External Message: no re‐ sults marked to transmit for stream %3 No results are marked for transmission. Comes from GC prior to transmission. Check trtval in result table. 320 ? External Message: %3 Timeout for %4 Advance DataHiway message timeout for ADREQ, REXD, results, HAE, Print, FUNCT. Reset SYSCON. If the alarm occurs again, contact Customer Support. 321 + External Message connec‐ tion opened on: %3 Normal message from reset. No action necessary. 322 ? No ADH connection detec‐ ted %3 failed No message handler. This means that that certain software components are not working. Contact Customer Support. 323 ? External Message: Invalid LOOP %3 detected ; set‐ ting loop/unit to zero An Advance DataHiway WRLP message has been received. Check Loop of GC. 324 ! Error processing database command %3 An error has occured in SQL messaging to a remote or local database table for Modbus or remote I/O. Check network communication and contact Customer Support. 30 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.2 Alarms 5.2 330 through 359 SNE Communication GCP 5.2 Alarm Descriptions 330 - 359 The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # 331 332 Text ! ! Description Action Run Method: No SNE The connection between the GC and the found or bad status on mod‐ SNE is invalid. ule: %3 Check cable between the SNE and SY‐ SCON. Run Method: No module found for detr: %3 Check hardware connections to SNE. The GC can contain references to inva‐ lid hardware channels. The SNE has not reported the detector, pressure controller, or temperature con‐ troller. Check the LEDs on the SNE to see if it is running. Check the pressure, temperature, and detector channels defined in the appli‐ cation for correct assignments. 333 ! Run Method: No Detr found Realtime chromatogram attempt on inva‐ Check hrdwr_id, module for app_detec‐ or bad status for meth‐ lid detector, or bad status on detector. tor. The GC can contain references to od.channel: %3 invalid hardware channels. Check the detector channels defined in the application for correct assignments. 334 ! Run Method: No Channel found for method: %3 335 + SNE connection opened on %3 System error Contact Customer Support. 336 ! SNE connection closed due to timeout or error. If IP address specified is not a 192.168.144.# network address, check for appropriate grounding of system. SNE connection closed on %3 error: %4 No channels are present or can't find de‐ Check app_detector, EZChrom method tector for channel. for proper hardware channel assign‐ ments. Otherwise check SNE for appropriate connections and software versions. 337 ! SNE connection replaced on %3 System error Contact Customer Support. 338 ? SNE %3 Method %4 Can‐ not Store Chrom Results received from SNE for unknown stream. Check stream table. It is possible to de‐ lete streams during the run of a cycle. If that is done, then this alarm may oc‐ cur. 339 ? SNE %3 Method %4 Appli‐ Can't find application or method to match cation %5 not found SNE results. This indicates that messag‐ es between the SNE and SYSCON are corrupted. Reset SNE to sychronize messages. It is possible to delete applications during the run of a cycle. If that is attempted, then this alarm may occur. 340 ! SNE %3 Method %4 Load - Invalid Method SNE has sent a status message that the method is invalid. No other information is available. Download method from EZChrom again. 341 ! SNE %3 Method %4 Inac‐ tive SNE sent message that method is inac‐ tive. No other information is available. Restart the application. 342 ! SNE %3 Method %4 Load - Max Method exceeded SNE sent message that maximum meth‐ Reduce number of methods, reset SY‐ ods has been exceeded. SCON. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 31 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description Action 343 # ! SNE %3 Method %4 Load - Invalid Mode Invalid run/hold sent to SNE. Reset SYSCON or try placing applica‐ tion in run. 344 ! SNE %3 Method %4 status - unknown error %5 Unknown error from SNE method status. Reset SNE/SYSCON. 345 ! Stream Valve does not ex‐ ist Can't find appdo or sys_do for DO set in cycle_events. Digital Output on cy‐ cle_event may not be valid. Check DO on application I/O tables to see if the DO exists for this application and has a normal status. 346 ! SNE %3 Write IO %4 does not exist %5 IO write was sent to SNE, where I/O does not exist. Reset SNE/SYSCON. Check the sys_hardware table for nor‐ mal I/O status. If any I/O is not normal, investigate the cause. 347 ! SNE %3 Read 　IO %4 does not exist IO read was sent to SNE where the I/O does not exist. Reset SNE/SYSCON Check the sys_hardware table for nor‐ mal I/O status. If any I/O is not normal, investigate the cause. 348 ? SNE %3 RT chrom %4 does not exist Realtime chromatogram request to nonexistent SNE. Reset SNE/SYSCON Check the sys_hardware table for nor‐ mal I/O status. If any I/O is not normal, investigate the cause. 349 ? SNE %3 Method %4 - Write attempted on active meth‐ od Ignore: Alarm was removed from Ver‐ sions 4.3 and later. 350 ! SNE Module I/O error 0x %3 on %4 An operation attempted on an attached SNE module failed. Report the error number and the mod‐ ule to Customer Support. 351 ! SNE pSOS error 0x %3 on %4 System Software Failure. Report the error number and the mod‐ ule to Customer Support. 352 ! SNE pSOS Driver error 0x %3 on %4 Driver Software Failure. Report the error number and the mod‐ ule to Customer Support. 353 ! SNE AAI Driver error 0x %3 AAI custom driver failure. on %4 Report the error number and the mod‐ ule to Customer Support. 354 ? SNE TFTP load Error on %3 : %4 Verify that TFTP server is running TFTP load failure during download of SNE software. Verify correct IP address Verify correct file location Retry TFTP load 355 ? SNE FLASH Driver Error on %3 : %4 Flash Memory Failure. If persistent, replace SNE. 356 ! SNE %3 Stream/Method %4 / %5 does not exist Results received from SNE: Can't locate stream/method. Deleting streams and methods or downloading methods while a cycle is running can cause this error. Check sequence. Place application in hold and then run again. 357 ! SNE Method %3 - Invalid message argument This indicates that the SNE has an obso‐ Check the SNE and SYSCON software lete software version or the messages versions with the upgrade tool. between the SNE and SYSCON have Reset the SYSCON and SNE. been corrupted. 32 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # Text Description Action 358 ! SNE Invalid I/O Write from This should only occur if the SNE has an Check the SNE and SYSCON software SNE on %4 , command %5 old software version or the messages be‐ versions with the upgrade tool. tween the SNE and SYSCON have been Reset the SYSCON and SNE. corrupted. 359 ! SNE I/O not found on I/O Write from SNE: %4 3.4.3 This should only occur if the SNE has an Check the SNE and SYSCON software old software version or the messages be‐ versions with the upgrade tool. tween the SNE and SYSCON have been Reset the SYSCON and SNE. corrupted. Alarms 5.2 360 - 399 GCP 5.2 Alarm Descriptions 360 - 399 The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # Text Description Action ! %!3 %4 General SNE Fault. Contact Customer Support. 361 ? %3 %4 General SNE warning. Contact Customer Support. 362 + %3 %4 General SNE note. Contact Customer Support. 363 ! Invalid function request %3 from SYSCON This indicates that the SNE has an obso‐ ● Check the SNE and SYSCON lete software version, or that the messag‐ software versions with the upgrade es between the SNE and SYSCON have tool. been corrupted. ● Reset the SYSCON and SNE. 364 ? No real-time buffer exists Detector data is being collected for a de‐ If received during a load sequence, it is for detector %3 on DPM %4 tector that wasn't properly enabled. an artifact of the shutdown sequence. Otherwise, record occurrence and DPM information and report to Custom‐ er Support. 365 ! Incomplete Analysis on channel %3 EZChrom analysis was not completed on channel. ● Send method to Customer Support. 366 ! Data Corruption Error Major Data corruption on SNE ● Reset SNE 360 ● Modify integration events in method. ● Report error to Customer Support. 367 ! System Error %3 in File %4 line %5 System Software Failure. Record sequence of events leading to occurrence and report error, along with the complete contents of the alarm mes‐ sage, to Customer Support. 368 ! Unable to find %3 number %4 Hardware specified in method is not in analyzer. Verify that the method is correct. 369 ! Unsupported channel type %3 Hardware channel operation requested for an invalid channel type. Inspect for current version of SNE soft‐ ware. May require a reload or rebuild of corrupted SYSCON database. 370 ? No channel %3 on DPM %4 for realtime display Realtime display requested for a detector Restore an older version of the data‐ channel that doesn't exist. Indicates da‐ base. tabase corruption. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 33 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description Action 371 # ! Invalid channel acquisition overlap on %3 Two channels referencing the same hardware detector are scheduled to ac‐ quire at the same time. If multiple application detector channels are assigned to the same hardware de‐ tector, do not allow their times to over‐ lap. 372 ! Scheduling error %3 scan‐ ning %4 # %5 channel %6 Unable to schedule all event and polling If method schedules many events as routines. May indicate a memory or hard‐ well as all 18 detectors, try removing ware failure. some of the events or deleting some of the detectors, then resetting the SNE. 373 ! Module I/O error %3 on %4 # %5 channel %6 Error between module and channel. Indi‐ Consider upgrading analyzer. cates obsolete anayler. 374 ! Internal communication er‐ ror %3 Software modules inside SNE are failing to communicate. 　Usually happens with out of memory condition resulting from SYSCON timeout. 375 ! End of cycle missed; stop‐ ping cycle The message that coordinates the end of Reset SNE. a method around the SNE tasks was lost. Reduce the complexity of the SNE set‐ up. Reduce processing requirements on SYSCON. Replace SNE. 376 + Adjusting cycle clock mas‐ ter Obsolete software version. Contact Customer Support. 377 ! Resource not found for scheduling ad‐ justment of event clock. SNE may be overloaded. Reduce complexity of tasks for SNE.Reset SNE to prevent event clock overflow. 378 + %3 samples adjusted on chrom from channel %4 An excessive number of samples re‐ Replace affected DPM. quired adjustment on chromatogram. Oc‐ curs in conjunction with DPM alarms. 379 ! Error %3 preparing analy‐ sis for channel %4 EZChrom processing error. Check integration events; modify events that may cause problems. 380 ! Error %3 finding chrom peaks for channel %4 EZChrom processing error. Check integration events and peak ta‐ ble; modify events that may cause prob‐ lems. 381 ! Error %3 generating re‐ sults for channel %4 EZChrom processing error. Example er‐ ror: Setting the threshold value too low, causing many peaks to be detected in the noise of the chromatogram. Check method for problems that could affect results. 382 ! EZChrom server failed er‐ ror %3 on channel %4 Resource problem on SNE. ● Reduce SNE workload. SNE is running out of processing capaci‐ Reduce SNE workload. ty. Replace SNE. Error %3 scheduling cycle clock master adjustment ● Replace SNE. 383 ? Software Watchdog Time‐ out 384 ! Method Modification Failed An attempt to modify a running method failed, most likely due to invalid data. 385 ? Event occurred before modification request Before a modification of a running meth‐ Contact Customer Support. od was completed, the event occurred. 386 ! Invalid Cycle Length %3 A cycle length larger than the maximum size was specified in a method. Usually caused by a corrupt method. Maximum cycle length is approximately 2 days. Verify correct values in method. 387 ! Invalid Sample Rate %3 on channel %4 Invalid sample rate value chosen for channel in method. Verify the methods and use only a sup‐ ported detector sample rate. 34 Verify that modification was valid. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description 388 # ! Acquisition time greater than cycle length on chan‐ nel %3 Start and stop acquisition times for a de‐ Decrease acquisition time or increase tector exceeded the method cycle length. cycle method time. 389 ! Invalid Event Type %3 for event %4 Invalid event downloaded with method. Check for proper SNE version. Rebuild method. 390 ! Invalid Start Time %3 for event %4 Event time specified that is outside the cycle start and stop times. Correct the method using EZChrom. 391 ? %3 messages not sent to SYSCON from SNE Some messages that the SNE attempted to send to SYSCON were lost. 　Results may be unpredictable. Reset the device. 392 ? %3 Detector underflows detected on channel %4 of module %5 Detector is reading a raw value of 0. 　It is potentially clipping the signal at the low value. Check the method. 393 ? %3 Detector opens detec‐ Detector channel is not connected. ted on channel %4 of mod‐ ule %5 Verify the detector hardware to ensure that it is properly connected and that the detector is not damaged. 394 ? %3 Unexpected Calibra‐ tion points on channel %4 of module %5 Detector channel unexpectedly went into calibration mode. Replace DPM if persistent. 395 ? %3 Detector overflows on channel %4 of module %5 Detector is reading above its maximum value and the signal is being clipped. Reduce the amount of sample or, if pos‐ sible, the detector gain. 396 ! SNE out of memory at %3 line %4 SNE is out of memory. Reduce SNE workload. Report to Cus‐ tomer Support. 397 ! Invalid Trace from channel %3 System error Contact Customer Support. 398 ! Invalid Number of Temper‐ The number of temperature program set‐ Rebuild temperature events for method. ature or Pressure Program points was different from the number Segments sent. 399 + Results not calculated for Channel %3 3.4.4 System error Action Contact Customer Support. Alarms 5.2 400 - 562 GCP 5.2 Alarm Descriptions 400 - 478 The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # Text Description Action Replace SNE. 400 ! Sync Bus Failure %3 Sync Bus Test failed. 401 ! No detector present for configured detector %3 On Advance Plus unit, configured detec‐ Check sys_detector_cfg configuration. tor is invalid. 402 + SNE reset requested Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 SYSCON requested a reset from the SNE. Usually means that the communi‐ cations between the SNE and SYSCON timed out. 　This is can happen when SYSCON is overloaded. Reset SNE. Reduce processing demands on SY‐ SCON. 35 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description Action 403 # ! Configured Detector %3 Balance Failure Balance Failure from an Advance+ de‐ tector. Check sys_detector_cfg configuration. 404 ? All Methods must be in Hold before Configuring Detectors All methods must be in hold while chang‐ Set all application in hold and wait for ing the configuration of any configured cycles to complete. Then reconfigure detectors. Advance Plus configured detector. 405 ! Method not on tracking list: SNE processing error. Count = %3 Track ID = %4 Contact Customer Support. 406 ! Error %3 Monitoring Purge Signal SNE or I2C error. Reset unit. 407 ? SYSCON-SNE Communi‐ cations Overload Detected SNE or I2C messaging error. Contact Customer Support. 408 ? Spurious detector acquisi‐ tion SNE error. Contact Customer Support. 409 ? SNE low on Memory SNE error. Reduce the memory consumption. Some examples of how to do this in‐ clude: Reduce the number of peaks detected by increasing the threshold. Reduce the length of cycles. Reduce the detector sampling rate. 420 ! Heartbeat timeout MicroSAM: error Contact MicroSAM support for assis‐ tance. 421 ! Heartbeat lost MicroSAM: error Contact MicroSAM support for assis‐ tance. 422 ! Cannot connect to RSP MicroSAM: error Contact MicroSAM support for assis‐ tance. 423 ! Method %3 has more than 8 simultaneous events MicroSAM: error Contact MicroSAM support for assis‐ tance. 424 ! Method %3 has more than 255 events MicroSAM: error Contact MicroSAM support for assis‐ tance. 425 ! EZChrom Method Verifica‐ tion failed, code %3 The method was successfully downloa‐ ded from the SYSCON to the EMSNE but failed an integrity verification test. 　The method is likely corrupted or may contain a feature which is not supported. Re-export the method to the SYSCON and attempt verification again. 426 ! 427 + Detector simulation activa‐ ted 36 SIMDIS not supported Rebuild the method, export to SYSCON and attempt verification again. Contact Customer Support. The EZChrom method contains the simu‐ Remove the SIMDIS option from the lated distillation analysis option which is method or use a separate SNECON if not supported by the EMSNE. SIMDIS is needed for this application. The detector data reported by the DPM is from a simulation chromatogram read from the EZChrom trace binary and not from actual data acquired by the DPM. This is normal when running a simulation. If simulation is not desired, the trace (TRC) binary must be removed from the EZChrom method for non-simulated chromatogram data to be collected. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description Action 428 # ! Invalid configuration for smoothing noise measure‐ ment The method contains a channel with smoothing noise measurement and the time range used for noise measurement is outside of the time range of the chro‐ matogram. 　The analysis was aborted and the results for this channel could not be calculated. Correct the method (on the workstation) so that the time range used for noise measurement falls within the time range of the chromatogram. 460 ! Invalid Method Write System error Not applicable 461 ! Argument %3 , Invalid Type %4 System error Not applicable 462 ! Invalid Method Section %3 System error Not applicable 463 ! Unable to Run Method, Hardware Initializing System error Not applicable 464 ! Unable to Run Method, In‐ strument Busy System error Not applicable 465 ! Error Running Method System error Not applicable 466 ! Error Installing Method System error Not applicable 467 ! Error Retrieving Method System error Not applicable 468 ! Unable to Run Method, Not on Method List System error Not applicable 469 ! Invalid component results System error Not applicable 470 ! Invalid Spectrum results System error Not applicable 471 ! Invalid calibration file %3 line %4 System error Not applicable 472 ? Unknown method status %3 System error Not applicable 473 ? Multiple component sets not allowed System error Not applicable 474 ? Multiple component scans not allowed System error Not applicable 475 ! Component report invalid System error Not applicable 476 ! Arguments do not match script System error Not applicable 477 ! Component report with no associated method System error Not applicable 478 ! Internal reset commanded System error Not applicable 511 ! Program Failed event # %3 %4 Error running MaxBasic program. Check message and program. If this program was written by Siemens, con‐ tact Customer Support. 512 ? Program execution cancel‐ Cancellation requested from HMI or CIM led: event # %3 Display. Informational. No action necessary. 513 ! Program Failed: Run re‐ quested on running event # %3 Occurs when overrun_option is set to 2 and event is run while event is still run‐ ning from a previous request. Check event timing or change overrun option. 514 ! Program Invalid frequency; disabling event # %3 Invalid program frequency. Check program_schedule setup. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 37 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description Action 515 # ? Program Overrun for event # %3 Occurs when overrun_option is set to 1 and warns that a program is running when a previous run of the same pro‐ gram has not finished. Check cycle event timing or frequency of program or ignore. 516 ! Formula Failure: %3 Occurs with result formula fails. Check the contents of the Alarm Text. 561 + EZChrom download Informational message. No action necessary. 562 + EZChrom upload for app %1 method %3 Informational message. No action necessary. 3.4.5 Alarms 5.2 671 - 699 GCP 5.2 Alarm Descriptions 671 - 699 The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # 671 ! Text Description Action Database: Failure: %3 1. Cannot find method; Check methods and sequences. 2. Cannot find MaxBasic program; Check program table. 3. Invalid stream for program; Check program streamcontext. 4. Bad status on external result. Verify extresult table entries. 672 ! Database: Remote Service lost on %3 A connection for remote I/O or result Check the status of the remote unit. transmission has been closed. This alarm is normal when the remote unit be‐ comes unavailable. 673 ! Database:value > limit: %3 Limit exceeded. See Alarm Text. See the Limits and Alarm Handlers ta‐ bles under the GCP Application View. 674 ! Database value < limit: %3 Limit exceeded. See Alarm Text. See the Limits and Alarm Handlers ta‐ bles under the GCP Application View. 675 ! Database: No Stream at cy‐ Cannot locate stream to start. cle start on applicaton %1 Check sequence to make sure that the entries are enabled. 676 ! Database: delay limit ex‐ ceeded on stream %3 Temperature or pressure wait set in the method has been exceeded. Check temp or press controller. Check wait_delta and maxwait in tem‐ perature or pressure controller table. 677 ? Next Stream Error Cannot locate next stream in sequence after a stream step. Check sequence to ensure that there is an enabled stream. 678 ! End of Cycle occurred be‐ fore events completed System error Contact Customer Support. 679 ! Application is out of service Attempt was made to move (approve) re‐ Put application in service. sults for an out-of-service application. 680 ? Print job failed: %3 for Print‐ Print failure. er: %4 38 Check printer. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # Text Description Action ! Application is disabled Attempt was made to set disabled appli‐ cation to run. Enable application. 682 ! Database: I/O failure: %3 Bad status on AO, DO write. Check I/O channels. 683 ? Database: no normal se‐ quence for application: %3 No active sequence. Check sequences. 684 ? Database: no enabled en‐ tries in sequence Cannot find enabled entry in sequence. Check sequence. 685 ? Printer: TCP connection or queue failed Printer connection failed. Check address in printer table. 686 ? Printer: TCP Print failed Communication failure with TCP printer. Try printing again. 687 ! Results for cycle %3 lost due to SNE reset This alarm marks results as uncertain un‐ Automatic repair: No action necessary. til a cycle has been completed after re‐ setting unit. 688 ! Method is corrupt: %3 re‐ load from EZChrom Method is corrupt. Download method from EZChrom. 689 ! Database: Fault on Slave Application %3 A fault is being transferred from the slave to the master to invalidate the master's results. Check fault in slave application. 690 ! Database: Slave Applica‐ tion not Complete %3 Master application is trying to run when Check cycle length of slave application; slave is not in hold. The slave must com‐ should be shorter than master. Also plete before the master. could occur if autocalibration sequence for master is shorter than for the slave. 691 ? Database: Warning: %3 System error 692 ! Database: Divide by zero in Peak measured value is zero during cal‐ Check method. %3 ibration for an autocalibration, so marginchecking cannot occur. 693 ? Database: I/O warning: %3 System error Contact Customer Support. 694 ? Database:value > limit: %3 Limit exceeded. Message should contain sufficient information. See the Limits and Alarm Handlers ta‐ bles under the GCP Application View. 695 ? Database value < limit: %3 Limit exceeded. Message should contain sufficient information. See the Limits and Alarm Handlers ta‐ bles under the GCP Application View. 696 ? DB: Screen access denied System error Contact Customer Support. 697 ! DB: Run requested on dis‐ abled program: %3 System error Contact Customer Support. 698 ? NAU %3 not available for communication 1. No analyzer reference in host table for Maxum Modbus Check the cables at the sending and receiving ends. 681 Contact Customer Support. 2. Cannot open connection to remote an‐ alyzer for Maxum Modbus or remote I/O. This is a sometimes-temporary error that indicates a problem in the host table or a network problem. 699 ? MODBUS: result is not in address map %3 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Cannot find address in map for result or analyzerstatus that came from an ana‐ lyzer. Check modbus_addmap for an incor‐ rect anlz attribute. 39 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.6 Alarms 5.2 700 - 736 GCP 5.2 Alarm Descriptions 700 - 736 The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # 700 ? Text Description Action Network: Analyzer %3 not available Analyzer cannot be opened from NAU to receive message from the DCS. Check network. Reset SYSCON. 701 ? MODBUS: scale factor or euhi absent for %3 Scale factor or EUHI is absent for scaled results. Check contents of modbus_addmap. 702 ? MODBUS: host command for %3 invalid; undefined database location A DCS command has been received for an undefined address. Check contents of modbus_addmap. 703 ? MODBUS: host command for undefined address: %3 DCS message received that is for an un‐ Check contents of modbus_addmap. known address. 704 ? MODBUS: host cannot write to this address: %3 The address written to by the DCS is not defined with a value_type that the host can send messages to. Check value_type of address in mod‐ bus_addmap. 705 ? MODBUS: mod‐ bus_msg_buffer cannot be processed: %3 1. Invalid DCS command was sent to an Optichrom or 1. Cannot clear alarms on optichrom or 2. EUHI, calibrate, stream select, skip stream, run/hold, doset set from host that cannot be located in analyzer table. 2. Check analyzer table to see if entry occurs or wait until analyzer broadcasts. 706 ? MODBUS: cannot locate euhi %3 Cannot find EUHI for result. 707 ? Calibration rejected: mar‐ gin exceeded for %3 Peak or group margins exceeded on auto Check peak or group margins in EZ‐ calibration. Chrom. 708 ? MODBUS: Data type fail‐ ure for address: %3 Data_type mismatch with value_type. 709 ! DB: AI averaging %3 Averaging is occurring on an AI with no Check configuration of AI averaging. result designated to receive the average. 710 ? DB: AI averaging %3 Averaging is occurring on an AI with no Check configuration of AI averaging. result designated to receive the average. 711 + Database: %3 System error Contact Customer Support. 712 ! SYSCON has been reset. No action necessary. %6 Start Ver: %3 - %4 on %5 Check EUHI address in modbus_add‐ map_result table. Check modbus_addmap. 　This is usu‐ ally self-correcting, but changes should be checked. Informational message. 713 + System backed up System error Contact Customer Support. 714 + All alarms cleared System error Contact Customer Support. 715 + Database Build System error Contact Customer Support. 716 ? DB: Invalid Sourcekey or SourceAttribute for Stat‐ Mon table: ID %3 Occurs when StatMon table is not prop‐ erly configured. Consult documentation. 717 ? DB: Calibration : margin check/reports are invalid for curve type Occurs when a margin is set in EZChrom for a curve type that does not support margin checking. Remove margin or change curve type. 40 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # Text Description Action Validation failed for %3 Validation has failed. Check report or validation results screen on the HMI or CIM Display. + Database: SNE reset re‐ quested SNE is indicating that it has been reset from a database request. May indicate a communication over‐ load. 720 ? Reprocess button pushed while applica‐ tion in run. Only push reprocess button when ap‐ plication is in hold. 721 + Application is in service Informational message. No action is necessary. 722 ? Reference Component not found; Component %3 , Reference %4 Quantra alarm. Contact Customer Support 723 ! Database: Method ID %3 not found Method ID is in sequence, but not in method table. Check method table. 724 ? Calibration or Validation failed; application in hold Calibration or validation was requested while one was already running. Check timing of calibration or validation events. 725 ? DB: Method %3 halted Application was halted from the HMI, No action necessary. CIM display, or a MaxBasic program. In‐ formational message. 726 ! DB: Slave application stream is invalid %3 A stream ID in slave does not line up with master application stream ID (new re‐ quirement for version 4.0). Check master and slave sequences. 727 ? DB: Master app autocali‐ bration completed before Slave app %3 Master autocalibration sequence is fin‐ ishing before slave autocalibration. Check length of sequences. Master au‐ tocalibration sequence must finish after slave autocalibration. 728 ? DB: application cannot au‐ tocalibrate Autocalibration was requested on appli‐ Check autocal attribute in application cation that is not defined for autocalibra‐ table. tion. 729 ! DB: message processing timeout for message %3; attempting recovery System error Contact Customer Support. 730 ! DB: Unnamed peak pro‐ cessing exceeded (2000) for channel %3 Processing for unnamed peaks must not exceed 2000 peaks for a channel. Ex‐ cess peaks were discarded. Increase the EZChrom threshold value to reduce the number of peaks. 731 ! CAN initialization failure for application %3 Application does not start until CAN Verify that all application I/Os are prop‐ cards required by the application are ini‐ erly initialized. Remove any I/O that de‐ tialized. The application starts regardless pends on a CAN card that is not present. of the error after 30 seconds. 732 ! IO: underflow or lower fail‐ safe condition detected for %3 The firmware is reporting an under-range error for analog NAMUR data types 6 or 8. Check the wiring for the secondary de‐ vice being used. Verify proper ranges for the I/O. 733 ! IO: overflow or upper fail‐ safe condition detected for %3 The firmware is reporting an under-range error for analog NAMUR data types 7 or 8. Check the wiring for the secondary de‐ vice being used. Verify proper ranges for the I/O. 734 ! %3 Process not communi‐ cating Occurs when ADHMaxumD or I2CDB connection is not present. Contact Customer Support. 735 ? IO: AO value was clamped for %3 to %4 Indicates clamping of AO value. Informa‐ No action necessary. tional message. 736 ? Untrusted Connection Re‐ fused from %3 A connection was refused from an exter‐ Trusted Connections are defined on the nal client due to the trusted-connection HMI. Please contact your site's admin‐ function. istrator or Siemens Customer Service. 718 ? 719 Database: Reprocess dur‐ ing Run not allowed Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 41 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.7 Alarms 5.2 801 - 999 GCP 5.2 Alarm Descriptions 801 - 999 The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. Text Description Action 801 # ? System Error %3 in File %4 line %5 System Error Contact Customer Support. 802 ? Error %3 opening Flash File %4 System Error Reset the device. If the error persists, replace the Flash/SRAM module. 803 ? Error %3 closing Flash File System Error Reset the device. If the error persists, replace the Flash/SRAM module. 804 ? Error %3 reading Flash File System Error Reset the device. If the error persists, replace the Flash/SRAM module. 805 ? Error %3 writing Flash File System Error Reset the device. If the error persists, replace the Flash/SRAM module. 806 ? Memory Corruption Error from Task %3 An attempt to free a block of memory was 1. Save a fresh copy of the database to unsuccessful because the header was your Maxum Workstation. 　 overwritten. The block of memory was 2. Connect to the SYSCON Debug port not returned to the free pool. with hyperterminal or equivalent with ‘save to file’ turned on. 　 3. Type the login and password individ‐ ually when prompted (maxum, maxum) 4. Type each of the diagnostic com‐ mands one at a time from the following list: ps, id, fr, st a, ck netstat, ifstatus, uptime. 　 5. Send the debug file and the .amd file to Customer Support. 807 + Region 0 Memory Low: %3 The amount of free memory in the SY‐ SCON is low. Verify the amount of memory installed in the SYSCON. Contact Customer Support. 808 + Excessive Network Com‐ munications 809 + System is excessively busy This is an overload situation, the process‐ To reduce processor load: or cannot keep up with the requests. ● Reduce the size of the Modbus table. The internal network communication buf‐ Investigate the cause of the high net‐ fers (PNA buffers) are abnormally low. work traffic. This indicates that the network traffic to the analyzer is abnormally high. ● Reduce the number and poll rate of AIs and DIs. ● Reduce the number of concurrent applications running. ● Reduce the communication burden with Optichrom analyzers. 42 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # Text Description Invalid dbdat file The db.dat file, containing the 'cold' da‐ Perform a manual save to flash as soon tabase on a Compact flash system, is as possible in order to have a valid missing or invalid. 　This may happen if db.dat file. the system was reset or powered down during a user initiated save to flash (initi‐ ated from the HMI, CIM display, or the workstation). Action 810 ? 811 + Excessive Maxum broad‐ casts were dropped Other analyzers on the network are gen‐ Investigate the network traffic. Contact erating network broadcast messages at Customer Support for assistance. an abnormal rate (greater than 200/min). The excessive traffic is ignored. As a re‐ sult, the status of the analyzers in the an‐ alyzer table may not be up to date. 812 ? The internal network communication buf‐ Reset the device. Contact Customer fers (PNA buffers) are full; the system Support. may not function normally. 813 + SYSCON-SNE Comm De‐ bug: %3 Debugging information, for internal use. No action necessary. 814 ? The built-in SYSCON clock has an inva‐ lid time. Check SYSCON clock battery and re‐ place if needed. 997 + %3 General alarm used for information. No action necessary. Used most often by MaxBasic programs. 998 ? %3 General warning alarm used for informa‐ Immediately report runtime errors to tion. Used most often by MaxBasic pro‐ Customer Support (please make care‐ grams. ful note of the alarm message). 999 ! %3 General fault alarm used for information. Immediately report runtime errors to Used most often by MaxBasic programs. Customer Support (please make care‐ ful note of the alarm message). Network communication overload Invalid CMOS time, check the battery 3.4.8 Alarms 5.2 1002 - 1096 GCP 5.2 Alarm Descriptions 1002 - 1128 SNE Common Module Errors The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # Text Description Action 1002 ! ID Key Not Connected on %4 All PICs: The module location ID connec‐ Verify that the location ID connector is tor is disconnected or set to 0. This is an in good condition and connected prop‐ abnormal condition; the module may not erly. be operational. 1003 ! ID Key Change on %4 All PICs: The module location ID value was changed while the module was op‐ erating. This is a transient error that cau‐ ses the module to automatically reset. The module can then be addressed and operated at the new location ID. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Verify that the location ID connector is in good condition and connected prop‐ erly. Check for intermittent connection. 43 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # 1004 1005 ! ? Text Description Action EEPROM Bad Checksum on %4 All PICs: A checksum error was detected in the module EEPROM. The firmware will still use all the information that it can read from the EEPROM. However, the module may not operate normally. Cycle power. Temp Diag Error on %4 All PICs: The on-board temperature sen‐ sor (LM-75) diagnostic failed. This alarm indicates that the ability of the board to detect a module overheat (alarm #1044) may be compromised. This alarm is may happen occasionally following a board reset. No action is required unless the error happens every time the board is reset. For these repetitive errors replace the module. If the error repeats, replace the module. This alarm is in no way related to and should not be confused with the Over‐ temp Shutdown related to heater temper‐ ature controls. 1007 ! Firmware Fault on %4 All PICs: A 'run-time' error was detected in the PIC firmware. For example, a timer is turned off at a point where the firmware expects it to be on. The firmware will at‐ tempt to recover. Usually an additional specific flag will be set to provide more information about the cause of the fault. Contact Customer Support. 1008 ! EEPROM Bad Value on %4 All PICs: A value read from EEPROM is Cycle power. out of range or invalid. This may happen If the error repeats, replace the module. if a board’s EEPROM was incorrectly in‐ itialized during manufacturing. 1009 ! Local I2C error on %4 All PICs: A fatal error was detected while Cycle power. accessing the internal, on-board I2C bus If the error repeats, replace the module. (not the private bus between a SNE and a DPM). The communication with the onboard EEPROM or the LM75 (on board temperature sensor) is not working nor‐ mally. 1010 ! Fatal error on %4 All PICs: An error or an invalid operation‐ Contact Customer Support. al condition was detected by the PIC firm‐ ware. The board is shut down to a failsafe mode. 1041 ? AO Out Of Range on %4 All PICs: An AO was set to a value out‐ side of the allowed range. The value was clipped to the allowed range. Locate the problematic AO and change the AO value to a value within the prop‐ er range. For example, an EPC has a 0 to 100 psi nominal range for the pressure setpoint. An attempt to set the setpoint to 150 psi results in an "AO out of range" and the setpoint is clipped to remain within the allowed range (100 psi). 44 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # 1042 ? Text Description Invalid Group Channel on %4 All PICs: The hardware I/O channel(s) ● Check the 'Sys Hardware' table for requested does not exist on the module. invalid entries. Action ● Check that only detector channels are specified in the detector I/O table. ● Check that only EPC are defined in the pressure controller table. ● Check that only temperature controllers are defined in the temperature controller table. 1043 ? Invalid EEPROM Address on %4 All PICs: The on-board EEPROM ad‐ dresses requested do not exist or cannot be accessed within a single command. Report to Customer Support for further investigation. 1044 ? Board overheating on %4 All PICs: A module temperature greater than the defined maximum operating temperature (default 65°C) has been de‐ tected.Overheating must be corrected as soon as possible to avoid permanent damage to the analyzer electronics, in‐ cluding reduced module life expectancy or other board failures. If the overheating condition is real, de‐ termine and correct the cause of high operating temperature. Possible causes include ambient tem‐ perature higher than specification or an inoperative fan in the electronics enclo‐ sure (restricted air flow inside the EC). Note: This alarm can occur together with alarm 1005 (Temp Diag Error) in which case the board may not actually be over‐ heating. This alarm concerns the temperature in the electronics enclosure. This alarm is not related to the Overtemp Shutdown related to heater temperature controls. 1045 ? Output Locked on %4 All PICs: The state of the DO or the value of the AO are locked and cannot be changed. The AO or DO command was ignored. Some DO and AO are locked during a board self-test. When performing a board self-test, sus‐ pend all other operations affecting the board. 1047 ? PIC firmware diagnostic 47 on %4 System error Contact Customer Support. 1048 ? PIC firmware diagnostic 48 on %4 System error Contact Customer Support. 1049 ? PIC firmware diagnostic 49 on %4 System error Contact Customer Support. 1050 ? PIC firmware diagnostic 50 on %4 System error Contact Customer Support. 1051 ? PIC firmware diagnostic 51 on %4 System error Contact Customer Support. 1052 ? PIC firmware diagnostic 52 on %4 System error Contact Customer Support. 1053 ? PIC firmware diagnostic 53 on %4 System error Contact Customer Support. 1054 ? PIC firmware diagnostic 54 on %4 System error Contact Customer Support. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 45 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description Action 1055 # ? PIC firmware diagnostic 55 on %4 System error Contact Customer Support. 1056 ? PIC firmware diagnostic 56 on %4 System error Contact Customer Support. 1081 + Data Not Ready on %4 All PICs: The data requested is not avail‐ Contact Customer Support. able. 1082 + Reset Detect on %4 %5 All PICs: A reset was detected. Normal indication that the PIC was reset. 1083 + Power Up on %4 %5 All PICs: A power-up cycle was detected. No action necessary. Normal indication that the PIC was pow‐ ered up. 1084 + I2C Timeout on %4 All PICs: An I2C communication timeout timer has expired. The timer is reset after each successful character processed. Only an addressed module may gener‐ ate a timeout. The timeout can occur on incoming and outgoing characters. Contact Customer Support. 1085 + I2C Read Past End on %4 All PICs: The I2C communication master did not stop reading after the complete response had been sent. Contact Customer Support. 1086 + I2C Buffer Overflow on %4 All PICs: The combination of the transmit and receive I2C message was too large, causing a buffer overflow. 　(With kernel revision 1: SSP_READ_UNEXPEC‐ TED_STOP, a stop condition occurred before the end of the response). Contact Customer Support. 1087 + I2C Write Past End on %4 All PICs: In an I2C message, more than the number of bytes specified by the length was written. The extra bytes are ignored. Contact Customer Support. 1088 + I2C Resync Error on %4 All PICs: Severe I2C error, causing the Contact Customer Support. current message to be dropped. Commu‐ nication will re-synchronize after the next START or STOP condition. Usually as‐ sociated with alarm 1092. 1089 + I2C Write Unexpected Stop All PICs: A new I2C message was re‐ on %4 ceived in the middle of a write. The old message was discarded and the new message is served (this message may be out of sequence and therefore cause other flags to be set).[With kernel revi‐ sion 1: SSP_WRITE_UNEXPEC‐ TED_STOP, during a slave write a stop condition occurred before the message was completed. The message is ignor‐ ed.] 46 No action necessary. Contact Customer Support. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # Text Description Action 1090 + I2C Write Unexpected Start on %4 All PICs: A new I2C message was re‐ Contact Customer Support. ceived in the middle of a read. The old message was discarded and the new message is served (this message may be out of sequence and therefore cause other flags to be set). [With kernel revi‐ sion 1: SSP_WRITE_UNEXPEC‐ TED_START, during a slave write a Start or Repeat Start (RS) condition was de‐ tected before the entire message was re‐ ceived (according to the length field). The message is ignored and processing re‐ sumes following the Start or Repeat Start.] 1091 + I2C Write Before Read on %4 All PICs: An attempt was made to write an I2C message before reading the re‐ sponse from a previous message. 　This indicates that an attempt was made to do a 　Slave Write - RepeatStart - Slave Write combination. Contact Customer Support. 1092 + I2C Read Unexpected on %4 All PICs: An I2C read from the peripheral was attempted before a slave write loa‐ ded a command. Contact Customer Support. 1093 + I2C Invalid Checksum on %4 All PICs: An I2C message with an invalid checksum was received. 　The mes‐ sage was ignored. Contact Customer Support. 1094 ! All PICs: Some data was lost and is no Cycle power. longer available. For a detector channel If the error repeats, replace the module it means that a 'Detector Read' command or the SNECON. was received with an invalid index. This can happen when a request to retransmit detector data came too late when the da‐ ta was already gone from the buffer. Data not available on %4 This situation may also happen while ac‐ cessing the I/O related to the LM75 (BOARD_TEMPERATURE and OVER‐ TEMP_SETPOINT). It indicates that the local I2C bus was not available to per‐ form the desired action. 1095 + Invalid Message on %4 1096 + Diagnostic mode enabled on %4 1121 ! All PICs: An I2C message with a valid checksum was not recognized or had an invalid op-code. Cycle power. Informational message. No action Necessary. Firmware Math error on %4 All PICs: An unexpected math operation error was detected by the PIC. It can be an un-handled overflow, underflow, etc. This flag is always associated with a FIRMWARE_FAULT flag. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 If the error repeats, replace the module or the SNECON. Cycle power. If the error repeats, replace the module. 47 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # Text Description Action 1122 ! Firmware Mem error on %4 All PICs: A jump or a call was made to an Cycle power. invalid PIC memory location causing the If the error repeats, replace the module. PIC to be reset. 　This flag is always as‐ sociated with a FIRMWARE_FAULT flag. 1123 ! Firmware Table error on %4 1124 ! Firmware Watchdog on %4 All PICs: The PIC watch dog timer has expired causing a module reset. This flag is always associated with a FIRM‐ WARE_FAULT flag. It can be an indica‐ tion that the I2C clock or data line was held low for more than the timeout dura‐ tion (nominally 30 ms). It can also indi‐ cate that the PIC oscillator is not working normally. Cycle power. Firmware System Monitor on %4 All PICs: The background system moni‐ toring task has discovered a problem causing the PIC to be reset. It can be that the interrupt or timer were disabled when they should have been enabled, or some similar error. 　This flag is always asso‐ ciated with a FIRMWARE_FAULT flag. Cycle power. 1125 ! All PICs: An error was detected when ad‐ Cycle power. dressing an internal PIC firmware table. If the error repeats, replace the module. The index in the table is likely to be inva‐ lid. This flag is always associated with a FIRMWARE_FAULT flag. If the error repeats, replace the module. If the error repeats, replace the module. 1126 ! Firmware Application on %4 All PICs: A general PIC firmware error Cycle power. was encountered causing a board reset. If the error repeats, replace the module. 1127 ! Firmware Stack Overflow on %4 An abnormal condition was detected in the firmware of a specified module. Reset the device. If the condition per‐ sists, replace the affected module. 1128 ! Firmware Unknown Reset on %4 An abnormal condition was detected in the firmware of a specified module. Reset the device. If the condition per‐ sists, replace the affected module. GCP 5.2 Alarm Descriptions 1317 - 1319 SVCM Errors The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. ! Text Description 1317 # ! Valve Switch Error on %4 SVCM PIC: The SVCM firmware has de‐ Replace the module. tected an invalid condition in the circuit driving the solenoid valves. 　One or more valves is likely to be malfunctioning. 1318 ! J10 Disconnected on %4 SVCM PIC: The SVCM J10 connector is not properly connected and the corre‐ sponding bank of solenoids may not work. Check the J10 connection. 1319 ! J11 Disconnected on %4 SVCM PIC: The SVCM J11 connector is not properly connected and the corre‐ sponding bank of solenoids may not work. Check the J11 connection. 48 Action Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.9 Alarms 5.2 1617 - 1697 Pecm Errors GCP 5.2 Alarm Descriptions 1617 - 1697 PECM Errors The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # 1617 - 1624 1625, 1626 1627 ! ! ! Text Description Action LWHn Output Fault on %4 PECM PIC: On-board diagnostic indicat‐ ing that a LWH is not working correctly. This diagnostic is active only when a SSR output is configured for PECM selfcontrol, when the loop-back connector is present. The diagnostic is not active when the control is from a temperature controller. If this happens when the out‐ put is controlled by a temperature con‐ troller, it indicates a defective harness between the DPM and the PECM. (The PLUG_DETECT pin (#5) is not grounded and the output is turned on). If associated with an 'Invalid configura‐ tion alarm' (1659), then check the J con‐ nector on the PECM associated with the specified LWH. PECM PIC: On-board diagnostic indicat‐ ing that an ABH is not working correctly. This diagnostic is active only when a SSR output is configured for PECM selfcontrol, when the loop-back connector is present. The diagnostic is not active when the control is from a temperature controller. If this happens when the out‐ put is controlled by a temperature con‐ troller, it indicates a defective harness between the DPM and the PECM. (The PLUG_DETECT pin (#5) is not grounded and the output is turned on). If associated with an 'Invalid configura‐ tion alarm' (1659), then check the J con‐ nector on the PECM associated with the specificed ABH. PECM PIC: The air bath heater control cable is missing in J9 and at least one of the air-bath heaters is non-disabled. 　If the cable is missing, the NO_AIR_ABH_x flag will also be set on the non-disabled air-bath heater channels. If the air bath heater is not used, then disconnect J91 and J92 on PECM in or‐ der to eliminate the alarm. ABHn Output Fault on %4 ABH Ctrl Plug Missing on %4 Otherwise, replace the PECM or the ca‐ ble between the DPM and PECM. Otherwise, replace the PECM or the ca‐ ble between the DPM and PECM. Otherwise check J9. 1628 ! ABH Air Plug Missing on %4 PECM PIC: The air-bath heater air-sen‐ sor connector is missing and at least one of the air bath heaters is non-disabled. Check J10 on PECM. 1629 ! Purge Indicator not availa‐ ble on %4 PECM PIC: Neither the SYSCON nor the HMI level 1 LED panel is connected. It indicates that there is no purge indicator connected, the PECM has nowhere to report the purge information. Check J1302 and J101 on PECM. Ver‐ ify the cable connected into J1302. 1630 ! The low wattage relay board is missing PECM PIC: The low wattage relay board is not connected properly to the PECM electronics. Confirm that the relay board is connec‐ ted properly. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Replace the relay board and/or the PECM electronics. 49 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # 1633 - 1638 1657 - 1658 ! ? Text Description Action Output error on solenoid valve, [location, group specified in alarm text] PECM PIC: The solenoid output status read-back value is incorrect for at least one valve in the group. This can happen when a solenoid cable is disconnected, even momentarily.　 Note that the readback check can only be accomplished when the state of the output to a solenoid is OFF (no verification can be done on an output when it is ON). ● Verify the cable connections. ABHn No Air on %4 ● Replace the solenoid group cable. ● Replace the solenoid group. ● Replace the PECM board. PECM PIC: The air bath heater #n is ● If the channel is not in use, turned off, as the air pressure is too low disconnect the loopback connector for a safe operation of the heater. This or temperature controller cable. flag is set only if the corresponding air bath heater is in use. 　The PECM con‐ ● Check the air pressure on the corresponding air bath heater. siders the air bath heater in use if a loop‐ Make sure that it is 10 psi or above. back connector or a cable from a temper‐ ature controller is connected. ● Electrically disconnect the pressure switch: – Verify that it operates normally by measuring the contact resistance with a multimeter at 0 and 10 psi. – Verify with a multimeter that there is no continuity to ground. ● Verify the harness with a multimeter. ● Replace the PECM. 1659 ? Invalid Configuration on %4 PECM PIC: An attempt was made to con‐ Install or verify the corresponding trol a heater output with a DO command PECM loopback plug. while the corresponding loopback is not installed. 1665 - 1670 ? Solenoid valve disconnec‐ This alarm can be generated as a result ted, [location, group speci‐ of either of the following: fied in alarm text] ● The cable to the corresponding valve group was disconnected since the last time the PECM board was reset. As a result, all valves in that group may not work properly. ● Verify that the solenoid valve cable is properly seated in the connector and reset the device. ● Verify the configuration of the DOs in all applications to ensure that no DO is referencing a valve in a nonconnected group. ● A digital output was invoked to a disconnected valve group. The output cannot be controlled. 1697 50 ? Purge Loss on %4 PECM PIC: Purge failure in the EC en‐ ● Verify that door is closed. closure. The pressure differential be‐ ● Check for damaged door gaskets. tween the interior and exterior of the EC ● Verify that all cables and tubes is not high enough. Depending on the entering the EC are sealed properly. environment classification where the an‐ alyzer is installed, this alarm may indi‐ cate an unsafe condition that requires immediate action to correct.Check sup‐ ply-air pressure. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.10 Alarms 5.2 1917 - 2005 DPM TCD GCP 5.2 Alarm Descriptions 1917 - 1999 DPM Errors The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. Text Description Action 1917 # ! Balance Hardware Failure TCD L %5 on %4 System error Contact Customer Support. 1918 ! Balance Hardware Failure TCD U %5 on %4 System error Contact Customer Support. 1919, 1920 ! A/D Failure TCD %5 on %4 TCD DPM Detector PIC: Set when the Cycle power. If the error repeats con‐ corresponding Analog to Digital Convert‐ sistently, replace the module. er hardware does not work properly. The flag will be set if the A/D internal calibra‐ tion cycle is not completed within a predetermined period of time or the A/D does not report any valid data within a pre-defined timeout period. Note: A firmware problem affecting the version 1.000 of the TCD detector PIC may cause an A/D failure flag to show-up occasionally following a PIC reset. This is not a sign of a defective A/D converter. 1921 ! PIC Timeout on %4 System error Contact Customer Support. 1922 ! Incompatible Hardware on %4 TCD DPM Detector PIC: The PIC firm‐ ware is not compatible with the DPM board. Replace the module. 1925 ? Glow Plug bad FID DPM Detector PIC: The glow plug is not working correctly. The diagnostic is performed when the board is reset or when an attempt is made to light the flame. The hardware diagnostic verifies that a minimum current and voltage is present, checking for a short and open glow plug. This may also indicate that a spark igniter that is not connected prop‐ erly. Confirm that the glow plug or spark ig‐ niter cable is securely inserted in the corresponding connector. Replace the glow plug. Replace the DPM. 1926 ! Invalid PIC index DPM Detector PIC: The PIC index is not Replace the module. valid, the DPM board is not working nor‐ mally. 1927 ! Mezzanine module discon‐ FID DPM Detector PIC: The mezzanine- ● Verify that the mezzanine module is nected module ID value is 0 or 15 indicating that properly connected. no module is present or is malfunctioning. ● Replace the module on the DPM. ● Replace the DPM. 1928 ! Mezzanine-module ID changed Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 FID DPM Detector PIC: The mezzanine- ● Verify that the mezzanine module is module ID value has changed since the properly connected. last time the board was reset. Indicates ● Replace the module on the DPM. a bad contact or a bad component. ● Replace the DPM. 51 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # Text Description Action 1929 ! Mezzanine-module ID inva‐ FID DPM Detector PIC: The mezzanine- ● Verify the DPM revision level and lid module ID value is not supported by this replace as needed. DPM board. 　More specifically, the ● Replace the mezzanine module on module value is pointing to a non-initial‐ the DPM. ized EEPROM region on the DPM. 　 This may indicate an invalid mezzanine module or an older revision of the DPM that was manufactured before the mez‐ zanine module was defined. 1930 ! Mezzanine-module ID re‐ served FID DPM Detector PIC: The mezzanine- ● Verify the DPM revision level and module ID value is set to a value re‐ replace as needed. served for future expansion. ● Replace the mezzanine module on the DPM. 1957, 1958 ! Balance Failure TCD [L or U] %5 on %4 TCD DPM Detector PIC: 　For Rev 1 TCD DPM: A detector balance sequence failed because of a hardware failure, an improper configuration, or sequence of events. Some possible causes include: The detector beads are too unbalanced to be 'balance-able'. The detector signal is not stable enough and proper balance could not be obtained before the maxi‐ mum number of iterations was reached. The A/D or D/A do not work properly. The detector is not configured for acquisition or turned off. SIMULATE_TCD_x is set to ‘1’ (the detector cannot be balanced in detector simulation mode).The balance is disabled (DISABLE_BAL‐ ANCE_TCD_x is set to ‘1’). The sampling period was changed during the balance sequence. 1959, 1960 ? Balance Out Of Limit TCD [L or U] %5 on %4 TCD DPM Detector PIC: For Rev 1 TCD ● If associated with a balance failure DPM: 　A detector balance value is (alarm 1957), then the source of the above the normal limits. The balance balance failure must be corrected. may still work as this is an early warning. ● If not associated with a balance failure and the balance limits are normal (greater than 9 Volts or 90%) then schedule maintenance to replace the detector beads. Contact Customer Support. ● If using Rev 2 TCD DPM or FID DPM, contact Customer Support. 1961, 1962 52 ! The ADC missed a sample on channel [1 or 2] on %4 A transient error was detected by the An‐ Reset the DPM. If the error repeats, re‐ alog-to-Digital Converter of the DPM, place the DPM. channel #n. The missing or invalid data point was replaced by a point with a value of zero. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description Action 1965 # ? Flame ignition failure TCD DPM Detector PIC: The FID flame could not be lit within the predefined de‐ lay (25 or 60 sec). No other attempt will be made to automatically light the flame until the MANUAL IGNITION DO is acti‐ vated. If associated with an alarm 2225 (Glow plug failure), then diagnose and fix this other alarm first. If a BASIC program is used to control the electronic pressure controller (EPC) to adjust the gas mix‐ ture for proper ignition, confirm that the poll rate of the 'IGNITE' DI is set to 2 sec. Check that the gas supply pres‐ sure is adequate. Verify the proper op‐ eration of the EPC. 1966 ? Gain override TCD DPM Detector PIC: An external sig‐ If no external signal is connected, re‐ nal is applied to the DPM, overriding the place the DPM. DPM gain control. This is a normal situa‐ tion if a signal is connected to the exter‐ nal gain-select connector. 1967 ? Gain select not supported TCD DPM Detector PIC: An attempt was Remove access to the GAIN_ALT_SE‐ made to change the gain on a configura‐ LECT DO. tion that does not support the dual gain feature. The request was ignored. 1968 ? Igniter type changed TCD DPM Detector PIC: The spark ignit‐ Verify that the igniter is properly con‐ er was connected or disconnected during nected. Replace the igniter. Replace an ignition sequence, causing the igni‐ the DPM. tion sequence to be aborted. 1997, 1998 ! Buffer Overflow TCD [L or U] %5 on %4 DPM Detector PIC: The PIC detector da‐ ● Stagger the balance events and ta buffer filled up before an I2C command valve switching events by was received to retrieve the data. 　 approximately 10-20 ms to Some data was lost. The SNECON was distribute the load on the I2C bus. not fast enough to retrieve the points or ● Disconnect the SNECON debug the SNECON stopped polling without cable (if connected) and reset. turning off the corresponding detector channel. This may happen with a combi‐ ● Reload the SNECON OS and APP nation of a very high speed detector with software. a large burst of I/O commands. 2005 ! Firmware error Firmware error Contact Customer Support. 2006 ! Bias off FID DPM Detector PIC: The detector is used while the 300 Volts bias is disabled. 　The data validity is unknown. Set the 'disable bias' DO to ‘0’. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 53 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.11 Alarms 5.2 2217 - 2306 DPM FID GCP 5.2 Alarm Descriptions 2217 - 2306 DPM Errors The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. Text Description Action 2217 # ! Balance Hardware Failure FID L %5 on %4 System error Contact Customer Support. 2218 ! Balance Hardware Failure FID U %5 on %4 System error Contact Customer Support. 2219 ! A/D Failure FID %5 on %4 2221 ! PIC Timeout on %4 System error Contact Customer Support. 2222 ! Incompatible Hardware on %4 The firmware has detected an invalid condition indicating that the hardware is not compatible with the firmware. Replace the module. 2225 ? Glow Plug Bad on %4 FID DPM Detector PIC: The glow plug is not working correctly. 　The diagnostic is performed when the board is reset or when an attempt is made to ignite the flame. 　The hardware diagnostic veri‐ fies that a minimum current and voltage is present, checking for a short and open glow plug. This may also indicate that a spark igniter is not connected properly. ● Confirm that the glow plug or spark igniter cable is securely inserted in the connector. 2220 ! FID DPM Detector PIC: Set when the Cycle power. If the error repeats con‐ corresponding Analog to Digital Convert‐ sistently, replace the module. A/D Failure TCD %5 on %4 er hardware does not work properly. The flag will be set if the A/D internal calibra‐ tion cycle is not completed within a predetermined period of time or the A/D does not report any valid data within a pre-defined timeout period. ● Replace the glow plug. ● Replace the DPM. 2226 ! Invalid PIC index DPM Detector PIC: The PIC index is not Replace the module. valid; the DPM board is not working nor‐ mally. 2227 ! Mezzanine module discon‐ FID DPM Detector PIC: The mezzanine- ● Verify that the mezzanine module is nected module ID value is 0 or 15 indicating that properly connected. no module is present or is malfunctioning. ● Replace the module on the DPM. ● Replace the DPM. 2228 54 ! Mezzanine-module ID changed FID DPM Detector PIC: The mezzanine- ● Verify that the mezzanine module is module ID value has changed since the properly connected. last time the board was reset. Indicates ● Replace the module on the DPM. a bad contact or a bad component. ● Replace the DPM. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # Text Description Action 2229 ! Mezzanine-module ID inva‐ FID DPM Detector PIC: The mezzanine- ● Verify the DPM revision level and lid module ID value is not supported by this replace as needed. DPM board. More specifically, the mod‐ ● Replace the mezzanine module on ule value is pointing to a non-initialized the DPM. EEPROM region on the DPM. This may indicate an invalid mezzanine module or an older revision of the DPM that was manufactured before the mezzanine module was defined. 2230 ! Mezzanine-module ID re‐ served 2257 ! Balance Failure FID on %4 FID DPM Detector PIC: A detector bal‐ Contact Customer Support. ance sequence failed because of a hard‐ ware failure or because of an improper configuration or sequence of events. Some possible causes are: FID DPM Detector PIC: The mezzanine- ● Verify the DPM revision level and module ID value is set to a value re‐ replace as needed. served for future expansion. ● Replace the mezzanine module on the DPM. ● The detector signal is not stable enough and proper balance could not be obtained before the maximum number of iterations was reached. ● The A/D or D/A do not work properly. ● The detector is not configured for acquisition or turned off. ● SIMULATE_FID is set to 1 (the balance cannot be done in detector simulation mode). ● The balance is disabled (DISABLE_BALANCE_FID is set to 1). ● The sampling period was changed during the balance sequence. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 55 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # 2258 ! Text Description Balance Failure TCD %5 on %4 FID DPM Detector PIC: A detector bal‐ Contact Customer Support. ance sequence failed because of a hard‐ ware failure or because of an improper configuration or sequence of events. Some possible causes are: Action ● The detector beads are too mismatched to be balance corrected. ● The detector signal is not stable enough and proper balance could not be obtained before the maximum number of iterations was reached. ● The A/D or D/A do not work properly. ● The detector is not configured for acquisition or turned off. ● SIMULATE_TCD is set to ‘1’ (the balance cannot be done in detector simulation mode). ● The balance is disabled (DISABLE_BALANCE_TCD is set to ‘1’). ● The sampling period was changed during the balance sequence. 2259 ? Balance Out Of Limit FID on %4 FID DPM Detector PIC: A detector bal‐ ance value is above the normal limits. The balance may still work as this is an early warning. ● If associated with a balance failure (alarm 2257), then the source of the balance failure must be corrected. ● If not associated with a balance failure and the balance limits are normal (greater than 9 Volts or 90%), schedule maintenance to clean or replace the FID detector. 2260 ? Balance Out Of Limit TCD %5 on %4 2261, 2622 ! The ADC missed a sample on channel [1 or 2] on %4 A transient error was detected by the An‐ Reset the DPM. If the error repeats, re‐ alog-to-Digital Converter of the DPM, place the DPM. channel #n. The missing or invalid data point was replaced by a point with a value of zero. 2265 ? Flame Ignition Failure on %4 FID DPM Detector PIC: The FID flame could not be ignited within the predefined delay (25 or 60 sec). 　No other attempt will be made to automatically ignite the flame until the MANUAL IGNITION DO is activated. 56 If associated with an alarm 2225 (Glow plug failure), then diagnose and fix that alarm first. If a BASIC program is used to control the electronic pressure con‐ troller (EPC) to adjust the gas mixture for proper ignition, confirm that the poll rate of the 'IGNITE' DI is set to 2 sec. Verify adequate gas-supply pressure. Verify the proper operation of the EPC. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description 2266 # ? Gain override FID DPM Detector PIC: An external sig‐ If no external signal is connected, re‐ nal is applied to the DPM, overriding the place the DPM. DPM gain control. This is a normal situa‐ tion if a signal is connected to the exter‐ nal gain-select connector. Action 2267 ? Gain select not supported FID DPM Detector PIC: An attempt was Remove access to the GAIN_ALT_SE‐ made to change the gain on a configura‐ LECT DO. tion that does not support the dual gain feature. The request was ignored. 2268 ? Igniter type changed FID DPM Detector PIC: The spark igniter was connected or disconnected during an ignition sequence, causing the igni‐ tion sequence to be aborted. ● Verify that the igniter is properly connected. ● Replace the igniter. ● Replace the DPM. 2297, 2298 ! Buffer Overflow [FID or TCD] on %4 FID DPM Detector PIC: The PIC detector ● Stagger the balance events and data buffer filled up before an I2C com‐ valve switching events by mand was received to retrieve the data. approximately 10-20 ms to 　Some data was lost. The SNECON distribute the load on the I2C bus. was not fast enough to retrieve the points or the SNECON stopped polling without ● Disconnect the SNECON debug cable (if connected) and reset. turning off the corresponding detector channel. This may happen with a combi‐ ● Reload SNECON OS and APP nation of a very high speed detector with software. a large burst of I/O commands. 2299 ! Detector Disabled on %4 FID DPM Detector PIC: An attempt was made to read detector information from a disabled detector. Cycle power. If the error repeats re‐ place the module. 2305 ! Flame Out on %4 FID DPM Detector PIC: The flame is out; the data generated on the FID channel is invalid. ● Verify adequate flame gas supply. FID DPM Detector PIC: The detector is used while the 300 Volts bias is disabled. 　The data validity is unknown. Set the 'disable bias' DO to ‘0’. 2306 ! FID Bias off on %4 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 ● Verify the operation of any associated EPC. 57 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.12 Alarms 5.2 2500 - 2577 Access Bus Driver Errors GCP 5.2 Alarm Descriptions 2500 - 2577 Access Bus Driver Errors The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # Text Description Action 2500 ? I2C Premature Stop on %4 SNECON I2C driver: A stop condition was detected in the middle of a transfer (SNECON hardware revision 2.x). Contact Customer Support. 2501 ? I2C No Acknowledge (Mod‐ SNECON I2C driver: No module re‐ Reset the analyzer. ule Disconnected?) on %4 sponding to the I2C address. A module was disconnected or is no longer re‐ sponding. 　This can also happen if the PIC-index is erroneously set to 0 as this is a way to bypass the I2C address reso‐ lution table and directly address the I2C bus. 2502 ? I2C NS486 Timeout Over‐ flow on %4 SNECON I2C driver: An 　I2C commu‐ nication timeout condition was detected (SNECON hardware revision 2.x). 2503 ? I2C Address is Odd on %4 SNECON I2C driver: Illegal I2C address. Reset the analyzer. 　Reload SNE‐ CON OS software. 2505 ? I2C Driver Not Initialized SNECON I2C driver: An attempt was made to communicate to the I2C driver before it was initialized. ● Reset the analyzer. SNECON I2C driver: No module re‐ sponding to the I2C address. A module was disconnected or is no longer re‐ sponding (SNECON hardware revision 2.x). Contact Customer Support. Contact Customer Support. ● Reload SNECON OS and APP software. 2508 ? I2C Improper Acknowl‐ edge on %4 2509 ? I2C Invalid Message SNECON I2C driver: A message was re‐ (SNECON hardware revision 2.x): Ver‐ Checksum Received on %4 ceived with an invalid checksum. ify that the application does not use a hardware address that does not exist. 2510 ? I2C Module Not Found: %4 SNECON I2C driver: No module of this 'module type' and 'location id' is listed in the address table. ● Reset the analyzer. I2C Invalid Opcode Re‐ ceived from %4 SNECON I2C driver: The message re‐ ceived corresponds to an unrecognized opcode. ● Reset the analyzer. 2511 ? ● Verify that the application does not use a hardware address that does not exist. ● Reload SNECON OS and APP software. Replace the SNECON. 2512 ? I2C Error Reading ISR Queue SNECON I2C driver: An error was detec‐ Reset the analyzer. ted reading a communication queue (SNECON hardware revision 2.x). 2513 ? I2C Message Too Big on %4 SNECON I2C driver: The I2C message received is too large and is not valid. 58 Contact Customer Support. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description Action 2515 # ! I2C Address Table Full SNECON I2C driver: No free addresses on the I2C bus. There is a limit of 120 addresses per bus (each PIC occupies one address). Reset the analyzer. 2516 ? I2C Invalid Bus on %4 SNECON I2C driver: Invalid I2C bus identification number. Reset the analyzer. 2518 ? I2C Unknown Address Re‐ ceived on %4 SNECON I2C driver: SNECON firmware internal error. Reset the analyzer. 2519 ? I2C Invalid Data Type on %4 SNECON I2C driver: SNECON firmware internal error. Reset the analyzer. 2520 ? I2C Invalid Number of I/O Channels on %4 SNECON I2C driver: SNECON firmware internal error. Reset the analyzer. 2521 ? I2C Bus Conflict; Lost Arbi‐ SNECON I2C driver: An I2C communica‐ Confirm that only one SNECON is tration on %4 tion error was detected (SNECON hard‐ present on the bus; a revision 2 SNE‐ ware revision 2.x). CON cannot share the I2C bus. 2522 ? I2C Using a Free Message Buffer on %4 SNECON I2C driver: SNECON firmware internal error. Reset the analyzer. 2523 ? I2C NS486SXF-C0 Patch Timeout on %4 SNECON I2C driver: SNECON firmware internal error. ● Reset the analyzer. I2C Invalid Driver Control Command on %4 SNECON I2C driver: SNECON firmware internal error. ● Reset the analyzer 2525 ? ● Replace the SNECON. ● Reload the SNECON OS and APP software. ● Replace the SNECON. 2526 ? I2C Capability Information Too Big on %4 SNECON I2C driver: SNECON firmware internal error. Reset the analyzer. 2527 ? I2C Message Lost in a Con‐ SNECON I2C driver: A pending I2C mes‐ Contact Customer Support. troller Reset: %4 sage could not be sent and was lost as a result of a reset of the I2C interface. The cause of the reset is usually a recurring communication error. 2529 ? I2C Invalid Capability Ver‐ sion; Incompatible Firm‐ ware on %4 SNECON I2C driver: An I2C module has provided an invalid device capability in‐ formation message. The associated 'Sys_Hardware' table may be invalid. ● Replace the module 　 ● Reload newer SNECON OS and APP software. 2530 ? I2C Internal Error; Invalid Daemon Function on %4 System error Contact Customer Support. 2531 ? I2C Internal Error; Invalid Info on %4 SNECON I2C driver: 　SNECON firm‐ ware internal error. Reset the analyzer. 2532 ? I2C Invalid Device ID Ver‐ sion; Incompatible Firm‐ ware on %4 SNECON I2C driver: An I2C module has provided an invalid device ID information message. 　The module type and loca‐ tion ID information may be invalid. ● Replace the module. ● Reload SNECON OS and APP software. 2534 ? I2C Internal Error; Bus Manager Invalid Command on %4 System error Contact Customer Support. 2537 ? I2C Address Table not ini‐ tialized on %4 SNECON I2C driver: SNECON firmware internal error. Reset the analyzer. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 59 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # 2538 2539 ? ? Text Description Action I2C ISR Lockup SNECON I2C driver: 　The SNECON message receive indicator is stuck 　 (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C Invalid Message Sta‐ tus Size on %4 SNECON I2C driver: SNECON firmware internal error. ● Reset the analyzer. I2C Message Too Short on %4 SNECON I2C driver: An I2C message received by the SNECON is too short to be valid. Contact Customer Support. ● Replace the SNECON. ● Replace the SNECON. 2540 ? 2541 + I2C FPGA Queue Full on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. ? I2C FPGA Write Before End on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C FPGA Write After End on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C FPGA Message Too Short on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. 2542 2543 2544 ? ? ● Replace the SNECON. ● Replace the SNECON. ● Replace the SNECON. ● Replace the SNECON. 2545 ? I2C FPGA Invalid Check‐ sum on %4 SNECON I2C driver: SNECON on-board communication error. 　Known to hap‐ pen very infrequently with SNECON I2C FPGA rev 23 or lower (SNECON revision 3.0 hardware only). Ignore the alarm. If occurring frequent‐ ly, replace the SNECON. 2546 ? I2C FPGA Invalid Size on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. ● Reload the SNECON OS software. ● Replace the SNECON. 2547 ! I2C Heartbeat Timeout Ex‐ SNECON I2C driver: A SNECON PIC ● Reset the analyzer. pired; Resetting Controller was not responding and was reset (SNE‐ ● Reload the SNECON OS software. CON revision 3.0 hardware only). ● Replace the SNECON. 2549 ? I2C Heartbeat Counter Mis‐ SNECON I2C driver: One or more mes‐ ● Reset the analyzer. match on %4 sages were lost on the on-board commu‐ ● Reload the SNECON OS software. nication (SNECON rev 3.0 hardware on‐ ● Replace the SNECON. ly). 2550 ? I2C Invalid Message Sta‐ tus on %4 2551 2552 60 ? ? SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C Internal Error; Invalid Block Structure ID on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C Internal Error; Invalid Block Offset on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. ● Reload the SNECON OS software. ● Replace the SNECON. ● Reload the SNECON OS software. ● Replace the SNECON. ● Reload the SNECON OS software. ● Replace the SNECON. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # 2553 2554 2555 2556 ? ? ? ? Text Description Action I2C Internal Error; Invalid Block ID on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C Internal Error; New Block Offset Non-Zero on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C Internal Error; Block Table full SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C Not Enough Memory SNECON I2C driver: SNECON firmware internal error. ● Reset the analyzer. ● Reload the SNECON OS software. ● Replace the SNECON. ● Reload the SNECON OS software. ● Replace the SNECON. ● Reload the SNECON OS software. ● Replace the SNECON. ● Reload the SNECON OS software. ● Replace the SNECON. 2557 2558 2559 2560 2562 ? ? ? ! ? I2C Internal Error; Block Too Large on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C Internal Error; Block Not Found on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C Internal Error; Invalid Block Size on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reload the SNECON OS software. ● Replace the SNECON. ● Reload the SNECON OS software. ● Replace the SNECON. ● Reset the analyzer. ● Reload the SNECON OS software. ● Replace the SNECON. I2C Driver OS and Applica‐ SNECON I2C driver: The version num‐ tion version mismatch ber of the SNECON OS is incompatible with the SNECON APP version. ● Reset the analyzer. I2C Internal Error; Bad state on %4 SNECON I2C driver: SNECON firmware internal error. ● Reset the analyzer. I2C FPGA bad version SNECON I2C driver: The SNECON I2C FPGA is incompatible or broken. ● Reload the SNECON OS software. ● Replace the SNECON. ● Reload the SNECON OS software. ● Replace the SNECON. 2563 ! ● Reload the SNECON OS with the newest version. ● Replace the SNECON. 2564 ! I2C Temperature Block Version Invalid SNECON I2C driver: The temperature Reload the SNECON OS and APP soft‐ controller PID parameter data block sup‐ ware to the corresponding SYSCON plied by the SYSCON is incompatible. version. 2565 ? I2C Opcode not expected in current state on %4 SNECON I2C driver: Unexpected I2C message opcode received by the SNE‐ CON from a module.I2C communication error. 2566 ! I2C Modules were reset fol‐ SNECON I2C driver: A fatal error or mul‐ Contact Customer Support. lowing multiple errors tiple consecutive retries have forced the I2C controller to reset. 2567 ! I2C Header Index Mis‐ match; Message Lost Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 System error Contact Customer Support. Contact Customer Support. 61 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # 2568 2569 2570 2571 2572 2573 ? ? ? ? ? ? Text Description Action I2C Internal Error; Invalid Block Index on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C FPGA Queue Full on %4 SNECON I2C driver: The SNECON I2C FPGA queue is full, the PIC is no longer processing I2C messages. ● Reset the analyzer. I2C FPGA Packet Too Big on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C FPGA Recovery Failed on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C FPGA Read in pro‐ gress not set after header on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. I2C Not enough memory in ISR on %4 SNECON I2C driver: SNECON firmware internal error (SNECON revision 3.0 hardware only). ● Reset the analyzer. ● Reload the SNECON OS software. ● Reload the SNECON OS software. ● Reload the SNECON OS software. ● Replace the SNECON. ● Reload the SNECON OS software. ● Replace the SNECON. ● Reload the SNECON OS software. ● Replace the SNECON. ● Reload the SNECON OS software. ● Replace the SNECON. 2574 ! I2C PIC Reset Detected on %4 SNECON I2C driver: A problem was de‐ If occurring frequently, replace the SNE‐ tected by a SNECON PIC and it went CON. through a reset. Can also be caused by an I2C communication error. 2575 ? I2C General AO error on %4 SNECON I2C driver: A channel specific error was detected while an AO com‐ mand was processed (Example AO out of range) . A more specific alarm will be reported by the module on the next poll. Provides the channel information for an alarm reported on the same module. 2576 ? I2C General DO error on %4 SNECON I2C driver: A channel specific error was detected while an DO com‐ mand was processed (Example DO out of range) . A more specific alarm will be reported by the module on the next poll. Provides the channel information for an alarm reported on the same module. 2577 ? I2C bus configuration changed The configuration between internal I2C (5V I2C) and external, SSSI (10V I2C) was changed. The configuration change is ignored until the next reset. If the configuration was changed inten‐ tionally, simply reset the device. Other‐ wise, verify that the cable in J3 and J13 on SNECON V4 or J1 and J3 on the SIB are properly inserted. 62 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.13 Alarms 5.2 2817 - 2904 DPM Temperature GCP 5.2 Alarm Descriptions 2817 - 2904 - DPM Temperature The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # ! Text Description Action 2817 ! 12V Error on %4 Temperature controller PIC: The 12 volt supply is not working normally. ● Disconnect the RTDs and feedthrough connector. If the error does not go away, replace the DPM. ● If the error goes away, confirm that there is no continuity between any RTD lead and ground. 2818 ! Setpoint Board Missing on %4 Temperature controller PIC: The OTS Install or replace the TLIM-OTS T-rat‐ and temperature limit configuration ing configuration board. board (t-rating configurator) is not detec‐ ted on J10. 　The temperature controller is non-functional. 2819, 2820 ! RTD Failure [1 or 2] on %4 Temperature controller PIC: An attempt was made use a temperature channel that has an invalid RTD signal. The RTD is shorted or open circuit. The tempera‐ ture controller cannot function. Verify the 4-wire temperature sense RTD on channel #1. The RTD resist‐ ance must be between 81 and 269 ohms. Confirm that none of the leads have any continuity with ground. 2823, 2824 ! SSR Cable [1 or 2] Missing on %4 System error Contact Customer Support. 2825 ! A/D Failure on %4 Temperature controller PIC: An Analog ● Cycle power. to Digital Converter chip does not work ● If the error repeats consistently, properly. 　The flag will be set if the A/D replace the module. internal calibration cycle is not completed within a pre-determined period of time or the A/D does not report any valid data within a pre-defined timeout period. 　 Note: 　A firmware problem affecting the version 1.002 of the Temperature con‐ troller PIC may cause an A/D failure flag to show-up occasionally following a PIC reset. 　This is not a sign of a defective A/D converter. 2899, 2900 ! Over Temp Shutdown [1 or 2] on %4 Temperature controller PIC: The OverCheck for: Temp Shutdown function is active on ● A disconnected TLIM-OTS channel #1. The heater cannot be turned configuration board. on. The overtemp shutdown condition in‐ ● A temperature setpoint too high for dicates that the temperature reached the the allowed T-rating. absolute limit.. ● A defective OTS or T-limit temperature probe. ● A defective DPM ● A defective (shorted) SSR. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 63 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # ! Text Description Action 2901, 2902 ? Deviation [1 or 2] Excee‐ ded on %4 Temperature controller PIC: The meas‐ ured temperature deviation (TEMP_DE‐ VIATION) has exceeded the correspond‐ ing MAX_DEVIATION value. 　The PID control was not successful to control the heater with the desired precision on channel #1. A large deviation is normal on power-up and immediately following a change in the temperature setpoint. Check for: ● Improper controller type 'temptype' selected in the 'App_tempctl' table. ● The PID parameters are not optimal. ● Fast variation in the ambient temperature, airflow or line voltage.Insufficient air flow. For an air bath heater with 1/8 inch spargers, 3 cfm is adequate for up to 100 DegC and then 4 cfm should be used. ● A temperature setpoint too high for the allowed T-rating. ● An Air pressure switch that works intermittently. ● A defective DPM. ● A defective PECM. ● A defective Solid State relay. 2903, 2904 64 ? Ramp has no origin [1 or 2] on %4 Temperature controller PIC: A ramp rate Set the power-up default ramp value to was set without a prior temperature set‐ 0. point on channel #1. 　A ramp must have an initial temperature defined by the pre‐ vious setpoint value. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.14 Alarms 5.2 3117 - 3204 EPC GCP 5.2 Alarm Descriptions 3117 - 3204 EPC The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. Text Description 3117, 3118 # ! Pressure [1 or 2] Out-OfControl on %4 EPC (Electronic Pressure Controller) Confirm that the flow is greater than the PIC: The measured pressure, on chan‐ minimum specification. Replace the nel #n, has exceeded the absolute maxi‐ EPC. mum allowed pressure and the corre‐ sponding channel was shutdown. The pressure controller is no longer working. Action 3119, 3120 ! A/D [1 or 2] Failure on %4 EPC (Electronic Pressure Controller) PIC: The Analog to Digital Converter chip does not work properly. The flag will be set if the A/D internal calibration cycle is not completed within a pre-determined period of time or the A/D does not report any valid data within a pre-defined time‐ out period. Cycle power. If the error repeats con‐ sistently, replace the module. Note: A firmware problem affecting the version 0.250 of the EPC PIC may cause an A/D failure flag to show-up occasion‐ ally following a PIC reset. This is not a sign of a defective A/D converter. 3157, 3158 ? Low Supply Pressure [1 or 2] on %4 EPC (Electronic Pressure Controller) Check air supply. Replace supply bottle. PIC: Set when the contact on the optional supply pressure sensor on [J5 or J6] is closed indicating that the supply pres‐ sure is getting low and that the bottle must be changed soon. 3159, 3160 ! Deviation [1 or 2] Excee‐ ded on %4 EPC (Electronic Pressure Controller) PIC: The measured pressure deviation has exceeded the corresponding MAX_DEVIATION value. The PID con‐ trol was not successful in controlling the pressure with the desired precision on channel #n. ● MAX_DEVIATION_x that is too small. An improper setting of TIME_LIMIT_DEVIATION_UP_x or TIME_LIMIT_DEVIATION_DN_x. ● Insufficient supply pressure. ● Flow too small or too large. ● Defective EPC. 3161, 3162 ? Setpoint [n, 1 or 2] changed following a change in Max Pressure Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 EPC (Electronic Pressure Controller) Set the SETPOINT_MAX_[n] value first PIC: The SETPOINT_[n] AO value was and then set the setpoint. modified internally as a result of the SET‐ POINT_MAX_[n] AO value set to a value lower than the SETPOINT_[n] value. 65 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description 3163, 3164 # ! EPC Shutdown on %4, Channel [n] The [n] channel of the Electronic Pres‐ No action required. The shutdown 　is sure Control (EPC) was temporarily shut temporary and the operation will auto‐ down. 　This happens when the EPC matically resume after 15s. control valve is fully opened for more than 5s and is meant to prevent over‐ heating of the valve. 　This situation typ‐ ically happens when the input pressure is too low, as from an empty cylinder. 3203, 3204 ! EPC ramp has no origin on %4, Channel [n] The starting point of the pressure ramp was set to the current measured pres‐ sure as the setpoint value was not previ‐ ously set. 　　When no prior setpoint is available, this alarm is issued and the current measured pressure is used as a substitute for setpoint #1. 3.4.15 Action Set a static setpoint first, and then set the ramp rate, followed by a new set‐ point. 　With this sequence, the starting point of the ramp will be setpoint #1 and the ending point will be setpoint #2. Alarms 5.2 3401 - 3454 TFTP GCP 5.2 Alarm Descriptions 3401 - 3454 TFTP The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # Text Description Action 3401 ? TFTP Protocol Error Protocol error detected, such as receipt of a non-DATA packet or lack of an ex‐ pected message acknowledgment. Most likely the gateway settings on the SNE are wrong. Power up the SNE connected to a serial terminal and change the settings in the startup dialog. 3402 ? TFTP Timeout The TFTP client didn't receive a re‐ sponse from the server. Verify that the TFTP server is running on the host computer, and that the host computer is connected to the SNE through the network. 3403 ? TFTP Server out of Sync The data packets requested by the TFTP client to not match those sent by the TFTP server. Either the TFTP client or TFTP server is not working properly. ● Reset the SNE. ● Restart the TFTP server on the host computer. 3404 ? TFTP Server out of Sockets TFTP server cannot create a portal from ● Wait for problem to clear. which to communicate. SNE or host com‐ ● Contact Customer Support. puter is low on resources. 3405 ? TFTP Max Channels ex‐ ceeded Too many TFTP load requests have been commanded. Only request one TFTP load at a time. 3406 ? TFTP Driver Not Initialized TFTP driver was not successfully initial‐ ized. Usually a problem of resource. ● Verify that the SNE has sufficient memory. ● Upgrade SNE. ● Reset SNE. 3450 ? TFTP Client Out of Memory Client ran out of memory loading file. ● Verify that the SNE has 16Mb SIMM. ● Reset SNE. 66 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # Text Description Action 3451 ? TFTP Client Checksum Er‐ File loaded had invalid checksum. ror Verify that loadfile is correct and uncor‐ rupted. 3452 ? TFTP Client Missing End of File Verify that loadfile is correct and uncor‐ rupted. 3453 ? TFTP Client Invalid OS File Attempt to load OS with invalid address range. 3454 ? TFTP Client Invalid App File 3.4.16 Attempt to load truncated file. Verify that loadfile is correct and uncor‐ rupted. Attempt to load App with invalid address Verify that loadfile is correct and uncor‐ range. Loadfile may be OS file or corrupt. rupted. Alarms 5.2 3500 - 3528 Advance GCP 5.2 Alarm Descriptions 3500 - 3528 Advance The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # Text Description Action System error Contact Customer Support. 3500 ? Reserved 3501 ! Advance Adapter Initializa‐ Advance Adapter detected, but respond‐ Repair or replace adapter. tion Failure ing improperly. 3502 ? Invalid Channel for Ad‐ vance Adapter %4 Reference to invalid channel on Advance Adapter. Check reference to I/O channels in ap‐ plication tables. 3503 ? Advance Adapter Back‐ plane Timeout on %4 The referenced I/O on backplane board did not respond. Reseat or replace board corresponding to hardware ID. 3504 ? Advance Adapter Back‐ plane Error on %4 The referenced I/O on backplane respon‐ Reseat or replace board corresponding ded improperly. to hardware ID. 3505 ? Resource for %4 not avail‐ able on Advance Adapter Memory or operating system object not available for hardware access. ● Verify that SNE has sufficient memory. ● Upgrade SNE. ● Reset SNE. 3516 ! No Advance Adapter detec‐ System error ted Contact Customer Support. 3517 ! Advance Adapter Driver Out of Memory Driver initialization failure due to lack of memory. Verify that SNE has sufficient memory. Upgrade SNE. Reset SNE. 3518 ! Invalid Advance Adapter Driver Command Application requested invalid command from Adapter Driver. Most likely a mis‐ match between the SNECON OS and application. Reload SNECON software. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 67 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.17 Alarms 5.2 3718 - 3804 SNE I/O GCP 5.2 Alarm Descriptions 3718 - 3804 SNE I/O The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. Text Description 3718 # ! FPGA Error Full on %4 SNECON PICs: The FPGA queue to the Reset the SNECON. NS486 was full and a packet could not Replace the SNECON. be sent. A best attempt is made to con‐ tinue but one or more packets were lost. 3719 ? FPGA error reset_W on %4 SNECON PICs: A FPGA reset was de‐ Reset the SNECON. tected during a packet write from the PIC. Replace the SNECON. 　The packet and any packet still in the FPGA queues were lost. 3720 ? FPGA error reset_R on %4 SNECON PICs: A FPGA reset was de‐ tected during a packet read by the PIC. The packet and any packet still in the FPGA queues were lost. Reset the SNECON. FPGA error_W on %4 SNECON PICs: An error was detected while writing the packet header or data to the FPGA. A best attempt is made to continue but one or more packets may be lost. Reset the SNECON. SNECON PICs: An error was detected when reading the packet header or data from the FPGA. A best attempt is made to continue but one or more packets may be lost. Reset the SNECON. 3721 3722 ? ? FPGA error_R on %4 Action Replace the SNECON. Replace the SNECON. Replace the SNECON. 3725 ! Error SCL on %4 SNECON PICs: An abnormal situation was detected on the I2C 'Serial Clock' line. This is an indication that the WDB is broken, a cable harness is broken or one board connected to the I2C bus is mal‐ functioning, pulling the I2C data signal to a logical low. Contact Customer Support. 3726 ! Error SDA on %4 SNECON PICs: An abnormal situation was detected on the I2C 'Serial Data' line. This is an indication that the WDB is broken, a cable harness is broken or one board connected to the I2C bus is mal‐ functioning, pulling the I2C data signal to a logical low. Contact Customer Support. 3727 ! I2C will not align on %4 SNECON PICs: I2C communication er‐ ror. Contact Customer Support. 3728 ? I2C msg not allowed on %4 SNECON PICs: A packet containing an ● Reset the SNECON. I2C message was received by the PIC ● Reload the OS for the SNECON. (from the NS486 through the FPGA) at a time when it is not allowed but after a val‐ ● Replace the SNECON. id configuration message was received. The message was discarded. 68 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description 3757 # ? NACK address on %4 SNECON PICs: An I2C message trans‐ Reset the analyzer. action failed after the required number of retries. 　A cause of this failure was a unacknowledged destination address byte (first byte in the message). 　This may happen if a module was disconnec‐ ted from the bus after its address has been reassigned. Action 3758 ? NACK Byte on %4 SNECON PICs: An I2C message trans‐ Contact Customer Support. action failed after the required number of retries. A cause of this failure was a un‐ acknowledged byte that is not the first byte in the message (any byte other than the destination address was not acknowl‐ edged). This may happen if a module is seriously corrupted or the I2C signal in‐ tegrity is a problem (noise, etc…). 3759 ? NACK Message on %4 SNECON PICs: An I2C message trans‐ action failed after the required number of retries. 　A cause of this failure was a NACK message with a non-zero flag. 　 This may happen if the firmware of the peripheral module is not responding properly.Reset the analyzer. 3760 ? Invalid Checksum on %4 SNECON PICs: An I2C message trans‐ Contact Customer Support. action failed after the required number of retries. 　A cause of this failure was an invalid checksum in the reply message. 　This may happen if the firmware of the peripheral module is not working proper‐ ly or the electrical properties of the I2C signals are marginal. 3761 ? Invalid Opcode on %4 SNECON PICs: An invalid private op‐ code was received from the NS486. The message was ignored. This may happen if the PIC firmware is out-of-date relative to the SNE software. ● Reload the OS and APP software for the SNECON. Reload the OS and APP software for the SNECON. Replace the module be‐ ing addressed. Replace the SNECON. Replace the module being addressed. ● Replace the SNECON. 3762 ? Invalid Message on %4 SNECON PICs: An I2C message trans‐ action failed after the required number of retries. A cause of this failure was a reply message that had a valid checksum and valid opcode but was invalid in any other way. This may happen if the firmware of the peripheral module is not working properly or the SNECON software is too old. 3763 ! Arbitration Loss on %4 SNECON PICs: An I2C message trans‐ Contact Customer Support. action failed after the required number of retries and a cause of this failure was that the PIC could not successfully arbitrate its way to the bus. Other bus-master de‐ vices are using all the I2C bus bandwidth. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 69 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description 3764 # ? Timeout SCL on %4 SNECON PICs: An I2C message trans‐ Contact Customer Support. action failed because the I2C clock was stretched beyond the allowed timeout pe‐ riod specified in the configuration. A mod‐ ule may be malfunctioning. 3765 ? Timeout SDA on %4 SNECON PICs: An I2C message trans‐ Contact Customer Support. action failed because the I2C data line was held beyond the allowed timeout pe‐ riod specified in the configuration. A mod‐ ule may be malfunctioning. 3766 ? Bus Not Sync on %4 SNECON PICs: The master-mode oper‐ Reset the SNECON. Replace the SNE‐ ation generated a start condition that was CON. not detected by the FPGA. 3767 ? Timeout Buffer on %4 SNECON PICs: A master-mode mes‐ sage has not been processed within a timeout period. This is a broad alarm with multiple possible causes. The PIC will discard the message and attempt to re‐ cover. Contact Customer Support. 3768 ? Invalid Handle on %4 SNECON PICs: The received header handle was not sequential. One or more I2C messages were lost. ● Reset the SNECON. The amount of traffic on the I2C bus has exceeded a configurable threshold. A heavy traffic may delay the I/O activity which ultimately can affect the operation (accuracy, repeatability) of the analyzer. Check the methods to ensure that the I/ O activity is distributed in time and not all at the same exact cycle time (Detec‐ tor balance event, valve events, tem‐ perature and pressure setpoint, etc). ● Replace the SNECON. 3769 ? 3797 + Invalid Checksum Slave on %4 SNECON PICs: An unsolicited I2C mes‐ ● Reset the SNECON. sage was received with a bad checksum. ● Replace the SNECON. The message was discarded and it is ex‐ pected that the master will retry the mes‐ sage. This is a communication error that can be ignored if not frequent. 3798 + Invalid Message Slave on %4 SNECON PICs: An unsolicited I2C mes‐ Reload the OS and APP software to all sage was received with an invalid mes‐ SNECONs. sage size, invalid opcode or invalid data. The message was discarded. There may be a firmware version conflict. 3799 ? Invalid Status Summary on %4 SNECON PICs: A packet was received ● Reload the OS and APP software by the PIC from the NS486 and the pack‐ for the SNECON. et had an undefined bit set in the Sta‐ ● Replace the SNECON. tus_summary field of the packet. The packet was processed normally. 3800 ? Module Not Ready on %4 SNECON PICs: An I2C message trans‐ action failed after the required number of retries and the cause of the failure was a series of consecutive message NACKs, all with a 0 flag. This may happen if the firmware of the peripheral module is not responding properly. 70 High I2C traffic on %4 Action ● Reload the OS and APP software for the SNECON. ● Replace the module being addressed. ● Replace the SNECON. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # 3801 3802 ? ? Text Description Action Invalid Status Data on %4 SNECON PICs: The content of the status buffer, 'Status_data', was invalid and not recognized by the PIC. This may happen if the PIC firmware is out of date relative to the NS486 software. ● Reload the OS and APP software for the SNECON. SNECON PICs: The value of the sta‐ tus_type was invalid and not recognized by the PIC. 　This may happen if the PIC firmware is out of date relative to the NS486 software. ● Reload the OS and APP software for the SNECON. Reload the OS and APP software to all SNECONs. Invalid Status Type on %4 ● Replace the SNECON. ● Replace the SNECON. 3803 + Invalid Msg Size on %4 SNECON PICs: A packet was received with an invalid I2C message size or no I2C message at all. The packet was dis‐ carded. 3804 + Arbitration Loss Slave on %4 SNECON PICs: The PIC lost a slave ● If sporadic, no action is necessary. read arbitration. It indicates that at least ● If repeating frequently, reset the one other module responded to the same analyzer. message request. 3.4.18 Alarms 5.2 4001 - 4124 EZChrom GCP 5.2 Alarm Descriptions 4001 - 4124 EZChrom The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # Text Description Action Method currently running when software load was commanded. Put method on hold and wait for it to complete before loading SNE software. 4001 ? TFTP cannot load with ac‐ tive method %3 4003 ! Zero Correction Out of Lim‐ its on %4 4022 ? I/O channel not found on %4 Hardware resource requested not present. 4024 ? Slope check failure on channel %4 Slope check commanded with invalid pa‐ Check method for slope check events rameters. and review data. 4025 ? Detector channel under‐ flow occurred on %4 A/D converter for detector reading lowest possible value. This error may also be a secondary error caused by an overflow on an FID DPM. 4026 ? Detector channel open oc‐ curred on %4 Open connection detected on A/D detec‐ Verify proper operation of the DPM. tor input. This error may also be a secon‐ dary error caused by an overflow on an FID DPM. 4027 ? Detector channel overflow occurred on %4 A/D converter for detector reading maxi‐ Check A/D inputs, potentially replace mum value possible. referenced DPM. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Contact Customer Support. Reload and or repair SYSCON data‐ base. Check A/D inputs, potentially replace referenced DPM. 71 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description 4028 # ? Detector channel unknown error occurred on %4 Undeterminable error occurred on detec‐ Reset. If error repeats, replace DPM. tor channel circuit. This error may also be a secondary error caused by an overflow on an FID DPM. Action 4029, 4030 ? Zero Correction failure on [1st/lower/right or 2nd/low‐ er/left] channel of %4 Should occur only with a revision 2 TCD DPM or revision 3 baseboard (PIC firm‐ ware revision 2.006 and up ). Or, the zero correction value exceeded the maximum allowed value for that particular board. 　 This is a balance failure situation. Eliminate the cause of the balance fail‐ ure: Ignite flame on unit. If flame is burning, board may be defective. ● On TCD detector, replace the detector bead or filament. ● On FID detector, clean or replace the FID. 4031 ! Flame out on %4 Flame out detected on an Advance+ FID or FPD Board. 4032 ? Purge Loss on %4 Loss of purge pressure has been detec‐ Investigate and correct cause of pres‐ ted. Possible causes include low pres‐ sure loss. sure for supply air, open door, and failed gaskets. Depending on the environment classification where the analyzer is instal‐ led, this alarm may indicate an unsafe condition that requires immediate action to correct. 4033 ! Zero Correction Out of Lim‐ The value of the zero correction (soft‐ Confirm that the corresponding balance its on %4 ware balance of the detector) has excee‐ limit values are not too small. See the ded the balance limits. maintenance instructions for the specif‐ ic detector type. 4120 ? Pulse DO Within a Pulse DO is Not Allowed on %4 4121 + Pulse DO Aborted on %4 A pulse DO was aborted as a result of a Informational message. No action nec‐ standard (non-pulsed) DO command. 　 essary. 　The non-pulsed DO command has precedence. 4122 ! Method Conflict: Concur‐ rent Chromatogram Chan‐ nel Acquisition on %4 It is not allowed to use the same detector channel for more than one chromato‐ gram acquisition at a time, whether within a method or across methods. 　The new‐ est request was cancelled. 4123 ! Unsupported detector sam‐ A request was made to run the specified Contact Customer Support for assis‐ pling rate on %4 detector channel at a standard rate but tance. the DPM hardware does not support that rate. The method file is likely corrupt. It may be necessary to rebuild the method. 4124 ! Run-time Operational Con‐ An operation was requested at a time flict on %4 when it is not allowed. e.g.: GainSelect VDO: A gain select was initiated before the previous GainSelect sequence was completed. 72 A pulse DO was requested by the SY‐ SCON while a pulse DO was already in progress. 　The latest requested pulse DO was ignored. Wait until the on-going pulse has com‐ pleted before requesting another pulse DO. Verify that the method does not contain 2 concurrent uses of the same detector channel hardware. Verify that the meth‐ ods running in separate applications are not erroneously reusing the same detector channels. Revise the method to remove the con‐ flicting events. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.19 Alarms 5.2 4217 - 4320 CAN Bridge GCP 5.2 Alarm Descriptions 4217 - 4320 CAN Bridge The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. Text Description Action 4217 # ! CAN:Underflow %4 System error Contact Customer Support. 4218 ! CAN: Overflow %4 System error Contact Customer Support. 4220 ! CAN: External AO uncali‐ brated The EEPROM does not contain valid fac‐ Replace the SIB to eliminate the alarm. tory calibration information for a local AO channel. 　Default calibration values are used.The module is operational. 4257 ? CAN: Underflow System error Contact Customer Support. 4258 ? CAN: Overflow System error Contact Customer Support. 4259 ? 4260 ? CAN: Node init failureIndicates that at ● Reset the device. least one CAN node failed during the ini‐ ● If the problem persists, replace the tialization process. No I/O operations are CAN card. allowed on the node. CAN: Node failure Indicates that at least one CAN node failed during normal operation. This flag is generated only if the node worked properly during initialization but failed at a later time. 　No further I/O operations are allowed on the node. The communi‐ cation with the card will be stopped and the card will set itself to failsafe output. ● Reset the device. ● If the problem persists, replace the CAN card. 4261 ? CAN: Bus HW init failure Indicates a failure of the CAN bus detec‐ ● Check the Database CAN node list ted during the CAN bus initialization. 　 for a stray card. No communication is possible with any ● Check data cable and power to node. 　This can be as a result of either: CAN Extension Unit (CEU). a) No CAN card is present, but yet at least one card is defined in the database b) The CAN hardware cannot communi‐ cate with a CAN device as a result of a hardware error (e.g. broken or shorted cable) and the PIC CAN module is re‐ porting a transmitter error. 4262 ? CAN: Bus HW Failure Indicates a fatal failure of the CAN bus Check power to CAN Extension Unit detected during the normal operation. 　 (CEU). This flag is generated only if the CAN system worked properly during initializa‐ tion but failed at a later time. No commu‐ nication is possible with any node. 4263 ? CAN: Invalid channel %4 A read or a write was attempted to a channel that does not exist. Verify the hardware ID of the I/O for val‐ id addresses. 4264 ? CAN: Node changed Indicates that at least one serial number has changed and that, as a result, the CAN bridge PIC will soon reset. This is normal as a result of a CAN node list configuration change. No action necessary. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 73 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions Text Description 4265 # ? CAN: Receive Init Buffer Overflow The CAN bus receive buffer that process‐ Contact Customer Support. es messages from uninitialized CAN cards has overflowed. Initialization will likely fail. 4266 ? CAN: Receive Heartbeat Buffer Overflow CAN card heartbeat replies have over‐ Contact Customer Support. flowed the heartbeat buffer. The heart‐ beat buffer is large enough to hold replies from all 20 cards. Overflow would indi‐ cate a serious loading problem. 4267 ? CAN: Receive I/O Buffer Overflow CAN card I/O replies/updates are not processing fast enough. This indicates that some received CAN messages have been lost because the CAN bridge can‐ not process them fast enough. Since CAN messages take longer to transmit on the CAN bus than it takes to process them this flag is unlikely to occur. If it ever occurs, the likely cause is very heavy I2C traffic combined with a large number of ADIO boards which add considerable CAN traffic to the bus. 4268 ? CAN: Transmit Buffer Over‐ There are too many pending CAN mes‐ flow sages and the transmit buffer is full. This indicates that the SYSCON is performing I/O operations faster than they can be transmitted on the CAN bus. The most likely cause would be heavy DO traffic since the I2C protocol can update many DO bits per transaction but it takes one CAN message for EACH DO bit. 4269 ? CAN: Channel not respond‐ Indicates that one or more channels have Reset the device. If the problem per‐ ing not properly communicated and recovery sists, replace the CAN card. efforts have failed. For outputs, this flag is set after several retries writing to a channel without proper confirmation from the CAN card that the message was re‐ ceived and handled. For inputs, this flag is set after enough time passes without getting an update from the channel. 4270 ? CAN: Hardware FIFO Overflow 4297 + CAN: init complete 74 Action Reset the device. If the problem per‐ sists, the I2C traffic to the CAN bridge or the number of ADIO boards in the system must be reduced. Contact Customer Support. The PICs hardware CAN message buffer has overflowed. Contact Customer Support. The initialization of the CAN card has completed. Informational message. No action necessary. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # 4300 Text Description + CAN: Unrecognized card 4301 + CAN: Node [1 – 20] abnor‐ - 4320 mal 3.4.20 Action This flag is set when an uninitialized card ● Verify the node list in the database is detected on the bus after the init se‐ for an exact match of all serial quence is complete. 　The most com‐ numbers. 　 mon cause of this condition is a Node/SN ● Make sure that no unused CAN list that does not precisely match the card card is present in the system. 　 mix on the bus either due to missing en‐ tries or typographical errors. ● If this is associated with a 'CAN: Node x abnormal' error, replace the corresponding card. CAN card I/O malfunction that causes in‐ ● Verify the node list in the database itialization failure, loss of heartbeat re‐ for an exact match of all serial sponses from a CAN card or loss of com‐ numbers. 　 munication with one or more channels of ● If this is associated with a 'CAN: the node. Node x abnormal' error, replace the corresponding card. Alarms 5.2 4525 - 5220 Advance TC GCP 5.2 Alarm Descriptions 4525 - 5220 Advance TC The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. # Text Description Action Advance Adapter Temperature Control‐ ● Reset the analyzer. ler PIC: The Advance Adapter tempera‐ ● Replace the Advance Adapter. ture A/D converter is not generating data points within the prescribed time interval. 4525 ! AD Failure on %4 4526 ! Over Temp Shutdown Pow‐ Advance Adapter Temperature Control‐ Replace the Advance Adapter. er Supply Failure on %4 ler PIC: The power supply used for over‐ temp shutdown is not working properly. 4557 ? Setpoint Changed follow‐ ing a change of Max Temp %4 Advance Adapter Temperature Control‐ Set the SETPOINT_MAX value first, ler PIC: The SETPOINT AO value was then set the setpoint value. modified internally as a result of the SET‐ POINT_MAX AO value set to a value low‐ er than the SETPOINT value. 4599 ! Over Temp Shutdown on %4 Advance Adapter Temperature Control‐ ler PIC: The Over-Temp Shutdown func‐ tion is active, the heater cannot be turned on. The overtemp shutdown condition in‐ dicates that the temperature reached the absolute limit. Check for: ● A temperature setpoint too high for the allowed T-rating. 　 ● A defective temperature probe. 　 ● A defective Advance Adapter. 　 ● A defective (shorted) SSR. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 75 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions # 4601 Text ? Description Action Temperature Deviation Ex‐ Advance Adapter Temperature Control‐ ceeded on %4 ler PIC: The measured temperature de‐ viation (TEMP_DEVIATION) has excee‐ ded the corresponding MAX_DEVIA‐ TION value. The PID control did not suc‐ cessfully control the heater with the de‐ sired precision. A large deviation is nor‐ mal on power-up and immediately follow‐ ing a change in the temperature setpoint. Only small deviations are expected dur‐ ing normal operation. Check for these causes of temperature instability: ● Fast variation in the ambient temperature, airflow or line voltage. Insufficient air flow. ● A temperature setpoint too high for the allowed T-rating. ● A defective DPM. ● A defective Solid State relay. 4817 ! AI Underflow Fault on %4 One or more AIs on the module has en‐ countered a voltage or current underflow situation. Make sure that the signal going to all AIs is within the range of the inputs. 4818 ! AI Overflow Fault on %4 One or more AIs on the module has en‐ countered a voltage or current underflow situation. Make sure that the signal going to all AIs is within the range of the inputs. 4819 ! External ADC HW is not re‐ Timeout or communication error with an sponding on %4 Analog to Digital Converter. ● Reset the device. External AO is not calibra‐ ted on %4 One or more AO channel has an invalid calibration record in the EEPROM of the module. ● Reset the device. External AI is not calibrated on %4 One or more AI channel has an invalid calibration record in the EEPROM of the module. ● Reset the device. 4820 4821 ! ! ● If the problem recurs, replace the module. ● If the problem recurs, replace the module. ● If the problem recurs, replace the module. 4857 ? External AI underflow on %4 One or more AIs on the module has en‐ countered a voltage or current underflow situation. Make sure that the signal going to all AIs is within the range of the inputs. 4858 ? External AI overflow on %4 One or more AIs on the module has en‐ countered a voltage or current overflow situation. Make sure that the signal going to all AIs is within the range of the inputs. 5117 - 5140 ! Alarm [5117 - 5140] on %4 A fault alarm was generated on an un‐ recognized I2C module. ● Update to the latest software version. 　 ● Make sure that the latest text files are loaded. 5157 - 5199 ? Warning [5157 - 5199] on %4 A warning alarm was generated on an unrecognized I2C module. ● Update to the latest software version. 　 ● Make sure that the latest text files are loaded. 5200 + Note [5200 - 5220] on %4 - 5220 A note alarm was generated on an un‐ recognized I2C ● Update to the latest software version. 　 ● Make sure that the latest text files are loaded. 76 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 3.4.21 Alarms 5.2 10000 - 11536 MicroSAM GCP 5.2 Alarm Descriptions - 10000 - 11536 MicroSAM The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm text, description, and actions. Text Description Action 10000 # ! Temperature control failure on %4 MicroSAM alarm Contact MicroSAM Support. 10001 ! Temperature sensor (RTD) of %4 defective MicroSAM alarm Contact MicroSAM Support. 10002 ! Temperature deviation on %4 exceeds limits MicroSAM alarm Contact MicroSAM Support. 10003 ! Temperature controller %4 disabled MicroSAM alarm Contact MicroSAM Support. 10004 ! Carrier gas pressure low on %4 MicroSAM alarm Contact MicroSAM Support. 10256 ! Detector %4 disabled MicroSAM alarm Contact MicroSAM Support. 10257 ! Detector %4 shorted MicroSAM alarm Contact MicroSAM Support. 10258 ! Detector %4 not connected MicroSAM alarm Contact MicroSAM Support. 10259 ! Carrier gas pressure low on %4 MicroSAM alarm Contact MicroSAM Support. 10512 ! Pressure controller %4 dis‐ MicroSAM alarm abled Contact MicroSAM Support. 10513 ! A/D converter failure on %4 MicroSAM alarm Contact MicroSAM Support. 10514 ? Operating pressure low on %4 MicroSAM alarm Contact MicroSAM Support. 10515 ! Pressure exceeds limits on %4 MicroSAM alarm Contact MicroSAM Support. 10516 ! Setpoint exceeds limits on %4 MicroSAM alarm Contact MicroSAM Support. 10517 ! Pressure out of control on %4 MicroSAM alarm Contact MicroSAM Support. 10518 ! Voltage exceeds limits on %4 MicroSAM alarm Contact MicroSAM Support. 10519 ! Operating pressure low MicroSAM alarm Contact MicroSAM Support. 10768 10775 ! Valve [1 – 8] operation fail‐ ure on %4 MicroSAM alarm Contact MicroSAM Support. 11536 ! General RSP communica‐ tion error on %4 MicroSAM alarm Contact MicroSAM Support. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 77 General Maintenance and Troubleshooting 3.4 Alarm Codes, Descriptions, and Suggested Actions 78 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.1 Power Supplies 4.1.1.1 Power System Module 4 Overview The Power System Module (PSM) is a 110/230 VAC switching power supply that provides 24 VDC operating system voltages. It also provides 110/220 VAC conditioning. The 24 VDC power supply provides high speed switching with power factor correction and universal input. The PSM is a stand-alone system consisting of a power supply, filtering, circuit fuse protection and a power monitor board. Line Voltage Selector Switch Power System Module Figure 4-1 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Fuse Holder Power System Module Location in EC 79 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components AC Line Input AC power input to the power supply is from the Power Entry Control Module. A line cord from the PECM plugs into the front AC receptacle of the power supply. A primary Line Voltage Selector selector switch (located above the AC receptacle) must be set to match the primary AC voltage input from the Power Entry Control Module. Output Connections Output 24 VDC is supplied to components within the Maxum II via a cable harness that exits the backside of the PSM. The cable terminates in quick disconnect connectors. Typically, a white connector supplies 24 volts to the SYSCON2.1 cage and an orange connector supplies 24 volts to the PECM, where it is distributed to various modules in the EC. DC/DC converters in the modules generate the other voltage levels needed by various circuits. Fuse Replacement The Power System Module is equipped with a fuse (Siemens Part Number A6X19905350). This fuse is located on the front of the PSM just above the power cord plug. The fuse is a 250 V, 4.0 A, “slow-acting” type. Although this fuse rarely fails, replacement is simple (disconnect power to the analyzer first). To remove the fuse, unplug the power cable that comes from the PECM. Access the fuse by removing the fuse cap with a large blunt screwdriver. Specifications Voltage Range 115 VAC (85 to 140 VAC), 230 VAC (185 to 264 VAC) Line Frequency Range 47 to 63 Hz Nominal Input Current 2 amp @ 115 VAC, 1 amp @ 230 VAC Nominal Output Voltage 24 VDC ±3%, 1% ripple plus noise at a bandwidth of 30 MHz Nominal Output Current 6 A @ < 104°F (40°C) 4 A @ 104° to 150°F (40° to 70° C) Static Load 0.2 A; 0.0 A open circuit permitted Dynamic Load Between 0.2 A to 3 A in the load range. A maximum load of 2 A at 1.8 kHz is switched. Switching is controlled by pulse width. Precision range is not exceeded in this operational mode. Overcurrent Cutoff Cutoff starts at 6.4 to 7.5 amps. When current drops, device switches on. Overvoltage Cutoff Cutoff starts at 27 to 31 VDC. When voltage drops, device switches on. Overtemperature Cutoff After temperature decreases to specified tolerance, device switches on. Power Fail Transitions Occurs 20 ms after a primary power failure. Should a power failure occur, a low 20 ms signal is generated. Electric Isolation Input/Output: 3.7 kV Dimensions Length: 10.24 inches (260 mm) Width: 2.36 inches (60 mm) Depth: 3.54 inches (90 mm) Cooling Convection and conduction through aluminum mounting plate. Output Wiring Cable harness 80 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.1.2 Replacement Procedure Power Supply Location Note This procedure assumes that power is off in the analyzer. The 24V power supply is easily accessed at the top of the electronics enclosure. Replacement Steps WARNING Voltage dangerous to life exists in the electronics enclosure. Failure to follow proper safety procedures may result in injury or death. Turn off line votage to the analyzer before disassembling power-supply components. Even though nothing appears to be operating, AC voltage can still be present on many of the components in the enclosure. NOTICE Obtain all permits that may be required to perform this work. Observe local codes and obtain any required permits before starting the work. The power supply has an integral bracket that slips under flanges in the top of the enclosure on the right side, and by two muts on threaded studs on the left side. Slots in the bracket allow removing the supply without completely removing the nuts. 1 2 3 4 6 5 7 7 A. Figure 4-2 B. C. Removing the Power Supply Module Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 81 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 1. Ensure that power has been disconnected from the analyzer. 2. Open the electronics enclosure door. 3. Unplug SYSCON power cable from the bottom of the SYSCON cage. 4. Unplug the PECM 24V cable. 5. Loosen nuts (1 in photo A above) 6. Slide the power supply forward enough to disengage the power-supply tabs from enclosure tabs as shown in photo below. (2 in photo A above) 7. Tilt the power supply clockwise to allow the tabs to clear the flanges. (3 in photo A above) 8. Drop the power supply off the nuts. (4 and 5 in photo B above) 9. Before completely removing the supply, unplug the safety ground wire from the spae lug on the back of the enclosure. (See 7 in the photo C Removing the Power Supply Module above.) 10.Slide the power supply out of encloure. (6 in photo B above) Mo un To safety ground lug on back wall To PECM power connector tin g fla n ge so ni ns ide top of en cl o su re Line-voltage selector switch Fuse holder To SYSCON power connector on bottom-left of cage Figure 4-3 Line-cord connector Power Supply Module Details Reinstalling the power supply The new supply is installed using the steps in reverse order. It may be necessary to slightly bend the flange edges down to allow the supply bracket to engage the flanges. See C in the photo Removing the Power Supply Module above. 82 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Note Verify proper position of line-voltage selector switch and fuse value. Incorrect settings can damage the equipment. See the information packet that was shipped with the analyzer for information on the individual analyzer. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 83 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.2 Power Entry and Control Module 4.1.2.1 PECM Overview Overview The PECM3-CTL board mounts on the PECM-SSR board. This assembly provides a variety of power and control functions. The connections are shown below. MWH out AC in LWH1 - LWH5 out HWH SSR power out Optional UPS input for 24vdc supply Purge Air Switch 24v in Fan power HWH SSR control out Temp RTD in F1 mo d OT TL/ F2 er) cov out h t i (w F4 ver) t co h ou t i w ( F3 PECM-SSR Board Filtered AC out to 24v supply on Hc W H/M LW i trol MW Air bath heater monitor in H Solenoid control out Atmospheric pressure sensor n PECM3-CTRL Board Figure 4-4 I2C bus u les t l ou o r t in on Hc trol H W H co n HW F5 Purge disable jumper Purge signal out I2C bus L1 MMI LED out (Ribbon-cable connector to PECM-SSR) PECM3 I/O Connections The PECM3 assembly part number is 2021828-002. An upgrade kit, part number 2022019-001 is available to replace earlier units. 84 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.2.2 Feature Additions Improvements in PECM3-CTL from PECM-CTL ● Seven I2C connectors are provided compared to 4 on the previous PECM-CTL, eliminating the need for a Wiring Distribution Board (WDB). ● An Atmospheric pressure sensor has been added. Improvements In PECM2 Assembly from Original PECM The PECM design has changed since its original release. The newest version of this part is also used as the spare-part replacement for the previous version. The original PECM was a single electronic circuit board with a metal protective shield. It provided connection points for the electrical power coming into the Maxum GC and mounted low power electrical relays which could switch power to any electrical heater with a power rating of less than 200 watts. The newest version of the module, PECM2, is a two part circuit board. One part connects the electrical power. The other part includes certain electronic circuits. Key features of the newer design are: ● Easy access (no cover) ● Two on-board temperature control circuits. May allow elimination of a DPM that is only used for temperature control, such as for heated valves or the methanator. ● Additional medium-wattage heater circuit ● Four connectors providing I2C and 24VDC power distribution have been added. This replaces some of the functions of the Wiring Distribution Board (WDB). ● Includes solenoid valve control which eliminates the need for individual SVCM controller boards. When converting an older analyzer and eliminating original SVCM controller boards, additional long cables are required. ● Improved low-profile fuse holders ● LED indicators for air pressure switch on air-bath heater circuits ● Built-in provision for connection of Uninterruptible Power Supply (UPS) for 24VDC circuits. The heaters are powered through different connectors to minimize the loading of the AC power needed for running the 24VDC circuits. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 85 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.2.3 PECM Functions AC Input and Distribution AC mains power is wired to TB1 and TB2. TB10 is an optional connection for an uninterruptable power supply for the 24 V power supply output, as shown in the diagram below. Note The power switching circuit is designed for either 115 VAC or 230 VAC. For safety reasons, the PECM is not designed to convert DC to AC. Attempted operation from a DC source will damage or destroy the PECM. To generate and control 115 VAC from a DC voltage system, the customer must use components external to the PECM. HN HNG HNG 1 N1 2 3 L2 1 N2 2 3 TB2 L1 TB1 1 2 TB10* *TB10 parallel-connected to TB1 if UPS is not used Filtered AC F3 3A Holder Hot F4 10A AC Chassis Ground Medium Wattage Heater Relays Hot AC Filter Plug (for 24V supply) Low Wattage Heater Relays 1- 5 Hot J1 H 1 G 2 N 3 F5 6A Hot Hot F2 16A ABH1 4 3 2 1 TB9 ABH2 Holder Holder F1 16A Air Bath Heater Power Figure 4-5 PECM AC Power Distribution Fuses ● F1-ABH2: 16A 115 VAC or 10A, 230 VAC ● F2-ABH1: 16A 115 VAC or 10A 230 VAC ● F3-FLT AC: 3A 115 VAC or 230 VAC ● F4-LWH1-LWH5: 10A 115 VAC or 230 VAC ● F5 LWH6, MWH 86 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Oven Temperature Control The PECM provides two channels to control overall oven temperature, plus PWM outputs to control the SSRs for 6 low-wattage heaters. An input from an air-supply switch allows the PECM to turn off the heaters if air pressure is lost. Air Bath Oven DPM SYSCON Temp Setpoint Modules I2C Analog Compare Temp Control, Temp Limit, Overtemp RTDs PECM PWM High-Wattage Heater SSR Pair Airflow Loss Shutdown Digital Air Pressure Switch Airflow Loss Temperature Shutdown Control AC Line Figure 4-6 SSRa SSRb Heater PECM Heater Control Functions Communication and Power Distribution The 24V power supply connects to one of two parallel power connectors, TB1 and TB2 on the PECM-CTL board. Another module can be powered from the other connector. Each of the 7 I2C connectors also provides 24VDC power to the connected module. A separate connector powers a 24V fan. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 87 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Onboard Solid State Relays Low-Wattage Heater SSR Control The PECM has six solid-state relay circuits. These circuits can control low wattage (10 to 250 Watts) air bath heaters, heaters in the heated Flame Ionization and Flame Photometric detector housings or in heated sample injection valves, and can be adapted for on-off control of a sample valve or other device. The output voltage from each relay can either be 115 VAC or 230 VAC depending upon the mains supply voltage. Available outputs from the relays are on TB3 through TB8. Corresponding inputs are labeled LWH1 through LWH6. The LWH6 input controls the medium wattage heater (MWH) output. When a relay output is used for sample valve control, the supplied jumpers must be inserted in the corresponding input LWH1 through LWH4. (See Additional Relay Outputs below for using the individual SSRs in outputs 5 and 6.) For safety, since the power switching circuits are primarily designed for low-wattage airbath heater control, each circuit has two series-connected SSRs, each being separately controlled. The jumper ties the two relays together to function as one output when they are not used for low wattage heater control. The circuitry is similar to the 1400-Watt High Wattage Heater Power Switching and it is controlled by signals from the Detector Personality Module (DPM) heater circuit. The diagram below shows a simplified schematic of the Low Wattage Heater Relay Circuit LWH4. TB2 AC Power Input R47 10kΩ LWH 4A On LWH 4A Enabled 3 5V J6 1 DET/CTRL A LWH 4B On 3 LWH 4 Plug Det 5 SSR EN A 6 1 10kΩ 2 5A R54 DET/CTRL B SSR EN B Plug Detect SSR4A 4 4 2 4 2 3 1 GND LWH4 CTRL PLUG LWH 4B Enabled TB5 5V SSR4B 1 Line 2 Neutral LWH4 Figure 4-7 88 LWH4 Heater Circuits Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Additional Relay Outputs Relay circuits LWH5 and LWH6 when used for purposes other than on/off control of low wattage heaters can supply four separate outputs. A simple jumper on pins 1 to 2 on output connector TB7 or TB8 makes this possible. With the jumper in place, each connector will provide two independent outputs; see the diagram below. Relay AC Supply Voltage Usage AC Hot Solid State Relay Figure 4-8 SSRA Hot Unused Sample System Relays Jumper A&B Common Heater Jumper TB7 (LWH5) or TB8 (MWH) SSRA Load Hot AC Neutral A Unused SSRB Hot To LWH Hot Load SSRB Load Hot AC Neutral B To LWH Neutral SSRA Load Neutral SSRB Load Neutral LW5 & LW6 Relay Circuit Jumper Connections Oven Functions Temperature Monitoring and Control The PECM_CTL board has two temperature monitor and control channels for use with the highwattage heaters (HWH). Each channel includes; ● RTD input ● Mounting location and connector for setpoint module ● Comparator circuit ● PWM control signal output ● Control input (can accept an external control signal from another module if desired) ● Control output for HWH SSR module ● AC power output for HWH SSR The HWH control path is shown below. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 89 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Air Bath Oven DPM SYSCON Temp Setpoint Modules I2C Analog Compare Temp Control, Temp Limit, Overtemp RTDs PECM PWM High-Wattage Heater SSR Pair Airflow Loss Shutdown Digital Air Pressure Switch Airflow Loss Temperature Shutdown Control AC Line Figure 4-9 SSRa SSRb Heater PECM Heater Control Functions Each circuit consists of two series-connected solid-state relays. One of these relays controls the 1400-Watt AC heater to maintain the set point temperature by monitoring the air bath RTD and heater pressure switch. The second relay is used for safety purposes. It performs an emergency analyzer heater shutdown if an over-temperature condition is detected. Both relay circuits are completely independent of each other. However; in order for the power circuit to be energized, both relays must be enabled. Temperature controls are monitored by the Detector Personality Module and routed to the PECM via a dedicated cable and connector, or by the temperature-control circuits on the PECM-CTL board itself. No other functions are connected to the temperature control circuit. The connections are EMC filtered. When over temperature is detected the PECM over temperature circuit inhibits the SSR from powering the heater. Alarm conditions are reported to the SYSCON over the I2C link. Solenoid Control Includes solenoid valve control which eliminates the need for individual SVCM controller boards. When converting older design and eliminating original SVCM controller boards, additional long cables are required. Air-Supply Monitoring for Air-Bath Oven The 1400-watt heater assembly is used in many air bath configurations (single isothermal; dual isothermal; or Programmed Temperature Control). A single heater is used for the single isothermal configuration and two heaters are used in the other configurations. Additionally, a “medium power” Solid State Relay Module (temperature control relay module) is available. These smaller relays are capable of controlling the 500 watt air bath heater assembly. This can be used in single isothermal configurations where the controlled oven temperature is 70°C or less. In addition, the “medium power” SSR Module can be used to control the two 250 watt heaters used in the Maxum airless oven configurations. See the PECM3 I/O Connections diagram in PECM Overiew for connector locations. 90 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Electronic Enclosure Environment Purge Monitoring The PECM monitors the state of the purge condition for the analyzer. If a loss of purge is detected the purge switch is enabled. The purge control alarm signal is controlled by the SYSCON. The purge signal cable from SYSCON to PECM plugs into connector J1302 on the PECM2. Connection SW1 on the PECM2 is used to connect atmospheric reference for the purge switch. When a purged enclosure is not required per the safety codes, connector J2 on the PECM2 can be used to disable the purge alarm. See the PECM3 I/O Connections diagram in PECM Overiew for connector locations. Atmospheric Pressure Monitoring (New for PECM-CTL3) This sensor allows a Maxbasic program to measure the ambient atmospheric pressure for custom applications. A tube must be connected from the sensor (J44 on the PECM-SSR board) to the exterior of the EC. L1 MMI LEDs Maintenance Panel Level 1 consists of LEDs on the outside of the analyzer door. It is intended for use in GCs that are not equipped with the full feature Maintenance Panel. The PECM supplies the control signals for Maintenance Panel Level 1, if equipped. For PECM-1, the Maintenance Panel Level 1 connects to position J17. See the PECM3 I/O Connections diagram in PECM Overiew for the location of connector J17. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 91 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Physical Location The PECM is mounted to the left inside wall of the EC cabinet. All fuses and electrical connections are readily accessible. Figure 4-10 92 PECM3 Mounted in EC Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.2.4 Replacement Procedure Overview General Precautions The PECM is the entry point for the line voltage for the entire analyzer. Note Specific additional instructions are provided with tags placed on the Maxum II and in the custom application drawing package noted below. Installation must include all of the items noted in both of these as well as the manuals. The tagging and custom application drawing package are unique to the particular Maxum II. ● This procedure must be performed by a user who has detailed knowledge of the Maxum. If a customer does not have the knowledge required for this procedure, then it is recommended that Siemens Field Service personnel be contracted to assist. ● A tool kit including both standard and metric wrenches, Hex wrenches, and nut drivers is required to perform this procedure. ● Before beginning replacement, be sure to save a current database of the application to be reloaded after the PECM is replaced in case this becomes necessary. WARNING Voltage danerous to life is present on the PECM. Failure to observe proper safety measure can cause severe injury or death. Before beginning to remove or install the PECM assembly, the power must be externally removed from the GC. AC power comes directly into this board for regulation and distribution in the electronics enclosure, so power must be removed and secured/tagged to prevent inadvertent application while this procedure is being performed. Troubleshooting PECM Status LEDs The PECM3 should start automatically once power is applied. If the unit is not operational after applying power, then review the information below to aid in correcting the problem. The most common issue with replacing the PECM3 is cables, wiring connections, and jumpers. Check all of the cable connections to ensure that they are seated and connected properly. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 93 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components The alarm system can also provide direct information on alarms for an error. Review the alarms to see if they provide an indication of the problem. Each alarm has a written description that may provide an indication of the problem area. The LEDs on the PECM board can help with LEFT Heater Status troubleshooting problems. There are two Heater 1 Air Pressure sets of LEDs: one on each side of the front Heater 1 Power Activate board as shown in the diagram to the right. Heater 1 Temp Limit The bottom set of three LEDs is the same as used on other boards (described below.) The Heater 1 Overtemp left set is for the PECM software. (The other LEDs are not used for PECM1 replacement.) The corrective action to take for each of the Normal LED indications is noted below with a correc‐PECM Status Fault tive action reference number on the diagram Warning at the right. The normal state indication is shown in the diagram below. RIGHT Heater status Heater 2 Air Pressure PECM-CTRL PCB Heater 2 Power Activate Heater 2 Temp Limit Heater 2 Overtemp Normal Fault Warning Temperature Controller Status 1. Reset the device or cycle power 2. Check communication cable connections State 6 1. 2. 3. 4. 5. 6. 94 Reset the device or cycle power Check communication cable connections Check for missing Temp Limit setpoint boards Check for shorted or open RTDs Replace the unit Replace other connected units State 6 - Fault condition; data invalid State 5 - Warning condition; data good temporarily State 4 - Normal operation State 3 - Address assignment State 2 - Self test State 1 1. If all units in this state, then power to the analyzer and/ or board is not active 2. Reset the device or cycle power 3. Check power connections to board (AC and 24VDC) 4. Replace unit State 2 1. Reset the device or cycle analyzer power 2. Replace unit State 3 1. Reset the device or cycle analyzer power 2. If all modules are in State 3, then SNECON is not communicating (check cabling and connections) 3. Replace unit State 4 Normal Operation State 5 State 1 - Power off PECM LEDs Normal Fault Warning PECM LED Interpretation Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Removing The PECM Precautions Before starting this procedure, follow the steps in the General Analyzer Shutdown Procedure. WARNING Voltage dangerous to life exists. Failure to follow proper safety procedures may result in severe injury or death. Before beginning to remove or install the PECM assembly, the power must be externally removed from the GC. AC power comes directly into this board for regulation and distribution in the electronics enclosure, so power must be removed and secured/tagged to prevent inadvertent application while this procedure is being performed. WARNING High-voltage circuitry. Failure to follow proper procedures may result in equipment damage, personal injury or death. The cable harness connectors and the chassis plugs associated with the Heater circuits are marked with orange identifier tags. Before reconnecting any connector or plug to a Heater circuit, ensure that the orange identifier tag on the connector or plug reads identical to the orange identifier tag on its mating connector. CAUTION Observe proper fuse values to prevent equipment damage or personal injury. The PECM1 is used in applications with both 115VAC and 230VAC power. Before installing a replacement assembly, ensure that the correct fuses for the particular application are installed in the replacement PECM3. Procedure 1. Open electronics door. If the latch is locked, use 4mm (5/32’”) Allen wrench to unlock. 2. Label all cable connections before disconnecting if they are not already labeled. Be sure to read the Warning below concerning those tagged with orange labels. 3. Unplug cables from all PECM connectors. 4. Unplug the atmospheric reference tube from the purge switch. (labelled “Purge SW”, tubing connection next to the back wall of the EC, on the PECM1. 5. Use a 5mm nut driver to loosen two hex nuts at the top of each side of base plate of the PECM. 6. Slide the PECM up and then lift the PECM off of the mounting bolts. See also General Analyzer Shutdown Procedure (Page 25) Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 95 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Installing The New PECM Procedure 1. On the replacement PECM3 assembly do the following: – Set the Purge Disable jumper JP2 to the same setting as the PECM being replaced. – Install the appropriate fuses for either 115VAC or 230VAC in Fuses F1 and F2 and install fuse covers. – Move jumper cables or termination plugs to the replacement PECM. – Move the TL/OT modules from the old PECM to the replacement PECM, in the mounting locations marked “TEMP CONTROL 1” and TEMP CONTROL 2”. These are required to avoid false alarm codes. – If Heater Termination Plugs are installed in the old PECM instead of cables at the positions marked “TEMP RTD 1” and “TEMP RTD 2”, move these to identical locations on the replacement PECM. The plugs disable the PECM temperature circuits, including the LEDs. 2. Ensure that there are no wires behind the mounting position of the PECM. 3. Because the atmospheric Purge switch SW1 is near the back wall after the PECM is installed, if desired, the Purge tube may be installed on SW1 before mounting the PECM in the next step. 4. Install the replacement PECM on the two mounting bolts. 5. Tighten the two 5mm hex nuts. 6. Start at the back of new controller and plug in the following cables (see the connector identification illustrations) – If not already connected in step 12, connect the Purge switch SW1 (tubing connection) – Relay power plug TB9 and Heater Relay Control cable – Fan power cable plug J18, and 24VDC power cables to the orange TB1 and TB2 on top board (there are TB1 and TB2 AC connectors on the bottom board as well - see illustration at right.) – I2C connections (J24 - J26, J30 - J33) – Low wattage heater connections (TB8, TB3 to TB5, and LWH1 to LWH6) – AC inputs (TB1, TB2, & TB10.) – Heater pressure switch (J10) (If no cable, then a jumper is needed.) 7. When replacing in a unit that has a MMI-1, then connect the MMI LED cable to J17. 8. Connect the Purge Signal cable to J1302. 9. Move 24V cable (from power supply) from WDB J1 to PECM3 TB1. 10.Add 24V power cable, 2021837-001 from PECM3 TB2 to WDB J1. 96 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 11.Ensure the correct fuses are in the correct positions, as shown in PECM AC Power Distribution illustration. 12.When the procedure is completed, follow the steps in the General Analyzer Startup Procedure. See also General Analyzer Startup Procedure (Page 25) 4.1.3 System Controller Version 2.1 (SYSCON2.1) 4.1.3.1 Description Overview The System Controller (SYSCON2.1) is a combination of two interconnected boards that together function as the control processor and motherboard for the Maxum analyzer. The SYSCON2.1 consists of two boards, the Communication and Analytical Control (CAC3) board and the SYSCON Interface Board (SIB3). The CAC3 contains the processor and memory functions for the SYSCON2.1 as well as control of external Ethernet communications (via the Ethernet Switch Board). The CAC3 is mounted on and operates in conjunction with the SIB3. With the exception of external Ethernet, the SIB3 contains all interfaces provided by the SYSCON2.1. The CAC3 on the SYSCON2.1 stores the analyzer application database, combines all data results, and performs additional high-level data processing and calculations. All network communications, maintenance panel and analyzer functions are also coordinated by the SYSCON2.1. The SYSCON2.1 provides communication between the Controller Board, I/O Boards and the EC operating modules. More information about the SYSCON can be found in the System Controller version 2 (SYSCON2.1) Installation Manual (Siemens part number A5E02643617001). Additional Functions ● Processing and communicating the measurement values ● Controlling system functions, such as calibration ● Display and operator control ● Controlling associated systems, such as gas supply ● Generating reports Software Support The SYSCON2.1 is supported only by software version 5.2 or greater. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 97 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.3.2 Mechanical Overview The SYSCON2.1 board pair resides in the SYSCON assembly. This assembly is a pullout, drop-down drawer located on a slide rail assembly mounted to the upper wall of the Electronic Enclosure. The SYSCON assembly is a card cage housing the SYSCON2.1 boards, the Ethernet Switch Board, and any other associated hardware such as I/O boards. SYSCON2.1 Cage Serial Ports Intrinsic-Safety Ground Connection Points External Ethernet Ports TIB Door Assembly I/O Connectors Figure 4-11 Display Cable Routing Into SYSCON SYSCON2.1 In Electronics Enclosure The Color Touchscreen cables directly to the SIB3 through an opening in the rear of the SY‐ SCON assembly. All PC boards in the SYSCON assembly are visible through the front of the drawer for making all I/O connections. Interface connectors to the front panel display, and communication connec‐ tors are also located and labeled on the front of the drawer. SYSCON2.1 Drawer 98 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.3.3 SYSCON2.1 Components Communication and Control Board (CAC3) Overview The Communication and Control board (CAC) is a standardized, single-board central processing unit for intended for use in Siemens products. For the Maxum family of products the third generation of the CAC board (CAC3) is used. The CAC3 includes an on-board 10/100 Ethernet controller, used for connection to external Ethernet. This is connected via a short RJ-45 patch cable to the Ethernet Switch Board, which resides in a card slot on the SIB3. More information and details pertaining to the CAC3 can be found in the System Controller version 2.1 (SYSCON2.1) Installation Manual (Siemens part number A5E02643617001). Figure 4-12 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 CAC3 Board (Part Number A5E02599492004) 99 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components CAC3 LEDs The CAC3 is equipped with several LEDs that communicate useful information about the operating status of the CAC3. Link Status Link Acknowledge LED7 LED2 LED3 LED1 Figure 4-13 LED4 LED5 CAC3 LED Locations LED1 Debug LED1 Green – On during normal operation. LED2 Debug LED2 Green – On during normal operation. Off during bootload. LED3 Power Good Green – Power to CAC3 is functional. LED4 Maintenance Yellow – Off during normal operation. On during bootload. LED5 Fault Red – CAC3 Board fault LED7 Ethernet Speed Green – On – Speed is 100 Mb/sec (or auto-negotiating) RJ-45 Green Link Status Green – LED is green when link is in full duplex mode. RJ-45 Yel‐ low Link Acknowl‐ edge Yellow – LED is on when link is active. Will flash off for transmit or receive activity. LED6 Off – Speed is 10 Mb/sec (or disconnected) 100 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components SIB3 SYSCON Interface Board (SIB3) Overview Compared to the SYSCON2 in previous Maxum II analyzers, the SIB3/CAC3 together with the Color Touchscreen equipped with a TIB module replaces the SIB2/CAC3 and Color Touchscreen equipped with a CIM module. This simplifies the internal cabling in the electronics enclosure. The SYSCON Interface Board version 3 (SIB3) is a board, with the CAC3 mounted on it, performs the function of the SYSCON2.1. Unlike the CAC3, the SIB3 is specific to the Maxum family of products (including the Maxum, the Maxum II, NAU). The combined SIB3 and CAC3 are an electrically and mechanically compatible replacement for the legacy SYSCON board in the Maxum. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 101 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components SIB3 LEDs LED Locations The SIB3 has several LEDs that indicate useful information about the operating status of various interfaces. Power LEDs Internal Ethernet to SNECON LEDs I2C LEDs I2C-Pullup Active LEDs CAC3 CAN Bridge LEDs 0 1 2 3 DI Mode Switch (Set to Mode 2) PCI Slot LEDs Reset I/O Connector Figure 4-14 102 SIB3 LEDs and Switches Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Power LEDs Located at the back of the board near the RJ 45 connector Description Color and Meaning Power Green – 3.3V power is available. Should be on at all times Power Bad Red – Power is faulty or SYSCON hardware reset switch is being pressed CAC Conn Bad Red – Connection from the SIB3 to the CAC3 is faulty or incomplete. After power up, this LED should turn off once CAC3 to SIB3 connection is completely initialized. I2C Bus LEDs, Buses A and B Located next to I2C Bus connectors Description Color and Meaning LED2/5 Norm/Comm Dim Green – I2C Bus is normal Bright Green - I2C Bus is communicating LED3/6 Warning Yellow – Warning on the I2C Bus LED4/7 Fault Red –I2C Bus fault I2C Bus Pullup-Active LEDs Located next to battery holder Description Color and Meaning LED19, 20 The Auto-pullup feature is supplying pullup current on the I2C Bus. Can Bridge LEDs Located to the left of the far left PCI slot Description Color and Meaning LED16 Ready/Comm Dim Green – Can Bridge is normal Bright Green – Can Bridge is communicating LED17 Warning Yellow – Warning on the Can Bridge LED15 Fault Red – Can Bridge fault Can I/O LEDs Located next to far left CAN direct connector, CAN direct 5 Description Color and Meaning LED8 TX Green – On when a valid CAN I/O message (other than a heartbeat reply) has been received and queued for processing LED9 RX Green – On when a CAN message (other than a heartbeat transmission) has been queued for sending to the CAN hardware Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 103 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Description Color and Meaning LED10 Heartbeat Green – Flashes once for each heartbeat message transmitted. This LED will flash once every 1.5 seconds for each active CAN card LED11 Fault Red – On when an error state is detected on the CAN bus hardware PCI Slot LEDs Located between PCI slots Description Color and Meaning LED14 Slot 0 Fault Red – Overcurrent or thermal shutdown on PCI slot 0 LED13 Slot 1 Fault Red – Overcurrent or thermal shutdown on PCI slot 1 LED18 Slot 2 Fault Red – Overcurrent or thermal shutdown on PCI slot 2 LED12 Slot 3 Fault Red – Overcurrent or thermal shutdown on PCI slot 3 Internal Ethernet LEDs Located next to and on SIB3 RJ-45 connector Description Color and Meaning Green LED on RJ-45 Green – LED is green when link is in full duplex mode Yellow LED on RJ-45 Yellow – LED is on when link is active. Will flash off for transmit or receive activity. LED1 Speed Green – On – Speed is 100 Mb/sec (or auto-negotiating) Off – Speed is 10 Mb/sec (or disconnected) 104 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components SIB3 Connectors Overview Other than external Ethernet, the SIB3 provides all interfaces for the SYSCON2.1. The connections are described below. All connectors in the SYSCON2.1 have the same pin assignments as the corresponding connectors in the original SYSCON, except where noted below. 42 3 5 Reset (Legacy) Ethernet Ethernet (to Ethernet to SNECON Switch) (if used) Maintenance Panel (Legacy) I2C B I2C A CAC3 Power Purge SYSCON Debug CAN Internal Serial Port 2 Color Touchscreen 2 3 4 5 0 1 2 3 CAN Direct Network Expansion Slot for Ethernet Switch Board Serial Port 1 I/O Mode Switch CAN Bus PCI Slots Serial Port 3 Serial Port 4 Reset I/O Connector Figure 4-15 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 SYSCON2.1 Connections 105 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components PCI and CAN Direct Slots The PCI slots on the SIB3 accommodate a variety of special function cards, including I/O boards or an ANCB board. Four PCI slots are equipped in the SYSCON2.1; however, typically only three slots are available for use in the standard configuration, because one SYSCON slot is used for serial/debug port hardware. In addition to PCI type cards, the card slots can also accommodate Maxum CAN I/O cards. The small green connector in line with the PCI slot allows CAN I/O cards to be installed in the slot. When a CAN card is installed, the green connector provides the power and CAN signals for the card. The PCI slot connector has no electrical connection for CAN cards. Note Only use cards specified and sold by Siemens for the SYSCON2.1. Installation of a card that is not approved by Siemens into a SYSCON2.1 PCI slot, may damage both the card and the SYSCON2.1. Network Expansion Slot The Ethernet Switch Board (or Ethernet Switch Board with Fiber) plugs into this connector, located on the far right side of the SYSCON2.1. The connector slot provides power to the Ethernet Switch, but no communication. All communication between the Ethernet Switch and the SYSCON2.1 is through a short CAT5 Ethernet Cable that connects from the CAC3 to the Ethernet Switch. 106 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Serial Ports ● SYSCON Debug – This serial RS-232 port provides the SYSCON2.1 debug function on the CAC3. The debug port has no support for hardware handshake. The debug port is accessed via a DB9 connector on the front of the SYSCON assembly cage. ● Serial Ports 1 and 2 – The SYSCON2.1 is equipped with two serial ports, each groundisolated and configurable for RS-232 or RS-485. Both ports support RTS/CTS hardware handshake. Maximum supported data rate on the serial ports is 115200 bits/second. Serial Port 1 supports Modbus and Serial Port 2 may be used to support a printer. Note RS-485 Operation When configured for RS-485 operation, the serial ports are designed to comply with the Profibus standard. This results in a different pinout than for the previous version of SYSCON (pins 8 and 2 reversed). For backward Modbus RS-485 compatibility when replacing a SYSCON+ with a SYSCON2.1, an adapter cable (part number A5E02283873001) is available. DB-9 Pin RS-232 Signal RS-485 Modbus Signal 1 - - 2 RX %v power 3 TX Line B (RxD+/TxD+) 4 - - 5 GND Common 6 - - 7 RTS - 8 CTS Line A (RxD-/TxD-) 9 - - ● Serial Ports 3 and 4 – These two serial ports, equipped on the same slot connector as the SYSCON Debug port, are not active in software release 5.0. I2C Bus The I2C connectors are shown in the upper right corner of the SYSCON2.1 Connections photo. Two I2C buses are equipped on the SYSCON2.1. These are labeled I2C Bus A and I2C Bus B. ● I2C Bus A includes the two connectors on the right as shown in the SYSCON2.1 Connections photo. I2C Bus A is dedicated and hard wired to the CAN Bridge function. This allows the new SYSCON2.1 to interface with legacy CAN I/O cards in the PCI slots. ● I2C Bus B includes the three I2C connectors on the left as shown in the SYSCON2.1 Connections photo. I2C Bus B is supports2 future configuration changes in the Maxum II. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 107 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Resets The SYSCON2.1 has a pushbutton reset switch at the front of the board. This switch may be accessed via the front of the newest version SYSCON assembly cage. The second connection consists of two pin connections at the back of the board (top left of the SIB3 connections photo) second connection operates using a simple loop closure, and supports legacy SYSCON assembly cages that provide a separate wired pushbutton reset. Both connections allow the user to initiate a hard reset of the SYSCON (same as initial power up). Purge The purge detect signal is received from the PECM and handled by the SYSCON as a digital input to generate a purge alarm. Display Connectors Interface and power for the Color Touchscreen connect to the SYSCON2.1 using a cable assembly. This cable runs directly from two connectors on the SIB3, out through tthe back of the SYSCON cage, to the Color Touchscreen panel. Power The 24 V power supply mounted beside the SYSCON cage powers the SYSCON2.1 directly through a cable that plugs into the bottom of the cage. On-board power conversion derives the other voltages needed for operation. Note Battery The real-time clock on the CAC3 board is powered by a long-life 3v cell mounted on the SIB3. This battery should last at least 5 years under normal operation. Because the battery is located on the SIB3 board while the real time clock is on the CAC3 board, if the CAC3 board is disconnected from the SIB3, then battery backup is lost. The time and date must then be set on the analyzer. Ethernet Port Expansion Ethernet Switch Board (ESB) The primary external communication for the SYSCON2.1 is via Ethernet connection. The CAC3 has an on board 10/100 Ethernet port. This is connected via a short RJ-45 patch cable to the Ethernet Switch Board (ESB) that resides on the SIB3. The ESB converts the single CAC3 Ethernet into four Ethernet connections. This allows the SYSCON2.1 to remain connected to an external network while, at the same time, allowing a laptop to be temporarily connected for maintenance and troubleshooting purposes. The remaining connections provided by the ESB are available to connect to other Maxum network options, such as an ANCB installed in the SYSCON chassis or an external connection to a Siemens redundant network interface. The ESB (or ESBF) is required when a SYSCON2.1 is installed in the Maxum. 108 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components The ports on the ESB are auto-negotiating for either 10Base or 100Base operation. The Ethernet Switch is plug-and-play as it does not require initial setup or configuration. Configuration of the ESB is not supported at this time. The ESB is equipped with a jumper setting, R2, located in the lower right portion of the board. For proper field operation this jumper should be set to default position, 2-3 (or the jumper can be removed for default operation as well). There are several LEDs equipped on the Ethernet Switch. These identify the operating speed of each port as indicated in the following table. LEDs for external connectors count from the bottom up (e.g. bottom LED is for top connector). LED Meaning Description 1 On=100Mb Off=10Mb Internal RJ-45 Connector to CAC3 2 External Top RJ-45 Connector 3 External Second RJ-45 Connector 4 External Third RJ-45 Connector 5 External Bottom RJ-45 Connector Figure 4-16 Ethernet Switch Board (ESB, Part Number A5E02368691001) Ethernet Switch Board with Fiber (ESBF) The Ethernet Switch Board with Fiber (ESBF) is similar to the Ethernet Switch Board (ESB) described previously. The primary difference is that for the ESBF one of the 10/100Base-T connectors has been replaced with a 100Base-FX 1300 nm fiber optic connection with duplex ST® connectors. This fiber connection is not compatible with 10 megabit fiber systems. As can be seen in Figure 2-22 on the following page, the ESBF is equipped with two edge connectors, one on the top of the board and one on the bottom. The board is designed in this manner to support its use in either the network slot (slot 5) of a SYSCON2.1 or in a PCI slot of a SYSCON2.1 or legacy SYSCON1. The slot edge connectors are labeled on the board as “SYSCON2.1 NETWORK SLOT” and “SYSCON/PCI SLOT”. Only one Ethernet Switch may be used in an analyzer for external Ethernet communication. However, It is possible to use an ESB in slot 5 for external Ethernet, and an ESBF in another slot in the alternate configuration for internal Ethernet in cases where legacy SNECON modules must be used. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 109 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Figure 4-17 Ethernet Switch Board with Fiber (ESBF, Part Number A5E02555919001) Multiple Mode Use of ESBF The unique dual edge connector allows the ESBF to be used in both the SYSCON2.1 and legacy SYSCON. The ESBF may be installed in the following configurations: ● Default – In the default configuration, the ESBF installs in the network slot of the SYSCON2.1 (far right slot 5). In this configuration the slot edge connector labeled “SYSCON2.1 NETWORK SLOT” is used (the fiber optic connection is on the top in this configuration). ● SYSCON2.1 Expansion – ESBF is capable of installing in one of the PCI slots (slots 1 through 4, counting from left) of the SYSCON2.1. This configuration is used in the SYSCON2.1 when communicating with more than one SNE or when additional Ethernet communication ports are required. In this configuration the ESBF is turned “upside-down” and the “SYSCON/PCI SLOT” slot edge connector is used (the fiber optic connection is on the bottom in this configuration). ● SYSCON1 Enhancement – ESBF installs in an empty PCI slot (slots 1 through 4, counting from left). This allows the original SYSCON1 to communicate to more than one Ethernet device at the same time (such as communication to a local laptop computer while still connected to the network). This also allows for easy configuration to support fiber Ethernet connection. In this configuration the ESBF is turned “upside-down” and the “SYSCON/PCI SLOT” slot edge connector is used (the fiber optic connection is on the bottom in this configuration). To support the dual edge connector configuration, the ESBF is equipped with a special reversible bracket. This bracket is detached and turned upside down when the board is installed upside down in a PCI slot. To reverse the bracket, unscrew it and turn it upside down. Then, connect the bracket using the opposite set of holes to align the bracket appropriately. 110 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Figure 4-18 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 ESBF Bracket Position (Default at left, Alternate at right) 111 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.3.4 Maintenance Overview Board Replacement A failure in the SYSCON2.1 will generally interrupt communication between the GCP networkbased software and the detectors. A simplified view of the system is shown below. 120/240VAC 120/240VAC PECM SSR Board 120/240VAC Heaters 24 V Supply 24VDC Color Touch Display I2C I2C DPMs SYSCON (SIB3) RS232 RS485 CAN CAC3 24VDC 24VDC PECM Controller Board I2C EPCs 24VDC I2C SVCMs Ethernet 24VDC GCP AC Supply GCP Ethernet Switch (optional) Analyzers I/O Boards (I2C) Ethernet Figure 4-19 DC Supply Digital Communication Power Distribution and Communication Paths Most problems can be resolved by checking interconnects between cable, boards, and connectors. If a component must be replaced, the following sections give detailed procedures. Remote Database Backup Because these procedures separate the CAC3 memory from the backup-battery voltage on the SIB3, the database must be backed up to a workstation on the network or directly connected. See also General Analyzer Startup Procedure (Page 25) General Analyzer Shutdown Procedure (Page 25) 112 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.3.5 Service Procedures Preparing to Replace A Component The analyzer must be shut down using the General Analyzer Shutdown Procedure. Replacing A CAC3 The CAC3 memory content depends on backup-battery voltage from the SIB3. When the CAC3 is removed from the SIB3, the memory content is lost. Observe safe ESD handling procedures. Removing the CAC3 1. Disconnect the ethernet cable from the CAC3 board. 2. Remove the two 2mm screws and o-rings as shown in the illustration below. Early SIB3s had threaded studs, with two nuts with o-rings. 3. Remove the CAC3 by gently pulling it straight up. Avoid rocking or tilting motions. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 113 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Early SIB3s with nuts on threaded studs securing the CAC3 Figure 4-20 Current SIB3s have screws in nuts swaged into the board to secure the CAC3 Mounting the CAC3 on the SIB3 Installing the CAC3 on the SIB3 1. Carefully align the CAC3 connectors over the mating connectors of the SIB3. 2. Press down to fully engage the connectors. 114 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 3. Install the 2mm screws with o-rings. Avoid overtightening. 4. Plug in the ethernet cable. 5. Follow the steps in the General Analyzer Startup Procedure. It will be neccessary to download the database saved earlier using GCP. Removing a SIB3 1. As each cable is disconnected, move it clear of the SIB so it can be removed. 2. Make note of – I/O board positions – I/O cable location – All cable positions to the SIB3 – SIB3 I/O Mode switch 3. Disconnect – I/O cables from SIB3 and I/O boards – Display cables – Ethernet cable from CAC3 – Internal ethernet cable to SNEs if used 4. Remove ESB 5. Remove I/O boards 6. Disconnect from the SIB3 – I2C cables – Purge cable – Power cable – Serial cables – CAN bus cable if present 7. If the existing CAC3 will be reused, remove it following the procedure in the preceding section and place in a static-protected area. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 115 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 8. Remove 6 mounting screws from the locations shown in the illustra‐ tion at right. Mounting Screw Locations SIB3 Mounting Screw Locations 9. Remove the SIB, rear edge first to pull the I/O connectors from the SYSCON cage opening. Installing a SIB3 1. Set the I/O mode switch on the SIB3 to the same position as the board that was removed. 2. Install a CAC3 using the procedure described earlier. The two boards together are called the SYSCON2.1. 3. Install the SYSCON2.1 in the tray and secure with the 6 mounting screws removed earlier. 4. Install these cables to the SIB3: – I2C cables – Purge cable – Power cable – Serial cables – CAN bus cable if present 116 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 5. Install the ESB and reconnect the Ethernet cable from the rear RJ-45 connector to the horizontal RJ-45 conncector on the CAC3. 6. Install the I/O boards. 7. Reconnect these cables: – I/O cables from SIB3 and I/O boards – Display cables – Ethernet cable from CAC3 – Internal ethernet cable to SNEs if used See also General Analyzer Shutdown Procedure (Page 25) General Analyzer Startup Procedure (Page 25) 4.1.3.6 Replacing the Lithium Battery on the SYSCON Module Introduction Both the original and newer version of the SYSCON module are equipped with a lithium battery for on‑board memory backup. For the original version SYSCON module this is a 3.6 V tube shaped battery. For the SYSCON2 module it is a 3.0 V flat battery. Siemens recommends that the battery be replaced every 5 years. The battery should only be replaced with an approved spare. Contact Siemens for a replacement. NOTICE Observe battery polarity. Reversing the battery can damage the board. Before removal of battery, note location of its positive end when installed in battery holder. The positive and negative terminals are marked on the battery. For the 3.6 V version (original SYSCON), note that the physical shape of the Positive and Negative terminals on the battery are NOT STANDARD. 4.1.3.7 Procedure Follow this procedure to replace the battery. 1. Power down the analyzer using standard procedures. 2. Open electronic enclosure door (using a 4 mm (5/32 inch) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 3. Using appropriate tools, loosen the topmost SYSCON Assembly fastening hardware that secures the assembly to electronic enclosure mounting bracket. 4. Pull the SYSCON drawer out and lower it so that it rests in the tilted-out position. 5. The battey holder is located on the left side of the SIB3 board. (Near the back on the original SYSCON board) Remove battery from its holder. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 117 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 6. When installing the lithium battery in its holder, place the positive (+) side following the marking on the holder. Refer to the applicable picture in the previous step. Note that for the original SYSCON (3.6 V tube shaped battery) the physical shape of the positive and negative terminals on the battery are NOT like a standard battery. 7. After installation, push the SYSCON assembly back into its mounting facility and secure assembly in place with the fastening hardware. 8. Before closing door and reapplying AC power, be certain the battery is securely installed in its holder.. 9. When the battery in a SYSCON is removed, current date and time information is lost. If the analyzer is configured to obtain date and time information from a central server, then it will update automatically. If no time server is set, it will be necessary to manually set the date and time on the analyzer. 4.1.4 Analog and Digital I/O 4.1.4.1 Overview How I/O Channels Are Used When low-power devices other than detectors are used either for measurements or control functions, I/O channels can be used. These fall into four categories: Digital Inputs allow the analyzer to detect whether some device is on or off. These can be either 'sinking' (Mode 2, the default configuration) or 'sourcing' (Mode1, used on legacy hardware and sometimes needed for a particular application). A switch on the SIB3 and on current I/O boards selects between the two modes. Digital Outputs are simply output relay channels that are either open or closed. These typically enable or disable a device, turn an indicator light on or off, or select a measurement range in a sensor. Analog Inputs accept a variable voltage level and convert the level to a digital value that can be used in software. Analog Outputs convert a digital value into a variable current that can be used to control some device or process. SIB3-Based I/O The SYSCON2.1 has ten on-board inputs/outputs. The connectors for these are wired from two orange connectors on the front of the SYSCON assembly cage. Switch SW3 selects sink (Mode 2) or source (Mode 1) for the digital inputs. 118 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components I/O Expansion Boards The I/O expansion boards are plugged into the SIB3 backplane. The I/O card circuitry is isolated from the connectors except for the 24v power connection on the CAN connector. The I/O cards communicate with the SYSCON over the I2C cable assembly. Although this cable assembly also supplies 24v, the board is only powered from the CAN edge connector unless the I/O board is being used outside of the backplane in a special configuration. 4.1.4.2 I/O Card Common Features Available I/O Boards The newest version of I/O board communicates over the I2C bus. The I2C I/O boards are the type available for new installation. See System Controller Connections for connection diagrams information. ● Analog I/O board (AIO_I2C, Part Number A5E02486267001): has 8 analog output channels, 8 analog input channels, and 2 digital input channels ● Digital I/O board (DIO_I2C, Part Number A5E02486268001): has 8 digital outputs and 6 digital inputs ● Analog and Digital I/O board (ADIO_I2C, Part Number A5E02359491001): has 4 digital outputs, 4 digital inputs, 4 analog outputs, and 4 analog inputs The DOs are rated for 1A resistive load. Inductive loads are different. A DO should not drive an inductive load greater than 0.5A. An example is the typical block-and-bleed application which uses two parallel solenoids at 0.4A each. Separate DOs should be used to drive each solenoid. Each DO connected to a solenoid should have a diode to suppress the solenoid load. The SYSCON supports up to two I2C I/O boards. These boards provide approximately twice the number of circuits as previous CAN I/O boards. However, if an application needs more than two I/O boards, a NAU can be installed. This allows installation of additional I2C I/O boards that the Maxum II can access remotely. I2C Bus Connections and Addressing There are two standard I2C bus connections on the top of each I2C I/O board. Either of these connections may be used as either a bus input or bus extension connection. In this manner the I2C bus can daisy chain from one board to another or to other I2C devices. The I2C I/O boards use an 8-bit board identification number as an address on the I2C bus. The address is a hex number from 00 to FF, corresponding to a decimal number from 0 to 255. Address numbers from 1 to 254 are used (numbers 0 and 255 are reserved). DIP switches are used to set the address for the physical board as shown below. When replacing a board, the user only needs to set the switches on the new board to match the old board being replaced. The DIP switches used to set the address are on the top back part of the board and are labeled BOARD ID. Together, the DIP switches correspond to an 8 bit binary number that is set to match the board address. Each switch is labeled for the binary digit it represents, and setting a switch is equivalent to setting that bit to 1. For example, if the switches for 1, 2, and 4 are set, then the board ID would be 1+2+4 = 7. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 119 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Legacy position Figure 4-21 120 Default position I2C ID Switches I/O Board Switches Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components I/O Board Status LEDs Each I2C-bus I/O board has three status LEDs; a green Normal, a yellow Waning, and a red Fault indicator. The Normal LED may flash to show active communication. I2C Bus CAN Bus I/O Board LEDs CAN Bus I/O Boards Figure 4-22 I/O Board LEDs I2C Bus I/O Board I/O Board Status LEDs In the illustration above, one I2C I/O board is shown on the right. Two legacy CAN boards are shown to the left. These boards have a number of additional status LEDs, described in the section on CAN I/O Board Information. I/O Board DI Mode Switch Switch SW1 located at the top of the board near the front (connector end) controls the mode setting for the on-board digital inputs (DIs). The switch sets the mode for all DI circuits on the board (mixing of modes on a board is not supported). The available options are Default/Sink (Mode 2) and Legacy (Mode 1) A diagram is printed on the back of each board showing the setting. The Legacy option is designed to adjust for a non-standard configuration that may be in use on some systems. The Mode switch should be set to Mode 2 unless instructed differently by Siemens. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 121 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.4.3 Digital I/O Card Circuits on the DIO board (DIO_I2C) are wired as shown in the following table. The table is the view is as seen when looking at the connector while the board is installed. Table 4-1 DIO_I2C Wire Side View Signal Signal DI Common 2 1 DI6 DI Common 4 3 DI5 DI Common 6 5 DI4 DI Common 8 7 DI3 DI Common 10 9 DI2 DI Common 12 11 DI1 DO8 Common 14 13 DO8 NC DO7 NC 16 15 DO8 NO DO7 NO 18 17 DO7 Common DO6 Common 20 19 DO6 NC DO5 NC 22 21 DO6 NO DO5 NO 24 23 DO5 Common DO4 Common 26 23 DO4 NC DO3 NC 28 27 DO4 NO DO3 NO 30 29 DO3 Common DO2 Common 32 31 DO2 NC DO1 NC 34 33 DO2 NO DO1 NO 36 35 DO1 Common Figure 4-23 122 Pin Digital Inputs: Optocoupler with internal 12-24VDC pow‐ er supply, switchable with floating contacts; alternative: switchable with external voltage 12-24VDC, common negative pole. Digital Outputs: Digital Outputs: Floating double-throw contacts, max. contact load rating 30V / 1A The DOs are rated for 1A resistive load. Inductive loads are different. A DO should not drive an inductive load greater than 0.5A. The typical block and bleed applica‐ tion, which uses two parallel solenoids at 0.4A each, should use separate DOs to drive each solenoid. Each DO connected to a solenoid should have a diode to sup‐ press the solenoid load. I/O Terminal Design: Plug-in terminal strips for stranded or solid conductors with a maximum diameter of 1.0mm2 or 18AWG. Digital I/O Board (DIO_I2C) Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.4.4 Analog I/O Board Circuits on the AIO board (AIO_I2C) are wired as shown in the following table. The table is the view is as seen when looking at the connector while the board is installed. Table 4-2 AIO_I2C Wire Side View Signal Signal AI8 -10V 2 1 AI8 +10V AI7 -10V 4 3 AI7 +10V AI6 -10V 6 5 AI6 +10V AI5 -10V 8 7 AI5 +10V AI4 -10V 10 9 AI4 +10V AI3 -10V 12 11 AI3 +10V AI2 -10V 14 13 AI2 +10V AI1 -10V 16 15 AI1 +10V 18 17 AO8 Current 20 19 AO7 Current 22 21 AO6 Current 24 23 AO5 Current 26 23 AO4 Current 28 27 AO3 Current 30 29 AO2 Current 32 31 AO1 Current 34 33 DI2 36 35 DI1 AO_GND DI Common Figure 4-24 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Pin Analog Inputs: -20 to 20mA into 50Ω or -10 to 10V, R10=1MΩ, mutually isolated 10V Analog Outputs: 0-4 to 20mA. Common negative pole, galvanically separated from ground, freely con‐ nectable to ground; working resistance 750Ω. Digital Inputs: Optocoupler with internal 12-24VDC power supply, switchable with floating contacts; alter‐ native: switchable with external voltage 12-24VDC, common negative pole. I/O Terminal Design: Plug-in terminal strips for stran‐ ded or solid conductors with a maximum diameter of 1.0mm2 or 18AWG. Analog I/O Board (AIO_I2C) 123 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.4.5 Analog and Digital I/O Board Circuits on the ADIO board are wired as shown in the following table. The table is the view is as seen when looking at the connector while the board is installed. Table 4-3 ADIO_I2C Wire Side View Signal AI8 -10V Pin 2 Signal 1 AI7 -10V 4 3 AI3 +10V AI6 -10V 6 5 AI2 +10V AI5 -10V 8 7 AI1 +10V 10 9 DI4 12 11 DI3 14 13 DI2 16 15 DI1 18 17 AO4 Current 20 19 AO3 Current 22 21 AO2 Current 24 23 AO1 Current 26 23 DO4 NC DI Common AO_GND DO4 Common DO3 NC 28 27 DO4 NO DO3 NO 30 29 DO3 Common DO2 Common 32 31 DO2 NC DO1 NC 34 33 DO2 NO DO1 NO 36 35 DO1 Common Figure 4-25 124 AI4 +10V Analog Inputs: -20 to 20mA into 50Ω or -10 to 10V, R10=1MΩ, mutually isolated 10V Analog Outputs: 0-4 to 20mA. Common negative pole, galvani‐ cally separated from ground, freely connectable to ground; work‐ ing resistance 750Ω. Digital Inputs: Optocoupler with internal 12-24VDC power supply, switchable with floating contacts; alternative: switchable with ex‐ ternal voltage 12-24VDC, common negative pole. Digital Outputs: Digital Outputs: Floating double-throw contacts, max. contact load rating 30V / 1A I/O Terminal Design: Plug-in terminal strips for stranded or solid conductors with a maximum diameter of 1.0mm2 or 18AWG. Analog and Digital I/O Board (ADIO_I2C) Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.5 Detector Personality Modules 4.1.5.1 DPM Types Three DPM types are used for temperature control and detector interface: ● Intrinsically Safe Thermal Conductivity DPM ● Base3DPM ● Temperature Control Personality Module (TC-PM) The interfaces available for each are shown in the table below. Function TC-PM Temperature control Intrinsic safety IS-TCD DPM x Base3DPM x x Detector inferfaces: RTD Thermistor 4.1.5.2 x x Filament x FID x FPD x VPD x Base3 Detector Personality Module (DPM) Output signals from any of the detectors connect to each associated Detector Personality Module (DPM) input. The transfer of detector data is based on the database method. The DPM digitizes the signal and then passes the data to the SYSCON via an I2C port. Results can then be viewed on the Color Touchscreen or the workstation. The method is the part of the application that contains the parameters for controlling the hardware used by one cycle clock. It provides peak areas and component concentrations and includes all cycle clock timed events. There is one cycle clock per method. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 125 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components RTD Temp Control Input Access hole for mounting screw for Temp Setpoint modules Flame Sense and Filament Detector Input Location ID Switch Status LEDs Mezzanine Module Mounting Location Ignite Signal/ Igniter Power Signal Cable from Detector Figure 4-26 Base3DPM With Mezzanine Module Part Number The Base3 DPM (Part Number A5E02645925001) is shipped with current analyzers. It can be used as a replacement part for earlier DPMs in Maxum I analyzers using an adapter, part number A5E34938458001. 126 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Overview of DPM Functions The Base 3 Detector Personality Module (DPM) combines these functions in a single module: Input from detector via mezzanine module Ignite signal / glow-plug output Range-select output FID 300-V bias output Flame-sense input (used in Maxum I analyzers only) Input from detector via mezzanine module Ignite signal / glow-plug output Range-select output Enable signal output Including Mezzanine Modules FPD 300V bias output Flame-sense input (used in Maxum I analyzers only) Input from detector via mezzanine module Analog volt‐ age input Filament Detector Range-select output Input via connector on right side (as viewed inside analyzer EC) Temperature setpoint module connector Two RTD inputs Temperature control Two heater-control outputs System communication I2C port with ID-select switch Input Signal Paths The input-signal functions are shown below. I2C Network GCP SYSCON I2C PECM BaseDPM A/D Mezzanine Analog Module (signal conditioning) Analog Flame Ionization or Flame Photometric Detector Color Touch Display Figure 4-27 FID, FPD, or Analog Input Detector Input Signal Path I2C Network GCP SYSCON I2C PECM BaseDPM A/D Analog Filament Detector Color Touch Display Figure 4-28 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Filament Detector Input Signal Path 127 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Detector Control Paths Several control signals are available to control various detector functions as shown below. I2C Network GCP SYSCON I2C PECM Color Touch Display BaseDPM A/D Digital (Range Select) Mezzanine Module (signal conditioning) Digital (Ignite) / Power (Glow Plug) FID FPD Analog Output 300 V Bias (FID) Enable (FPD) 5 V Power (FPD) Figure 4-29 Maxum II Detector Control Functions Location ID Switch The Location ID Switch, shown previously in the photograph, selects the DPM location that is incorporated in the address, to be reported in the results. The DPM I2C port is connected directly to the system controller via the PECM or a wiring distribution board. In this scenario, the following values are applied: Switch Value Location 1 Left 2 Center 3 Right NOTE: If the DPM I2C port is connected to an SNE, the value is always set to “1”. The actual location value is determined by the SNE. 128 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components DPM-Based Temperature Control The Base3 DPM has two temperature-control channels. Two RTD inputs feed two comparator circuits to drive two heater-control outputs. The heater-control outputs connect to inputs on the PECM in most analyzers. The control path is shown below. Air Bath Oven DPM SYSCON Temp Setpoint Modules Analog Compare Temp Control, Temp Limit, Overtemp RTDs PECM I2C PWM High-Wattage Heater SSR Pair Airflow Loss Shutdown Digital Air Pressure Switch Airflow Loss Temperature Shutdown Control AC Line Figure 4-30 SSRa SSRb Heater Heater Control Path Using DPM A mounting location and connector are provided for two Temperature Setpoint Modules. The modules are installed on the left side (back) of the DPM, shown below. This same position is used in the Temperature Control DPM. RTD Temp Control Inputs I2C Status LEDs Location ID Switch Heater Control Outputs to PECM Temp Setpoint Module Mounting Screw Access Temp Setpoint Module Mounting Location Figure 4-31 Temperature Setpoint Modules Installed on Left Side of Base3 DPM Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 129 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Mezzanine Modules A mezzanine module conditions the signal from a non-conductivity detector. The mezzanine plugs into the Base3 DPM in order to tailor the DPM for a specific measurement. Three primary types of mezzanine are available to accommodate FID and FPD detectors, and various detectors that produce a scaled analog output (AI) mezzanine. Some of the mezzanines have a dual range function for maximum flexibility. See the table below for details relating to the various mezzanine options. The AI mezzanine can be used for reading a detector voltage signal from a specialized or third party detector, such as the Valco PDD, where the device only supplies a scaled voltage output. The AI signal will be treated like a normal detector signal, with a 50% balance range. Table 4-4 Mezzanine 2020960-001 Mezzanine Part Number Descriptions Detector Sub Module Type FID 2020960-003 2021328-002 2021328-001 FPD 2021328-003 2021326-001 Universal 1901614-001 Dummy Plug 4.1.5.3 Usage Normal Range Alternate Range Low level FID 0.2nA none Standard FID 1nA 20nA Large Scale FID 100nA 1000nA FPD 100nA none FPD, 0.18 Hz Filter 100nA none Voltage AI ±1V ±10V When Base DPM is Filament only, and no mezzanine required none none Replacing a Base3DPM Removing the Base3DPM See the illustration Base3 DPM With Mezzanine Module and Temperature Setpoint Modules Installed on Left Side of Base3DPM for connector and module locations. 1. Back up and shut down the unit using the General Analyzer Shutdown Procedure. 2. Open the electronics enclosure door. 3. Disconnect the detector signal cable from the mezzanine module. – FID and FPD mezzanine modules use SMA coaxial cables. Unscrew the nut to unplug the cable. – Analog input mezzanine modules use small terminal block connectors that can be unplugged. 4. Disconnect the fIlament detector cable if present. 5. Disconnect the RTD temperature input cables (top rear of unit, if present). 6. If present, take out screws holding the IS ground cables (typically only installed on modular oven models). 7. Remove the nut on the bottom-front of DPM bracket. 8. Slide the unit forward to disengage the rear mounting lug. 130 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 9. Lift the unit up and part way out of the enclosure. 10.Disconnect the I2C/power cable and temperature control output cables from the rear edge of the board. 11.Remove the unit from the analyzer and place on ESD-safe work surface. 12.Unscrew the two mounting screws at the top corners of the mezzanine module, and unplug it from the Base3 DPM. 13.Unscrew the mounting screw for the temperature setpoint module stack using the access hole in the metal plate near the filament detector input. 14.Unplug the temperature setpoint module stack from the left side of the board. 15.Remove the two mounting screws near the upper corners and remove the old board from the cage. Configuring the New Base3DPM Set the location ID switch on the replacement unit to match the unit being removed. Installing the Replacement Base3DPM 1. Install the new unit into the DPM cage. Insert the bottom edge into the slot in the plastic DPM mounting rail on the DPM cage, and secure with the two screws removed from the old unit. 2. Plug the temperature setpoint module stack onto its mount on the left side of the unit. 3. Reinstall the screw to secure the temperature setpoint module stack through the access hole on the right side of the unit. 4. Plug the mezzanine module onto its connector on the right side of the unit, and reinstall the two screws ear the top edge. 5. Insert the rear lug into the slot at the rear of the DPM mounting position with the mounting stud at the front inserted through the slot in the DPM bracket. 6. Slide backward to lock the rear mounting lug into the slot. 7. Reinstall the nut on the threaded stud to secure the DPM. 8. Reconnect the I2C/power cable and temperature control output cables from the rear edge of the board. 9. Reconnect the RTD temperature input cables (top rear of unit, if present). 10.Reconnect the fIlament detector cable if present. 11.Reconnect the detector signal cable from the mezzanine module. 12.Follow the steps in the General Analyzer Startup Procedure. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 131 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.5.4 Intrinsically-Safe Thermal Conductivity DPM (IS-TCD3) Overview Output signals from Thermal Conductivity Detector (TCD) in the Modular Oven are input to the associated Detector Personality Module (DPM). The DPM is mounted inside the Electronics Enclosure (EC) on the floor of the compartment. The DPM digitizes the incoming analog signal and then passes the data to the SYSCON via an I2C port. The resulting data is then processed by the Embedded SNE software. Results can then be viewed on the maintenance panel or the workstation. Network GCP I2C SYSCON I2C PECM IS-TCD DPM (A/D) Analog TCD Beads (thermistor) Color Touch Display Figure 4-32 Thermal Conductivity Detector Signal Path The IS-TCD3 DPM is an enclosed unit that is not field repairable. Opening the case may violate the safety protection of the device. Service is limited to replacement of the entire DPM. Part Number The IS-TCD3 DPM (part number A5E02645923001) is shipped with current analyzers. It can be used as a replacement part for earlier DPMs in Maxum I analyzers using an adapter, part number A5E34938550001. Intrinsic Safety The intrinsic safety feature of this module is only used in the Maxum II Modular Oven. The following two paragraphs apply only if this feature are used. The TCD DPM in the Maxum II, as well as the actual detector controlled by the TCD, is protected by intrinsic safety. Intrinsic safety is a method of protection where a circuit is designed such that it will not create a spark or other condition capable of causing ignition of flammable vapors or gases, even under fault conditions. Various circuits in the Maxum analyzer use this form of protection, including the IS-TCD3. Note To preserve the intrinsically safe design protection of the IS-TCD3, certain measures are required. Failure to adhere to all requirements for use of the IS-TCD3 in the Maxum　II could violate the safety protections of the analyzer. See the Maxum II Explosion Protection Safety Standards Manual (A5E02220442001) for more information on the safe use of intrinsically safe circuitry in the Maxum II.Maxum II Explosion Protection Safety Standards Manual (A5E02220442001) for more information on the safe use of intrinsically safe circuitry in the Maxum II. 132 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Connections The connections to the IS-TCD3 DPM are shown below. I2C Connector DPM Cage Intrinsic Safety Ground Connection Lugs DPM Mounting Screw Inputs from Detector DPM Mounting Screw Position ID Switch Reference Selector Switches DPM Mounting Rail Figure 4-33 IS-TCD3 DPM Connector Locations Orange connectors to detectors: Each IS-TCD3 DPM consists of two connections. Each connection is capable of interfacing to two pairs of TCD elements (four total channels, 1 for reference and 3 for signal). Figure 4-34 Detail of Detector Connectors Intrinsic Safety Grounds: The intrinsically safe design of the IS-TCD3 DPM (not normally used with airless or airbath ovens) requires two ground connections to the chassis terminated to two different terminals. The Maxum II Modular Oven is shipped with these grounds connected correctly. Refer to the Maxum II Explosion Protection Safety Standards Manual (A5E02220442001) for more information on the safe use of intrinsically safe circuitry in the Maxum II. I2C Bus Connection: The white connector on the reverse side of the DPM connects to the I2C Bus on the PECM. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 133 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Position ID Switch: 1 = Left 2 = Center 3 = Right (Described in Location ID Switch) Figure 4-35 4.1.5.5 Reference Selector Switches: Selects reference channel IS-TCD3 DPM Switches Replacing an IS-TCD DPM Removing the IS-TCD3 DPM See the illustration IS-TCD3 DPM Connector Locations for connector locations. 1. Back up and shut down the unit using the General Analyzer Shutdown Procedure. 2. Open the electronics enclosure door. 3. Disconnect the detector cables by unplugging the orange connectors. 4. Disconnect the I2C/power cable. 5. If present, take out screws holding the IS ground cables (typically only installed on modular oven models). 6. Remove the nut on the bottom-front of DPM bracket. 7. Slide the unit forward to disengage the rear mounting lug. 8. Lift the unit up and out of the enclosure and place on an ESD-safe work surface. 9. Remove the two mounting screws near the upper corners and remove the old unit from the DPM cage. Configuring the New IS-TCD3 DPM Set the location ID switch and reference-selector switches on the replacement unit to match those on the unit being removed. 134 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Installing the Replacement IS-TCD3 DPM 1. Install the new unit into the DPM cage. Insert the bottom edge into the slot in the plastic DPM mounting rail on the DPM cage, and secure with the two screws removed from the old unit. 2. Insert the rear lug into the slot at the rear of the DPM mounting position with the mounting stud at the front inserted through the slot in the DPM bracket. 3. Slide backwar to lock the rear mounting lug into the slot. 4. Reinstall the nut on the threaded stud to secure the DPM. 5. Reconnect the I2C/power cable. 6. Reconnect the IS ground cables if used. 7. Reconnect the detector cables. 8. Follow the steps in the General Analyzer Startup Procedure. 4.1.5.6 Temperature Control Personality Module Overview The Temperature Control DPM is identical to the Base3 DPM except that it includes only the temperature-control components. This is useful when extra temperature-control functions are needed. A Location ID Switch is also included, and functions as described in Location ID Switch in the Base3 DPM section. RTD Temp Control Inputs I2C Status LEDs Location ID Switch Heater Control Outputs to PECM Temp Setpoint Module Mounting Screw Access Temp Setpoint Module Mounting Location Figure 4-36 Temperature Control DPM Connections Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 135 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components The Temperature Control DPM (Part Number A5E02645925002) can be used as a replacement part for earlier DPMs in Maxum I analyzers using an adapter, part number A5E34938458001. 4.1.5.7 Replacing a TC-PM Removing the TC-PM See the illustration Temperature Control Personality Module Connections for connector and module locations. 1. Back up and shut down the unit using the General Analyzer Shutdown Procedure. 2. Open the electronics enclosure door. 3. Disconnect the RTD temperature input cables (top rear of unit, if present). 4. Remove the nut on the bottom-front of DPM bracket. 5. Slide the unit forward to disengage the rear mounting lug. 6. Lift the unit up and part way out of the enclosure. 7. Disconnect the I2C/power cable and temperature control output cables from the rear edge of the board. 8. Remove the unit from the analyzer and place on ESD-safe work surface. 9. Unscrew the mounting screw for the temperature setpoint module stack using the access hole near the center of the metal plate. 10.Unplug the temperature setpoint module stack from the left side of the board. 11.Remove the two mounting screws near the upper corners and remove the old unit from the cage. Configuring the New TC-PM Set the location ID switch on the replacement unit to match the unit being removed. Installing the Replacement TC-PM 1. Install the new unit into the DPM cage. Insert the bottom edge into the slot in the plastic DPM mounting rail on the DPM cage, and secure with the two screws removed from the old unit. 2. Plug the temperature setpoint module stack onto its mount on the left side of the unit. 3. Reinstall the screw to secure the temperature setpoint module stack through the access hole on the right side of the unit. 4. Insert the rear lug into the slot at the rear of the DPM mounting position with the mounting stud at the front inserted through the slot in the DPM bracket. 5. Slide backward to lock the rear mounting lug into the slot. 6. Reinstall the nut on the threaded stud to secure the DPM. 136 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 7. Reconnect the I2C/power cable and temperature control output cables from the rear edge of the board. 8. Reconnect the RTD temperature input cables (top rear of unit, if present). 9. Follow the steps in the General Analyzer Startup Procedure. 4.1.6 Sensor Near Electronics (SNE) Software The Sensor Near Electronics (SNE) is a software module that provides Maxum II Gas Chromatograph physics control, data analysis and data reduction. This virtual SNE operates as a set of intercommunicating tasks running on the pSOS+ operating system. These functions run on the SYSCON2.1 hardware in recent Maxum II analyzers. In older analyzers, these functions run on processors mounted in the SNE cage along with the DPMs. Configuration The SNE is configured by the System Controller (SYSCON) and periodically reports analysis results. It can be interactively controlled for Real-Time decisions on operation scenarios. The SNE software controls all sampling relating to its internal configuration and sensor setup. Components The major SNE software components are as follows: ● Data Manager ● Communications Manager ● Hardware Manager ● Computational Engine Data Manager The Data Manager maintains configuration data that controls hardware sequence of events and controls what manipulation is performed on sampled data. The Data Manager also provides results and status information to externally connected devices via the Communication Manager. This data is organized as a set of Sensor Analyzer Module (SAM) structures. The data represents the unit as a standard sensor to external host. Communication Manager The Communication Manager acts as a central point of control for communication links attached to the Sensor Near Electronics (SNE). This allows Internal SNE software to function regardless of which communication link is being used to communicate with the system. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 137 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Hardware Manager The Hardware Manager provides scheduling and communication services for the hardware in the analysis zone. These include devices such as the following: ● Detectors ● Sample valves ● Relays ● Pressure monitors and controllers ● Temperature monitors and controllers ● Flow control valves Computational Engine The Computational Engine takes acquired chromatography data and performs system calculations. Most of these calculations are performed by functions contained in the EZChrom method, which provides all peak identifications and integration and response factors. 4.1.7 Solid State Relay Module The Solid State Relay (SSR) Module is made up of two pairs of high wattage heater relays that are used for controlling the oven air bath heaters. One pair controls ABH1 and the other ABH2. Each pair of relays controls Temperature Limit and Oven Temperature shut down. If the over temperature limit is exceeded, the power to the air bath heater is shutdown. Two different configurations of SSR are available, the SSR and the Medium Wattage SSR. There are also original and new versions of the standard SSR. Original SSR Figure 4-37 New SSR Medium Wattage SSR Solid State Relay Modules The SSR module assembly is mounted to the left side of the EC back wall. A metal cover not shown in the photograph above protects the relays for the standard version of the SSR. The standard version of the SSR is equipped with heat dissipating fins that extend through the back of the enclosure wall to dissipate generated heat to the outside atmosphere. The medium wattage version dissipates heat to the interior of the electronics enclosure using heat sinks. The standard SSR, also called high wattage, can provide switching for two heater elements of up to 1400 watts each. The medium wattage version can control two heater elements of up 138 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components to 500 watts each. Relays for both the original and new standard SSR versions are available as spare parts. For the medium wattage SSR, individual relays cannot be replaced. NOTICE The SSR module supports either 115 VAC or 230 VAC power. For 115 VAC power the in-line fuses to the SSR should be rated at 16 A. For 230 VAC, the fuses must be rated at 10 A. DO NOT use a 16 A rated fuse for 230 VAC primary AC power. This could result in overheating and equipment damage. High Wattage SSR The relays on the newer SSR provide an indicator LED which shows the operational status of the control signals. In addition the newer SSR is equipped with a plastic shield which covers the connection screw terminals and helps prevent inadvertent contact. Note, however, that the older SSR is entirely enclosed in a sheet metal housing so human contact is not possible without disassembly of the module. The PECM provides the voltage to the two pairs of 1400-Watt AC Air Bath heater power switching circuits located on the rear wall of the electronic enclosure. A dedicated cable connects the PECM to the relay assembly. Each circuit has two solid-state relays connected in series. One series-connected relay controls the 1400-Watt AC heater functions to maintain controller initiated set point temperature. In conjunction with the control signal, the air bath heater pressure switch enables the relay. The second series-connected relay is used for safety purposes. It performs an emergency analyzer system shutdown if an over-temperature condition is detected. Both relay circuits are completely independent of each other. However, in order for the power switching to occur both relays must be enabled. Temperature controls are monitored on the Detector Personality Module located in the SNE and routed to the PECM via a dedicated cable. No other functions are connected to the temperature control circuit. Schematic A 3 1 4 2 4 2 3 Zero voltage LED detect Control Voltage 4 Figure 4-38 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 1 Rc Snubber 3 1 Load or 2 AC Line Load Air Bath Heater Relay Schematic 139 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Medium Wattage SSR A medium wattage version of the Solid State Relay (SSR) module is available. The original assembly included four large relays suitable for switching two of the 1400 watt air bath oven heater elements. However, many Maxum GCs do not require that much power. Therefore, a new SSR Module was added to the Maxum spare part offering. The newer board provides smaller relays which are capable of controlling the new 500 watt air bath heater assembly described previously. In addition, the “medium power” SSRB can be used to control the two 250 watt heaters used in the Maxum airless oven configurations. The newer board can also be used to control the low wattage heaters in the heated Flame Ionization and Flame Photometric detector housings or in heated sample injection valves. The relays on the medium wattage SSR cannot be replaced individually. However, the module is easily replaced. Another difference between the high wattage SSR and medium wattage SSR is that the medium wattage version does not required heat dissipating fins on the back of the enclosure. The relays are equipped with heat sinks on the front of the module as shown in the photograph below. Status LEDs Status LEDs Power Cable from PECM Control Cable from PECM or DPM Figure 4-39 Medium Wattage SSR Module 4.1.8 Solenoid Valves 4.1.8.1 Solenoid Valve Control Module (SVCM) The Solenoid Valve Control Module (SVCM) provides pneumatic interface to control flow to the oven sampling and column valves. Solenoid valves are suitable for air, nitrogen and helium on the pressure side and vacuum on the vent side. The electronic enclosure has space for up to three modules. 140 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components SVCM Versions There are two configurations of SVCM. The old version, which is still supported as a spare part, is equipped with a valve driver circuit board. For the newer version of the SVCM, this valve drive circuitry has been moved to the PECM2 module. The newer version has a lower cost and is more reliable and robust. The SVCM electronics, whether onboard for the old version or on the PECM for the new version, receives commands from the SYSCON module (via the I2C bus). Pulse timing is controlled from the SVCM electronics. Solenoid Control Connectors (cable assembly to PECM) Plastic Tubing Connectors Solenoids Test Buttons (bottoms of solenoids) Solenoid Valve Tubing Manifold Legacy SVCM Figure 4-40 Present SVCM Solenoid Valve Control Module (SVCM) Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 141 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Mechanical Each SVCM incorporates 8 solenoid valve circuits for driving 3-way and 4-way solenoid valves. The SVCM is mounted in the Controller Enclosure on the manifold block. It can also be mounted in a Division 2 purge enclosure. Up to 3 SVCM assemblies can be mounted in the Maxum II. This allows for up to twelve 3-way solenoids and twelve 4-way solenoids. SVCM-1 is mounted in the lower right portion of the back wall. SVCM-2 is mounted in the lower left portion of the back wall. SVCM-3 is mounted (vertically) in the upper right portion of the back wall. The original SVCM is equipped with Parker solenoids. The newer SVCM is equipped with SMC solenoids. Manifold in/out SST tubing connections incorporate one touch push type tubing connectors. Figure 4-41 142 Solenoid Control Module Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Digital Control Channels On present Maxum II analyzers, the solenoid control circuitry is on the PECM. Digital outputs assigned to each solenoid valve are shown in the table below. If a digital output is 0 the valve is OFF; if the output is a 1, the valve is ON. Each group of four valves is identified as being left or right. There are no digital inputs. See the table below for the numbering pattern of solenoid valves (same for original and newer versions). Each solenoid valve can be manually set to the ON or OFF conditions by manually depressing the red button on each solenoid. This button is on the top-front of each Parker (original) solenoid and on the bottom of each SMC (new) solenoid. Table 4-5 Digital Output Solenoid Valve Groups Group Solenoid Valve Left Valve 1 Valve 2 Valve 3 Valve 4 Right Valve 1 Valve 2 Valve 3 Valve 4 Table 4-6 SYSCON Channel Number SVCM I/O Assignments I/O Name Group Channel DO1 LEFT_GROUP_VALVE_1 80h DO 2 LEFT_GROUP_VALVE_2 40h DO 3 LEFT_GROUP_VALVE_3 20h DO 4 LEFT_GROUP_VALVE_4 10h DO 5 RIGHT_GROUP_VALVE_1 DO 6 RIGHT_GROUP_VALVE_2 DO 7 RIGHT_GROUP_VALVE_3 02h DO 8 RIGHT_GROUP_VALVE_4 01h Table 4-7 08h 1 SVCM Fault Indicators Fault Indicator Fault Condition VALVE_SWITCH_ERROR Valve status read back is incorrect J10_DISCONNECTED (left bank connector) J10 connector not connected J11_DISCONNECTED (right bank connector) J11 connector not connected Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 04h 143 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Table 4-8 Specifications Function Specification Switching Speed (Maximum response time on/off ms) 4-way 15ms 3-way non-latching 15ms Operating Voltage 24VDC Pressure Range, 3-way 25 to 100psi Pressure Range, 4-way 25 to 100psi Vacuum Range 0 to 27" of Hg Ambient Temperature Range -18°C to 65°C -0.4°F to 149°F (dry air) Leakage ≤ 50 microLiter/min, air @ 69.8?F (21°C) with 50psig on the common port. Operation Test 1. Using a fine-pointed object, press Solenoid Valve red button. 2. When pressed, pressure is applied to the piston that moves to either the open or closed position. Resulting pressure is then applied to the column or sample valve. 3. If piston does not operate when the button is pressed, check for correct gas pressure. 4. If piston does not operate and pressure is 75 psig, Solenoid Valve is defective and must be replaced. 5. Repeat for each valve operating on and off. Allow at least 1 second between button presses. 4.1.8.2 Replacing a Solenoid Valve The solenoid valves are mounted on either the floor or back of the electronic enclosure, depending on configuration. Valves are replaced individually. The Solenoid Valve Replacement Kit is available as part number 2020149-001. WARNING Voltage dangerous to life exists. Failure to follow proper procedures may result in equipment damage, personal injury or death. Before performing the removal and installation procedures, turn off primary AC power to the Maxum II from the main circuit breaker. Observe all site safety requirements before performing any repair or maintenance on the Maxum II. 144 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Procedure 1. Back up and shut down the unit using the General Analyzer Shutdown Procedure. 2. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). 3. Unplug the cable to the solenoid to be replaced. 4. As show below, use a small screwdriver to remove the two screws that fasten the solenoid to the manifold. If the black gasket adheres to the manifold after removing the solenoid, then remove the gasket manually. Solenoid Valve Retaining Screws Solenoid Valve Mounting Position 5. Install the new solenoid, using a new gasket from the kit. 6. Reattach the cable to the solenoid. 7. Follow the steps in the General Analyzer Startup Procedure. 4.1.9 Electronic Pressure Control Module 4.1.9.1 EPC Module Description The Electronic Pressure Control (EPC) Module reduces oven set-up time by using precise pressure control without restrictors or needle valves. This module also allows programmed pressure control for faster chromatography and modern applications. It allows precise control of pressures. The EPC can be used for both carrier and fuel gas supply, which eliminates the less reliable mechanical regulation. Four independent EPCs can be installed in one Maxum II. Each EPC provides two independently regulated pressures for use on carrier and flame fuel sources in the oven. Gas connection is located in the regulator section. Regulated pressure range is 5-100 psig. Two slightly different versions of the EPC are available. The primary difference between the two versions is that the newer version is equipped with DIP switches that identify the location ID of the module. The older version uses a jumper plug to identify the ID. The differences between these methods of identification are described fully in the procedure to replace the EPC. There are no other functional differences. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 145 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Tubing Manifold Ch2 Ch1 Location ID Selector Switches Low Pressure Switch Inputs Figure 4-42 I2C Connector EPC Module Connections Mechanical The EPC is mounted to right side wall of the Electronic Enclosure. Up to four (a total of 8 EPC channels) can be installed in a single Electronic Enclosure. The EPC is easily field replaceable using common tools. EPCs mounted on right-hand wall of analyzer EPC Location In Analyzer Electrical The EPC is made up of a printed circuit board with two pressure transducers, two proportional valves with associated electronic circuitry, manifold for pneumatic connections, PC connector for communication signals and a DC power connector. See Figure 2-44. The EPC provides electrically controlled pressure for helium, hydrogen and nitrogen carriers etc., as well as low flow and low pressure (<100psi) applications such as flame detector fuel. The EPC operates from 24VDC at 4 watts. Electrical connections are made using plug type connectors. 146 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components The EPC receives commands from the SYSCON via I2C bus regarding timing and pressure setpoint. The timing of messages from the SYSCON controls timing within the EPC. There is no time base in the EPC. Module control is established by sending parameters, such as setpoint pressures and ramp rates to the EPC. The EPC is used in the Maxum II to control the carriers and/or fuels for the detector modules. The EPC can also be used in field-mounted installations. The EPC communicates with other components via the I2C bus and communicates actual pressure back to the SYSCON. Regulated pressure range is 5-100psig. Channels Each EPC channel consists of a pressure sensor amplifier and analog filter followed by an A/ D Converter. The converter is read by the local controller that calculates a new control value used to control the proportional solenoid valve. Control parameters, such as set-point pressures are sent via the I2C bus to the EPC. Status and diagnostic data is available via software. Diagnostics EPC diagnostics are read-back of setpoint pressure via the software, DC power within operating limits, monitoring of line and short-term pressure variations with respect to the setpoint regulation, out of range pressure alarm and a diagnostic failure. Specifications Parameter Value Maximum inlet pressure 120psig Pressure output range 5-100psig Minimum differential between EPC inlet and outlet 5psi Flow range from EPC (see note below) 5-500cm3/s Controlled pressure stability over temperature range ±0.5% of setpoint Short-term pressure stability ±0.0005 psi over 30s interval Typical response time for step change in setpoint. Stable to within 0.1% of final value with‐ in 0.5 seconds (For hydrogen the re‐ sponse time is approximately 1 second). Note When running applications with column flow rates of less than 5 cm3/s, a separate bleed flow path is recommended in order to reduce the time required to achieve pressure stability when variable setpoints are used. Depending on the volume involved, a bleed flow rate of 5-10 cm3/s is recommended. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 147 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 4.1.9.2 Replacing an EPC Module Procedure WARNING Voltage dangerous to life exists. Failure to follow proper procedures may result in equipment damage, personal injury or death. Before performing the removal and installation procedures, it is important that primary AC power to the Maxum II be turned off from the main circuit breaker. Observe all plant safety requirements before performing any repair or maintenance on the Maxum II. Note Do not over-tighten ferrules. Oertightening may damage the ferrules. The ferrules connected on the gas supply side of the EPC manifold are composed of vespelgraphite. To prevent damage, these ferrules must NOT be over-tightened. Proper tightness is typically ½ turn past finger-tight. Note Do not disassemble the EPC. The EPC is made up of a manifold that is mounted to the electronic enclosure wall on standoffs and the module itself. Due to safety and certification issues, it is necessary to replace both the EPC and manifold as one assembly. 1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the display panel interface cable. 2. Disconnect any external interface connectors to EPC. It is recommended that all cables be identified with their EPC connector location. 3. Remove the external gas connections from the EPC, labeling each if necessary. 4. Remove the four 4mm Allen screws that secure the manifold to the Electronics Enclosure and then remove the assembly. These are captive screws and will be completely removed with module. 5. If the replacement EPC a module ID jumper, move the jumper that is connected to location J2 (bottom side of PC board) from the old module to the new module. 6. If the EPC is equipped with ID switches, set the switches on the replacement EPC to match the ID of the EPC that was removed (see Setting Location ID). 7. To reinstall the new EPC, perform steps 1 to 4 in reverse order. Use caution when reconnecting gas lines. Do not over-tighten. 8. Before applying AC power, be certain the gasket between the manifold and the Electronics Enclosure is properly seated and interface cable connectors are correctly connected. 9. Inspect the system for leaks. 148 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Setting the Location ID The newest version of the EPC has DIP switches in place of the J2 ID Connector used in the previous version. These are used to set the location ID, which is used in software as part of the hardware ID string. The location ID is set using a binary counting of the switches from right to left (as numbered on the board and not on the actual switches). Note that this also matches binary wiring of the first three pins of the J2 plugs used on the bottom side of the older version EPC. Location ID #1 1st switch / connector pin set (binary 1) 4.1.10 Color Touchscreen 4.1.10.1 Description Location ID #2 Location ID #3 Location ID #4 Second switch / connec‐ 1st & 2nd switch / con‐ 3rd switch / connector tor pin set (binary 2) nector pin set (binary 3) pin set (binary 4) Overview The color touchscreen display is a convenient tablet-like panel that combines a high-resolution color LCD display with an intuitive touch interface. TIB SIB3 (in SYSCON2.1) Touch Interface Data, Power (Touch Interface Board) LCD Data, Power Display Panel Figure 4-43 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 TIB Door Components 149 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components Components The LCD display panel controller and power supply are integrated into the SIB3 board in the SYSCON2.1. The touch interface board (TIB) is mounted directly to the LCD panel / touchscreen as a single assembly. The TIB and LCD panel are individually replaceable. 4.1.10.2 Maintenance Overview General Care and Cleaning of the Display Keep touch screen surfaces clean and free of any dust and dirt to prevent small particles from scratching the touch screen under a sliding finger or stylus. Use a soft lint-free cloth dampened with isopropyl alcohol to clean contaminates from the touch screen. 4.1.10.3 Replacement Procedures Overview Replacing the color touchscreen panel requires removal and disassembly of the door. WARNING Follow Safety Precautions. Failure to follow proper procedures may result in equipment damage, personal injury or death. Full safety precautions must be followed throughout all sections of this procedure to prevent possible injury, equipment damage, or death. Verify that the area is clear of flammable gases and vapors and that appropriate authorization is obtained to do the work (hot work permits). NOTICE Electrostatic Discharge Precautions. The TIB can be damaged by electrostatic discharge (ESD). Take appropriate precautions when unpacking and handling these components to avoid ESD damage. 150 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 1. Allow any applications to complete, and place in Hold. 2. Using GCP, save the existing database of the NAU to the hard drive of the Workstation. – From the Network Portal, select the line entry for the device and then click the Backup button at the top of the view. – The "Save backup file as..." dialog box will appear. Type or select a name for the backup file in the File Name field. If the user does not identify a file extension, then the default extension of .amd will be used. – Click the Save button in the dialog box to begin the backup. A progress dialog box will appear, showing the saving of the database to flash memory and then the saving of the file to the computer. When the backup is complete the progress box displays "Successful". – Click “OK” to close the progress box. The .amd database file is saved to the hard drive of the PC. 3. Power down the analyzer. 4. Open the analyzer door. 5. Disconnect the door-to-chassis ESD ground wires. 6. Disconnect the intrinsic safety wires from the studs above the PECM. Intrinsic-Safety Ground Connection Points TIB Door Assembly ESD Ground Connection Display Cable Routing Into SYSCON Figure 4-44 TIB Door and Display Cables Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 151 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 7. Pull out the SYSCON2.1 drawer and disconnect the display cables from the SIB3 as shown below. The cables can then be pulled out through the rear of the cage. Display Cable Routing Display Cable Connections Figure 4-45 152 Display Cable Connectors In SYSCON2.1 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 8. Remove door by lifting it out of its hinge sockets and place on work surface. Figure 4-46 Removing or Installing Electronics Enclosure Door The following steps refer to the exploded assembly view below. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 153 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components A C B Display panel to TIB cable LCD from SIB3 Intrinsic safety ground wires D E B E E Backlight Connector E Hole for wire-tie E E Hole for wire-tie Figure 4-47 Wire-tie anchors, insertion points ESD ground connection points D TIB Color Touchscreen Door Exploded View 9. Remove the TIB protective cover by removing the 4 screws. (A in exploded view) This allows access to two of the 6 mounting studs for the LCD assembly. (E in exploded view) 10.Disconnect the three connectors of the display cable assembly; the backlight connector, the TIB cable connector, and the LCD connector. (B in exploded view) 154 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.1 Electronic Enclosure Components 11.Disconnect the two cables from the display panel to the TIB 12.Unscrew the four standoffs and remove the TIB. (C in exploded view) Keep touch screen surfaces clean and free of any dust and dirt because small particles could scratch the touch screen.) 13.Cut the three wire ties securing the cable assemblies to the display assembly. (In small slot on panel steel slab adjacent to cutout for LCD connector, small hole near corner of slab for backlight connector, and TIB lower standoff) (D in exploded view) 14.Unplug the two wire-tie anchors by compressing the nylon anchor as shown below. (The cable assembly and anchors may be left in place if desired.) Figure 4-48 Removing Wire-Tie Anchors 15.Remove the 6 nuts (E in exploded view) and remove display assembly. Assembly Considerations Reassembly of the TIB door is generally the reverse order of the disassembly steps given above. Display Panel The replacement display panel has a protective plastic sheet on the glass surface. Remove this prior to mounting on the door. When replacing the mounting nuts, use between 3 and 5 inch-pounds of torque. Do not overtighten. Wire Ties Three wire ties are required on the display steel slab. See the exploded view above and the illustration below for installation locations. When installing the wire tie for the LCD connector, orient the head flat to keep it clear of the protective cover when it is reinstalled. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 155 Component Descriptions and Maintenance Procedures 4.2 Oven Components Install wire tie on the lower TIB standoff near the intrinsic safety ground lugs. Install wire tie for the LCD connector through hole adjacent to the cutout. Figure 4-49 Install wire tie for backlight connector through small hole at the corner of the panel plate. Wire Tie Installation Detail 4.2 Oven Components 4.2.1 Using Valco and Swagelok Fittings Assembling Fittings The ports are machined for a 1/16” Valco internal nut. The Valco ferrule or the 2-piece Swagelok ferrule can be used. It is important to follow the manufacturer’s procedures when cutting tubing and seating ferrules to ensure that the fitting does not leak. Nut Tube Ferrule Fitting Detail Pilot Figure 4-50 Valco Fitting Use a wheel-cutting tool (such as Supelco 58692-U) to score the tubing, and then with a pair of straightening pliers (such as Supelco 58646) and a pair of needle nose pliers snap the tubing at the score line. Make certain that all tubing ends are cut square with the tube axis, and that both the ID and the OD are thoroughly deburred, use a deburring tool (such as Supelco 58804). Inspect the end of the tubing where the ferrule will seat for scratches along its length. Visible scratches along the tubing where the ferrule will seat are not acceptable, but those behind the front edge of the ferrule will not interfere with the integrity of the fitting. 1. Slide the nut and ferrule onto the tubing. 2. Insert this assembly in the fitting detail (valve body), screwing the nut 2 or 3 turns by hand. 3. Push the tubing all the way forward into the details so that it seats firmly. 4. Manually turn the nut until it is finger tight. 156 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 5. Turn the nut ¼ turn (90 degrees) past the point where the ferrule first starts to grab the tubing. 6. Remove the fitting and inspect it. The ferrule may be free to spin axially on the tubing but should have no lateral movement along the tubing. If it does, reinstall the fitting and tighten it another 1/8 turn past finger tight. Remove, re-inspect and repeat if necessary. 4.2.2 Model 50 Valve 4.2.2.1 Model 50 Valve The Model 50 valve is a pneumatically operated diaphragm valve that is equipped with 10 ports. It can perform the function of two Model 11 valves, although it is less than half the size of a Model 11 valve. The valve is turned On or Off using air pressure applied to diaphragms. This air pressure activation eliminates the need for pistons, plungers, or any other moving parts. The valve can both inject vapor samples and switch columns simultaneously. The Model 50 is capable of switching gasses up to 75 psig (515 kPa). Actuation air for the Model 50 can be either carrier gas or other bottled inert gas. Consumption of gas for actuation is negligible. One primary distinction that separates the Model 50 from the Model 20 and Model 11 valves is the port switching. When the valve is On, flows between the following ports are open: ports 1 & 10, ports 2 & 3, ports 4 & 5, and ports 8 & 9. When the valve is Off, flows between the following ports are open: ports 1 & 2, ports 3 & 4, ports 5 & 6, ports 7 & 8, and ports 9 & 10. Note that when the valve is On, flow between ports 6 & 7 is not active as might be expected (see figure below). This patented feature is unique to the Model 50 and allows elimination of external hardware that would be required otherwise. The Model 50 is designed such that the pressure is required to turn the valve either On or Off. Actuation ports are located on the side of the valve between ports 1 and 10. The Off actuation port is labeled "0" and the On actuation port is labeled "1". When pressure is applied to the Off actuation port, the valve is set to Off. When pressure is applied to the On actuation port, the valve is set to On. When no pressure is applied to either actuation port, ALL ten valve ports are interconnected.            4.2.2.2    Figure 4-51      Flow Path On  Flow Path Off Flow Paths for the Model 50 Valve Basic Maintenance: Model 50 Valve Introduction This section provides basic maintenance instructions for the Model 50 valve. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 157 Component Descriptions and Maintenance Procedures 4.2 Oven Components The following equipment is required to repair the Model 50 valve: ● Model 50 Repair Kit: Siemens PN 2020164-001 (includes 10 diaphragms, 10 screws with washers, and 12 Valco fittings). ● Valve Assembly Fixture: Siemens PN 2020281-001 ● Torque screwdriver with Allen head bit: Siemens PN 1631005-003 Figure 4-52 4.2.2.3 Model 50 Valve Preventing Port to Port Leaks Particulates introduced to the valve either from the sample or from the columns can prevent the diaphragms from sealing against the center plate of the valve. Also, to insure proper sealing of the diaphragms, the actuation pressure should be 25 psig higher than the carrier gas or sample gas pressure. To help prevent leaks, always turn the sample and carrier gas off before the actuation gas is turned off. Without actuation gas, the Model 50 valve is in an undefined state where ALL ports are interconnected, and the flow path of the carrier or sample cannot be controlled. Leaks in the actuation gas lines could result in a lower actuation gas pressure which could result in port to port leaks. The symptoms can include small peaks, repeatability problems, contaminated columns and noise on the detector. 4.2.2.4 Maintenance Considerations If customer maintenance personnel are not technically trained to repair the Model 50 valve on site, it is recommended that the valve be returned to Siemens for service, repair, or direct replacement. To repair the Model 50 valve on site, the customer must have the necessary maintenance tools and replacement parts. Recommended valve spare parts can be obtained from Siemens. When cleaning the Model 50 valve and associated components, it is imperative that the maintenance be performed in a clean and contaminant free facility. Components should be placed on a lint free cloth to prevent impurities from contaminating the valve and its components. Hands should be clean and free of contaminants. Presence of any foreign contamination can cause additional valve problems after reinstallation. All foreign contamination adhering to valve must be removed using cleaning solvent, such as hexane, acetone, or methanol and a dust/lint free cloth. After cleaning Model 50 valve 158 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components components, shake or blow with clean air the excess cleaning fluid from the individual components. Ensure that the components are air dry before reassembling. Note Do not allow Model 50 valve polished surfaces to rest on any surface other than a lint free cloth. Clean sample flow openings in top plate, center plate, bottom plate and Valco fitting nuts using a syringe filled with cleaning solvent such as hexane, acetone, or methanol. CAUTION Potential burn hazard. Handling hot components may result in personal injury. Before servicing the Model 50 valve, it is important that primary AC power to the Maxum II be turned off from the main circuit breaker, and the oven be allowed to cool. Only maintenance personnel with proper authorization should open the electronic enclosure. Failure to observe safety precautions can result in personal injury. 4.2.2.5 Figure Refer to figure 6-2 during the procedures for disassembling and cleaning the Model 50 valve. 2 (50) 1 1/2 (38) 1 5/16 (33) 1 1/8 (29) Dimensions are shown as Inches (Millimeters) Valve Assembly Flow Path in On Position Screw Washer Top Plate Flow Path in Off Position Sample Gas & Carrier Gas Connections (10) Diaphragm Center Plate Ferrule Nut Actuation Air or Gas Connections (2) Figure 4-53 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Bottom Plate Exploded View of Model 50 Valve 159 Component Descriptions and Maintenance Procedures 4.2 Oven Components 4.2.2.6 Model 50 Valve Maintenance Procedure If customer maintenance personnel are not technically trained to repair the Model 50 valve on site, it is recommended that the valve be returned to Siemens for service, repair, or direct replacement. Valve Removal 1. From primary AC circuit breaker, turn analyzer AC primary power OFF. 2. Shut off the air to the oven heater. 3. Open door to the Maxum II oven using a 4mm (5/32’") Allen wrench. 4. To remove Model 50 valve from the oven, first disconnect all tubing to the valve. Note When disconnecting Valco fastening nuts from Model 50 valve, exercise caution not to bend or crimp the stainless steel tubing. Note Before removing Model 50 valve from oven, make note of its orientation within the oven. 5. Remove the valve from the oven by unscrewing the two M3 x 35 socket head cap screws securing the Model 50 valve. These mounting screws are located between ports 2 and 3 and ports 8 and 9. Refer to Figure 6-2 for port locations. Note If the valve is to be sent back to Siemens for service, then skip to the "Valve Reinstallation" portion of this procedure to install the replacement valve. Valve Disassembly, Cleaning, and Reassembly 1. Place the valve on a clean dust lint free cloth within a clean work environment. Note Do not place polished top plate, center plate or bottom plate against any abrasive surface. Place components on a lint free cloth free of foreign contaminants. 2. Place the valve bottom plate on a lint free cloth. Using a 2.5 mm Allen wrench, remove the five socket head fastening cap screws. Refer to Figure 6-2. 3. Separate Top, Center and Bottom plates of the valve, placing them on a lint free cloth. Both diaphragms are visible. 4. Remove the old diaphragms from the plates. DO NOT attempt to reuse the old diaphragms. 160 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 5. Clean the valve parts by wiping with a dust/lint free cloth and a cleaning solvent (or clean using an ultrasonic cleaner) as described at the beginning of this chapter. After cleaning, shake excess cleaning fluid from all parts and allow to air dry before reassembling. Note Use the Valve Assembly Fixture, Siemens Part Number 2020281-001, to properly align the diaphragms when rebuilding the Model 50 valve. The fixture consists of a base, two guide pins, and a diaphragm placement disc. This fixture will allow the user to place the diaphragm in the center of the valve. If the diaphragm is not in the center, it may leak. 6. With the pins installed in the base of the assembly fixture, place the bottom plate of the valve on the center of the base. The pins should fit in the mounting holes on the bottom plate and hold it in place. 7. Position the placement disc on the bottom plate and set the diaphragm in place . 8. Carefully remove the placement disc without moving the diaphragm. Inspect the diaphragm for proper alignment. If the diaphragm is not in the center of the plate, repeat the placement procedure using the placement disc. 9. Place the middle plate on the valve taking care to use the correct holes. Check the alignment mark on the side of the plate. It should align with the mark on the bottom plate. If not, the middle plate is upside down and must be removed, turned over, and reinstalled correctly. 10.Repeat steps 7 and 8 with the middle plate. 11.Place the top plate on the valve, verifying alignment using the alignment marks. 12.Install the 5 screws and washers finger tight. 13.Tighten the screws down evenly (2.5mm Allen wrench) to 6 to 8 inch-pounds of torque. (It is recommended to use the torque wrench available from Siemens, PN 1631005-001, which is calibrated at 7.2 inch pounds). Remove the assembled valve from the valve fixture. Valve Reinstallation 1. Reinstall the valve in the oven and connect all tubing. 2. Power up and check for leaks. Verify valve operation by running chromatograms. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 161 Component Descriptions and Maintenance Procedures 4.2 Oven Components 4.2.3 Liquid Injection Valve 4.2.3.1 Description Overview The Siemens Liquid Injection Valve (SLIV) is used to automatically inject a fixed quantity of liquid sample followed by fast, complete vaporization. Small gas quantities can also be injected using the valve. Figure 4-54 Liquid Injection Valve Components The Siemens Liquid Injection Valve (SLIV) consists of three components: ● Temperature-controlled vaporization system ● Sample flow unit with seals ● Pneumatic drive (actuator) 162 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components Functional Description The SLIV uses a moving injection tappet attached to a piston actuator. Sample is injected via a groove or cross hole in the tappet. In the filling position, the sample flows continuously through the cross hole or the ring groove of the injection tappet. When injecting, the tappet is pushed pneumatically into the heated vaporization area. The liquid in the cross hole or ring groove is vaporized and flushed by the carrier gas into the column. The tappet is then shifted pneumatically, via the piston actuator, back into its original position. Sample then passes through the injection hole again. Figure 4-55 Sample Injection Parameter Value Maximum vaporization temperature 60 - 350°C (140 - 622°F) with explosion-proof analyzers ac‐ cording to the temperature class Injection volume 0.1 to 9.5μl Ambient temperature -20 to150°C (-4 to 302°F) Material of parts in contact with the sample V4A, mat. No. 1.4571 Hastelloy, Monel or special Control pressure 400 to 600 hPa Maximum sample pressure 6000 kPa, recommended 50 to 100 kPa Connections For tubing with 3.14 mm (1/8 in.) outer diameter Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 163 Component Descriptions and Maintenance Procedures 4.2 Oven Components Vaporization System The vaporization tube is inserted with an aluminum sleeve into the heating mushroom plate whose temperature is regulated by a heating cartridge. In addition to the standard vaporization tube, a version of the SLIV is offered with a glass lined vaporization tube. The carrier gas is routed via tube into the vaporizer and heated up to the vaporization temperature in the process. Sample Flow Unit The sample flow unit is located in the middle section (body) of the valve between the vaporizer and the actuator piston. It is isolated from the vaporizer and actuator by lens shaped Teflon gaskets. An adjustable adapter and Belleville washers position the Teflon gaskets with a constant pressure and compensate for temperature expansion effects and gasket wear. Figure 4-56 164 Sample Flow Unit Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components Vaporization Temperature The vaporization temperature can be set independent of the oven temperature. It is selected according to the sample and the boiling point of the sample. The optimum vaporization temperature must be determined experimentally. The amount by which the vaporization temperature should be above the sample’s boiling point depends on the heat of vaporization of the sample. Samples with a high heat of vaporization, such as aqueous samples, only vaporize sufficiently fast for chromatographic purposes at high temperatures (above 200?C), as shown below. Figure 4-57 Vaporization Temperature Note Ex units: To comply with electrical hazardous area requirements ensure that: ● The sensor of the temperature sensor is fully inserted into the heating plate. ● The purge tube vent is not being obstructed. Filter Requirements The tappet and gaskets will wear faster if the sample contains solid particles. In these cases, a filter is required upstream of the injection. Siemens recommends a filter with the following characteristics: ● 98% for 0.3-μm particles with liquid samples ● 99.99% for 0.1-μm particles with gaseous samples Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 165 Component Descriptions and Maintenance Procedures 4.2 Oven Components 4.2.3.2 Maintenance Overview Schedule This section provides routine maintenance and repair procedures for the liquid injection valve. A 6-week preventive maintenance schedule is recommended for servicing the valve; however, the schedule you choose will depend upon the: ● Sample properties ● Vaporization temperature ● Ambient temperature ● Sample pressure ● Analysis Duty Cycle Valve Service Life You can expect a 1 year service life for the valve. However, the service life of the valve is also dependent upon the properties of the sample as well as the preventive maintenance schedule. The service life of the valve is adversely effected if the sample is injected at a high sample pressure >20 bar (290 psi.). Part Locations Throughout this section, the numbers located next to part names, such as “Flange (17)”, refer to callouts listed in the Liquid Injection Valve Exploded View. Operational Notes ● If the sample has a corrosive effect on the surface of the injection stem (also called a tappet), the stem must be replaced with a different material type (e.g. Hastelloy). ● Over time, particles from the sample build up on the gaskets and will eventually obstruct the sample flow. Gaskets made of Teflon and Rulon are less subject to build up, but are not suitable for all applications. In addition, if the gaskets are subjected to temperatures outside of their rating they will loose their shape and reduce the service life of the valve. ● A sample that contains non-volatile or easily polymerized components (salts, proteins, monomers etc.) can deposit residues in the vaporizer (16), in the injection hole, on the sample flow unit (15), and on the injection stem (6). Therefore, these parts should be cleaned regularly if the sample contains materials which are not vaporized. ● The sample flow unit (15) should be oriented vertically when the valve is installed. This is so that the sample will flow vertically through the valve to prevent air bubbles from forming in the valve. Make note of this when reinstalling the valve after service. 166 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 4.2.3.3 Liquid Injection Valve Component Locations Bevel up Bevel down 1. Control Cylinder 2. Hex Set Screws Bevel up 3. Control Piston 4. Large O-Rings Belleville Washer Orientation 5. Guide Pin (Only on Cross-Hole) 6. Injection Stem (tappet) 7. Valve Body 8. Small O-Ring and Piston Guide Hole 9. Label Indicating Injection Volume 10. Belleville Washer Plate Springs (approx. 8) 11. Adjustment Nut 12. Adjustment Counter Nut 13. Adjustment Assembly 14. Gaskets (2) Note: The guide pin (5) is only applicable 15. Sample Flow Unit to pistons with the “cross-hole” type stem. 16. Vaporizer Pistons with the much more common 17. Flange “groove/notch” stem are not equipped 18. Carrier Gas Inlet Tube with a guide pin. Figure 4-58 Liquid Injection Valve Exploded View Groove for sample-flow unit Label for Dosing Volume Alignment Groove for attaching to Control Cylinder using hex set screws Groove for O-ring Figure 4-59 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Liquid Injection Valve Body 167 Component Descriptions and Maintenance Procedures 4.2 Oven Components 4.2.3.4 Troubleshooting Faults, Causes, Remedies Fault Causes Remedy All peaks appear smaller Sample flow unit (15) or injection blocked. Buildup of material on in‐ jection stem. Clean injection hole, stem (6), va‐ porizer (16) and sample flow unit (15). Peaks are becoming wide and shifted to longer times. Baseline becomes negative before injec‐ tion of sample. Vaporizer (16) is contaminated. Replace gaskets (14) if necessary. Baseline becomes positive before injection of sample. Gasket (14) between sample flow and vaporizer is leaking. Interruption in chromatogram: sample is not get‐ Leaky pneumatic actuator, grease Clean pneumatic actuator, replace ting injected. used up, O-rings (4) damaged, con‐ O-rings, and grease sliding surfa‐ trol pressure too low. ces and O-rings. Peaks too small and too wide, especially those with higher boiling points. Heating plate is faulty. Vaporization temperature too low. Replace heating plate. Set higher equalization temperature. Injection quantity slowly rises until a double peak results (with calibration medium). Poor peak form, platform following peak. Increase in base‐ line. Visible discharge of sample. Worn gaskets (14) and/or stem (6). Replace gaskets (14) or stem (6). The section of the injection stem that is normally in the sample flow stream (near the notch) is rough. Material wear on this section of the stem is visible using a magnifier. The effect is signifi‐ cantly less on the rest of the stem. Corrosive sample Possibly replace injection stem (6) by version made of another material more compatible with the sample chemical, such as Hastelloy. Thin scratches are visible (with a magnifying glass) on the stem near the sample groove. These scratches run along the stem for several millimeters. Sample is contaminated by particles Check filter from sample system (most frequent case). The particles and replace if necessary. Replace get lodged in the gasket and scratch stem (6) and gasket (14). the stem during injection. The space between the stem (6) and the inside wall of the vaporizer (16) is filled by deposits. This can block the supply of carrier gas. The sample contains dissolved salts The deposits in the vaporizer (16) and other nonvolatile materials. may be removed mechanically (drill/ ream with 3.3 mm diameter), or the part may be replaced. In extreme cases deposits may result on the stem (6). Brown deposits are present on the vaporizer gasket (14) at the outlet to the vaporization area. 168 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 4.2.3.5 Service Procedures Overview These procedures refer to the Liquid Injection Valve Component Locations and Liquid Injection Valve Exploded View illustrations. CAUTION Temperature and Heating Components in Explosion Proof analyzers If the heating assembly is removed, exchanged or retrofitted, the assembly must be tested and certified in accordance with appropriate regulations before the analyzer can be placed back in service. Removing the Valve Perform the following procedure to remove the valve from the oven. Removing the vaporizer (16) and flange (17) is optional when removing the valve. CAUTION Potential burn hazard. Handling hot components may result in personal injury. To prevent injury from burns always switch off the oven and valve heaters and allow the oven and liquid injection valve to cool down before touching the valve. Procedure 1. Switch off oven and valve heaters and allow oven and valve to cool down. 2. Switch off sample flow at the sample conditioning system and allow sample line to empty. 3. Shut off power to the chromatograph. 4. Shut off carrier gas and control air supplies. Note Before doing the next step, purge the sample line including the valve with Nitrogen to avoid exposure to hazardous substances. 5. Unscrew the sample line and pneumatic actuation control lines from the liquid injection valve. 6. (If removing entire valve) Disconnect the carrier gas inlet line from the carrier inlet tube (18), and disconnect the column from the vaporizer (16) outlet inside the oven and then remove the valve. 7. (If not removing vaporizer and flange) Do not disconnect carrier gas or column. Unscrew the valve body (7) from the flange (17) and pull out. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 169 Component Descriptions and Maintenance Procedures 4.2 Oven Components Disassembling the Valve NOTICE Clean Work Area Required Perform all work on a clean dry surface to avoid contamination. Parts should be placed on a clean lint free cloth and hands should be clean. 1. If vaporizer (7) and flange (8) were not removed from the analyzer, then skip this step. 2. Unscrew the valve body (7) from the flange (17) and vaporizer (16) and separate the components. 3. Remove the 2 hex set screws (2) and remove the control cylinder (1). 4. Lift off the sample flow unit (15) and adjustment assembly (13) from the injection stem (6). 5. Remove the sample flow unit and the lens shaped gasket (if the gasket is not present it is stuck in the vaporizer) to allow the Belleville washer plate springs (10) to drop out. 6. Pull the control piston (3) with stem (6) out of the valve body (7). Do NOT use any tools such as a screwdriver as a wedge between the piston and the valve body. This would damage the valve body and control piston. Replacing the Teflon Gasket Replace the Teflon gaskets if they show any signs of wear or contamination. Procedure 1. Remove the gaskets (14) from the adjustment assembly (13) and vaporizer (16). To do this, gently insert the tip of the stem (6) approx. 5 mm into the gasket and then tip to the side until the gasket is loose and can be pulled out with the stem. 2. Insert new gaskets (14) into the adjustment assembly (13) and vaporizer (16). Use the correct type gasket according to the application and temperature class. 3. There should be no play between the new gasket and the injection stem. It should be extremely difficult to move the gasket. O-Ring Replacement The silicone O-rings of the pneumatic drive should be regularly greased with a high-quality lubricant such as DuPont Krytox EG2000 or equivalent (Siemens part number G87004). Procedure 1. Carefully remove the two large O-rings (4) and the small O-ring (8) out of the valve body (7) and control piston (3) using a small screwdriver or a needle. Only use silicone O-rings, temperature class -40°C to 200°C. 2. Insert new O-rings in all three locations (4 & 8). 3. Apply a thin film of grease to the new O-rings and the sliding surfaces of the control cylinder (1) and the piston guide (2 & 8). 170 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components Valve Assembly Read the following notes before performing the assembly procedure. Refer to Figure 4-51 for the following procedures. Notes • The screw threads on the flange plate (17) must move freely. Grease if necessary. • The diameter of the piston guide hole (8) should be 5.7 mm and be smooth. Replace the part if there are traces of wear on the piston shaft. • The adjustment assembly (13) must slide smoothly down inside the valve body (7). Procedure 1. Before assembling the valve, apply a thin coat of grease (discussed in O-Ring Replacement above) to the following parts. – Internal wall of control cylinder (1) – Shaft of Control Piston (3) – Piston Guide hole/small O-ring (8) – Outside of Large O-rings (4)following reassembly of valve body (7) and piston (3) 2. Insert the piston (3) with stem (6) into the valve body (7) such that the stem does not become greasy. 3. Drop the Belleville washer plate springs next to one another over the stem into the valve body. Washers must be positioned in an alternating bevel up/bevel down manner (to form a spring). See Liquid Injector Valve Exploded View for washer orientation. 4. Slide the adjustment assembly (13) with nut (11), counternut (12) and Teflon gasket (14) onto the stem. 5. Insert the sample flow unit (15) into the valve body (7) over the stem (6). See the Liquid Injection Valve Body illustration. Note that the stem hole through the sample flow unit is tapered. This tapering is not readily apparent when looking at the uninstalled sample flow unit, but it will be visible when it is installed on the stem. The narrowest side of the hole in the valve body should face outward (toward the vaporizer). The narrowest side of the hole will be apparent because it will have the least spacing between the stem and the side of the hole. Newer sample flow units have this orientation marked with an arrow. 6. Move stem (6) into filling position. This means that the stem should be “pushed in” towards the control cylinder (1) 7. If you have completely removed the liquid injection valve, fit the flange (17) over the vaporizer (16), and screw the valve body (7) and the flange together. 8. If the the flange plate (17) and vaporizer (16) were not removed from the analyzer, screw the partially reassembled valve onto the already installed flange plate. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 171 Component Descriptions and Maintenance Procedures 4.2 Oven Components Figure 4-60 Orientation of Sample Flow Unit Hole Belleville Washer Spring Adjustment It may be necessary to adjust the amount that the Belleville washer springs are being compressed. These washers should compress about 2 mm when adjusted appropriately. This compression distance is called “spring travel” and it is adjusted using the following procedure. ● Standard setting with 7 Belleville Washers: smooth round nut (11) extending about 0.5 mm past end of the threads on the adjustment assembly (13). ● Standard setting with 8 Belleville Washers; about 0.5 mm of threads showing below the round nut on the adjustment assembly (13). . The spring travel is not critical, but more compression distance should be used for higher pressures (greater than 20 bars) and less should be used for low pressures (less than 2 bars). Adjust accordingly. Procedure 1. Check the spring travel and correct using the adjustment assembly (13) if necessary. The spring travel is correctly set if the flange (17) can be rotated a further 2.5 rotations starting with the first pressing of the Belleville washer plate springs until the flange rests on the valve body. The plate springs can be viewed through a hole when pressing together. If the flange is tightened firmly, there should be a gap of 0.3 to 0.5 mm between the plate springs. 2. If the adjustment is necessary, loosen the flange from the valve body again, and screw the nut and counternut in or out as necessary. Then repeat the preceding step. 3. This step is only necessary if using the less common cross-hole stem and should only be executed if the entire valve including the vaporizer is removed from the analyzer. Rotate the vaporizer (16) using a 6mm wrench until the carrier gas inlet (18) is parallel to the sample flow unit (15). The carrier gas should flow through the hole in the stem when injecting. 4. If the entire valve was completely removed from the analyzer (including the flange and vaporizer), reinstall it at this time, but do not connect control lines, sample lines, or carrier gas. When installing the valve, adjust the valve body (7) so that sample will flow vertically through the valve. This is necessary to prevent bubbles from forming in the valve. 172 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 5. Position the control cylinder (1), and tighten the two hex set screws (2) on the side. The screws must firmly grip the groove in the valve body (5) wall. See the Liquid Injection Valve Body illustration. 6. Connect the control lines. 7. Activate the actuator pneumatically. Check that you can hear the switching and movement noises. 8. Connect the sample lines. After connecting the sample lines inspect that they are not subjected to any strain and that sample will flow through the valve vertically (to prevent bubbles from collecting in the valve). 9. Complete re-installation of valve into analyzer including reconnection of carrier gas and column tubing (if these were disconnected during removal). Dosing Stem Replacement Although it is possible to replace the control piston (3) and stem (6) without disassembling the valve body (7), Siemens recommends that the valve body be disassembled and serviced whenever the stem is replaced. See also Liquid Injection Valve Component Locations (Page 167) 4.2.4 Model 20 Valve 4.2.4.1 Basic Maintenance Basic Maintenance: Model 20 Valve Introduction This section presents information to perform fault diagnostic testing, maintenance and repair and installation of Model 20 valve. To assure optimum valve operation, a clean contaminant free operating environment is required at all times. Maintenance procedures for the Model 20 valve are divided into three types. These are: diagnostic, mini-maintenance, and maxi-maintenance. Diagnostic procedures can determine problems by a visual examination of valve. Mini-maintenance involves removal and cleaning of the valve cap, which can be performed while the valve is installed in the analyzer. Maximaintenance procedures are more involved and include complete disassembly of the valve. In this manual, only diagnostic and mini-maintenance procedures are discussed. More detailed maintenance procedures are discussed in other manuals; however, it is recommended that the valve be returned to Siemens for service when more detailed maintenance is needed. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 173 Component Descriptions and Maintenance Procedures 4.2 Oven Components Maintenance Considerations If customer maintenance personnel are not technically trained to repair the Model 20 valve on site, it is recommended that the valve be returned to Siemens for service, repair, or direct replacement. To repair the valve on site, the customer must have the necessary maintenance tools and replacement parts. Recommended valve spare parts, including the Model 20 repair kit (PN K21000), can be obtained from Siemens. When cleaning the Model 20 valve components, it is imperative that the maintenance be performed in a clean and contaminant free facility. Components should be placed on a lint free cloth to prevent impurities from contaminating the valve and its components. Hands should be clean and free of contaminants. Presence of any foreign contamination can cause additional valve problems after reinstallation. All foreign contamination adhering to valve components must be removed using cleaning solvent, such as hexane, acetone, or methanol and a dust/lint free cloth. After cleaning valve cap and tubing, shake or blow with clean air the excess cleaning fluid from the individual components. Ensure that the components are air dry before reassembling. It is possible to remove the valve cap of the Model 20 valve while the valve is installed in the Maxum oven. However, there may be situations where the user wishes to remove the valve from the oven. While this is not described in this manual, it is a straightforward process to detach air connections, loosen the mounting clamp, and remove the valve. Note Do not allow polished face of valve cap to rest on any surface other than a lint free cloth. Clean metal parts using only a syringe and a cleaning solvent such as hexane, acetone, or methanol. CAUTION Potential burn hazard. Handling hot components may result in personal injury. Before servicing the Model 20 valve, it is important that primary AC power to the Maxum II be turned off from the main circuit breaker, and the oven be allowed to cool. Only maintenance personnel with proper authorization should open the electronic enclosure. Failure to observe safety precautions can result in personal injury. 174 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components Figure 19 12c 3 16 12 2 12b 17 1 12a 3. 4. 13 19 5. 4 6. 18 5 432 15 6 5 61 20 BODY CAP 1. 2. 21 14 Valve Cap Belleville Washers (6 total) Allen Screws (3 total) Teflon Disc Seal Diaphragm Dacron Cushion Diaphragm Plungers (6 total) 12. Air Loaded (Upper) Piston 13. Valve Plunger Body 14. Cylinder Base 15. Spring Loaded (Lower) Piston 16. Allen Screws (3 total) 17. Belleville Washers (6 total) 18. Inner (small) O-Ring 19. Outer (large) O-Rings 20. Large Belleville Washers (3 total) 21. Control Port (Upper, Middle, or Lower depending on location) BASE Figure 4-61 Model 20 Valve Exploded View Diagnostic Procedures Depending on the installation, the following tests can be performed with the valve mounted in the analyzer. Other tests require the analyzer to be shut down and valve ports disconnected. These diagnostic tests indicate specific areas of the fault or trouble. Valve Leakage Sample Pressures Lower Than Carrier Gas Pressure: Leakage may be from a carrier-gas port to a sample port within the valve regardless of whether valve is actuated or deactivated. With sample inlet flow turned off, sample outlet should be zero. Check carrier and sample gas for leakage. Carrier and Sample Gas Leakage: Bubbles indicate internal leakage. For a liquid carrier, check for liquid dripping from sample outlet tube. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 175 Component Descriptions and Maintenance Procedures 4.2 Oven Components Sample Pressure Higher Than Carrier Gas: Leakage between ports is visually displayed on analyzer recorder as a baseline shift when sample pressure is removed from valve. Plugged Valve If the valve is plugged, plungers are pressed upward by air pressure or spring action and will not release to their open position when sample pressure drops. Ruptured Diaphragm Escaping air from valve vent hole indicates a ruptured diaphragm (4), which must be replaced. Check for liquid substances escaping from the vent hole. Slow Erratic Piston Switching Improper lubrication and/or contamination of O-rings will increase friction on valve-actuating piston. This causes valve switching to be erratic, slow or inoperative. This condition requires disassembly of the entire valve (maxi-maintenance). It is recommended that the valve be returned to Siemens for service. Model 20 Valve Cap Maintenance Procedure If customer maintenance personnel are not technically trained to repair the Model 20 valve on site, it is recommended that the valve be returned to Siemens for service, repair, or direct replacement. Within the following procedures, the numbers in parenthesis are callouts. They denote parts referenced in the lists contained in the figure in section 6.5.2; refer back to the figure for locations. Valve Cap Disassembly, Cleaning, and Reassembly 1. Loosen the three Allen screws (16), holding the plunger valve body (13) to the valve cylinder base (14). The screws should be loosened to the point that most of the spring pressure is relieved (approximately 1/8 inch or 3.2 mm). DO NOT remove these three screws. 2. To remove valve cap (1), remove the three Allen screws (3) and six Belleville washers (2) holding the valve cap (1) to the valve plunger body (13). 3. Remove the valve cap (1) from the plunger valve body (17). NOTICE Do not place polished valve cap (1) against any abrasive surface. Place it on an uncontaminated lint free cloth. 176 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 1. Inspect the valve cap Teflon® base seal disc diaphragm (4) and the Dacron® disc cushion diaphragm (5) for dirt, contamination or breaks. Regardless of whether damage or contamination is evident, discard old seal and cushion, and replace them with new component(s). Note If Teflon® sealing disc and Dacron® cushion disc are brittle or dirty, but not ruptured, or they are ruptured but clean, visually inspect the rest of the valve. If it is clean and in good order, it is possible to continue with this procedure. If ruptured discs appear to have caused contamination of the valve, it will need to be disassembled in order to be cleaned. It is recommended that the valve be returned to Siemens for service. Note All valve fittings and tubing must be clean and valve diaphragms inspected for cleanliness, catalyst or polymer buildup. Valve cap or plunger valve body faces should be wiped clean using hexane, acetone or methanol and a lint free cloth. 2. Prepare a large syringe with a Tygon® tubing adapter installed. Fill syringe with a recommended cleaning solvent. 3. An ultrasonic cleaner filled with a recommended cleaning solvent is recommended for cleaning all components. Solvent must not leave any residue on evaporation. Clean valve cap while it is disassembled. After cleaning of cap, using syringe, flush solvent through each port in the valve cap. NOTICE When reassembling the valve cap, always install a new Teflon® Seal Disc diaphragm (4) and Dacron® Cushion Disc (5). DO NOT install the previously used Seal and/or Cushion Disc. 4. Position the Dacron® cushion disc diaphragm (5) between the three alignment pins on the plunger valve body (13). 5. Using tweezers, hold Teflon® seal disc diaphragm (4) by its edges. Before installing disc, remove lint, dust and oils by sliding disk between your index and middle fingers. 6. Install Teflon® seal disc diaphragm (4) over the Dacron® diaphragm disc cushion (5). 7. Align valve cap (1) over the valve body three-plunger guide pins (13). Port 1 must be placed toward the upper control port. 8. Lower valve cap (1) over plunger valve body plunger guide pins (13) then install valve cap (1) onto the plunger valve body. 9. Install, but DO NOT securely tighten, the three Allen screws (3) each with two Belleville lock washers (2). Note To assure proper tightness in the following two steps, it is recommended to use the torque wrench available from Siemens, PN 1631005-002, which can be adjusted over the range of torque measurements listed below. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 177 Component Descriptions and Maintenance Procedures 4.2 Oven Components 10.Referring to the following screw tightening rotation sequence, securely tighten the three Allen screws (3) that connect the valve cap (1) to the valve plunger body (13). One at a time, tighten each screw to first torque. Then continue with the next torque value until the final value is reached. – Finger tighten – 20 inch pounds (2.3 Nm) – 40 inch pounds (4.5 Nm) – 60 inch pounds (6.8 Nm) 11.Tighten the three Allen screws (16) that secure the plunger valve body (13) to the cylinder base (14) to approximately 30 to 40 inch-pounds (3.4 to 4.5 Nm). NOTICE Be certain all Allen screws are securely tightened. DO NOT overtighten. 4.2.4.2 Disassembly and Cleaning M20 Description This section presents information to disassemble, clean, and rebuild the Model 20 Valve. Maintenance procedures for the Model 20 valve are grouped into two types, Mini-Maintenance procedures and Maxi-Maintenance procedures. Mini-Maintenance procedures involve working on the valve while it is still installed in the analyzer. Maxi-Maintenance procedures may be used when Mini-Maintenance does not correct a valve fault. However, it is often cheaper and easier to replace the valve or return it to Siemens for service. This manual covers the Maxi-Maintenance procedures in the following order. ● Valve Cap Disassembly ● Actuator Disassembly ● Cleaning Actuator, Fittings, Tubing, etc. ● Actuator Assembly ● Valve Cap Cleaning and Assembly To assure optimum valve operation, a clean contaminant free work environment is required for this procedure. To repair the valve on site, the customer must have the necessary maintenance tools and replacement parts. Recommended valve spare parts can be obtained from Siemens. Recommended tools will include an ultrasonic cleaner and a clean workstation with lint-free cloth. It may be easier and less expensive to replace a valve or return it to Siemens for service rather than perform Maxi-Maintenance. M20 Intended Users This procedure is intended for qualified users with sufficient training to safely repair a valve in the field. If customer maintenance personnel are not technically trained to repair the valve on site, it is recommended that the valve be returned to Siemens for repair or direct replacement. 178 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components In addition to training, the customer must have a clean work environment available for rebuilding and cleaning the valve. Performing the work in a contaminated environment, or performing the work incorrectly may damage the valve. M20 Safety and Certification Information This procedure is not likely to directly impact the safety systems of the analyzer. However, care must be exercised at all times when working with the analyzer. Since the valve is located in the oven of the Maxum II, appropriate care must be taken to ensure that the environment is safe to perform the work. Maintenance work on the Maxum II analyzer should only be performed when the area is known to be safe for the work to be done. Note This procedure must only be executed with the consent and approval of all applicable local safety personnel and/or the local authority having jurisdiction. M20 Procedure - Overview Throughout this procedure there are steps that instruct the user to inspect the valve to determine whether additional disassembly is necessary. This is to prevent unnecessary effort and to prevent the possibility of damaging the valve through further disassembly. M20 Procedure - Maintenance Facility When cleaning the valve and associated components, it is imperative that the maintenance be performed in a clean and contaminant free facility. Components should be placed on a lint free cloth to prevent impurities from contaminating the valve and/or components. Hands should be clean and free of contaminants. Presence of any foreign contamination can cause additional valve problems after reinstallation. All foreign contamination adhering to valve must be removed quickly using a dust/lint free cloth and a cleaning solvent such as hexane. After cleaning valve cap and tubing, shake excess cleaning fluid from tubes and let valve cap air dry before reassembling. NOTICE Do not allow polished face of valve cap to rest on any surface other than a lint free cloth. Clean metal parts using a syringe or ultrasonic cleaner and an appropriate cleaning solution as described in this procedure. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 179 Component Descriptions and Maintenance Procedures 4.2 Oven Components M20 Procedure - Figures The following figures are intended for use as a reference throughout the procedure. The numbers in the diagrams relating to individual components are referenced in parentheses in the procedure steps. Figure 4-62 180 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Valve Cap Allen Screws (3 total) Belleville Washers (6 total) Teflon Disc Seal Diaphragm Dacron Cushion Diaphragm Plungers (6 total) Ferrule Top Ferrule Bottom Connector Port Tubing 12. 13. 14. 15. 16. 17. 18. 19. 20. Air Loaded (Upper) Piston Valve Plunger Body Cylinder Base Spring Loaded (Lower) Piston Allen Screws (3 total) Belleville Washers (6 total) Inner (small) O-Ring Outer (large) O-Rings Large Belleville Washers (3 total) Section View of Model 20 Valve Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components Figure 4-63 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Valve Cap Belleville Washers (6 total) Allen Screws (3 total) Teflon Disc Seal Diaphragm Dacron Cushion Diaphragm Plungers (6 total) Ferrule Top Ferrule Bottom Connector Port Tubing 12. 13. 14. 15. 16. 17. 18. 19. 20. Air Loaded (Upper) Piston Valve Plunger Body Cylinder Base Spring Loaded (Lower) Piston Allen Screws (3 total) Belleville Washers (6 total) Inner (small) O-Ring Outer (large) O-Rings Large Belleville Washers (3 total) Exploded View of Model 20 Valve M20 Procedure - Cleaning of Parts All parts must be inspected for cleanliness, including catalyst or polymer buildup on the valve cap. Before re-assembly, faces of the plunger valve body (13) should be wiped clean using hexane, acetone, or methanol and a lint free cloth. An ultrasonic cleaner filled with a recommended cleaning solvent or detergent is recommended for cleaning all components. However, after cleaning, there must not be any remaining residue. If cleaning solution becomes contaminated during cleaning, it must be replaced with an uncontaminated supply. A syringe and appropriate solvent can be used to flush the ports of the valve cap. This is described in the procedure. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 181 Component Descriptions and Maintenance Procedures 4.2 Oven Components It is important for proper procedures to be used when cleaning valve and detector parts. All foreign contamination adhering to the part should be removed using an appropriate cleaning solvent, such as hexane, acetone, or methanol and a dust/lint free cloth. Use of an ultrasonic cleaner is often helpful. After cleaning, it is necessary remove excess cleaning fluid from the components by blowing with clean air or shaking. Components must be air dry before reassembling. It is possible and often better to use an appropriate detergent, such as Alconox® for cleaning instead of solvent. However, after cleaning with a detergent, it is necessary to rinse the part thoroughly with deionized water (distilled water is also acceptable) in order to remove detergent residue. All water must then be removed by blowing with clean air or shaking. Components must be completely dry before reassembling. M20 Procedure - Valve Cap Disassembly 1. Loosen the three Allen screws (16), holding the plunger valve body (13) to the valve cylinder base (14). The screws should be loosened to the point that most of the spring pressure is relieved (approximately 1/8" or 3.2 mm). Do not remove the three Allen mounting screws at this time. 2. To remove valve cap (1), remove the three Allen screws (3) and six Belleville washers (2) holding the valve cap (1) to the valve plunger body (13). 3. Remove the valve cap (1) from the plunger valve body (13). NOTICE To prevent damage to the valve cap (1), do not place polished surface of the valve cap against any abrasive surface. Place it on a lint free cloth free of foreign contaminants. 4. Inspect the valve cap Teflon base seal disc diaphragm (4) and the Dacron disc cushion diaphragm (5) for dirt, contamination or breaks. Regardless of whether damage or contamination is evident, discard old seal and cushion, and replace them with new component(s). 5. Visually inspect the rest of valve. If it is clean and in good condition, install a new disc seal diaphragm (4) and cushion diaphragm (5). To reassemble the valve cap, refer to the applicable steps later in this chapter. Note The valve cap and fittings will be cleaned before reassembly. This step will be executed later in this chapter. M20 Procedure - Actuator Disassembly Note In the next three steps, valve plungers (6) are checked for sticking. 182 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 1. Using even finger pressure around edges of plunger valve body (13), push valve plunger body against cylinder valve base (14). All six plungers should rise. 2. Release plunger valve body (13). The six plungers should drop. If plungers do not drop, check for oil film on plungers. This can prevent plungers from dropping. 3. Apply gentle pressure to the top of each of the six plungers. If plungers drop, without excessive pressure, the valve is operating normally and does not require additional disassembly. If plungers stick or are sluggish in their operation, they must either be thoroughly cleaned with a recommended cleaning solution, repaired, or the entire actuator must be replaced. 4. Remove all connections from the valve and remove the entire valve from the oven. While removing the valve, hold it upright to prevent plungers from falling out. Additional work should be on a clean workspace. 5. Turn actuator on its side. Remove the three screws (16) which secure the plunger valve body (13) to the cylinder valve base (14). Note When performing the following step, DO NOT allow actuator plungers to fall from plunger valve body (13). 6. With plunger valve body (13) in the horizontal position, remove it from the cylinder base (14). Carefully remove all six plungers (6). Note Perform EITHER step 7 or step 8 to remove the actuator piston from the cylinder base. 7. Place cylinder valve base (14) in upright position. Insert a 6-32 hex threaded standoff screw into the center-threaded hole and pull to remove air loaded piston (12) and spring-loaded piston (15). Note In the following step, DO NOT use more than 30 psig (210 kPa) of air pressure when using this method. 8. Alternate method for removing actuator piston. Carefully apply 10 psig (70 kPa) air pressure on bottom port of cylinder valve base (14). This extends the pistons allowing them to be pulled out of cylinder valve base by hand. 9. Inspect actuator cylinder walls and the three Belleville washers (20). These components must be clean and show no evidence of damage. If necessary, clean parts or replace them. 10.Separate the upper air loaded piston (12) and lower spring loaded piston (15). Inspect pistons (12 and 15), silicone O-rings (18 and 19) and finger loaded valve spring (12c). These components must be clean and show no evidence of damage. If necessary, clean parts or replace them. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 183 Component Descriptions and Maintenance Procedures 4.2 Oven Components M20 Procedure - Actuator Reassembly Note It is extremely important that, when reassembling the actuator, that the assembly area be clean and dust free. Hands of maintenance personnel must be clean and not oily and tools must also be clean. Note Be certain valve cap (1) does not rest on abrasive surface and valve cap has completely air dried before reassembly. Rest valve cap on a clean lint free cloth. 1. Install the three large Belleville washers (20) in cylinder valve base (14). Washers must be positioned in an alternating bevel up, bevel down manner (to form a spring). Refer to Figures 5-1 and 5-2. 2. Apply a bead of Krytox 240 AC lubricant, or equivalent; in "O" ring grooves of spring-loaded piston (15). 3. Install new silicon O-rings (18 and 19) in spring loaded piston (15) and apply a coating of lubricant over each "O" ring. 4. Apply bead of lubricant in upper groove of air loaded piston (12a). 5. Install a new silicon "O" ring (19) in the upper groove of air loaded piston (12a) and apply a coating of lubricant over the "O" ring. 6. Place upper piston (12a) over the small diameter of lower piston (15). Position pistons using guide pin (12b) for proper orientation. 7. Apply Krytox 240C lubricant to each of the six finger spring (12c) pressure points. This is the point where the spring fingers contact the plunger body (13). 8. Position the valve upright with its three ports on the left. Install a #6-32 screw in the centerthreaded hole of air loaded piston assembly (12) and bottom spring-loaded piston (15). 9. Lift the combined assembly (12 and 15), and orient it with the upper piston guide pin (12b) facing toward maintenance person. 10.Press the piston assembly into the cylinder base (14). After installation, remove the #6-32 screw. 11.Align plunger valve body (13) and insert the piston guide pin (12b) into one of the three bottom holes of plunger valve body (13). 12.Rotate plunger valve body (13) to align body screw holes with cylinder base (14) threaded holes. 13.Install three #10-32 7/8" socket head screws (16) and Belleville washers (17). 14.Hand tighten screws. DO NOT compress the Belleville washers (20) into the cylinder base (14). 15.Install six plungers (6) into the plunger valve body (13). Plunger recess must face up. A clean plunger will fall with its own weight, and, when dropped into the valve body (13), it will bounce. 184 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 16.Place a small drop of Krytox 143 AY or equivalent oil between each plunger. 17.Using a pair of tweezers, lift each plunger up and down to allow the oil to flow around a plunger. M20 Procedure - Valve Cap Reassembly Note Before reassembling the valve cap, clean it as described below. 1. Prepare a large syringe with a Tygon tubing adapter installed. Fill syringe with a recommended cleaning solvent. 2. Using syringe, flush solvent through each port in the valve cap. Note When reassembling the valve cap, always install a new Teflon Seal Disc diaphragm (4) and Dacron Cushion Disc (5) on plunger valve body (13). Do not install the previously used Teflon Seal (4) and/or Dacron Cushion Disc (5). Before reinstalling seal and cushion on plunger valve body, remove lint and any dust particles. 3. Place the actuator assembly upright on a clean lint free cloth surface. Refer to Figures 5-1 and 5-2. 4. Position the Dacron cushion disc diaphragm (5) between the three alignment pins on the plunger valve body (13). 5. Using tweezers hold the Teflon seal disc diaphragm (4) by its edges. Before reinstalling disc, remove lint, dust and oils by sliding disk between your index and middle fingers. 6. Install Teflon seal disc diaphragm (4) over the Dacron diaphragm disc cushion (5). 7. Align and lower valve cap (1) over the three guide pins of the valve plunger body (13). Then install valve cap (1) onto the plunger valve body. 8. Install, but do not securely tighten, the three Allen screws (3) each with two Belleville lock washers (2). Note To assure proper tightness in the following two steps, it is recommended to use the torque wrench available from Siemens, part number 1631005-002, which can be adjusted over the range of torque measurements listed below. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 185 Component Descriptions and Maintenance Procedures 4.2 Oven Components 9. Referring to the following screw tightening rotation sequence, securely tighten the three Allen screws (3) that connect the valve cap (1) to the valve plunger body (13). One at a time, tighten each screw to first torque. Then continue with the next torque value until the final value is reached. a. Finger tighten b. 20 inch-pounds (2.3 Nm) c. 40 inch-pounds (4.5 Nm) d. 60 inch-pounds (6.8 Nm) 10.Tighten the three Allen screws (16) that secure the plunger valve body (13) to the cylinder base (14) to approximately 30 to 40 inch-pounds (3.4 to 4.5 Nm). BE CERTAIN ALL ALLEN SCREWS ARE SECURELY TIGHTENED. DO NOT OVERTIGHTEN. 4.2.5 Model 20 HT Valve 4.2.5.1 M20HT Description This section presents information to disassemble, clean, and rebuild the Model 20 High Temperature (Model 20 HT) Valve. The Model 20 HT Valve is similar to the standard Model 20 with a few distinct differences. Procedures to disassemble and clean the Model 20 HT are very similar to the Model 20. However, procedures to re-assemble the Model 20 HT valve are different from the standard Model 20. Like the standard Model 20 valve, maintenance procedures for the Model 20 HT valve are grouped into two types, Mini-Maintenance procedures and Maxi-Maintenance procedures. Mini-Maintenance procedures involve working on the valve while it is still installed in the analyzer. Maxi-Maintenance procedures may be used when Mini-Maintenance does not correct a valve fault. This manual covers the Maxi-Maintenance procedures in the following order. ● Valve Cap Disassembly ● Actuator Disassembly ● Cleaning Actuator, Fittings, Tubing, etc. ● Actuator Assembly ● Valve Cap Cleaning and Assembly To assure optimum valve operation, a clean contaminant free work environment is required for this procedure. To repair the valve on site, the customer must have the necessary maintenance tools and replacement parts. Recommended valve spare parts can be obtained from Siemens. Recommended tools will include an ultrasonic cleaner and a clean workstation with lint-free cloth. Mini-Maintenance procedures can be found in the Maxum II Maintenance Manual. This manual can be found on the Maxum II Documentation CD (part number 2000597-001). Additional procedures related to the Model 20 High Temperature Valve can be found in the Model 20 High Temperature Valve Repair Manual, which can also be found on the Maxum II Documentation CD. 186 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components It may be easier and less expensive to replace a valve or return it to Siemens for service rather than perform Maxi-Maintenance. 4.2.5.2 M20HT Intended Users This procedure is intended for qualified users with sufficient training to safely repair a valve in the field. If customer maintenance personnel are not technically trained to repair the valve on site, it is recommended that the valve be returned to Siemens for repair or direct replacement. In addition to training, the customer must have a clean work environment available for rebuilding and cleaning the valve. Performing the work in a contaminated environment, or performing the work incorrectly may damage the valve. 4.2.5.3 M20HT Safety and Certification Information This procedure is not likely to directly impact the safety systems of the analyzer. However, care must be exercised at all times when working with the analyzer. Since the valve is located in the oven of the Maxum II, appropriate care must be taken to ensure that the environment is safe to perform the work. Maintenance work on the Maxum II analyzer should only be performed when the area is known to be safe for the work to be done. NOTICE Obtain appropriate permits. This procedure must only be executed with the consent and approval of all applicable local safety personnel and/or the local authority having jurisdiction. 4.2.5.4 M20HT Procedure - Overview Throughout this procedure there are steps that instruct the user to inspect the valve to determine whether additional disassembly is necessary. This is to prevent unnecessary effort and to prevent the possibility of damaging the valve through further disassembly. 4.2.5.5 M20HT Procedure - Maintenance Facility When cleaning the valve and associated components, it is imperative that the maintenance be performed in a clean and contaminant free facility. Components should be placed on a lint free cloth to prevent impurities from contaminating the valve and/or components. Hands should be clean and free of contaminants. Presence of any foreign contamination can cause additional valve problems after reinstallation. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 187 Component Descriptions and Maintenance Procedures 4.2 Oven Components All foreign contamination adhering to valve must be removed quickly using a dust/lint free cloth and a cleaning solvent such as hexane. After cleaning valve cap and tubing, shake excess cleaning fluid from tubes and let valve cap air dry before reassembling. NOTICE Do not allow polished face of valve cap to rest on any surface other than a lint free cloth. Clean metal parts using a syringe or ultrasonic cleaner and an appropriate cleaning solution as described in this procedure. 4.2.5.6 M20HT Procedure - Figures The following figures are intended for use as a reference throughout the procedure. The numbers in the diagrams relating to individual components are referenced in parentheses in the procedure steps. Figure 4-64 188 13. 14. 15. 16. 17. 18. 19. 20. 21. Outer (Large) Bal-Seals (2 total) Plungers (6 total) Spring Loaded (Lower) Piston Cylinder Base Valve Plunger Body Air Loaded (Upper) Piston Large Belleville Washers (3 total) Inner (Small) Bal-Seal Actuator Air Input 32. 33. 34. 35. 36. Valve Cap Teflon Disc Seal Diaphragm Nomex Cushion Diaphragm Allen Screws (6 total) Belleville Washers (12 total) Cutout View of Model 20 HTV Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components Figure 4-65 13. 14. 15. 16. 17. 18. 19. 20. 21. Outer (Large) Bal-Seals (2 total) Plungers (6 total) Spring Loaded (Lower) Piston Cylinder Base Valve Plunger Body Air Loaded (Upper) Piston Large Belleville Washers (3 total) Inner (Small) Bal-Seal Actuator Air Input 32. 33. 34. 35. 36. Valve Cap Teflon Disc Seal Diaphragm Nomex Cushion Diaphragm Allen Screws (6 total) Belleville Washers (12 total) Cross Section View of Model 20 HTV Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 189 Component Descriptions and Maintenance Procedures 4.2 Oven Components 13. 14. 15. 16. 17. 18. 19. CAP Figure 4-66 190 Outer (Large) Bal-Seals (2 total) Plungers (6 total) Spring Loaded (Lower) Piston Cylinder Base Valve Plunger Body Air Loaded (Upper) Piston Large Belleville Washers (3 total) BODY 20. 21. 32. 33. 34. 35. 36. Inner (Small) Bal-Seal Actuator Air Input Valve Cap Teflon Disc Seal Diaphragm Nomex Cushion Diaphragm Allen Screws (6 total) Belleville Washers (12 total) BASE Exploded View of Model 20 HTV Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 4.2.5.7 M20HT Procedure - Cleaning of Parts All parts must be inspected for cleanliness, including catalyst or polymer buildup on the valve cap. Before re-assembly, faces of the plunger valve body (17) should be wiped clean using hexane, acetone, or methanol and a lint free cloth. An ultrasonic cleaner filled with a recommended cleaning solvent or detergent is recommended for cleaning all components. However, after cleaning, there must not be any remaining residue. If cleaning solution becomes contaminated during cleaning, it must be replaced with an uncontaminated supply. A syringe and appropriate solvent can be used to flush the ports of the valve cap. This is described in the procedure. It is important for proper procedures to be used when cleaning valve and detector parts. All foreign contamination adhering to the part should be removed using an appropriate cleaning solvent, such as hexane, acetone, or methanol and a dust/lint free cloth. Use of an ultrasonic cleaner is often helpful. After cleaning, it is necessary remove excess cleaning fluid from the components by blowing with clean air or shaking. Components must be air dry before reassembling. It is possible and often better to use an appropriate detergent, such as Alconox® for cleaning instead of solvent. However, after cleaning with a detergent, it is necessary to rinse the part thoroughly with deionized water (distilled water is also acceptable) in order to remove detergent residue. All water must then be removed by blowing with clean air or shaking. Components must be completely dry before reassembling. 4.2.5.8 M20HT Procedure - Valve Cap Disassembly 1. Loosen the three Allen screws (35), holding the plunger valve body (17) to the valve cylinder base (16). The screws should be loosened to the point that most of the spring pressure is relieved (approximately 1/8" or 3.2 mm). Do not remove the three Allen mounting screws at this time. 2. To remove valve cap (32), remove the three Allen screws (35) and six Belleville washers (36) holding the valve cap (32) to the valve plunger body (17). 3. Remove the valve cap (32) from the plunger valve body (17). NOTICE To prevent damage to the valve cap (32), do not place polished surface of the valve cap against any abrasive surface. Place it on a lint free cloth free of foreign contaminants. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 191 Component Descriptions and Maintenance Procedures 4.2 Oven Components 4. Inspect the Teflon seal disc diaphragm (33) and the Nomex cushion diaphragm (34). Examine valve cap base seal (33) and cushion diaphragm (34) subassemblies for dirt, contamination or breaks. Regardless of whether damage or contamination is evident, discard old seal and cushion, and replace them with new component(s). 5. Visually inspect the rest of valve. If it is clean and in good condition, install a new disc seal diaphragm (33) and cushion diaphragm (34). To reassemble the valve cap, refer to the applicable steps later in this chapter. Note The valve cap and fittings will be cleaned before reassembly. This step will be executed later in this chapter. 4.2.5.9 M20HT Procedure - Actuator Disassembly Note In the next three steps, valve plungers (14) are checked for sticking. 1. Using even finger pressure around edges of plunger valve body (17), push valve plunger body against cylinder valve base (16). All six plungers should rise. 2. Release plunger valve body (17). The six plungers should drop. If plungers do not drop, check for oil film on plungers. This can prevent plungers from dropping. 3. Apply gentle pressure to the top of each of the six plungers. If plungers drop, without excessive pressure, the valve is operating normally and does not require additional disassembly. If plungers stick or are sluggish in their operation, they must either be thoroughly cleaned with a recommended cleaning solution, repaired, or the entire actuator must be replaced. 4. Remove all connections from the valve and remove the entire valve from the oven. While removing the valve, hold it upright to prevent plungers from falling out. Additional work should be on a clean workspace. 5. Turn the actuator on its side. Remove the three socket head screws (35) which secure the plunger valve body (17) to the cylinder valve base (16). Note When performing the following step, DO NOT allow actuator plungers to fall from plunger valve body (17). 6. With plunger valve body (17) in the horizontal position, remove the assembly. Carefully remove all six plungers (14). Note Perform EITHER step 7 or step 8 to remove the actuator piston from the cylinder base. 192 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 7. Place cylinder valve base (16) in upright position. Insert a 6-32 hex threaded standoff screw into the center-threaded hole and pull to remove air loaded piston (18) and spring-loaded piston (15). Note In the following step, DO NOT use more than 30 psig (210 kPa) of air pressure when using this method. 8. Alternate method for removing actuator piston. Carefully apply 10 psig (70 kPa) of air pressure on bottom port of cylinder valve base (16). This extends the pistons allowing them to be pulled out of cylinder valve base by hand. 9. Inspect actuator cylinder walls and the three Belleville washers (19). These components must be clean and show no evidence of damage. If necessary, clean parts or replace them. 10.Separate the upper air loaded piston (18) and lower spring loaded piston (15). Inspect pistons and spring loaded Bal-Seal (20) and Belleville washer (19). These components must be clean and show no evidence of damage. If necessary clean parts or replace them. 4.2.5.10 M20HT Procedure - Actuator Re-assembly Note It is extremely important that, when reassembling the actuator, that the assembly area be clean and dust free. Hands of maintenance personnel must be clean and not oily and tools must also be clean. Note Be certain valve cap (32) does not rest on abrasive surface and valve cap has completely air dried before reassembly. Rest valve cap on a clean lint free cloth. 1. Install the three large Belleville washers (19) in cylinder valve base (16). Washers must be positioned in an alternating bevel up, bevel down manner (to form a spring). Refer to Figures 6-2 and 6-3. 2. Apply a bead of Krytox 240 AC lubricant, or equivalent, in Bal-Seal grooves of spring loaded piston (15). 3. Lubricate outside diameter of assembly tool (Part Number A00145). Be certain springloaded Bal-Seal (13) is properly oriented with the associated spring facing up. 4. Using an "O" ring as a cushion, push spring loaded Bal-Seal (13) down on the assembly tool until it snaps firmly into spring loaded piston (15) ring groove. Refer to Figure 6-4 on the next page. NOTICE When installing Bal-Seals, handle them with extreme care. Do not remove Bal-Seal springs for installation and do not nick or scratch Bal-Seals. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 193 Component Descriptions and Maintenance Procedures 4.2 Oven Components 5. Apply a bead of Krytox 240 AC lubricant, or equivalent, in both Bal-Seal grooves of airloaded piston (18). Figure 4-67 Assembling Bal-Seal (13) on Piston (15) 6. Using the pads of your fingers (or an "O" ring as a cushion), install the small spring loaded Bal-Seal (20) in air loaded piston (18) groove with associated spring facing up. DO NOT use a fingernail. Refer to Figure 6-5. 7. Push spring loaded Bal-Seal (20) to the bottom of groove. 8. Apply small bead of Krytox 240 AC lubricant, or equivalent, on the small Bal-Seal sealing surface of lower spring loaded piston (15). 9. Place upper air loaded piston (18) over the small diameter of lower piston (25). Position pistons using guide pin for proper orientation. 10.Screw the assembly stud and washer into the threaded hole in the lower spring loaded piston (15) and evenly force the spring loaded Bal-Seal (20) over the bearing surface of lower spring loaded piston (15). Leave the assembly stud and washer in place. 11.Moderately lubricate outsides of Bal-Seals with Krytox 240 AC lubricant, or equivalent. Also lubricate each of the six fingers of spring. This is where fingers contact plunger valve body (17). 194 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 12.Position valve upright with the three ports on the left. Place assembly guide tool (Part Number T11000) on the valve, with the cutout on the lip of assembly tool over the upper tube fitting. Refer to Figure 6-6. 13.Lift piston and Bal-Seal assembly and orient assembly with the upper piston index guide pin towards the maintenance person. 14.Firmly, but evenly, press the piston and Bal-Seal assembly through the assembly guide tool into the cylinder valve base (16). Refer to Figure 6-7. 15.Remove guide tool assembly stud and lock washer. Figure 4-68 Installing Bal-Seal (20) in Piston Groove (18) A Figure 4-69 B Placing Assembly Guide Tool on Valve Base (16) Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 195 Component Descriptions and Maintenance Procedures 4.2 Oven Components Figure 4-70 196 Inserting Piston Assembly (15 and 18) into Base (16) Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 1. Align plunger valve body (17) and insert piston index guide pin into one of the three bottom plunger valve body holes. 2. Rotate plunger valve body (17) to align the plunger valve body screw holes with cylinder valve base (16) threaded holes. 3. Install three Allen screws (35) each with two Belleville washers (36). Hand tighten screws but DO NOT compress the Belleville washers (19) in cylinder valve base. 4. With the recessed tip facing up, install the six plungers (14) in the plunger valve body (17). A clean plunger will fall under its own weight and bounce when dropped into the plunger valve body. 5. Place a small drop of Krytox 143 AY or equivalent oil between each plunger. 6. Using a pair of tweezers, lift each plunger up and down to allow the oil to flow around a plunger. 4.2.5.11 M20HT Procedure - Valve Cap Re-assembly Note Before reassembling the valve cap, clean it as described below. 1. Prepare a large syringe with a Tygon tubing adapter installed. Fill syringe with a recommended cleaning solvent. 2. Using syringe, flush solvent through each port in the valve cap. Note When reassembling the valve cap, always install a new Teflon Seal Disc diaphragm (33) and Nomex Cushion Disc (34) on plunger valve body (17). Do not install the previously used Teflon Seal (33) and/or Nomex Cushion Disc (34). Before reinstalling seal and cushion on plunger valve body, remove lint and any dust particles. 3. Place the actuator assembly upright on a clean lint free cloth surface. Refer to Figures 6-1 and 6-2. 4. Position the Nomex cushion disc diaphragm (34) between the three alignment pins on the plunger valve body (17). 5. Using tweezers hold the Teflon seal disc diaphragm (33) by its edges. Before reinstalling disc, remove lint, dust and oils by sliding disk between your index and middle fingers. 6. Install Teflon seal disc diaphragm (33) over the Nomex disc cushion diaphragm (34). 7. Align and lower valve cap (32) over the three guide pins of the valve plunger body (17). Then install valve cap (32) onto the plunger valve body. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 197 Component Descriptions and Maintenance Procedures 4.2 Oven Components 8. Install, but do not securely tighten the three Allen screws (35), each with two Belleville lock washers (36), that secure the valve cap (32) to the valve plunger body (17). Note To assure proper tightness in the following two steps, it is recommended to use the torque wrench (PN 1631005-002) and bit (PN 1631005-701) which are available from Siemens and can be adjusted over the range of torque measurements listed below. 9. Referring to the following screw tightening rotation sequence, securely tighten the three Allen screws (35), that connect the valve cap (32) to the valve plunger body (17). One at a time, tighten each screw to first torque. Then continue with the next torque value until the final value is reached. a. Finger tighten b. 20 inch-pounds (2.3 Nm) c. 40 inch-pounds (4.5 Nm) d. 60 inch-pounds (6.8 Nm) 10.Tighten the three Allen screws (16) that secure the plunger valve body (13) to the cylinder base (14) to approximately 30 to 40 inch-pounds (3.4 to 4.5 Nm). BE CERTAIN ALL ALLEN SCREWS ARE SECURELY TIGHTENED. DO NOT OVERTIGHTEN. 4.2.6 Model 11 Valve 4.2.6.1 M11 Description This section presents information to disassemble, clean, and rebuild the Model 11 Valve (including the Model 11 Low Dead Volume Valve). This Model 11 valve (M11) is broken down into two primary types, the standard Model 11 Valve and the Model 11 Low Dead Volume (LDV) valve. The primary difference between the Model 11 and the Model 11 LDV valves is the sample ports on the valve cap. The sample ports on the Model 11 valve have tubing connected as part of the cap. For the Model 11 LDV the ports are threaded holes and tubing is not part of the cap. Within this section, steps for these two types of valve are the same except where noted. 198 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components Model 11 Valve Figure 4-71 Model 11 Low Dead Volume Valve Model 11 Valve Types Maintenance procedures for the Model 11 Valves are grouped into two types, MiniMaintenance procedures and Maxi-Maintenance procedures. Mini-Maintenance procedures involve working on the valve while it is still installed in the analyzer. Maxi-Maintenance procedures may be used when Mini-Maintenance does not correct a valve fault. This manual covers the Maxi-Maintenance procedures in the following order. ● Mini-Maintenance procedures: – Valve Cap Disassembly – Cleaning Fittings and Tubing – Valve Cap Assembly ● Maxi-Maintenance procedures – Valve Body Disassembly – Valve Body Cleaning – Valve Body Assembly To assure optimum valve operation, a clean contaminant free work environment is required for this procedure. To repair the valve on site, the customer must have the necessary maintenance tools and replacement parts. Recommended valve spare parts, including the Model 11 Valve repair kit (PN K21040) and Model 11 LDV repair kit (PN 2015581-001), can be obtained from Siemens. Recommended tools include an ultrasonic cleaner and a clean workstation with lint-free cloth. In addition, special pliers that are available from Siemens (PN V16031) are required to completely disassemble the valve. These pliers are part of the tool kits mentioned above. Additional procedures related to the Model 11 Valve can be found in the Model 11 Valve Repair Manuals, which can also be found on the Maxum II Documentation CD. It may be easier and less expensive to replace a valve or return it to Siemens for service rather than perform Maxi-Maintenance. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 199 Component Descriptions and Maintenance Procedures 4.2 Oven Components 4.2.6.2 M11 Intended Users This procedure is intended for qualified users with sufficient training to safely repair a valve in the field. If customer maintenance personnel are not technically trained to repair the valve on site, it is recommended that the valve be returned to Siemens for repair or direct replacement. In addition to training, the customer must have a clean work environment and the proper tools available for rebuilding and cleaning the valve. Performing the work in a contaminated environment, performing the work incorrectly, or using incorrect tools may damage the valve. 4.2.6.3 M11 Safety and Certification Information This procedure is not likely to directly impact the safety systems of the analyzer. However, care must be exercised at all times when working with the analyzer. Since the valve is located in the oven of the Maxum II, appropriate care must be taken to ensure that the environment is safe to perform the work. Maintenance work on the Maxum II analyzer should only be performed when the area is known to be safe for the work to be done. Note This procedure must only be executed with the consent and approval of all applicable local safety personnel and/or the local authority having jurisdiction. 4.2.6.4 Diagnostic Procedures Depending on the installation, the following tests can be performed with the valve mounted in the analyzer. Other tests require the analyzer be shut down and valve ports disconnected. These diagnostic tests indicate specific areas of the fault or trouble. Valve Leakage Vapor analyzers generally have the sample at atmospheric pressure, so any leakage would be from a carrier-gas port to a sample port within the valve. With the sample inlet flow turned off, the sample outlet flow should be zero in either the "air off" or "air on" condition. Check for small leaks by immersing the sample outlet tubing in a beaker of water. Bubbles indicate internal leakage. The liquid sample streams may have pressures several hundred pounds higher than the carrier gas. Leaking between ports will show up on the analyzer chromatogram as base-line shift when the sample pressure is removed from the valve. Plugged Valve Plungers in the valve are pressed upward by air or spring action, but when released depend on their own weight and sample pressure to drop them to the "open" position. For very small sample pressures, for example below 5 psi (34 kPa), it may be possible to see problems where the flow path may not open. This is more likely if the sealing disc has been held against the cap for a long time (such as a valve in storage). Check for flow across alternate flow paths, such as air on and air off. It may be necessary to temporarily increase the sample pressure to get the flow started, and then reduce it to normal after a few cycles. For the Model 11 valve, samples are typically run at 15 psi (103 kPa). 200 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components Ruptured Sealing Disc To test for a ruptured sealing disc apply air to valve ports, one at a time, while sealing off all others. Place a small amount of soap solution such as Leak Tec® over the upper control port's bleed tube air signal manifold (23). Any escaping air at this point indicates a ruptured disc. If this occurs, proceed with a disc replacement. If the disc does not appear to be ruptured, remove the valve from service and replace it with a new valve. Slow Erratic Piston Switching Excessive friction on the actuating pistons of the valve can be caused by lack of lubricant, or dirt or contamination on the O-rings. As a result, the valve may switch erratically, switch slowly or not switch at all. These conditions can cause a leak port to port, across the sealing disc, double sampling, or complete closing of flow between two or more ports. This condition requires disassembly of the entire valve (maxi-maintenance). It is recommended that the valve be returned to Siemens for service. 4.2.6.5 M11 Procedure - Maintenance Facility When cleaning the valve and associated components, it is imperative that the maintenance be performed in a clean and contaminant free facility. Components should be placed on a lint free cloth to prevent impurities from contaminating the valve and/or components. Hands should be clean and free of contaminants. Presence of any foreign contamination can cause additional valve problems after reinstallation. All foreign contamination adhering to valve must be removed quickly using a dust/lint free cloth and a cleaning solvent such as hexane. After cleaning valve cap and tubing, shake excess cleaning fluid from tubes and let valve cap air dry before reassembling. NOTICE Do not allow polished face of valve cap to rest on any surface other than a lint free cloth. Clean metal parts using a syringe or ultrasonic cleaner and an appropriate cleaning solution as described in this procedure. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 201 Component Descriptions and Maintenance Procedures 4.2 Oven Components 4.2.6.6 M11 Procedure - Figures The following figures are intended for use as a reference throughout the procedure. The numbers in the diagrams relating to individual components are referenced in parentheses in the procedure steps. 8. Valve Body 9. O-Ring 10. Finger Spring of Air Loaded Piston 11. Air Loaded Piston 12. O-Ring 13. O-Ring 14. Spring Loaded Piston 15. Compensation Plate 16. Compression Spring 17. Compression Plate 18. Retaining Base 19. Retaining Ring Clip 20. Ball 5/32” 21. Set Screw 22. O-Rings (3 total) 23. Air Signal Manifold 24. Screw 3/8” 25. Screw 1/2” Figure 4-72 202 Model 11 (or Model 11 LDV) Valve without Valve Cap Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 1. 2. 3. 4. 5. 6. 7. Figure 4-73 Screw (3 total required) Belleville Washer (6 total required) Valve Cap Teflon Seal Disc Dacron Cushion Disc O-Ring Plungers (6 total required) Model 11 Valve Cap Exploded View This end toward valve cap This end toward pistons Figure 4-74 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Model 11 Plunger Orientation 203 Component Descriptions and Maintenance Procedures 4.2 Oven Components 20 21 19 18 17 16 15 14 13 11 12 10 9 8 22 To Valve Cap 23 24 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. Valve Body O-Ring Spring Air Loaded Piston O-Ring O-Ring Spring Loaded Piston Compensation Plate Compression Spring Compression Plate Retaining Base Retaining Ring Clip Ball 5/32” Set Screw O-Rings (3 total) Air Signal Manifold Screw 3/8” Screw 1/2” 25 Figure 4-75 Valve Body Exploded View Align Pin with Index Hole V16022 (Air Loaded) Figure 4-76 204 V16023 (Spring Loaded) Valve Base Alignment Pin Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components P49510 S52000 P49500 V16052 B00065 H10648 Figure 4-77 Assembly of Compression Spring V16022 Apply Loctite Piston Spring Pressure Points Figure 4-78 4.2.6.7 Greasing of Spring Pressure Points Mini-Maintenance Procedures (Valve Cap and Fittings) M11 Procedure - Valve Cap Disassembly 1. Disconnect the Model 11 valve from the column and air lines and remove the valve from the analyzer. 2. Relieve the pressure on the base Allen Set Screw (21) by turning it counterclockwise until it turns easily. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 205 Component Descriptions and Maintenance Procedures 4.2 Oven Components 3. Remove the three Allen head cap socket screws (1) and separate the cap (3) from the valve body (8). When the valve cap is removed, the following components are exposed. Refer to Figures 7-2 and 7-4. - Teflon Sealing disc (4) [clear] - Dacron Cushion disc (5) [white] and - "O" ring (6) 4. Inspect the Teflon sealing disc (4), Dacron cushion disc (5) and silicon rubber "O" ring (6) for dirt or breaks. If damage is evident on the O-ring, discard damaged part and replace with new component(s). Regardless of whether damage or contamination is evident on the old seal and cushion, replace them with new components. 5. Visually inspect the rest of valve. If it is clean and in good condition, it may be possible to install a new disc seal diaphragm (4) and cushion diaphragm (5) and re-assemble the valve. 6. Examine each of the six plungers (7) for evidence of damage or contamination. If damage is evident, discard defective plunger(s) and replace with new ones. Refer to Figure 7-3. 7. To reassemble the valve cap (3), refer to the Valve Cap Assembly section later in this chapter. If the valve actuating piston assembly is contaminated or malfunctioning, refer to Valve Body disassembly. Note The valve cap and fittings will be cleaned before reassembly. This step will be executed later in this chapter. M11 Procedure - Cleaning of Parts All valve fittings and tubing must be clean and valve diaphragms inspected for cleanliness, catalyst or polymer buildup. Before re-assembly, valve cap and plunger valve body faces should be wiped clean using hexane, acetone or methanol and a lint free cloth. An ultrasonic cleaner filled with a recommended cleaning solvent or detergent is recommended for cleaning all components. However, after cleaning, there must not be any remaining residue. If cleaning solution becomes contaminated during cleaning, it must be replaced with an uncontaminated supply. A syringe and appropriate solvent can be used to flush the ports of the valve cap. This is described in the procedure. It is important for proper procedures to be used when cleaning valve and detector parts. All foreign contamination adhering to the part should be removed using an appropriate cleaning solvent, such as hexane, acetone, or methanol and a dust/lint free cloth. Use of an ultrasonic cleaner is often helpful. After cleaning, it is necessary remove excess cleaning fluid from the components by blowing with clean air or shaking. Components must be air dry before reassembling. It is possible and often better to use an appropriate detergent, such as Alconox® for cleaning instead of solvent. However, after cleaning with a detergent, it is necessary to rinse the part thoroughly with deionized water (distilled water is also acceptable) in order to remove detergent residue. All water must then be removed by blowing with clean air or shaking. Components must be completely dry before reassembling. 206 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components M11 Procedure - Valve Cap Cleaning and Re-assembly Note If solvent becomes contaminated during performance of the following cleaning steps, it must be replaced with a clean supply from a clean beaker. 1. (For Model 11 Valve) – Clean valve cap (3) while disassembled using a syringe and appropriate solvent. Clean each port and attached tubing on the valve cap by flushing solvent back and forth through each port while cap is immersed in a beaker of solvent. 2. (For the Model 11 LDV Valve) - Clean the valve cap (3) while disassembled and visually verify that ports are clear. Use of an ultrasonic cleaner and an appropriate cleaning solution is recommended. 3. Place the actuator assembly upright on a clean lint free cloth surface with the two valve cap guide pins facing upwards. 4. Using a syringe with Krytox 143 AY lubricating oil, place a drop of oil on sidewall of each valve body (8) plunger hole. 5. Reinstall the six plungers (7) into their valve body positions. Using tweezers, move each plunger up and down to thoroughly lubricate them. Plungers must not protrude above valve body (8) top surface. Refer to Figure 7-3 for plunger orientation. 6. Using clean lint free cloths wetted with acetone, remove excess lubricating oil from top of valve body (8). NOTICE When installing "O" ring (6), Dacron cushion disc (5) and clear Teflon seal disc (4), do not use any type of grease as a lubricant. There must be no foreign contaminants on discs. 7. Install silicon "O" ring (6), Dacron cushion disc (5) and clear Teflon seal disc (4). Do not lubricate "O" ring (6). Note The clear Teflon seal disc (4) must be mounted ON TOP of the Dacron cushion disc (5). Align discs over plungers (7). 8. Securely holding valve cap (3), blow out each port and/or tube with compressed air to remove all acetone and foreign matter. NOTICE Do not use grease when installing O-ring. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 207 Component Descriptions and Maintenance Procedures 4.2 Oven Components 9. It is recommended that appropriate torque wrenches be used for this step (available from Siemens – PN’s 1631005-002 and 1631005-003). Install valve cap (3) using the three 10-32 Allen screws (1). Screws must be tightened evenly in sequence 1, 2, 3, 1 sequence. Tightening steps are as follows. Refer to Figure 4-40. - Run screws down until they contact valve cap. - Tighten screws with Allen driver until they are finger tight. - Tighten screws to approximately 15 inch-pounds (1.69 Nm). This is a ¼ turn maximum. - Tighten screws to approximately 20 inch-pounds (2.26 Nm). This is another ¼ turn maximum. - Tighten screws to approximately 35 inch-pounds (3.95 Nm) - Torque bottom adjusting set screw to 6.5 inch-pounds (0.73 Nm). 10.Valve is now ready for reinstallation and placing into operational service. 4.2.6.8 Maxi-Maintenance Procedures (Valve Body) M11 Procedure - Valve Body Disassembly 1. Remove the six plungers (7) by inverting valve body (8) and then shaking it. Plungers should fall into the palm of the hand. If a plunger(s) is stuck and does not fall out, delay removing it until after the spring loaded and air loaded pistons (14 and 11) are removed. The plungers can then be forced out from bottom of valve body. NOTICE When shaking plungers from valve body, do not allow them to fall on any abrasive surface. It is recommended that a lint free cloth, free of contaminants, be placed under the hand to protect plungers from damage. 2. Examine plungers for damage. Any plunger showing defects, such as nicks, must be discarded and replaced with a new part. 3. Remove air signal manifold (23) by removing the two screws (24&25) that secure it to the valve body (8). After manifold is detached, inspect the three o-rings (22) and replace if necessary. If the o-rings are undamaged, then set them aside (on a clean surface) for installation later. 4. Use the special set of pliers supplied with the repair kit to remove the retaining ring clip (19). Inset the tips of the pliers into the holes in the clip and firmly squeeze. Extract the clip from the base of the valve, holding the pliers firmly to prevent clip from flying off. 5. Remove retaining base (18), compression plate (17), compression spring (16) and compensation plate (15) from bottom of valve body (8). Refer to Figure 7-4. 6. Use the special retaining clip pliers supplied with the repair kit to remove the spring‑loaded piston (14) from valve body (8). Insert the tips of the pliers into the holes in the underside of the piston and pull slowly. 7. Remove air-loaded piston (11) from valve body (8) 8. Using care to catch plungers (7), remove any stuck plunger using one of the tips from the retaining ring pliers. 208 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 9. Examine plungers (7) for damage. Any plunger showing defects, such as nicks, must be discarded and replaced with a new part. 10.Inspect interior of valve body (8), spring loaded piston (14) and air loaded piston (11) and silicon rubber "O" rings (13, 12 and 9) for contamination, odor or mechanical wear. Any part showing evidence of excessive wear or defects must be replaced with a new component. Do not re-install any defective component. M11 Procedure - Valve Body Cleaning 1. To clean the valve body, the following components are recommended: - Ultrasonic cleaner - Cleaning solution as described in the section of this chapter titled, Cleaning of Parts. Where indicated, use only Krytox 240AC grease (Siemens part # G87004) If a strong detergent solution is used, all cleaned parts must be thoroughly rinsed with deionized water or distilled water to remove detergent residue before reassembly of valve body. All parts must be thoroughly dried by shaking, allowing to air dry, or blowing with clean air. Note If cleaning solution becomes contaminated during performance of the following steps, replace it with an uncontaminated supply. NOTICE Do not place polished valve body (8), or associated parts, against any surface in ultrasonic cleaner or against any abrasive surface. Place parts on a lint free cloth, free of foreign contaminants. Do not wash O-rings in any type of cleaning solvent. 2. Fill Ultrasonic cleaner with cleaning solution. 3. Before placing valve body parts in Ultrasonic cleaner, wipe off all grease and foreign contaminants from valve parts. 4. Place valve body parts on a lint free cloth in ultrasonic cleaner. 5. Turn Ultrasonic cleaner ON and allow to run for 10 minutes. 6. Remove parts and shake cleaning solution from tubes. If detergent is used make sure that no residue remains by rinsing thoroughly with deionized water or distilled water. Let parts air dry before reassembling. M11 Procedure - Valve Body Re-assembly 1. Before reassembling valve body parts, clean hands, tools and perform reassembly procedures in a clean dust free area. 2. Apply KRYTOX 240 AC in both "O" ring grooves of spring-loaded piston (14) 3. Install silicon rubber O-rings (12 and 13) and apply KRYTOX 240 AC grease to their outer surfaces. 4. Apply KRYTOX 240 AC grease to each of the fingers of the finger spring (10) of air-loaded piston (11). Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 209 Component Descriptions and Maintenance Procedures 4.2 Oven Components 5. Place air loaded piston (11) over the small diameter of spring-loaded piston (14) with finger springs (10) outside. Align piston with guide pin. Refer to Figure 7-5. 6. Apply a bead of KRYTOX 240 AC grease to the "O" ring air-loaded piston (11) groove. Refer to Figure 7-7. 7. Install silicone "O" ring (9) and apply KRYTOX 240 AC grease to the "O" ring outer surface. 8. Apply a thin film of KRYTOX 240 AC grease to inside of valve body (8) where the pistons (14 and 11) will be sliding. 9. Insert both pistons (14 and 11) into the bottom of cylinder. Use retaining ring pliers to install the pistons with the guide pin in the hole of the valve body (8). Refer to Figure 7-5. NOTICE Exercise care not to damage the O-rings when sliding them past the lower retaining ring groove. 10.Apply KRYTOX 240 AC grease to the compression plate (17) beveled cone. Insert the ball (20) into the greased cone. 11.Insert both the compression plate (17) and ball (20) into retaining base (18). Refer to figure 7-6. 12.Apply KRYTOX 240 AC grease to base socket head set screw (21) then screw it into retaining base (18). Leave about one thread of set screw showing. 13.Place compression spring (16) on compression plate (17). 14.Place compensation plate (15) over the compression spring (16). 15.Before final assembly of components, apply a thin film of KRYTOX 240 AC grease to the outside of compensation plate (15) and inside of retaining base (18). 16.Place the compression spring (16), compression plate (17); socket head set screw (21), retaining base (18) and compensation plate (15) into the valve body (8). 17.Use the retaining ring pliers supplied with the repair kit to reinstall the retaining ring (19). NOTICE Be certain the retaining ring (19) sets into its mounting groove. 18.Prepare to install the manifold (23) by cleaning the flat surface on the side of the valve body (8) and then installing the three small O-rings (22) into the manifold (23). 19.Align and install manifold (23) onto valve body (26) with two 8-32 screws (24 and 25). The shorter screw is installed in the top. Attach the manifold so that inlet holes on the manifold align with inlet holes on the valve body. Refer to Figure 7-4. When installing the manifold be careful not to damage the air tubes. If the tubes are bent too close to the manifold, it is possible to break them. 210 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.2 Oven Components 4.2.7 Live T Switch 4.2.7.1 Live T Switch The Live T Switch is a valve-less switch that can be used in place of a valve for switching columns. The Live T switch is virtually maintenance free since it has no moving parts, no temperature limitations and the sample only comes into contact with metal parts inside the switch. It can be used for heartcut and backflush functions. The Live T Switch is essentially a tube with special built in air vents that are used to control carrier flow through the tube. Carrier gas is connected to the vents. Carrier gas pressure at the vents is adjusted such that carrier sample flow can be either stopped, diverted, or allowed to pass unimpeded through the switch, Example Application The following is an example of an actual application using the live tee. Actual flows and pressures are indicated and chromatograms are provided to illustrate the set up process. Pm (+) Pm (-) PA Injector Pre Column Main Column NV Purge NV Cut Split and Backflush Vent To FID Cut Vent to FID Purge Vent to TCD Figure 4-79 Live Tee Switch Example Application Switching Configuration: Split Vapor Injection Backflush To Vent With Heartcut (Cut Vent Flow To FID) Purge Flow to ITC (TCD) Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 211 Component Descriptions and Maintenance Procedures 4.3 Detectors Switching Configuration: Split Vapor Injection Pre Column: 50 m, 0.32 mm id, 1.2 um, Carbowax FSOT Main Column: 50 m, 0.32 mm id, 5 um, ALOX Na2SO4 FSOT Oven Temperature: 100°C Carrier Gas: Nitrogen Pa EPC 2-1 Carrier Inlet Pm(-) EPC 3-1 T-Piece Inlet (end of A- or Pre Column) Pm(+) EPC 3-2 T-Piece Outlet (Inlet of B- or Main Column) 4.3 Detectors 4.3.1 Detector Introduction Several different types of detector modules are available for the Maxum ll as follows: ● Thermal Conductivity Detector (TCD) - This is a concentration responsive detector for moderate sensitivity of most components. It is available as an 8 cell version with thermistors or as a 2 cell version with filaments. ● Flame Ionization Detector (FID) – The FID is a very sensitive detector for combustible hydrocarbons. ● Flame Photometric Detector (FPD) – This is a selective detector used to detect substances containing sulfur. ● Pulsed Discharge Detector (PDD) – This detector is manufactured by Valco Instruments Inc. It can be equipped to operate in either the Helium Ionization, Photo Ionization, or Electron Capture modes. All of the detector modules within the Maxum II can be used in conjunction with both air bath and airless ovens. Depending upon the application requirements, a Maxum II can include up to three detector modules in a single air bath oven, or up to 2 detector modules, one for each oven, in an airless oven. Three detectors are used in special configurations. With the exception of the thermal conductivity detectors, the detector modules are mounted in the detector compartment. The detector compartment is located between the electronics enclosure (EC) and the oven. The detector compartment houses the detector modules and provides a safe path for the electrical connections between the detector modules and the detector personality module (DPM). It also allows the detector to easily connect to the analytical components in the oven. 212 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors 4.3.2 Thermal Conductivity Detector 4.3.2.1 Thermal Conductivity Detector (TCD) The Thermal Conductivity Detector (TCD) is a concentration responsive detector of moderate sensitivity. The detector cell, containing the sensing element, is an explosion-proof unit located in the chromatograph oven. The TCD is the only Maxum II detector type that is not mounted in the detector compartment. The TCD works on the principle that the thermal conductivity of the carrier gas is different than the thermal conductivity of the sample components. This means that the carrier gas conducts either more or less heat from the heated element than the sample components. The electronic circuits sense the change in heat flow and produce a proportional analog voltage signal. Two types of TCD are used within the Maxum II. ● Thermistor Model – This TCD type utilizes thermistor beads. It includes six independent measurement cells and two reference cells ● Filament Model – For higher temperature requirements a 2-cell TCD is available that utilizes filaments for thermal conductivity sensing. The 2-Cell Filament TCD is often used as an Inter‑Column Detector in conjunction with an FPD or FID application. 4.3.2.2 Replace TCD Thermistor Beads/Filaments Introduction This section provides the procedure to replace the Thermistor Board or Filament Board for the Thermal Conductivity Detector (TCD). Possible configurations for the TCD include the 2-Cell Filament Detector and the 8-Cell Thermistor Detector. The drawings in this section are for the 8-Cell Thermistor Detector. However, replacement of the Filament Board on the Filament Detector follows the same basic procedure. It is possible to replace the Filament/Thermistor Board with the detector installed in the analyzer. TCD parts should be removed or replaced only by a trained Siemens maintenance engineer or by the user’s maintenance personnel trained by Siemens. Note Do NOT attempt to open the TCD with the power on. Note When removing materials from the analyzer, all items must be placed on a clean, non-abrasive surface. Use a clean lint-free cloth. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 213 Component Descriptions and Maintenance Procedures 4.3 Detectors 4.3.2.3 Figures The following figures are used during the maintenance procedure. 14 6 5 13 7 11 12 10 8 9 1. Label, Certification 2. Hammer Drive Screw (2 each) 3. Hex Head Screw and Lock Washer (4 each) 4. Detector Block 5. Detector Connector Block 6. Hex Head Screw (4 each) 7. Lock Washer (4 each) 8. Detector Wiring 9. Button Head Hex Screw 10. Lock Washer 11. Flat Washer 12. Thermistor Board 1 (Filament Board for 2-Cell) 13. O-Ring 14. Flow Diverter (or Low Volume Metal Insert) Figure 4-80 4 3 2 TCD 8-Cell Assembly Thermistor / Filament Lead Groove Screw Hole Metal Insert / Flow Diverter Figure 4-81 214 Tube Holes in Detector Block Proper Alignment of Metal Inserts Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors 4.3.2.4 Procedure to Replace Beads/Filaments Within this procedure, the numbers in parenthesis denote parts referenced in the list contained in Figure 6-9 earlier in this section. Refer back to the figure for locations. 1. Shut off flows and shut down power to the analyzer. Allow the detector to cool down. 2. Remove the 4 screws and lock washers (3) that secure the cover to the detector block (4) and remove the cover. 3. Making note of the connection location for each wire, remove the wiring (8) that is connected to the Thermistor/Filament Board (12) that is to be removed. 4. Remove the Thermistor/Filament Board (12) by removing the Button Head Hex Screw (9), the Lockwasher (10), and the Flat Washer (11). 5. Discard board (12) and O-rings (13). Do not attempt to reuse old O-rings. 6. Remove the two metal inserts (14). These CAN be reused. 7. Before installing new board, examine the mounting surface and the holes for the Filaments/ Thermistors to verify there is no contamination or scratches on the machined surface. If there is contamination on the surface, clean it using a lint free cloth and a cleaning solvent such as acetone or hexane. If the surface is scratched it may be necessary to replace the complete assembly. Note The elements on the board are exposed and are very delicate. Handle the board only by its edges. Hands and tools must be clean. 8. Install the metal inserts (14) in the detector block (4). These inserts should be installed with the groove perpendicular to the tube holes in the block (so that air cannot flow in a straight path between the holes). Refer to Figure 6-10. 9. Install the new O-rings (13) in hole in the Detector Block (4). It is also possible to install the O-rings on the Thermistor / Filament board (12) instead of in the hole. If installing the O-rings on the board, be careful not to damage the element. 10.Install the Board (12) into the Detector Block (4). When installing the board, exercise caution not to damage the exposed elements. 11.Reinstall the Flat Washer (11), Lock Washer (10), and Button Head Hex Screw (9). Do not over tighten the screw as this can damage the Board (12). 12.Reconnect wiring (8) to the board (12). Wiring MUST be connected to the same cells as before. Verify all termination points. Note: The color coding information for the wiring should be on the Detector Certification Label (1). Also note that there are two wires of each color. For a specific cell it does not matter which wire is connected to which lead as long as the color is correct. 13.Before installing cover back on the Detector Block (4), turn on carrier air to verify there are no leaks between the Board (12) and the Block (4). Turn off carrier after this check is complete. 14.Set the cover in place and reinstall the 4 screws and lockwashers (3) that secure the cover to the detector block (4). Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 215 Component Descriptions and Maintenance Procedures 4.3 Detectors 4.3.3 Flame Ionization Detector 4.3.3.1 Flame Ionization Detector (FID) The Flame Ionization Detector (FID) is a very sensitive detector that is used for measuring hydrocarbons. It responds to most carbon containing compounds. Using a methanator, the FID can also be utilized to detect carbon monoxide (CO) and carbon dioxide (CO2). Operation of the FID involves combustion of the sample compounds. This combustion produces ions. The ions are captured by an electrode in the FID, creating an electrical signal current. The FID is very sensitive to all types of hydrocarbons and to any contamination in gases or supply lines. For a high signal/noise ratio, ensure that the gases have a purity of 99.995% and hydrocarbon content below 2 ppm*. For special detection sensitivity, filter all supply gases using a molecular sieve filter. If plant air is used, a catalytic Air Treater is strongly recommended to reduce the possible hydrocarbon content of the air. * 2 ppm refers to the total hydrocarbon concentration expressed as methane. 4.3.3.2 Replacing the FID Mesh Filter Mesh Description This section describes the procedure to replace the mesh filter inside the FID in the Maxum II. The mesh filter is a small round filter located inside the combustion chamber of the FID. This filter is for the combustion air input. Because of the very small diameter of the air restrictor though which combustion air passes, it is unlikely that the filter will become clogged. Because it is difficult to remove this filter without damaging it, in the event that the filter does become clogged or it should become necessary to remove the filter for some reason, then it should be replaced and not reused. It will be necessary to power down the analyzer for this procedure. When performing this procedure, it should NOT be necessary to remove the FID from the Maxum II. Mesh Intended Users This procedure is written to be understood by personnel who are trained to perform maintenance and troubleshooting of the Maxum II analyzer. Users of this procedure must have strong working knowledge of the safety systems of the Maxum II analyzer and have the knowledge to safely power the analyzer down and back up. Users must also have a good working knowledge of the Maxum II hardware and should be very familiar with the operation and day to day maintenance of the analyzer. This procedure involves opening and servicing the Flame Ionization Detector which may impact the safety protection of the analyzer. This procedure should only be executed with the approval of applicable local safety personnel and/or the local authority having jurisdiction. 216 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors Mesh Safety and Certification Information This retrofit may impact the safety protection of the analyzer. This procedure involves servicing of the Flame Ionization Detector (FID). The FID is an explosion-proof device that is equipped with required safety systems. It is important that these safety systems not be compromised. All instructions and warnings in this procedure must be followed. Refer to the Maxum II Explosion Protection Safety Standards Manual for more information regarding the safety systems related to the FID. Maintenance work on the Maxum II analyzer should only be performed when the area is known to be safe for the work to be done. Note This procedure must only be executed with the consent and approval of all applicable local safety personnel and/or the local authority having jurisdiction. Mesh Procedure - Figures The following figures are intended for use as a reference throughout the procedure. The numbers in the diagrams relating to individual components are referenced in parentheses in the procedure steps. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 217 Component Descriptions and Maintenance Procedures 4.3 Detectors 22 21 19 20 3 18 17 15 2 14 Quartz Jet Assembly 16 1 13 11 12 6 10 4 5 9 8 7 Figure 4-82 218 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Flame Arrestor Insert Assembly Flat Washer Detector Body (Bottom) Filter Retainer Clip - Small Retainer Clip - Large Outer Ferrule Graphite Ferrule Pressure Ferrule Burner Nut Quartz Jet (with flame tip nozzle) 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Graphite Seal Hammer Drive Screws (for Label) Label Socket Heat Cap Screw Detector Body (Upper) Teflon Seal Collector Socket Heat Cap Screw (M5 x 60) Flame Arrestor Bushing Flat Washer Flame Arrestor FID Assembly Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors 6 4 3. 4. 5. 6. 5 Detector Body (Bottom) Filter Retainer Clip - Small Retainer Clip - Large 3 Figure 4-83 FID Mesh Filter and Retaining Clips Mesh Procedure - Steps to Replace Mesh Filter 1. Shut off the detector Hydrogen and allow the detector to cool down. Carrier gas should remain on during cool down to prevent condensation. 2. Turn off all supply gasses. WARNING Possible ignition source. Failure to follow proper safety procedures may result in injury or death. If the analyzer is equipped with a purged methanator and explosive gasses are present, it is necessary to wait at least 8 minutes for the methanator to cool after powering down the analyzer before opening the analyzer door. 3. Power off the analyzer. 4. Remove Cap Screws (19) and detach Upper Detector Body (16) from Lower Detector Body (3). CAUTION Possible ignition source. Failure to follow proper safety procedures may result in injury or death. Do not open the FID with the flame burning or with the power on. 5. Unscrew Burner Nut (10) and remove the Quartz Jet and attached hardware (7, 8, 9, 10, and 11). Set these items aside on a clean, lint free cloth. 6. Using a small flat-head screwdriver or similar tool, remove the Small and Large Retainer Clips (5 and 6). 7. Turn on the air supply to the FID in order push the Mesh Filter (4) up so that it can be removed. If turning on the air supply does not dislodge the Mesh Filter (4), use a flat screwdriver to carefully pry up the Filter (be careful not to scratch the surface of the FID body. 8. Turn off the FID combustion air. 9. Discard the old Mesh Filter (4) and install a new one in the FID. 10.Re-install the Small and Large Retainer Clips (5 and 6) Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 219 Component Descriptions and Maintenance Procedures 4.3 Detectors 11.Re-insert the Quartz Jet and attached hardware (7, 8, 9, 10, and 11) into the FID Bottom Body (3). Verify that the nozzle tip of the Quartz Jet (11) is still adjusted correctly (there should be 10.5 mm from the nozzle tip to the Lower Body (3). 12.Tighten the Burner Nut (10) with fingers. Then retighten one quarter to one half rotation using a wrench. The nozzle can break if it is tightened more. 13.Replace the graphite seal (12) before reassembling the FID body. 14.Reattach Upper Body (16) and Lower Body (3) and reinstall Cap Screws (19). Tighten Cap screws firmly but do not over tighten (about 1/2 turn past finger tight). 15.Power the analyzer back on. 16.After the oven and FID has had time to heat up, check the flows and light the flame. 4.3.3.3 Replacing the FID Quartz Jet Quartz Jet - Description This section describes the procedure to replace the Quartz Jet inside the FID in the Maxum II. The Quartz Jet is a thin quartz tube that includes the burner nozzle tip for the FID flame. This item rarely needs replaced. It will be necessary to power down the analyzer for this procedure. When performing this procedure, it should NOT be necessary to remove the FID from the Maxum II. Quartz Jet - Intended Users This procedure is written to be understood by personnel who are trained to perform maintenance and troubleshooting of the Maxum II analyzer. Users of this procedure must have strong working knowledge of the safety systems of the Maxum II analyzer and have the knowledge to safely power the analyzer down and back up. Users must also have a good working knowledge of the Maxum II hardware and should be very familiar with the operation and day to day maintenance of the analyzer. This procedure involves opening and servicing the Flame Ionization Detector which may impact the safety protection of the analyzer. This procedure should only be executed with the approval of applicable local safety personnel and/or the local authority having jurisdiction. Quartz Jet - Safety and Certification Information This retrofit may impact the safety protection of the analyzer. This procedure involves servicing of the Flame Ionization Detector (FID). The FID is an explosion-proof device that is equipped with required safety systems. It is important that these safety systems not be compromised. All instructions and warnings in this procedure must be followed. Refer to the Maxum II Explosion Protection Safety Standards Manual for more information regarding the safety systems related to the FID. 220 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors Maintenance work on the Maxum II analyzer should only be performed when the area is known to be safe for the work to be done. Note This procedure must only be executed with the consent and approval of all applicable local safety personnel and/or the local authority having jurisdiction. Quartz Jet Procedure - Steps to Replace Quartz Jet 1. Shut off the detector Hydrogen and allow the detector to cool down. Carrier gas should remain on during cool down to prevent condensation. 2. Turn off all supply gasses. WARNING Possible ignition source. Failure to follow proper safety procedures may result in injury or death. If the analyzer is equipped with a purged methanator and explosive gasses are present, it is necessary to wait at least 8 minutes for the methanator to cool after powering down the analyzer before opening the analyzer door. 3. Power off the analyzer. 4. Remove Cap Screws (19) and detach Upper Detector Body (16) from Lower Detector Body (3). 5. Unscrew the Burner Nut (10) and remove the Quartz Jet and attached hardware (7, 8, 9, 10, and 11). 6. Detach the Quartz Jet (11) from the Ferrules (7, 8, 9) and the Burner Nut (10). Make note of the way they are assembled. 7. If Quartz Jet (11) is dirty or clogged, it may be possible to clean it using solvent in an ultrasonic cleaner. However, replacement is recommended. If attempting to clean the quartz jet, allow any excess solvent to evaporate before reinstalling. 8. Assemble the replacement (or cleaned) Quartz Jet (11) and associated hardware (7, 8, 9, and 10). 9. Reinsert the Quartz Jet (and other hardware) into the Lower Detector Body (3). Before tightening the Burner Nut (10), adjust the nozzle (flame tip). The distance from nozzle tip to the Lower Body (3) should be 10.5 mm. Tighten the Burner Nut (10) with fingers. Then retighten one quarter to one half rotation using a wrench. The nozzle can break if it is tightened more. 10.Replace graphite seal (12) between the Upper Detector Body (16) and Lower Detector Body (3) before reassembling the FID body. 11.Reattach Upper Body (16) and Lower Body (3) and reinstall Cap Screws (19). Tighten Cap screws firmly but do not over tighten (about 1/2 turn past finger tight). 12.Power the analyzer back on. 13.After the oven and FID has had time to heat up, check the flows and light the flame. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 221 Component Descriptions and Maintenance Procedures 4.3 Detectors 4.3.3.4 Replacing the FID Igniter Description This section describes the procedure to retrofit the FID igniter in the Maxum II. This involves replacing the original FID igniter module with a new version FID igniter module. The procedure also involves replacing of some of the related hardware, such as the purge tube and heater tube. It will be necessary to power down the analyzer for this procedure. Intended Users This procedure is written to be understood by personnel who are trained to perform everyday maintenance of the Maxum II analyzer. Users of this procedure must have strong working knowledge of the safety systems of the Maxum II analyzer and have the knowledge to safely power the analyzer down and back up. Users must also have a good working knowledge of the Maxum II hardware and should be very familiar with the operation and day to day maintenance of the analyzer. However, this procedure involves retrofit of the Flame Ionization Detector which may impact the safety protection of the analyzer. This procedure should only be executed with the approval of applicable local safety personnel and/or the local authority having jurisdiction. Safety and Certification Information This retrofit may impact the safety protection of the analyzer. This procedure involves a retrofit of the Flame Ionization Detector (FID). The FID is an explosion-proof device that is equipped with required safety systems. It is important that these safety systems not be compromised. All instructions and warnings in this procedure must be followed. Refer to the Maxum II Explosion Protection Safety Standards Manual for more information regarding the safety systems related to the FID. Maintenance work on the Maxum II analyzer should only be performed when the area is known to be safe for the work to be done. Note This procedure must only be executed with the consent and approval of all applicable local safety personnel and/or the local authority having jurisdiction. Procedure - Parts 222 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors A parts kit (Siemens part number 2022073-001) is required for this procedure. This kit contains the following items. Callout Description Quantity 1 COVER, DETECTOR, FID, W/O PEMS 1 2 TUBE, FID PURGE 1 3 GASKET, FID PROTECTIVE PIPE 1 4 GROMMET, 1-1/32 ID, 1/16 GR, 1-3/4 OD 1 5 BUSHING, FID PURGE TUBE 1 6 SCREW, M3X 4, SOCKET HEAD CAP, SST 2 7 WASHER, M3, HELICAL SPRING LOCK, SST 1 8 O-RING, SIZE 020, 0.964 X .O70, KALREZ 1 9 IGNITER,FID ASSEMBLY, MAXUM II 1 10 STRAP, GROUND, FID 1 11 SCREW, M3 X 6 SOCKET BUTTON HEAD CAP SST 1 12 TUBE, HEATER, FID 1 13 FTG,FERRULE,BACK,3/8T,SST 1 14 FTG,FERRULE,FRONT,3/8T,SST 1 15 FTG,NUT,3/8T,SST 1 16 GROMMET,3/8 ID,1/16 THK PNL,BUNA-S 1 17 ALUMINUM SEAL WASHER 1 The list above is provided for reference only. The official parts list for the kit is included with the kit when it is shipped. The Callouts above will be used throughout this procedure to help the user identify the proper part to use for a specific step. Also required is a tool kit including both standard and metric wrenches, Allen wrenches, and nut drivers. A lubricant such as Krytox 240 AC or equivalent will be needed in order to lubricate the new grommets. If the EC Cover Plate Gasket (Part Number 2021171-001) is damaged, a replacement gasket will be required as well. Procedure - Removal of Detector Note All figures are located at the end of this procedure. 1. From GCP, backup the database of the Maxum analyzer that is to be modified (refer to the Maxum Maintenance Manual for instructions). 2. From GCP, verify operation of analyzer. Verify that there are no alarms or that all alarms are accounted for. (Refer to the Maxum Maintenance Manual for instructions). 3. Verify that all parts of the new FID igniter kit are on site prior to starting. Contents of the kit are listed in the inventory list that is shipped with the kit. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 223 Component Descriptions and Maintenance Procedures 4.3 Detectors 4. Extinguish the flame to the FID either by shutting off the air supply to the detector (for hydrogen carrier) or shutting off the hydrogen to the detector (if not using hydrogen carrier). In order to prevent condensation in the detector, allow carrier to flow for several minutes after flame is extinguished. Use a mirror to check for condensation at the FID vent to verify the flame is not lit (no condensation means the flame is not lit). WARNING Possible ignition source. Failure to follow proper safety procedures may result in injury or death. If the analyzer is equipped with a purged methanator and explosive gasses are present, it is necessary to wait at least 8 minutes for the methanator to cool after powering down the analyzer before opening the analyzer door. 5. Power down the analyzer. 6. Open the electronics enclosure door, mezzanine door, and oven door. Use a 4mm Allen wrench if necessary and be careful not to place tension on the ribbon cable connecting to the Maintenance Panel. 7. Disconnect the FID heater power cable from the PECM. Note the plug-in location. 8. Disconnect the FID heater RTD cable from the DPM connector board. Note the plug-in location. 9. Disconnect the FID bias, igniter, and signal cables from the DPM making note of the plugin locations. 10.Disconnect tubing from the FID flame arrestor insert tube in the oven. Refer to Figure 3-2. 11.Remove the flame arrestor insert from the FID bottom body using a 9/16" open-end wrench. Refer to Figure 3-2. 12.Remove the ¼ " vent tube from the top of the FID block using a 9/16" open-ended wrench. Refer to Figure 3-3. 13.Using a 3.0mm Allen wrench, remove the FID cover set screw from the front of the FID Assembly. Refer to Figure 3-1. 14.Remove the cover from the FID block by pulling up and out, and then remove the insulation from the FID block. 15.Disconnect utility gas lines from the FID at the connecting union using a 5/16" open-end wrench. Temporarily label the gas line leads to make sure they can be reconnected correctly. Refer to Figure 3-6. 16.Remove the four M4 nuts from the FID EC cover plate using a 7mm nut driver. Refer to Figure 3-1. 17.Using a 2.5mm Allen wrench, remove the four M4 screws that secure the FID mounting plate to the mezzanine. Refer to Figure 3-1. 18.Remove the FID assembly from the mezzanine by pulling up and then out when the FID bottom body clears the hole. 224 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors Procedure - Igniter Replacement Note A clean work surface should be used for disassembly of the old igniter and installation of the new igniter. This is to prevent contamination of the detector gas inputs and electrical contacts. 1. Remove the four screws that secure the purge tube to the electrodes of the detector. Refer to Figure 3-6. 2. Pull the purge tube about 1 inch away from the detector assembly and carefully remove the wires from the electrodes. 3. The purge tube, EC cover plate, and igniter assembly will not be reused. Set these items aside. However, the screws that were used to connect the tube to the detector will be reused. 4. Using an 11/16" wrench, remove the old RTD tube from the detector heater assembly. This is the bent 3/8" tube that connects from the heater assembly near the base of the detector to the smaller hole on the EC cover plate. Refer to Figure 3-6. Note that this tube will be replaced with a different one to allow for installation of the larger purge tube. 5. Attach the new nut and ferrule (items 13, 14, and 15) to the new RTD heater tube (item 12). Refer to Figure 3-7. 6. Install the new 3/8" RTD tube (12) onto the detector heater assembly. To allow for easier installation of the cover plate, do not completely tighten the nut at this time. Refer to Figure 3-7. 7. Install the Kalrez high-temperature O-ring (item 8) into the groove on the new purge tube bushing. Refer to Figure 3-10. 8. Install the new purge tube bushing (item 5) onto the FID using the 4 screws removed from the purge tube earlier in this procedure. The new pipe gasket (item 3) should be positioned between the bushing and the FID body. Install the bushing such that the tab (used to attach the igniter fastening strap) is on the bottom. Refer to Figures 3-9 and 3-10. 9. Using a 2.5mm Allen wrench, attach the fastening strap (item 10) to the new igniter board (item 9). Use a socket head cap screw (item 6) from the kit for this connection. Refer to Figure 3-9. Note Because the wires from the igniter to the electrodes are stiff, it is best to plug the wires in before attaching the strap to the bushing. 10.Plug both igniter wires into the appropriate detector electrode positions. Refer to Figure 3-11. The wires from the igniter board to the DPM should not be connected yet. 11.Using a 2.5mm Allen wrench, attach the new igniter board to the bushing on the detector assembly using the fastening strap. Use a socket head cap screw (item 6) and lock washer (item 7) from the kit for this connection. Note that the igniter board is installed with the flat side up and the round transformer down. Refer to Figure 3-9. 12.Plug the white signal wire (from the DPM) into the appropriate detector electrode position. Refer to Figure 3-11. The wire should not be connected at the DPM end yet. 13.Place the white signal wire (from the DPM) across the top of the new igniter board as shown in Figure 3-8. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 225 Component Descriptions and Maintenance Procedures 4.3 Detectors 14.Insert the unplugged ends of the wires into the new FID purge tube (item 2) and slide the purge tube over the igniter board and wiring. Make sure that the white signal wire remains positioned against the flat top side of the igniter board. Note that it does not matter which end of the tube is inserted towards the detector since both ends of the tube are identical. 15.Line up the hole on the new purge tube with the hole on the bushing and fasten the tube to the bushing using a 2.0mm Allen wrench. Use the button head cap screw (item 11) from the kit for this connection. Refer to Figure 3‑12. 16.If the new grommets (items 4 and 16) are not installed into the holes on the new EC cover plate (item 1), then install them now. Refer to Figure 3-7. 17.Apply a coating of Krytox 240 AC or similar lubricant around the inside diameter of the grommets to allow for easy sliding of the new purge tube. 18.Feed the detector wiring through the appropriate holes on the new EC cover plate and install the cover plate onto the detector assembly. Refer to Figure 3-4. 19.Tighten the nut on the new RTD heater tube at this time. Refer to Figure 3‑7. Procedure - Reinstallation of Detector 1. Inspect the FID EC cover plate gasket (part # 2021171-001) and replace if worn or damaged. 2. Route the FID Module Assembly wiring into the EC and install the module into the analyzer. Make sure that the FID bottom body fits into the hole at the bottom of the mezzanine section. 3. Install the 4 M4 screws into the FID mounting plate and tighten using a 2.5mm Allen wrench. 4. Make sure that the EC cover plate gasket is in the correct position and install the 4 M4 nuts. Tighten the nuts using a 7mm nut driver. Verify that the nuts are not over-tightened by making sure that the gasket is not pushed out more than about 1/16" along the edges of the EC cover plate. 5. Connect the utility gas lines to the correct connecting unions and tighten using a 5/16" openend wrench. Remove the temporary labeling that was added earlier in this procedure. 6. Place the insulation and then the FID cover onto the FID block. 7. Install the FID cover set screw and tighten using a 3mm Allen wrench. Note The next step is important in order to maintain the explosion proof protection of the FID. The threads of the FID flame arrestor must be clean and lubricant or other substances must NOT be applied to the threads. 8. Place the FID flame arrestor insert and washer into the FID bottom body and tighten using a 9/16" open-end wrench. Make sure the flat washer (item 17) fits into the recessed cavity at the lower end of the FID bottom body to insure it does not leak. Refer to Figures 3-4 and 3-5. 9. Connect the FID flame arrestor insert tubing to the correct connection union in the air bath oven using either a 1/4" or 5/16" open-end wrench depending on the fitting size. 10.Route the bias cable, the igniter cable, and the signal cable through the EC and connect them to the FID DPM board locations from which they were unplugged earlier in this procedure. 226 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors 11.Route the FID heater RTD cable through the EC and plug it into the DPM location from which it was unplugged earlier in this procedure. 12.Route the FID heater power cable through the EC and plug it into the PECM location from which it was unplugged earlier in this procedure. 13.Turn on utility gases and check for leaks. 14.Turn on power to the analyzer and switch the valves checking all possible flow paths for leaks. Refer to plumbing diagram provided in the custom documentation package for flow paths. 15.Turn up oven air to the normal setting and allow the oven to come to temperature and stabilize. 16.Set all gas flows after the detector is up to its temperature set point. 17.With the new igniter, it will be necessary to start Real Time Chromatograms on the HMI in order to light the FID flame. On the HMI, choose the Maintenance Menu, and then select option 5 (Detectors & Real Time Chroms). Then highlight the appropriate FID and then press "View Chrom". 18.At this time you can ignite the FID using the HMI. 19.After 15 to 30 minutes the analyzer will be ready for operation. Verify that the FID operates correctly and put analyzer back on line. Procedure - Figures FID EC Cover Plate FID Cover Set Screw FID Mounting Plate Figure 4-84 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 FID Assembly w/ Original Igniter (without Vent Tube) 227 Component Descriptions and Maintenance Procedures 4.3 Detectors Old Igniter FID Bottom Body Flame Arrestor Insert Figure 4-85 Tubing Connection FID Assembly Bottom View (w/ Original Igniter) Vent Tube Figure 4-86 228 Location of Vent Tube on FID Assembly Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors New Igniter FID Bottom Body Flame Arrestor Insert Figure 4-87 Tubing Connection FID Assembly Bottom View (w/ New Igniter) Insert Washer Narrow End of FID Bottom Body FID Flame Arrestor Insert Figure 4-88 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 FID Flame Arrestor Insert Detail 229 Component Descriptions and Maintenance Procedures 4.3 Detectors Purge Tube Utility Gas Lines RTD Heater Tube Figure 4-89 230 FID Parts (with Old Igniter) Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors Grommets EC Cover Plate Utility Gas Lines RTD Heater Tube Figure 4-90 FID Parts (with New Igniter) Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 231 Component Descriptions and Maintenance Procedures 4.3 Detectors Figure 4-91 New Igniter Connections to Detector Mounting strap/ground strap Note Mounting Screw Positions Note Board and transformer are upside down New Detector Bushing (The ceramic feed through does not change) Figure 4-92 232 New Igniter Attachment to Detector Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors Groove for Kalrez O-Ring Figure 4-93 New Bushing (with Tab for Connecting Strap) White Signal Wire (from DPM) Note: The black wire appears blue due to a Teflon coating over the wire. Black Wire (from igniter) Red Wire (from igniter) Figure 4-94 Electrode Connections for New Igniter Figure 4-95 Tube Orientation with Screw Holes Aligning Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 233 Component Descriptions and Maintenance Procedures 4.3 Detectors 4.3.4 Flame Photometric Detector 4.3.4.1 Flame Photometric Detector (FPD) The FPD is a selective detector that can detect sulfur based on the emission of light during combustion. Two versions of the FPD have been available for the Maxum II. In 2007, enhancements were made to the original FPD that improved the performance. The enhanced FPD is called FPD II. Other than their performance, the original FPD and FPD II are very similar. The FPD detects sulfur by combusting the sample components in a hydrogen rich flame. This generates light of specific wavelengths. A filter passes light wavelengths which are characteristic for sulfur. This is converted into an electrical signal using a photomultiplier device. The FPD is equipped with an external heater that maintains the internal temperature at or above 80°C (176°F) in order to prevent condensation. The FPD is a very sensitive detector. Because of this the combustion fuel and combustion air gases must be extremely clean and sulfur free to prevent excess noise. Specifications Detection limit for sulfur (Original FPD) Detection limit for sulfur (FPD II) Characteristic for sulfur Operating temperature range Ignition type Electrical Data 2 × 10-11 g/s 7 × 10-13 g/s Quadratic: [S]2 80°C to 150°C Glow Plug 2V at 3A (Maximum, only for flame ignition) Conditions for Safe Use per ATEX Certificate ● The FPD shall be protected against mechanical damage by mounting inside another enclosure. ● The relative maximal pressure existing inside the flameproof enclosure shall not exceed 0.065 bar. ● The grounding of the FPD shall be ensured by mounting to a metallic frame. ● The external part of the bushing shall be protected by pressurized enclosure “p”; not included in the ATEX certificate. 234 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors Original FPD Label FPD II Label Figure 4-96 FPD Certification Lables Components The FPD comprises: ● Bottom part contains connections for combustion gas, combustion air, column and exhaust, and a burner nozzle. ● Top part contains combustion chamber, glow plug and fiber optic interface. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 235 Component Descriptions and Maintenance Procedures 4.3 Detectors Figure 4-97 Flame Photometric Detector Major Components Combustion Chamber ● The burner nozzle consists of two annular gaps. The combustion gas H2 flows out of the outer annular gap and mixes with the combustion air from the inner gap. The carrier gas flows from the nozzle into the dome-shaped flame. ● The exhaust is taken from the combustion chamber output via a flameproof joint. ● The glow plug is located above and to the side of the burner. Optics ● The flame burns in a recessed area shielded from the fiber optic interface. ● The fiber optic cable connects to the photo multiplier tube (PMT) module in the EC. ● The optical interference filter is built into the PMT module ● All connections between the combustion chamber and the photomultiplier are absolutely light-tight. ● The ignition cable of the FPD is routed through an EEx-e feed through to the EC. Heater he FPD is supplied with an external heater. Condensation would be formed in the FPD at temperatures below 80°C and have a negative influence on the measuring properties. The detector is insulated to prevent moisture from entering it. The detector temperature is factory set depending upon the application. The temperature is normally set equal to or higher than the oven temperature and at minimum 80°C. 236 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors Detector Gas Supply The FPD requires the following gases: Type of Gas Gas Quantity Combustion Gas Hydrogen (Original FPD) Combustion Gas Hydrogen (FPD II) 75-85 ml/min. 60- 130 ml/min. Combustion Air (Original FPD) Combustion Air (FPD II) 110-130 ml/min. 50-135 ml/min. Note The FPD is a very sensitive detector. The gases and their supply lines must be extremely clean and sulfur free to achieve a high signal/noise ratio. Selection of Carrier Gas Nitrogen, helium, argon or hydrogen can be used as the carrier gas. If hydrogen carrier is used, the required flow of hydrogen flame fuel will be reduced. For the FPD II, the total hydrogen flow (combined flame fuel and carrier) will be ~100-130 mL/min. Increasing the Sensitivity The sensitivity of the FPD can be increased by reducing the flow of combustion air. Most of the time, the FPD cannot be ignited with a normal air/hydrogen ratio. If an electronic pressure controller (EPC) is used for the combustion gasses an event will be written at the factory, which will automatically adjust the flows during the ignition sequence. To obtain the recommended flow settings for an analyzer, refer to the custom documentation supplied with that analyzer. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 237 Component Descriptions and Maintenance Procedures 4.3 Detectors Figure 4-98 4.3.4.2 FPD Exploded View Upgrade Description This section describes the procedure to replace the original Flame Photometric Detector (FPD) in the Maxum II with a newer version FPD. This involves replacing the FPD assembly, called FPD I, with the new FPD assembly, called FPD II. The existing light pipe and photomultiplier tube from the FPD I will be reused. It will be necessary to power down the analyzer for this procedure. The Flame Photometric Detector (FPD) is a selective detector that can detect sulfur based on the emission of light during combustion. In 2007 a new version of the FPD was released for the Maxum II. The original version is now known as FPD I. The new version is called FPD II. The FPD II is a more sensitive and more consistent detector than the FPD I. 238 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors 4.3.4.3 Intended Users This procedure is intended for either Siemens personnel or for highly skilled users who have been trained by Siemens to perform this type of procedure. Users of this procedure must have strong working knowledge of the safety systems of the Maxum II analyzer and have the knowledge to safely power the analyzer down and back up. Users must also have a good working knowledge of the Maxum II hardware and should be very familiar with the operation and day to day maintenance of the analyzer. This procedure involves replacement of the Flame Photometric Detector which may impact the safety protection of the analyzer. This procedure should only be executed with the approval of applicable local safety personnel and/or the local authority having jurisdiction. 4.3.4.4 Safety and Certification Information This retrofit may impact the safety protection of the analyzer. This procedure involves a retrofit of the Flame Photometric Detector (FPD). The FPD is an explosion-proof device that is equipped with required safety systems. It is important that these safety systems not be compromised. All instructions and warnings in this procedure must be followed. Refer to the Maxum II Explosion Protection Safety Standards Manual for more information regarding the safety systems related to the FPD. Maintenance work on the Maxum II analyzer should only be performed when the area is known to be safe for the work to be done. Note This procedure must only be executed with the consent and approval of all applicable local safety personnel and/or the local authority having jurisdiction. 4.3.4.5 Procedure - Upgrade FPDI to FPDII Note The existing light pipe and PMT module are kept and used for the FPD II. Note Because this procedure is intended for expert users, many of the steps have limited detail. 1. Put the analyzer in Hold. 2. Turn off the flame to the FPD by stopping the flow of hydrogen to the detector. Wait at least 15 minutes for the water vapor to clear the detector. 3. Turn off the power to the analyzer. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 239 Component Descriptions and Maintenance Procedures 4.3 Detectors 4. If the analyzer has mechanical regulators, shut off the hydrogen and air supplies to the detector. CAUTION Potential burn hazard. Handling hot components may result in personal injury. Detector may still be hot during removal. Exercise care when handling detector parts. 5. Remove the cover and insulation from the old detector. Use caution at this point as the detector may still be hot. 6. Disconnect the hydrogen and air lines to the detector and the detector vent line from the back of the detector. 7. Disconnect the column from the detector in the Maxum II oven. NOTICE Sensitive components. Failure to observe proper procedures may damage the equipment. The photomultiplier in the FPD is sensitive to light. Avoid prolonged exposure of the multiplier to excessive light, even when powered down. Never subject the light entry window to a bright light source. 8. Disconnect the light pipe from the side of the analyzer. Remove and discard the brown Viton O-rings on the light pipe. The new FPD does not require O-rings in this location. 9. Remove the screws from the detector mounting plate and the cover plate on the back of the mezzanine. 10.Remove the detector from the Maxum II along with its mounting bracket, heater and cover plate. The heater wiring, glow plug supply wiring and the associated purge tubes need to taken out as well. Note the wiring connections as you remove them from the DPM. 11.Before installing the new detector, the cover and insulation need to be removed. Replacing the insulation and cover will be the last step in the installation. 12.Install the FPD II. As you install the detector feed the wiring through the mezzanine and up to the DPM. Connect the screws on the mounting plate. 13.Attach the mezzanine cover plate. 14.Connect the heater, thermocouple, and glow plug wiring to the DPM. 15.Connect the column inlet, hydrogen and air supplies, detector vent and the light pipe. 16.Replace the insulation and cover on the detector. Restore power to the Maxum II. 17.After the Maxum II has had time to heat up, check the flows and light the flame. 240 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors 4.3.5 Pulse Discharge Detector 4.3.5.1 Valco Pulsed Discharge Detector (PDD) The detector can be used in three different versions: HID (helium ionization detector), ECD (electron capture detector) and PID (photo ionization detector). Installation in the Maxum GC is possible without further modification, and the detector can only be used in non-hazardous areas. The PDD uses stable, pulsed DC discharges in helium as the ionization source. The detector's performance data is equal to or better than that of detectors which use radioactive ionization sources. Since a radioactive source is not used, the complex directives for radiation protection need not be observed by the customer. 4.3.6 Methanator 4.3.6.1 Methanator The methanator is used with a Flame Ionization Detector (FID) when it is necessary to detect carbon monoxide (CO) or carbon dioxide (CO2). In the methanator CO and CO2 are chemically changed to methane using excess hydrogen and a catalytic reaction. The concentration of methane, which can be detected using an FID, is proportional to the concentration of CO and CO2. In this manner, it is possible to detect CO and CO2 using an FID. The methanator operates at a very high temperature of approximately 400°C (752°F). Two versions of the methanator exist. The original version is designed such that it is an extension of the purged Electronics Enclosure (EC). It is connected to the CD via a pipe through which purge air flows. This prevents explosive gases or vapor from entering the methanator and contacting the hot surfaces. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 241 Component Descriptions and Maintenance Procedures 4.3 Detectors Figure 4-99 Purged Methanator The newer version of the methanator is an explosion proof version. This version is sealed within an explosion proof enclosure. The interior of the explosion proof methanator is designed somewhat differently than the original, but the theory of operation is identical. Figure 4-100 Explosion-Proof Methanator 242 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Component Descriptions and Maintenance Procedures 4.3 Detectors Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 243 Component Descriptions and Maintenance Procedures 4.3 Detectors 244 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 5 Specifications 5.1 Maxum II Specifications MAXUM edition II classic oven Table 5-1 General Smallest measuring ranges ● Thermal conductivity: 0 - 500ppm (depending on application) ● Flame ionization: 0 - 1ppm Temperature range in oven Application-specific, depending on temperature class 5 - 350°C depending on oven version and temperature class Temperature control ±0.02°C EMI/RFI design ● CE-compatible; certified according to 2004/108/EC(EMC directive) ● CE-compatible; certifiedaccording to 2006/95/EC(low-voltage directive) ● Tested according toEN 61010-1 / IEC 1010-1 Calibration Comparison measurement with external standard ● Type Manual or automatic ● Zero value Automatic baseline correction ● Span Standard sample cylinder (single or multipoint calibration possible) Table 5-2 Design, enclosure Mounting • Spacing on left: 460mm from walls and other devices • Spacing on right: 460mm in all cases • Spacing at front: 654mm in all cases • Wall-mounted units • Center-to-center: 1,120mm in all cases Weight 77kg Degree of protection IP54, Category 2 Danger class Standard configurations: ● Certified according to ATEX with air or nitrogen purging for Zones 1 and 2 (EEx pyedmib IIB + H2) ● Suitable for use in non-hazardous areas and with non-dangerous conditions ● Certified according to CSA C/US for use in Class 1, Div. 1, Groups B, C, D with air or nitrogen purging ● Certified according to CSA C/US for use in Class 1, Div. 2, Groups B, C, D Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 245 Specifications 5.1 Maxum II Specifications Note Important Use in non-hazardous areas requires purging of the electronics area with air or nitrogen. PDD is not certified for hazardous areas. Table 5-3 Configuration Oven options ● Single isothermal oven or divided oven with two independent isothermal zones ● Single oven or two independent airless ovens. The dual version has two separate oven areas with separate doors which operate completely independently. Detector modules Number of detector modules Thermal conductivity, flame ionization, flame photometry, helium ionization, photo-ionization and electron capture ● 1, 2 or 3 in any combination of detector module types for airbath ovens ● 1, or 2 in any combination of detector module types for airless ovens,up to 3 in special configurations Sample and column valves Diaphragm valves, diaphragm piston valves, sliding vane rotary valves, slider valves, or liquid injection valve Valveless option Live switching Columns Packed, micropacked or capillary columns Gas supply regulation Up to 8 electronic pressure regulator channels and up to 6 mechanical pressure regulators Table 5-4 Electrical characteristics Power supply ● Single-phase AC, 100 - 130V or 195 - 260V (selectable), 47 - 63Hz ● Single oven: max. 14A ● Dual oven: 2 circuits, max. 14A each Table 5-5 Gas inlet conditions Sample flow 5 - 100ml/min (depending on application) Sample filter size 0.1 - 5μm with gaseous samples depending on type of valve Max. 0.3μm with liquid samples Minimum sample pressure 35kPa, standard Maximum sample pressure 200kPa standard, higher pressure as option Maximum sample tempera‐ ture 121°C standard; higher temperature as option Materials wetted by sample Stainless steel and Teflon; other materials as option Table 5-6 Liquid injection (valve) Vaporization temperature 60 - 350°C depending on application and temperature class Injection volume 0.1 - 9.5μl 246 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Specifications 5.1 Maxum II Specifications Sample temperature -20 - 150°C Material of parts wetted by sample Stainless steel, mat. no. 1.4571, Hastelloy, Monel or special materials Control pressure 400 - 600kPa Sample pressure Max. 6,000kPa, recommended 50 ... 100 kPa Connections for pipe 3.14 mm (1/8") outer diameter Table 5-7 Measuring response Sensitivity (depending on ap‐ ±0.5% of span plication) Linearity (depending on appli‐ ±2% of span cation) Effects of vibrations Negligible Repeatability in % of full span between 2 and 100%: ±0.5% 0.05 and 2%: ±1%; 50 and 500ppm: ±2%; 5 and 50ppm: ±3%; 0.5 and 5ppm: ±5% Detection limits Table 5-8 Influencing variables Effects of ambient tempera‐ ture Table 5-9 See detectors None with electronic pressure control Different effects with mechanical pressure control (depending on application) Electrical inputs and outputs Standard input and output ● 2 analog outputs; ● 4 digital outputs (1 for output of system faults, 3 are user-configurable); ● 4 digital inputs; ● 3 serial outputs Card slots for optional inputs andoutputs via internal I2C bus 2 Input and output cards ● AIO: 8 analog outputs, 8 analog inputs, 2 digital inputs ● DIO: 6 digital inputs and 8 digital outputs ● ADIO: 4 digital inputs and 4 digital outputs, 4 analog inputs and 4 analog outputs Digital inputs ● Optocoupler with internal power supply (12 - 24V DC); switchable by dry contacts. ● Alternative: switchable by external power supply 12 - 24V DC (only dry relay contacts), external power supply, negative connection linked to ground, for a specific digital input. Digital outputs Dry changeover contacts, max. contact rating:1A with 30V DC. Diode bypass suppression should be used for inductive loads. Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 247 Specifications 5.1 Maxum II Specifications Analog inputs ±20mA into 50Ω or ±10V RIN = 0.1MΩ, insulation up to 100V Analog outputsAnalog out‐ puts 0/4 ... 20mA into max. 750Ω, common negative pole, electrically isolated from ground; freely connectable to ground Termination Screw terminal for stranded or solid cable with a maximum size of 18AWG or 0.82mm2 Table 5-10 Climatic conditions Ambient temperature Table 5-11 -18 ... 50°C application-dependent Gas Supply Instrument air ● At least 350kPa for units with valves Model 11 or Valco ● At least 825kPa for units with valves Model 50 ● At least 175kPa for airbath ovens; 85l/min per oven ● No instrument air for fan-free ovens Combustion gas ● Nitrogen or helium in compressed gas cylinder, purity 99.998%, or hydrogen with a purity of 99.999%(depending on application). ● Typical consumption quantity: 5 - 100l/month per detector module Combustion gas ● Hydrogen with a purity of 99.999% ● Typical consumption quantity: 2,000l/month per detector module Combustion air ● Reference air (<1ppm THC, O2 concentration 20 - 21%). Supply through instrument air with catalytic purification (optional). ● Typical consumption quantity: 26,000l/month Corrosion protection ● Purging with dry air to protect the electronics ● Air bath oven with stainless steel lining ● Airless oven made of aluminum ● Steel lining painted on outside (epoxy powder coating) Table 5-12 Communication Serial output RS 232, RS 485, such as Modbus Ethernet Standard 10/100 BaseT Ethernet with 4 RJ45 connectors such as Modbus TCP IP or OPC Optional ESBF board Fiber-optic 100BaseFX multimode with ST connection 3x RJ45 and 1x optical or Scalance network components such as used for redundant con‐ nections. 248 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 Index A S ABH1, 138 ABH2, 138 Applet, 13 Applet Module, 13 Application, 13 Sensor Near Electronics, 17 Sensor Near Electronics software module, 17 SNE, 17 SNE functions, 19 Solid State Relay Module, 138 C T Columns, 20 TEMP CONTROL, 96 Thermistor, 21 D DHCP, 26 E EC, 20 Ethernet IP, 26 F Filament, 21 Flame Ionization, 21 Flame Photometric, 21 Fuses, 139 H Heater Termination Plug, 96 I IP address, 26 M Method, 13 P Pulsed Discharge, 21 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001 249 Index 250 Maxum II Maintenance Manual Manual, 10/2015, 2000596-001