Siemens Maxum II Maintenance Manual

Maxum edition II Process Gas Chromatograph Copyright Notice © 2012 by Siemens All rights reserved. This publication is for information only. The contents are subject to change without notice and should not be construed as a commitment, representation, warranty, or guarantee of any method, product, or device by Siemens. Reproduction or translation of any part of this publication beyond that permitted by Sections 107 and 109 of the United States Copyright Act without the written consent of the copyright owner is unlawful. To Contact Us: Siemens AG I IA SC PA PM Process Analytics Oestliche Rheinbrueckenstrasse 50 76187 Karlsruhe Germany Tel: Fax: E-mail: +49 721 595 4802 +49 721 595 5211 processanalytics@siemens.com Siemens Industry Inc. 7101 Hollister Road Houston, TX 77040 USA Tel: Fax: E-mail: +1 713 939 7400 +1 713 939 9050 saasales.industry@siemens.com www.siemens.com/processanalytics www.usa.siemens.com/pa Training Tel: +49 721 595 4035 E-mail: pia-training.i-ia@siemens.com Training Tel: +1 800 448 8224 (USA) Tel. +1 918 662 7030 (International) E-mail: saatraining.industry@siemens.com Spares Contact your local Siemens Sales Representative Support Tel: +49 721 595 7216 E-mail: helpdesk.chromatography.iia@siemens.com Siemens Pte. Limited IA SC Process Analytics 9 Woodlands Terrace Singapore 738434 Tel: Fax: E-mail: +65 6309 1700 +65 6309 1710 splanalytics.sg@siemens.com www.siemens.com.sg Spares Tel: +1 800 448 8224 (USA) Tel: +1 918 662 7030 (International) E-mail: PASpareparts.industry@siemens.com Support Tel: +1 800 448 8224 (USA) Tel: +1 918 662 7030 (International) E-mail: GCsupport.industry@siemens.com Trademarks Maxum and Maxum edition II are trademarks of Siemens ii • 2000596-001 Chapter 1 Knowing Your System Introduction Overview The Maxum edition II system, hereafter referred to as Maxum II, represents a significant advance in process chromatography. This was accomplished by combining 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. A single air bath oven can accommodate up to 3 detector modules, and an airless oven can house a single detector module in each oven. The Maxum II Maintenance Panel provides maintenance personnel with access to all maintenance functions and data. In addition, the Maintenance Panel will display both real time and archived chromatograms. A PC based network workstation incorporates Gas Chromatograph Portal software. In this chapter This chapter covers the following topics: Topic 2000596-001 Page Introduction 1-1 Maxum II Specifications 1-3 About the Maxum II 1-10 Maxum II Operation Overview 1-19 Functional Tasks 1-23 Analyzer Internal Communications 1-26 Maxum II Hardware Identification 1-29 Advance Communication System 1-31 Advance Data Hiway Communications 1-32 Knowing Your System • 1-1 Introduction, Continued Important Information 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 will 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 Applicable Wiring Diagrams Oven Plumbing Diagram - Sensor Near Electronics Recommended Spare Parts - Analyzer Manufacturing Test Charts Stream Composition Data Data Base 1-2 • Knowing Your System 2000596-001 Maxum II Specifications Configuration Oven Single isothermal air bath oven or split airbath oven with 2 independent isothermal zones or split airbath oven with one side isothermal and one side programmed temperature. Single or dual independent airless ovens. Dual version has two distinct oven compartments for complete operating independence. Any isothermal dual-configuration is rated for up to a maximum temperature differential of 100°C. Detector Modules Thermal Conductivity, Flame Ionization, Flame Photometric, or Pulse Discharge Detector (in Helium Ionization, Photoionization, or Electron Capture Mode) Number of Detector Modules 1, 2, or 3 in any combination of detector module types for air bath oven (except restricted to a single pulse discharge detector). 1 or 2 in any combination of detector module types for airless oven (except restricted to a single pulse discharge detector). Detector combinations can total up to 18 channels. Sample/Column Valves Pneumatic-driven diaphragm, diaphragm-plunger, heated liquid injection, rotating, or linear transport Valveless Option ‘Live’ Switching Columns Packed, micro-packed, or capillary Gas Supply Regulation Up to 8 electronic pressure controls and up to 8 mechanical pressure controls Performance Minimum Range (general)* Thermal Conductivity: 0-500 ppm Flame Ionization: 0-1 ppm FPD: 0-1 ppm (application dependent: some lower ranges may be available) Repeatability (general)* ± 0.5% of full scale for full scale ranges from 2-100%; ± 1% of full scale for full scale ranges from 0.05-2%; ± 2% of full scale for full scale ranges from 50-500 ppm; ± 3% of full scale for full scale ranges from 5-50 ppm; ± 5% of full scale for full scale ranges from 0.5-5 ppm; (All values expressed at 2 times standard deviation and are application dependent.) Sensitivity* Varies by component and with application. Specific Minimum Detectable Level of measured components can be estimated for some applications. Consult factory. Linearity* ± 2% of full scale *Confirm with application 2000596-001 Knowing Your System • 1-3 Maxum II Specifications, Continued Performance (continued) Oven Temperature Range (Dependent on T – Rating) 40 to 440°F (5 to 225°C) for airbath oven (dependent on T-rating) 40 to 625°F (5 to 330 ºC) for programmed temperature column compartment 122 to 535°F (50 to 260°C) for airless oven (dependent on T-rating) Temperature Control ± 0.05°F (± 0.02°C) Cycle Time 30 seconds to 3 hours (application dependent) Ambient Temperature Effect None with electronic pressure control Varying effect with mechanical pressure control Vibration Effect Negligible Communication Options Serial Output RS232, RS485 Port 1 – RS223/RS485 (Modbus) Port 2 – RS232/RS485 (Serial Printer) Port 3 – RS223/RS485 (Modbus) Port 4 – RS223/RS485 (Modbus) Ethernet Standard Four 10/100BaseT Ethernet connections with RJ45 connectors autosense and auto-negotiate Optional (with ESBF board): Three RJ45 plus one Fiber Optic 100Base FX multimode with ST® connector Redundant Ethernet Siemens Scalance high speed TCP/IP communication network optional Data Hiway Proprietary serial communication network (redundant pair cable) Input/Output Options Standard I/O 2 analog outputs; 4 digital outputs (1 indicates system error, 3 are user configurable); 4 digital inputs Board Slots for Optional I/O Up to 2 2 I C I/O Boards I2C AIO:8 analog inputs, 8 analog outputs, 2 digital inputs I2C DIO: 6 digital inputs, 8 digital outputs I2C ADIO:4 analog inputs, 4 analog outputs, 4 digital inputs, and 4 digital outputs Note: The Maxum II is also compatible with original version CAN bus I/O from Siemens. CAN I/O boards have lower I/O channel count and capacity; consult factory for detail as needed 1-4 • Knowing Your System 2000596-001 Maxum II Specifications, Continued Input/Output Options (continued) Digital Inputs Optically coupled with a common for all inputs. Self powered floating contact input, or configurable for sinking or sourcing current. Sourcing current mode: 24V internal isolated supply, with positive terminal of supply at common. Sinking current mode: 5V internal isolated supply, with negative terminal of supply at common. Digital Outputs Floating double-throw contacts, maximum contact load rating 1 A at 30 V (AC or DC). External diode shunt suppression should be used for inductive DC loads, preferably at the load. Analog Inputs Each input configurable for current or voltage; -20 to +20 mA into 50 ohms or -10 to +10 V with 100K. Ohm input resistance, fully differential. Each differential channel operates within the range of -100 to +100V common mode to chassis ground. Analog Outputs 0/4 to 20 mA into 750 ohms maximum, common negative pole, galvanically separated from ground, freely connectable to ground. Termination Terminal strip for braided or solid cable with maximum section of 16 2 AWG or 1.5 mm . Gas Sample Requirements Sample Flow 50-200 cc/min (application dependent) Sample Filtration 0.1 μm Minimum Sample Pressure 5 psig (35 kPa), lower pressure optional Maximum Sample Pressure 75 psig (517 kPa), standard; higher pressure optional Maximum Sample Temperature 250°F (121°C) standard; higher temperature optional Material in Contact with Sample Stainless steel, Teflon©, and polyimide; other material optional Liquid Sample Requirements Sample Flow 5-20 cc/min (application dependent) Sample Filtration 0.3-5 micron (sample valve dependent) Minimum Sample Pressure 5 psig (35 kPa), standard Maximum Sample Pressure 300 psig (2070 kPa) standard; higher pressure optional Maximum Sample Temperature 250°F (121°C) standard; higher temperature optional Material in Contact with Sample Stainless steel and Teflon©, other material optional 2000596-001 Knowing Your System • 1-5 Installation Configuration Single unit with multiple enclosures Dimensions CAUTION Height: Width: Depth: 39 3/4” (1010 mm) 26 1/16” (662 mm) 16 3/16” (411 mm) When mounting the analyzer on a wall, care should be taken to ensure that the wall (vertical mounting surface) can withstand four times the minimum weight of the analyzer when mounted with the appropriate hardware. In some cases, it is recommended that brackets, such as Unistrut or angle iron be added to the mounting surface to help distribute the weight. Mounting Weight Wall mount: center to center 44” (1120 mm) Left side clearance: 18" (460 mm) Front side clearance: 25 ¾’’ (654 mm) Right side clearance: 18” (460 mm) 170 lb (77 kg) – typical, dependent on application Enclosure Rating NEMA 3, IP44 Category 2 EMI/RFI Rating CE Compliance; certified to 89/336/EC and 2004/108/EC (EMC directive) CE Compliance; certified to 73/23/EC 2006/95/EC (Low Voltage directive) Tested per EN 61010-1 / IEC 61010-1 Hazardous Class Standard Configurations: • Certified by CSA C/US for use in Class I, Division 1, Groups B,C,D with air or nitrogen purge • Certified by CSA C/US for use in Class I, Division 2, Groups B,C,D • Certified according to ATEX with air or nitrogen purge and purge control for Zone 1 or Zone 2 (Ex pyedmib IIB + H2) • Suitable for use in general purpose and non-hazardous areas. Important: General Purpose, Division 2 and Zone 2 applications require environmental purge of Electronic Enclosure (EC) to maintain operation integrity and performance. PDHID is not rated for hazardous areas. Altitude Up to 2000m (6561 ft.) for analyzers using 230 VAC Supply Up to 3000m (9842 ft.) for analyzers using 115 VAC Supply 1-6 • Knowing Your System 2000596-001 Maxum II Specifications, Continued Installation (continued) Ambient Temperature and Humidity (for Normal Operation, Storage, and Transport) 0 to 122 °F (-18 to 50°C) (application dependent**) Minimums - 0°F (-18°C) and 0% humidity Maximums – Up to 104°F (40°C) at 50% relative humidity Up to 86°F (30°C) at 80% relative humidity Operational Maximums – The Maxum II may be operated at ambient conditions of up to 122°F (50°C) (application dependent**) and 95% relative humidity provided the electronic doors are not opened and the electronics compartment is purged with clean, dry instrument air. The instrument air must be dry enough to prevent humidity condensation inside the electronics enclosure. Note: If the Maxum II is exposed to high condensing humidity with the electronics open or without dry purge air applied, then it must be allowed to re-stabilize at the above stated conditions for at least 8 hours before electrical power is applied. ** Depending on application characteristics such as number of detectors, oven temperature, and electronic loading, the acceptable ambient temperature range may be reduced. Consult factory for application-specific detail. AC Power 100-130 VAC or 187-264 VAC (configurable); 47-63 Hz, single phase Typical applications: single circuit, max. 1800 VA Complex applications may require 2 circuits at max. 1800VA per circuit. Wiring should be rated for 80°C (176°F) or higher. Mains buffering (maximum power interruption): >20 ms Instrument Air 50 psig (345kPa) minimum for units using Model 11 or Valco valves 120 psig (828 kPa) minimum for units using Model 50 valves 25 psig (173 kPa) minimum for air bath oven; 3 scfm (85 liters/minute)/oven No instrument air for airless oven heating (electronics compartment purge still required). 100 psig (690 kPa) minimum for units using Vortex tubes; at dewpoint -40°F (-40°C) 15 scfm (85 liters/minute) Configuration 2000596-001 Single unit with multiple compartments. Indoor mounting with protection from weather and corrosive or dirty atmosphere is strongly recommended to enhance life and improve maintainability. Knowing Your System • 1-7 Maxum II Specifications, Continued Installation (continued) Carrier Gas Cylinder nitrogen, helium, or argon at 99.998% purity, or hydrogen at 99.999% purity depending on application Typical consumption – 180 scf/month/detector module (5100 liters/month/detector module) Flame Fuel Hydrogen at 99.999% purity with no more than 0.5 ppm total hydrocarbons Typical consumption – 70 scf/month/detector module (2000 liters/month/detector module) Flame Air Zero grade air (< 1ppm THC, O2 content 20-21%). Supplied from instrument air with catalytic purifier (optional). Typical consumption – 900 scf/month (26,000 liters/month) Corrosion Protection Dry air purge to protect electronics. Stainless steel oven protection Painted steel exterior (epoxy powder coat) Calibration Type Manual or automatic Zero Automatic baseline correction Span Standard sample cylinder 1-8 • Knowing Your System 2000596-001 Maxum II Specifications, Continued Notes: Unless otherwise specified dimensions are shown as millimeters (inches) 2 Recommended Clearance Left Side - 460 (18”) Right Side – 460 (18”) Front Side – 654 (25 ¾”) Center to Center – 1120 (44”) 3 Left Exhaust For Single Oven Applications (1”Nipple) Left and Right Exhaust For Split Oven Applications (1”Nipple) 2000596-001 Knowing Your System • 1-9 About The Maxum II Description The Maxum II GC 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. Figure 1-1: Maxum II Process Gas Chromatograph 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. Figure 1-2: Maxum II Electronics Enclosure 1-10 • Knowing Your System 2000596-001 About The Maxum II, Continued 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. 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 sub-ambient 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. Oven Configurations 2000596-001 Split Airless: Fully independent dual ovens with separate oven doors. The oven uses cartridge heaters in each side to heat the oven enclosure and its components. Single Air Bath: Large, spacious compartment for complex applications and for ease of maintenance. Programmed Temperature Air Bath Dual Air Bath: Split Oven Configuration: Offers two temperature zones for one or more applications. Knowing Your System • 1-11 About The Maxum II, Continued Switching and Sample Valves 1-12 • Knowing Your System The type of valves used in an Maxum II is application dependent. Application Model Description Vapor Samples Model 50 10-port plunger-less 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 Samples 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-tovalve tubes can be connected directly to the caps of the Model 11 LDV (Low Dead Volume) version of the valve. Vapor or High Pressure 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 (milliseconds), 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 Live Column Switching The device has no parts to fail or wear out and exhibits essentially zero dead volume for fast column switching and sample injection with capillary columns. 2000596-001 About The Maxum II, Continued Detectors Several different types of detector modules are available for the Maxum ll. All of the detector modules 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. 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. All wiring meets hazardous area and safety requirements. Mineral insulated cable provides the flameproof path for detector cabling from the oven to the electronic enclosure. Simplicity of the detector design allows the detectors to be easily serviced. The thermal conductivity and filament detectors can be serviced without removing the detectors from the oven. Type Description Thermal Conductivity Detector (TCD) TCD is a concentration response detector for moderate sensitivity of most components. Thermistor TCD: 8-cell thermistor includes six independent measurement cells and two reference cells. Also available in 4-cell version identical to the 8-cell version except equipped with 3 measurement cells and one reference cell. Filament TCD: 2-cell filament TCD can be used as an Inter-column Detector (ITC) in conjunction with a FPD or FID application. Flame Ionization Detector (FID) 2000596-001 FID is low mass detector for combustible hydrocarbons. The components from the separation column are burned in a hydrogen flame that produces ions. The resultant ionization current is converted to a measurement signal. Knowing Your System • 1-13 About The Maxum II, Continued Detectors, cont’d Type Description Flame Photometric Detector (FPD) FPD is a selective detector used to detect substances containing sulfur. The column effluent is fed to a fuel rich hydrogen flame. Optical emissions are generated with wavelengths specific to the sulfur. An optical filter passes only these wavelengths characteristic for sulfur to a photomultiplier where the measurement signal is generated. Valco Pulse Discharge Detector The Valco Model D-2 Pulse Discharge Detector (PDD) is manufactured by Valco Instrument Co. Inc. The PDD uses a stable, low powered, pulsed DC discharge in helium as an ionization source. This provides the advantage that the need for a radioactive source is eliminated. However, performance of the PDD is comparable to detectors with conventional radioactive sources. Three variations of the PDD are available for use in the Maxum II Process Chromatograph. These are Helium Ionization (PDHID), Photoionization (PDPID), and Electron Capture (PDECD). For more information regarding this detector and its applicable operating modes refer to the Pulse Discharge Detector Models D-2 and D-2-I Instruction Manual available from Valco Instruments Co. Inc. Maintenance Panel 1-14 • Knowing Your System The Maintenance Panel 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 real-time chromatograms include zoom and pan features. The stored chromatograms include voltages and cycle times for future comparison. All of the GC’s operational and daily routine maintenance tasks can be performed from the Maintenance Panel interactive display screens and menus. System security is assured with multiple levels of password protection for all analyzer-operating functions. A Maintenance Panel emulator (also called a Human Machine Interface, or HMI, emulator) is available from the Maxum System Manager Workstation software. This emulator allows a user to perform Maintenance Panel tasks without being located at the unit. 2000596-001 About The Maxum II, Continued Work Station 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 Maintenance Panel, 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. System security is assured with multiple levels of password protection for all analyzer-operating functions. 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). EZChrom allows a user to choose the best peak gating and basing methods automatically. It is also possible to: • • • 2000596-001 Re-process captured chromatograms with different methods Measure unknown component peaks automatically Record multiple detector measurements simultaneously. Knowing Your System • 1-15 About The Maxum II, Continued Terms 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 (AI), Solenoid Valve Control Module channel (AO), Electronic Pressure Control channel (DI), Temperature Controller (DO). 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. Standard Configurations Since the chromatography is broken into parallel operating modules, it is possible to use standard configurations for common applications. For example, 95% of the vapor thermal conductivity detector applications in a typical olefins plan can be done with various combinations of fewer than 12 standard mini-applications. Many of these measurements can be performed in less than two minutes. Standard applications modules and methods can be taken off-the-shelf and installed in the analyzer. These mini-applications are referred to as “applets”. Applets can be configured alone or in any combination of parallel groups, depending on the measurement requirements. By using parallel chromatography and applets, it is possible to significantly reduce application development. 1-16 • Knowing Your System 2000596-001 About The Maxum II, Continued Duplicate Modules Parallel Chromatography can reduce the cycle time for complex applications and also increase chromatograph analysis frequency by running duplicate modules in parallel at staggered times. Since times are staggered the system will provide more frequent measurement updates. If similar measurements are performed on different streams, parallel modules can be used for each stream instead of switching the stream to a single module. This will reduce overall cycle time on multiple stream applications. Redundant Measurements Use of 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. Example Figure 1-3: Applet Example 2000596-001 Knowing Your System • 1-17 About The Maxum II, Continued Intended Use 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”. Qualified Personnel Only suitably qualified personnel may operate or perform maintenance on the Maxum II. For the purposes of safety, qualified personnel are defined as follows: 1. Those who have been appropriately trained for the tasks which they are performing (for example, commissioning, maintenance, or operation). 2. Those who have been appropriately trained in the operation of automation technology equipment and are sufficiently acquainted with Maxum II documentation. 3. Those who are familiar with the safety concepts of automation technology and are sufficiently acquainted with Maxum II documentation. 4. 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 1-18 • Knowing Your System 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. 2000596-001 Maxum II Operation Overview Description This section provides an overview of the operation of the Maxum II analyzer. Figure 1-4 is an operational block diagram showing how a sample is processed within the analyzer. For simplicity the block diagram only depicts a single stream and one detector. The accompanying narrative traces the sample through the Maxum II and how the various modules interact during the analysis. The SNE functions are performed in software in new systems; older systems still have hardware versions. Figure 1-4: Operational Block Diagram More Information 2000596-001 See Chapter 2, Maxum II Modules. Knowing Your System • 1-19 Maxum II Operation Overview, Continued Analyzer Operation Refer to Figure 1-4 for the following narrative. 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. 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 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 the set of Valco valves that are designed for high temperatures and very low sample volumes, and 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 2 solenoids. The (SVCM) receives commands from the I C bus. Solenoid commands are received from the SNE. Solenoid relay status is read back to the SNE to indicate whether a selected solenoid is to be deactivated or activated. Timing is controlled by SNE timing. There is no time base in SVCM. 2 Commands from I C 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 SNE and SYSCON database. Columns 1-20 • Knowing Your System The sample is injected by the sample valve(s) into the chromatograph columns where the sample is separated into individual components. Many different types of columns may be used including 1/16-inch micropacked, 1/8-inch packed and fused silica or metal capillaries. The columns used are dependent on the requirements of the application. 2000596-001 Maxum II Operation Overview, Continued 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 Sensor Near Electronics Module located in the electronics control section. 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 pneumatics for the EPCM is digitally controlled by the Sensor Near Electronics (SNE) 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. 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 Sensor Near Electronics. 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 coupled through the feed-through assembly to the Sensor Near Electronics (SNE) module located in the EC. The detector is assembled as part of the FeedThrough-Module. The Feed-Through-Module electrically connects the oven to the EC and provides electrical safety between the oven and the EC. 2000596-001 Knowing Your System • 1-21 Maxum II Operation Overview, Continued Sensor Near Electronics (SNE) 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 controller (SNECON) software. The DPM 2 is interfaced to installed peripherals connected to the I C 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 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 to the SNE. 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 SNE and SYSCON is via the internal signal bus. The original SYSCON consists of a single controller board. The newest version of SYSCON, called SYSCON2, is comprised of a base SIB (SYSCON Interface Board) with an attached CAC3 (Communication and Control board). The SYSCON combines all data results from the SNE and performs additional high level data processing and calculations. The SYSCON connects to a Maintenance Panel 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 SNEs schedule of timing events Sequence of sampling streams Calculations of calculated values Formatting of results and location and outputting results How to report or correct error conditions The SYSCON communicates with the SNE via an internal Ethernet. The SNE communicates with the electronics enclosure (EC) installed modules 2 via the I C bus. 1-22 • Knowing Your System 2000596-001 Functional Tasks Overview This section provides an operational overview of the Real-Time functional tasks of the Maxum II. • • Startup Tasks 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 User Interface On start-up, when primary AC power is applied to the analyzer, the analyzer first processes whatever electronic self-tests and diagnostics are required (for example, PROM, RAM, A/D, communication ports, etc.). The 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. Self Test After the self-test, the following conditions occur: • • • • Installed hardware is initialized Interrupts 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 checks to be certain a valid database is resident. If it is, the appropriate temperature and carrier set points are output. If not, default set points are left in place. Oven Temperature 2000596-001 The oven temperature is monitored to check for being at set point and stable before automatically proceeding. Depending on how long primary AC power has been off, this may take from 2 seconds to 45 minutes. Knowing Your System • 1-23 Functional Tasks, Continued Cycle Control Flag A check is made to see if the analyzer is to run a diagnostic type cycle. This is for the purpose of validating the analytical hardware, such as solenoid valves, detectors, carrier regulators, etc. This is optional based on a custom application being initiated per the power fail alarm. Cycle control flags are checked to see 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 that mode prior to powering down, then that mode should be started in progress without waiting for intervention. Event Scheduling The TOD (Time of Day) 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 events typically occur at a frequency of every 5 or 10 seconds. 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 TOD clock, they are put on queue. This allows them to be performed at the next appropriate time. Typically, this is after completion of current analysis cycle. If a calibration is scheduled, it will be put in queue. The calibration is then initiated after completion of current cycle and appropriate time has been allotted for 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. 1-24 • Knowing Your System 2000596-001 Functional Tasks, Continued Analysis Cycle Clock The Analysis Cycle Clock (ACC) is another clock that provides the time base 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 SNE Event Table Scan Rate, which is independent of detector scan rates. All SYSCON cycle clocks and associated Sensor Near Electronics (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 Important 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. Manual Operations Manually controlled functions can be initiated through the Maintenance Panel. A manual controlled event can occur asynchronously with any event and control some of the analyzer operations. Controlled items include: • • • • • • • 2000596-001 Activation of solenoid valves Balancing detectors Changing a pressure or temperature set point Initiating a calculation Report logging event Change the cycle time of an event Initiate a calibration Knowing Your System • 1-25 Analyzer Internal Communications Description Several internal communication links are used to provide the communication paths from the SYSCON to the SNEs and from the SNEs to the SVCM, EPC, PECM and from SYSCON to the I/O bus. • • • 2 I C Internal Bus Support for legacy CAN Internal Bus Legacy 10BaseT Internal Bus for SYSCON2 (10Base2 for original SYSCON) Physical Connections The Advance Communication System (ACS) Ethernet is accessed via the SYSCON Peripheral Control Interface (PCI) board 10base2 port. The SNEs are accessed internally via the 10baseT internal bus on the SYSCON2 (or the 10Base2 internal bus on the original SYSCON). 10 BaseT Internal Bus In the SYSCON2, the internal data bus configuration is dependent on the number of installed SNEs, which is, in turn, dependent on the analyzer/data base configuration. This is particular to the number of oven installed detectors being serviced and the detector sampling rates. For most applications, a single SNE is equipped. In this situation, the internal Ethernet port on the SYSCON2 connects directly to the Ethernet port on the SNE. For very complex or high sampling rate configurations, more than one SNE may be equipped. In this case, an Ethernet Switch Board with Fiber (ESBF) module is plugged into a PCI slot of the SYSCON2. The switch then connects to all installed SNEs as shown in Figure 1-5. Note that an ESBF (with Fiber) is required because only this board is capable of plugging into a PCI slot. Note also that the Ethernet Switch Board (ESB) in the network slot should NOT be used because this board must be connected for external Ethernet. Figure 1-5: Internal Ethernet for SYSCON2 with Multiple SNEs (Single SNE Configurations Cable Directly) 1-26 • Knowing Your System 2000596-001 Analyzer Internal Communications, Continued I2C Internal Bus to SNE Detector Interface 2 The I C Internal bus is used to interface the detector signal from the Detector Personality Module to the SNE controller board and then to the SYSCON; see Figure 1-6. The Internal bus also interfaces the SNEs associated modules with the SNE; see Figure 1-7. 2 I C BUS DETECTOR AMPLIFER SNE DETECTOR 2 Figure 1-6: I C Internal to SNE Detectors SNE or SYSCON II 2 I C TO MODULES SVCM PECM EPC 2 I C I/O SAMPLE SYSTEM CONTROLLER 2 Figure 1-7: I C Internal Bus to Enclosure Installed Components 2000596-001 Knowing Your System • 1-27 Analyzer Internal Communications, Continued CAN Bus The CAN Bus interfaces the CAN Extension Unit with the SYSCON; see Figure 1-8. Figure 1-8: CAN Bus CAN Module Addressing Installed CAN Modules are identified by physical address which consist of module type, serial number and I/O channel number. A serial number must be entered when adding or replacing (changing) system modules; see Chapter 3 Maintenance Panel Operation; Setting up CAN I/O modules page 3-142. The serial number is indicated on the module. The entire 14-digit serial number must be entered (for example): 00200000012301 Always 01 Serial number per tag on module Always 0000 002 Analog I/O Board 003 Digital I/O Board 004 Analyzer Module 1-28 • Knowing Your System 2000596-001 Maxum II Hardware Identification Overview The Maxum II modules located in the electronic enclosure section have 2 their own physical address and communicate via the I C Internal Bus; see Figure 1-9. Address information is contained in the SYSCON database and identifies modules by their location. 2 Figure 1-9: I C Bus Configuration 2000596-001 Knowing Your System • 1-29 Maxum II Hardware Identification, Continued Identification Number ALL modules within the Maxum II electronic enclosure have a unique identification number as related to the Sensor Near Electronics 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 I/D) Sub Module Type & Description) Module Type SNE ID 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. SNE ID String 2 One SNE in the enclosure serves as the Bus Manager for the I C bus (identifies all installed modules, assigns each module an address and manages communications with the associated module). Each SNECON has only one Bus Manager for its associated module. The SNECON initializes the address to be certain there is no conflict with other Bus manager capable devices Figure 1-10: SNE ID String 1-30 • Knowing Your System 2000596-001 Advance Communication System Network Connectivity The Advance Communication System (ACS) uses industry standard protocols and provides high-speed communication among all devices. The ACS can function alone or may be connected to a Distributed Control System (DCS) or plant-wide Local Area Network (LAN). As with other Siemens systems, the network has complete backward compatibility with existing Advance Data Hiway systems. The network supports the following Advance products (note that some products may be legacy products no longer offered): • Flexible high speed peer-to-peer communication • Open TCP/IP connectivity to industry standard networks for large, open systems. • Single Ethernet or redundant DataNET implement in any combination. • Interconnection to Advance Data Hiway and Advance Optichrom Chromatographs for backward compatibility. • Maintenance Panel availability • Remote Maintenance Panel access (optional) to any GC attached to the ACS • Slots for optional analog and digital I/O boards which can be used by any GC attached to the ACS • Multiple units can be attached anywhere in one ACS CAN Extension (CEU) • Additional I/O board slots allows for expansion of I/O capability Hub • Redundant version of ACS DataNET • Twisted pair wire or fiber optics • True message confirmation • Hazardous area hardware ratings Advance Network Gateway (ANG) • Interface high speed Ethernet or DataNET to existing Advance Data Hiway for backwards compatibility Work Station • User interface for maintenance • Programming interface for engineering changes • Real time network status monitoring Maxum II and Optichrom GCs Network Access Unit 2000596-001 Knowing Your System • 1-31 Advance Data Hiway Communications Description This section presents information on how the Analyzer communicates with devices on the Advance Data Hiway (ADH) network. Refer to Figure 1-11. 10b2 DataNET.SNE Dual ADH SNE Advance Network Communication Board SNE SYSCON Dual DataNET 10bT Figure 1-11: ADH Signal Flow Diagram Powering Up When analyzer system is powered up, a file is transferred from the SYSCON to the Communication Board Ethernet port and the Loop and Unit address for the ADH ports. This allows the Communication Board to be configured from the SYSCON Application Set information. Analyzer Message When the analyzer sends a message to another device connected on the Advance Data Hiway (ADH), the SYSCON formulates the ADH message. It then encapsulates the message as a TCP/IP message on the DataNET with a SYSCON source IP and Communication Board destination IP. The ADH message indicates the preferred ADH channel for transmission. The Communication Board retrieves this message, strips off TCP/IP protocol information, and then transmits the message on the selected ADH channel. Broadcast Message For a broadcast message, the SYSCON sends one message to the Communication Board. The channel is set to A and the broadcast bit is set. The Communication Board transmits the broadcast message on both ADH channels. 1-32 • Knowing Your System 2000596-001 Advance Data Hiway Communications, Continued Another ADH Device For messages directed to the analyzer, from another installed ADH device, the message will have the destination Loop and Unit address as those of the Communication Board ADH ports. The Communication Board retrieves this message, encapsulates the ADH message in TCP/IP protocol, and then transmits it to the SYSCON with the destination IP. Receiving Broadcast Signal When the analyzer receives a broadcast signal on the ADH network, the Communication Board treats it as any other message. Typically the SYSCON receives two messages for each ADH broadcast set. One is from channel A and the other from channel B. 2000596-001 Knowing Your System • 1-33 Maxum II Modules Chapter 2 Maxum II Modules Overview Description This chapter describes each replaceable module installed within the ® Maxum edition II Gas Chromatograph (also called Maxum II). Chapter Highlights In this Chapter the following information is provided: Topic 2000596-001 Page Overview 2-1 New Maxum II Components 2-2 System Controller Version 2.1 (SYSCON2.1) 2-5 Analog & Digital I/O Boards 2-18 Base 3 Detector Personality Module (DPM) 2-27 Intrinsically-Safe Thermal Conductivity DPM (IS-TCD3) 2-32 Temperature Control DPM 2-34 PECM Assembly 2-35 Solid State Relay Module 2-43 Solenoid Valve Control Module (SVCM) 2-48 Electronic Pressure Control Module (EPC) 2-52 Power System Module (PSM) 2-54 Siemens Liquid Injection Valve (SLIV) 2-57 Flame Photometric Detector (FPD) 2-61 Flame Ionization Detector (FID) 2-65 Methanator 2-68 Thermal Conductivity Detector (TCD) 2-70 Pulse Discharge Detector (PDD) 2-71 Live Tee Switch 2-74 2-1 Maxum II Modules New Maxum II Components New Maxum II Components Several improvements are incorporated into this new version of the Maxum II. These include: • • • • • • New color touchscreen interface New system controller (SYSCON 2.1) Redesigned PECM with added features An Intrinsically-Safe TCD DPM A new Base3 DPM A Temperature-Control DPM An Appendix is included at the end of this manual with information on previous components The SYSCON 2.1 assembly, including the System Interface Board version 3 (SIB3) with the Communication and Control board version 3 (CAC3) module mounted on it, handles the processing and database 2 requirements of the analyzer. It communicates internally via I C interface, and externally via an Ethernet port. PCI-bus expansion slots are provided with additional CAN connectors to support legacy I/O boards 2 The PECM now has 7 I C ports, eliminating the need for the Wiring Distribution Board used in previous analyzers. Figure 2-1 2000596-001 Maxum II Power Distribution and Communication Paths 2-2 Maxum II Modules New Maxum II Components As shown in Figure 2-2, the electronics enclosure (EC) is simplified compared to earlier analyzers. This example shows one DPM; there are three DPM mounting positions available. Figure 2-2 Maxum II Electronics Enclosure and Color Touchscreen Door Detector Input Paths Detectors are connected in three basic ways as sown in Figure 2-20 through Figure 2-21. More information is available in the Base3 Detector Personality Module (DPM) section on page 2-27 and the IntrinsicallySafe Thermal Conductivity DPM (IS-TCD3) section on page 2-32. Detector Control Many detectors require various control signals as shown in … For more information see Base3 Detector Personality Module (DPM) on page 227. Figure 2-3 2000596-001 Maxum II Detector Control Functions 2-3 Maxum II Modules Heater Control Options New Maxum II Components Heaters can be controlled by circuitry on the Base3 and Temperature Control DPMs, or on the PECM. The signal path is shown below: Figure 2-4 2000596-001 Heater Control Loop 2-4 Maxum II Modules System Controller Version 2.1 (SYSCON2.1) System Controller Version 2.1 (SYSCON2.1) Description 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). Part Numbers The Syscon2.1 cage assembly, part number A5E02599491004, is available in an upgrade kit, part number A5E02599495001. The SIB3 board part number is A5E31994086001 The CAC3 part number is A5E02599492004 Additional Functions • • • • • Processing and communicating the measurement values Controlling system functions, e.g. calibration Display and operator control Controlling associated systems, e.g. gas supply Generating reports Software Support The SYSCON2.1 is supported only by software version 5.2 or greater. Mechanical 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. The Color Touchscreen cables directly to the SIB3 through an opening in the rear of the SYSCON 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 connectors are also located and labeled on the front of the drawer. 2000596-001 2-5 Maxum II Modules System Controller Version 2.1 (SYSCON2.1) Figure 2-5 SYSCON2.1 Operation The SYSCON2.1 performs these functions: • • • • • Enhancements of the SYSCON2.1 over the SYSCON2: • • • Enhancements of the SYSCON2 over the SYSCON: • • • • • 2000596-001 SYSCON Assembly for SYSCON2.1 Contains the application programs and data that are accessible directly or via the external network Contains and runs MaxBasic programs Controls the Color Touchscreen Coordinates all network communications Coordinates and runs all analyzer functions Simpler cabling and cleaner EC interior LED backlight power and LCD screen interface to support the new Touchscreen Interface Board (TIB), mounted on the door with the color touchscreen. Automatic pullup sensing to eliminate the pullup switches Superior performance 2 2 Two on-board I C buses. This allows the SYSCON2 to support I C functions such as sample system control. Four serial ports, each configurable for either RS-232 or RS-485 operation. Using the Ethernet Switch Board, four Ethernet connections are available. Advantages include allowing a user to connect a local computer for maintenance purposes without disconnecting the analyzer from the network. The Ethernet Switch Board with Fiber eliminates the need for a dedicated fiber-optic converter board. 2-6 Maxum II Modules Communication and Control (CAC3) Board System Controller Version 2.1 (SYSCON2.1) The Communication and Control board (CAC) is a standardized, singleboard 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. See Figure 2-6. 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 2-6 2000596-001 CAC3 Board 2-7 Maxum II Modules CAC3 LEDs System Controller Version 2.1 (SYSCON2.1) The CAC3 is equipped with several LEDs that communicate useful information about the operating status of the CAC3. These LEDs are shown in Figure 2-7 and described in Table 2-1. Figure 2-7 Table 2-1 CAC3 LEDs 2000596-001 LEDs on the CAC3 Board LED1 LED2 Debug LED1 Debug LED2 LED3 LED4 Power Good Maintenance LED5 LED7 Fault Ethernet Speed Green LED on RJ-45 Yellow LED on RJ-45 Link Status Link Acknowledge Green – On during normal operation. Green – On during normal operation. Off during bootload Green – Power to CAC3 is functional Yellow – Off during normal operation. On during bootload. On – Maintenance fault or bootload Red – CAC3 Board fault Green – On – Speed is 100 Mb/sec (or auto-negotiating) Off – Speed is 10 Mb/sec (or disconnected) Green – LED is green when link is in full duplex mode. Yellow – LED is on when link is active. Will flash off for transmit or receive activity. 2-8 Maxum II Modules SYSCON Interface Board (SIB3) System Controller Version 2.1 (SYSCON2.1) Compared to earlier 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. The SYSCON Interface Board version 3 (SIB3) is a board that, when combined with the CAC3, creates 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. 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. See Figure 2-8 and Figure 2-9 for physical connector locations in the SYSCON2.1: • CAUTION PCI and CAN Direct Slots – The PCI slots on the SIB3 accommodate a variety of special function cards, including I/O boards or 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 as shown in Figure 2-9. 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. In addition to PCI type cards, the card slots can also accommode 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. 2000596-001 • 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. • 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 ground-isolated 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. 2-9 Maxum II Modules System Controller Version 2.1 (SYSCON2.1) Note: 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# 1 2 3 4 5 6 7 8 9 2000596-001 RS-232 RS-485 Modbus RX TX GND RTS CTS - 5 V Pwr Line B (RxD+/TxD+) Common Line A (RxD–/TxD–) - • Serial Ports 3 and 4 – These two serial ports, equipped on the same slot connector as the SYSCON Debug port, are planned for future expansion and are not active in software release 5.0. • I C Bus – The I C connectors are shown in the upper right 2 corner of Figure 2-8. Two I C buses are equipped on the 2 2 SYSCON2.1. These are labeled I C Bus A and I C Bus B. 2  I C Bus A includes the two connectors on the right as 2 shown in Figure 2-8. I C 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. 2 2  I C Bus B includes the three I C connectors on the left 2 as shown in Figure 2-8. I C Bus B is intended for use to support future configuration changes in the Maxum II. • Analog and Digital Inputs/Outputs – 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. • Interface to External CAN Bus (for CEU) – This connector on the SYSCON2.1 is provided to allow support for the CAN Extension Unit (CEU) • Internal CAN Bus Interface – This connector is used for extension of the internal CAN bus to allow for additional CAN I/O cards. It is only used when the SYSCON2.1 is installed in a NAU. 2 2 2-10 Maxum II Modules 2000596-001 System Controller Version 2.1 (SYSCON2.1) • Resets – The SYSCON2.1 is equipped with two connections for SYSCON reset. The first connection, located at the front of the board (bottom of Figure 2-8), is a pushbutton switch. This switch may be accessed via the front of the newest version SYSCON assembly cage as seen in Figure 2-9. The second connection consists of two pin connections at the back of the board (top left of Figure 2-8). This second connection operates using a simple loop closure and is provided to support 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. • Interface to display hardware – The Color Touchscreen connects to the SYSCON2.1 using a physical cable assembly. This cable runs directly from the SIB3 to the Color Touchscreen panel. • Power – The source of power for the SYSCON2.1 is the 24 V power supply equipped in the Maxum analyzer. The SYSCON2.1 is equipped with on-board power conversion to derive the other voltages needed for operation. • Battery – The SYSCON2.1 is equipped with a long-life 3 V battery backup to support the real time clock on the CAC3 board. This battery should last at least 5 years under normal operation. Note that 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, affecting the time and date on the analyzer. 2-11 Maxum II Modules System Controller Version 2.1 (SYSCON2.1) Figure 2-8 2000596-001 SYSCON2.1 Connections 2-12 Maxum II Modules System Controller Version 2.1 (SYSCON2.1) Figure 2-9 SIB3 LEDs and Options 2000596-001 SYSCON2.1 Assembly Front Connections The SIB3 has several LEDs that indicate useful information about the operating status different interfaces. These LEDs are shown in Figure 210 and described in Table 2-2. The SIB3 is also equipped with certain option switches, described below, that must be set correctly for proper operation. Before installation, verify all switch settings. When replacing a SYSCON2.1 verify that the switch settings on the new board match the switch settings on the board being removed. • DI Mode Switch – Switch SW3 located near the orange I/O connectors controls the mode setting for the on-board digital inputs. The available options are Mode 1 (source) and Mode 2 (sink). This switch should be set to Mode 2 regardless of the configuration unless instructed differently by Siemens. • Reset Switch – The function of the reset switch is described in the SIB3 connector description section. 2-13 Maxum II Modules System Controller Version 2.1 (SYSCON2.1) Figure 2-10 SIB3 LED and Switch Locations 2000596-001 2-14 Maxum II Modules Table 2-2 SIB3 LEDs System Controller Version 2.1 (SYSCON2.1) LED Type Power Description Power (Located at the back of the board near the RJ-45 connector) Power Bad 2 CAC Conn Bad I C Bus LEDs Buses A and B LED2/5 Norm/Comm (Located next to 2 I C Bus connectors) LED3/6 Warning LED4/7 Fault LED19, 20 2 I C Bus PullupActive LEDs (Located next to battery holder) CAN Bridge LEDs (Located to the left of the far left PCI slot) CAN I/O LEDs (Located next to far left CAN direct connector, CAN direct 5) LED16 Ready/Comm LED17 Warning LED15 Fault LED8 TX LED9 RX LED10 Heartbeat LED11 Fault 2000596-001 Color / Meaning Green – 3.3V power is available. Should be on at all times Red – Power is faulty or SYSCON hardware reset switch is being pressed 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. 2 Dim Green – I C Bus is normal. 2 Bright Green - I C Bus is communicating 2 Yellow – Warning on the I C Bus 2 Red –I C Bus fault The Auto-pullup feature is supplying pullup current on the 2 I C bus Dim Green – CAN Bridge is normal Bright Green – CAN Bridge is communicating Yellow – Warning on the CAN bridge Red – CAN Bridge fault Green – On when a valid CAN I/O message (other than a heartbeat reply) has been received and queued for processing Green – On when a CAN message (other than a heartbeat transmission) has been queued for sending to the CAN hardware Green – Flashes once for each heartbeat message transmitted. This LED will flash once every 1.5 seconds for each active CAN card Red – On when an error state is detected on the CAN bus hardware 2-15 Maxum II Modules System Controller Version 2.1 (SYSCON2.1) PCI Slot LEDs (Located between PCI slots) Internal Ethernet LEDs (located next to and on SIB3 RJ45 connector) LED14 Slot 0 Fault LED13 Slot 1 Fault LED18 Slot 2 Fault LED12 Slot 3 Fault Green LED on RJ-45 Yellow LED on RJ-45 LED1 Speed Red – Overcurrent or thermal shutdown on PCI slot 0. Red – Overcurrent or thermal shutdown on PCI slot 1. Red – Overcurrent or thermal shutdown on PCI slot 2. Red – Overcurrent or thermal shutdown on PCI slot 3. Green – LED is green when link is in full duplex mode. Yellow – LED is on when link is active. Will flash off for transmit or receive activity. Green – On – Speed is 100 Mb/sec (or auto-negotiating) Off – Speed is 10 Mb/sec (or disconnected) Note: Refer to figure 2-20 for physical locations of SIB3 LEDs 2000596-001 2-16 Maxum II Modules SYSCON I/O Connections System Controller Version 2.1 (SYSCON2.1) Figure 2-11 shows the on-board SYSCON I/O connections. The actual pin layout with input and output DO1–DO4 signals in a delivered system will be shown in 4 digital outputs: floating double-throw the System Documentation package. contacts, max. contact load rating 30 V/ 1 A. DO1 is not administrable and is dedicated to “Maxum Fault” (active when the Maxum has an active alarm). AO1–AO2 2 analog outputs: 0/4–20 mA, common negative pole, galvanically separated from ground, freely connectable to ground, max. gain vs. local protective ground potential 50 V, max. working resistance 750 Ω DI1–DI4 4 digital inputs: Optocoupler with internal 12– 24 VDC power supply, switchable with floating contacts; alternative: switchable with external 12–24 VDC supply, common negative pole Design: Two 12-pin terminal strips for braided or solid cable with maximum cross-section of 2 1.5 mm or 16 AWG. Figure 2-11 2000596-001 System Controller Connection Diagram -X04, -X05 2-17 Maxum II Modules Analog & Digital I/O Boards Analog & Digital I/O Boards The I/O board options for the SYSCON2.1 are the same as for the original version of SYSCON and are described in the previous section. See the section “Analog and Digital I/O Boards” under the original SYSCON section and refer back to “System Controller Connections”, Figure 2-8 through Figure 2-10 and Table 2-1 through Table 2-3 for connection diagrams. 2 The SYSCON2.1 supports up to two I/O boards, either I C or CAN. In preexisting applications needing more than two I/O boards, a legacy CAN Extension Unit (CEU) may have been installed. This device allows up to 10 additional I/O boards. The CEU, if used, connects to the Maxum II Gas Chromatograph via a Serial Link (CAN Bus). 2 I C I/O boards provide approximately twice the number of circuits as 2 previous CAN I/O boards. If an application needs more than two I C I/O boards, a Network Access Unit (NAU) can be installed. This allows 2 installation of additional I C I/O boards that the Maxum II can access remotely. I/O Slot Assignments If expansion boards are added to the SIB3 of the SYSCON2.1, they must be installed in the following slots. These slots are numbered from left to right when viewing the SYSCON2.1 from the front. • Advance Network Communication Board (ANCB) for Advance Data Highway (ADH) – Slot 1 • No board is installed in slot 2. This slot provides the connectors for external debugging and for serial ports 3 and 4. • Analog and Digital I/O boards (CAN or I C)– Slots 1, 3, or 4 (only 2 may be used at a time) • Ethernet Switch Board (ESB) or Ethernet Switch Board with Fiber (ESBF) for external Ethernet – Slot 5 2 All network communications, Maintenance Panel and analyzer functions are coordinated by the SYSCON2.1. The SYSCON2.1 does not control sample analysis performed by the Sensor-Near Electronic Module (SNE). The SNE manages and performs all analysis functions independently of the SYSCON. 2000596-001 2-18 Maxum II Modules Ethernet Switch Board (ESB) Analog & Digital I/O Boards 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. 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. Table 2-3 ESB LEDs LED Meaning 1 2* 3* 4* 5* On=100Mb On=100Mb On=100Mb On=100Mb On=100Mb Meaning/Designation Off=10Mb Off=10Mb Off=10Mb Off=10Mb Off=10Mb Internal RJ-45 Connector to CAC3. External Top RJ-45 Connector External Second RJ-45 Connector External Third RJ-45 Connector External Bottom RJ-45 Connector *Note: LEDs for external connectors count from the bottom up (e.g. bottom LED is for top connector). Figure 2-12 Ethernet Switch Board (ESB) Part Number A5E02368691001 2000596-001 2-19 Maxum II Modules Ethernet Switch Board with Fiber (ESBF) Analog & Digital I/O Boards 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. Figure 2-13 Ethernet Switch Board with Fiber (ESBF) Part Number A5E02555919001 Multiple Mode Use of ESBF 2000596-001 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” 2-20 Maxum II Modules Analog & Digital I/O Boards 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. Figure 2-14 Reversing the ESBF Bracket 2000596-001 2-21 Maxum II Modules Analog & Digital I/O Boards – I2C bus Analog & Digital I/O Boards 2 2 The newest version of I/O board connects to an I C bus. The I C I/O boards are the version generally available for new installation. See System Controller Connections, Tables 2-1 through 2-3, for connection diagrams information. • • • 2 Analog I/O board (AIO_I C, Part Number A5E02486267001): has 8 analog output channels, 8 analog input channels, and 2 digital input channels 2 Digital I/O board (DIO_I C, Part Number A5E02486268001): has 8 digital outputs and 6 digital inputs 2 Analog and Digital I/O board (ADIO_I C, 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. Additional I/O Boards 2 The SYSCON supports up to two I C 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 2 be installed. This allows installation of additional I C I/O boards that the Maxum II can access remotely. 2 For the I C I/O boards that contain digital inputs (DIs) switch SW1 located at the top of the board near the front (connector end) controls the mode setting for the on-board DIs. (See Figure 2-15). The switch sets the mode for all DI circuits on the board (mixing of modes on a board is not allowed). The available options are Default/Sink and Legacy (see back side of board for diagram of 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. 2 Three status LEDs have been included on each I C I/O board. These LEDs are visible on the top front of the board. The LEDs follow the Maxum standard as follows: • LED3 (Norm) - The top (green) LED indicates that the board is powered when lit. When this is the only LED illuminated, then the board is operating normally. • LED2 (Warn) - When lit, the middle (yellow) LED indicates that there is a warning status for the board. • LED1 (Fault) - When lit, the bottom (red) LED indicates that the board has a fault. I C I/O Board DI Mode Switch I C I/O Board Status LEDs 2000596-001 2 2 2-22 Maxum II Modules Analog & Digital I/O Boards 2 There are two standard I C bus connections on the top of each I C 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 2 from one board to another or to other I C devices. 2 The I C I/O boards use an 8-bit board identification number as an 2 address on the I C 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). I C Bus Connections on 2 I C I/O Boards I C I/O Board Address DIP Switches 2 2 2 DIP switches are used to set the address for the physical board as shown in Figure 2-15. When replacing a board, the user only needs to set the switches on the new board to match the old board being replaced. 2 Figure 2-15 I C I/O Address Switches 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. 2000596-001 2-23 Maxum II Modules Analog I/O Board (AIO) Connections Analog & Digital I/O Boards Circuits on the AIO 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. AIO I2C Wire Side View Lead Pin Pin Lead 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 AO_GND 18 ∎ ∎ 17 AO8 Current AO_GND 20 ∎ ∎ 19 AO7 Current AO_GND 22 ∎ ∎ 21 AO6 Current AO_GND 24 ∎ ∎ 23 AO5 Current AO_GND 26 ∎ ∎ 25 AO4 Current AO_GND 28 ∎ ∎ 27 AO3 Current AO_GND 30 ∎ ∎ 29 AO2 Current AO_GND 32 ∎ ∎ 31 AO1 Current DI Common 34 ∎ ∎ 33 DI2 Signal DI Common 36 ∎ ∎ 35 DI1 Signal Analog Inputs: -20 to +20 mA into 50 ohms or -10 to +10V, R10=1 M-ohm, mutually isolated 10 V Analog Outputs: 0/4-20 mA. Common negative pole, galvanically separated from ground, freely connectable to ground, max. gain vs. local protective ground potential 50B, max. working resistance 750 ohms. Digital Inputs: Optocoupler with internal 12-24 VDC power supply, switchable with floating contacts; alternative: switchable with external voltage 12-24 VDC, common negative pole. Design: Terminal strips for braided or solid conductors with a maximum diameter of 1.5 mm or 16 AWG. 2 Figure 2-16 I C AIO Board Connection Diagram -X10 - -X11 2000596-001 2-24 Maxum II Modules Digital I/O Board (DIO) Connections Analog & Digital I/O Boards Circuits on the DIO 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. DIO I2C Wire Side View Lead Pin Pin Lead DI Common 2 ∎ ∎ 1 DI6 Signal DI Common 4 ∎ ∎ 3 DI5 Signal DI Common 6 ∎ ∎ 5 DI4 Signal DI Common 8 ∎ ∎ 7 DI3 Signal DI Common 10 ∎ ∎ 9 DI2 Signal DI Common 12 ∎ ∎ 11 DI1 Signal DO8 C 14 ∎ ∎ 13 DO8 NC DO7 NC 16 ∎ ∎ 15 DO8 NO DO7 NO 18 ∎ ∎ 17 DO7 C DO6 C 20 ∎ ∎ 19 DO6 NC DO5 NC 22 ∎ ∎ 21 DO6 NO DO5 NO 24 ∎ ∎ 23 DO5 C DO4 C 26 ∎ ∎ 25 DO4 NC DO3 NC 28 ∎ ∎ 27 DO4 NO DO3 NO 30 ∎ ∎ 29 DO3 C DO2 C 32 ∎ ∎ 31 DO2 NC DO1 NC 34 ∎ ∎ 33 DO2 NO DO1 NO 36 ∎ ∎ 35 DO1 C Digital Inputs: Optocoupler with internal 12-24 VDC power supply, switchable with floating contacts; alternative: switchable with external voltage 12-24 VDC, common negative pole. Digital Outputs: Digital Outputs: Floating double-throw contacts, max. contact load rating 30 V/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 application, 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 suppress the solenoid load. Design: Terminal strips for braided or solid conductors with a maximum diameter of 1.5 mm or 16 AWG. 2 Figure 2-17 I C DIO Board Connection Diagram -X10 - -X11 2000596-001 2-25 Maxum II Modules Analog & Digital I/O Boards 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. Analog and Digital I/O Board (ADIO) ADIO I2C Wire Side View Lead Pin Pin Lead AI4 -10V 2 ∎ ∎ 1 AI4 +10V AI3 -10V 4 ∎ ∎ 3 AI3 +10V AI2 -10V 6 ∎ ∎ 5 AI2 +10V AI1 -10V 8 ∎ ∎ 7 AI1 +10V DI Common 10 ∎ ∎ 9 DI4 Signal DI Common 12 ∎ ∎ 11 DI3 Signal DI Common 14 ∎ ∎ 13 DI2 Signal DI Common 16 ∎ ∎ 15 DI1 Signal AO_GND 18 ∎ ∎ 17 AO4 Current AO_GND 20 ∎ ∎ 19 AO3 Current AO_GND 22 ∎ ∎ 21 AO2 Current AO_GND 24 ∎ ∎ 23 AO1 Current DO4 C 26 ∎ ∎ 25 DO4 NC DO3 NC 28 ∎ ∎ 27 DO4 NO DO3 NO 30 ∎ ∎ 29 DO3 C DO2 C 32 ∎ ∎ 31 DO2 NC DO1 NC 34 ∎ ∎ 33 DO2 NO DO1 NO 36 ∎ ∎ 35 DO1 C Analog Inputs: -20 to +20 mA into 50Ω or -10 to +10V, R10=1 MΩ, mutually isolated 10 V Analog Outputs: 0/4-20 mA. Common negative pole, galvanically separated from ground, freely connectable to ground, max. gain vs. local protective ground potential 50B, max. working resistance 750 ohms. Digital Inputs: Optocoupler with internal 12-24 VDC power supply, switchable with floating contacts; alternative: switchable with external voltage 12-24 VDC, common negative pole. Digital Outputs: Digital Outputs: Floating double-throw contacts, max. contact load rating 30 V/1A Design: Terminal strips for braided or solid conductors with a maximum diameter of 1.5 mm or 16 AWG. Figure 2-18 2000596-001 2 I C ADIO Board Connection Diagram -X10 - -X11 2-26 Maxum II Modules Base3 Detector Personality Module (DPM) Base3 Detector Personality Module (DPM) Description 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 2 passes the data to the SYSCON via an I C port. Results can then be viewed on the Color Touchscreen or the workstation. See Figure 2-19. 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. Figure 2-19 Base3 DPM With Mezzanine Module Part Number 2000596-001 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. 2-27 Maxum II Modules Base3 Detector Personality Module (DPM) The Base 3 Detector Personality Module (DPM) combines these functions in a single module: Overview of DPM Functions Input from detector via mezzanine module Including Mezzanine Module Ignite signal / glow-plug output FID Range-select output 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 FPD Enable signal output 300-V bias output Flame-sense input (used in Maxum I analyzers only) Analog voltage input Filament Detector Input from detector via mezzanine module Range-select output Input via connector on right side (as viewed inside analyzer EC) Temperature setpoint module connector Temperature control Two RTD inputs Two heater-control outputs System communication Input Signal Paths 2 I C port with ID-select switch The input-signal functions are shown in Figure 2-20 and Figure 2-21. Figure 2-20 FID, FPD, or Analog Input Detector Input Signal Path Figure 2-21 Filament Detector Input Signal Path 2000596-001 2-28 Maxum II Modules Detector Control Paths Base3 Detector Personality Module (DPM) Several control signals are available to control various detector functions as shown in Figure 2-22. Figure 2-22 Maxum II Detector Control Functions Location ID Switch The Location ID Switch, shown in Figure 2-19, selects the DPM location that is incorporated in the address, to be reported in the results. 2 The DPM I C 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 NOTE: 2000596-001 Location 1 Left 2 Center 3 Right 2 If the DPM I C port is connected to an SNE, the value is always set to “1”. The actual location value is determined by the SNE. 2-29 Maxum II Modules DPM-Based Temperature Control Base3 Detector Personality Module (DPM) 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 in . Figure 2-23 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 in Figure 2-24. This same position is used in the Temperature Control DPM. Figure 2-24 Temperature Setpoint Modules Installed on Left Side of Base3 DPM 2000596-001 2-30 Maxum II Modules Mezzanine Modules Base3 Detector Personality Module (DPM) 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 Table 2-4 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 2-4 Mezzanine Part Number Descriptions Mezzanine Detector Sub Module Type Usage Normal Range Alternate Range 2020960-001 FID Low level FID 0.2nA none 2020960-003 2021328-002 2021328-001 2021328-003 FID FID FPD FPD Standard FID Large Scale FID FPD FPD 0.18 Hz Filter 1nA 100nA 100nA 100nA 20nA 1000nA none none +/-1V none +/-10V none 2021326-001 1901614-001 Dummy Plug 2000596-001 UNIVersal Voltage AI UNIVersal When Base DPM is Filament only, and no mezzanine required 2-31 Maxum II Module Intrinsically-Safe Thermal Conductivity DPM (IS-TCD3) 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 2 then passes the data to the SYSCON via an I C port. The resulting data is then processed by the Embedded SNE software. Results can then be viewed on the maintenance panel or the workstation. See Figure 2-25. Figure 2-25 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. CAUTION 2000596-001 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. 2-32 Maxum II Module Connections Intrinsically-Safe Thermal Conductivity DPM (IS-TCD3) The connections to the IS-TCD3 DPM are shown in figure 2-13 below. The connections are described below. Figure 2-26 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 2-27 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. 2 I C Bus Connection: The white connector on the reverse side of the DPM 2 connects to the I C Bus on the PECM as shown in Figure 2-25. 2000596-001 2-33 Maxum II Module Intrinsically-Safe Thermal Conductivity DPM (IS-TCD3) Switch Settings Position ID Switch: 1 = Left 2 = Center 3 = Right (Same function described in Location ID Switch) Reference Selector Switches: Selects which TCD element in each set of 4 to use as the reference Figure 2-28 IS-TCD3 DPM Switches Temperature Control DPM 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. Figure 2-29 Temperature Control DPM Connections Part Number 2000596-001 The Temperature Control DPM (Part Number A5E02645925002) 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. 2-34 Maxum II Module PECM Assembly PECM Assembly 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 in Figure 2-30. Figure 2-30 PECM3 I/O Connections Part Number 2000596-001 The PECM3 assembly part number is 2021828-002. An upgrade kit, part number 2022019-001 is available to replace earlier units. 2-35 Maxum II Module PECM Assembly Feature Additions Improvements in PECM3CTL from PECM-CTL • • Improvements In PECM2 Assembly from Original PECM 2 7 I C 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. 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 smaller 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: • • • • • • • • 2000596-001 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 and the methanator. Additional medium-wattage heater circuit. 2 4 connectors providing I C and 24V power distribution have been added. This replaces some of the function of the Wiring Distribution Board (WDB). 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. 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 24-vdc circuits. 2-36 Maxum II Module PECM Functions AC Input and Distribution Fuses PECM Assembly The PECM provides connection points to facilitate the functions listed below. 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 Figure 2-31. • • • • • F1-ABH2: 16 Amperes, 115 VAC or 10 Amperes, 230 VAC F2-ABH1: 16 Amperes, 115 VAC or 10 Amperes, 230 VAC F3-FLT AC: 3 Amperes 115 VAC or 230 VAC F4-LWH1-LWH5: 10 Amperes 115 VAC or 230 VAC. F5 LWH6, MWH Figure 2-31 PECM AC Power Distribution NOTICE 2 I C and 24 VDC Distribution 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. 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. 2 Each of the 7 I C connectors also provides 24V power to the connected module. A separate connector powers a 24V fan. 2000596-001 2-37 Maxum II Module Low-Wattage Heater SSR Control PECM Assembly 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 lowwattage air-bath 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. Figure 2-32 shows a simplified schematic of the Low Wattage Heater Relay Circuit LWH4. Figure 2-32 LWH4 Heater Circuits 2000596-001 2-38 Maxum II Module Additional Relay Outputs PECM Assembly 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 Figure 2-33. Figure 2-33 LW5 & LW6 Relay Circuit Jumper Connections 2000596-001 2-39 Maxum II Module PECM Assembly Oven Temperature Monitoring and Control The PECM_CTL board has two temperature monitor and control channels for use with the high-wattage 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 in Figure 2-34. Figure 2-34 PECM High-Wattage Heater Control 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. 2 Alarm conditions are reported to the SYSCON over the I C link. 2000596-001 2-40 Maxum II Module PECM Assembly 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-Bath Oven Air Supply Monitoring 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 Figure 2-34 for connector locations. 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 Figure 234 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 Figure 2-34 for the location of connector J17. 2000596-001 2-41 Maxum II Module Physical Location PECM Assembly The PECM is mounted to the left inside wall of the EC cabinet. All fuses and electrical connections are readily accessible. Figure 2-35 Power Entry and Control Module – Version 3 (PECM3) 2000596-001 2-42 Maxum II Module Sensor Near Electronics (SNE) Software Sensor Near Electronics (SNE) Software Overview 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. See Figure 2-36. Figure 2-36 SNE Software Top Level Diagram Configuration 2000596-001 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. 2-43 Maxum II Module Components Sensor Near Electronics (SNE) Software The major SNE software components are as follows: • • • • Data Manager Communications Manager Hardware Manager Computational Engine A synopsis of each major component is presented in the following sections. See Figure 2-36. 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. Hardware Manager The Hardware Manager provides scheduling and communication services for the hardware in the analysis zone. These include devices such as the following: • • • • • • Computational Engine 2000596-001 Detectors, Sample valves, Relays, Pressure monitors and controllers, Temperature monitors and controllers and Flow control valves, etc. 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. 2-44 Maxum II Module Solid State Relay Module Solid State Relay Module Description The Solid State Relay 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 Solid State Relay Module are available, the SSR and the Medium Wattage SSR. There are also two slightly different versions of the standard SSR. See Figure 2-37. Old SSR New SSR Figure 2-37 Solid State Relay Modules (High Wattage) Mechanical Information (High Wattage SSR) The Solid State Relay Module assembly is mounted to the left side of Enclosure back wall. A metal cover not shown in Figure 2-37 protects the relays. The Module is equipped with heat dissipating fins that extend through the back of the enclosure wall to dissipate generated heat to the outside atmosphere. 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. Both the original and newer relays can be replaced and both are available as spare parts. 2000596-001 2-45 Maxum II Module Solid State Relay Module Electrical Information (High Wattage SSR) 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 overtemperature 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. Power Source The heater element can operate from either 115 VAC or 230 VAC power sources with a total power output capacity of 1400 to 1500 watts. Figure 2-38 is a schematic of the air bath heater relay. 115VAC or 230VAC If the primary AC voltage is changed from 115 VAC to 230 VAC, the Power Entry Control Module (PECM) AB1 and AB2 fuses must be changed. For 115 VAC power the fuses are rated at 16 amps. For 230 VAC, the in-line fuses must be changed to 10-amp rating. Also the 115/230 VAC switch must be set to 230 VAC. The switch is located on the Power Supply Module, mounted to the left side of SYSCON. In addition the correct power adapter must be plugged into the Heater 115V/230V connector; 115 VAC Power Adapter P/N 2017595-001 and 230 VAC Power Adapter P/N 2017595-002. NOTICE DO NOT use a 16-amp rated fuse for 230 VAC primary AC power. This could result in overheating and equipment damage. Figure 2-38 2000596-001 Air Bath Heater Relay Schematic 2-46 Maxum II Module Solid State Relay Module Medium Wattage SSR Module 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 which can lower spare parts costs. The newer board provides smaller relays which are capable of controlling the new 500 watt air bath heater assembly (described above). 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 (which can be seen in the picture below). Figure 2-39 2000596-001 Medium Wattage Solid State Relay Module 2-47 Maxum II Module Solenoid Valve Control Module (SVCM) Solenoid Valve Control Module (SVCM) Description 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. 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. The SVCM electronics, whether onboard for the old version or on the PECM for the new version, receives commands from the SYSCON 2 module (via the I C). Pulse timing is controlled from the SVCM electronics. Original SVCM New SVCM Figure 2-40 Solenoid Valve Control Module (SVCM) Mechanical 2000596-001 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 4way 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. 2-48 Maxum II Module Solenoid Valve Control Module (SVCM) 3-way 4-way Figure 2-41 Original Solenoid Control Module Figure 2-42 New Solenoid Control Module Digital Outputs 2000596-001 Digital outputs assigned to each solenoid valve are shown in Table 2-5. 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. Refer to See Table 2-5 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 topfront of each Parker (original) solenoid and on the bottom of each SMC (new) solenoid. See Figure 2-41 and Figure 2-42 for the button location. 2-49 Maxum II Module Solenoid Valve Control Module (SVCM) Table 2-5 Digital Output Solenoid Valve Groups Group Solenoid Valve Left Left Left Left Right Right Right Right Valve 1 Valve 2 Valve 3 Valve 4 Valve 1 Valve 2 Valve 3 Valve 4 SVCM I/O Assignments Table 2-6 shows the specific digital output I/O assignment summary. For location of solenoid valves, see Figure 2-41 and Figure 2-42. There are no analog inputs or outputs. Table 2-6 SVCM I/O Assignments Signal Type SYSCON Channel # DO DO DO DO DO DO DO DO 1 2 3 4 5 6 7 8 SVCM Fault Indicators Table 2-7 Fault Indicators Status Lights 2000596-001 I/O Name LEFT_GROUP_VALVE_1 LEFT_GROUP_VALVE_2 LEFT_GROUP_VALVE_3 LEFT_GROUP_VALVE_4 RIGHT_GROUP_VALVE_1 RIGHT_GROUP_VALVE_2 RIGHT_GROUP_VALVE_3 RIGHT_GROUP_VALVE_4 Group # Channel # 1 1 1 1 1 1 1 1 80h 40h 20h 10h 08h 04h 02h 01h Table 2-7 shows the specific SVCM fault indicators and condition causing the error. For J10 and J11 connector locations in the original SVCM, see Figure 2-41. See Figure 2-30 in the PECM2 section of this chapter for the locations of connectors for the new SVCM. 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 Table 2-8 shows the SVCM board mounted status lights (for the original SVCM) and their assignments. For location of LED status lights, see Figure 2-41. 2-50 Maxum II Module Table 2-8 Status Lights for Original SVCM Solenoid Valve Control Module (SVCM) LED Status Light Assignment LED1 Green When illuminated, it indicates valve communication and power is ON. LED2 Red When illuminated, it indicates there is a condition causing a fault. LED3 Yellow When illuminated, it indicates a warning status. Operation Test Specifications Color Step Procedure 1. Using a fine pointed object, depress Solenoid Valve red button. 2. When depressed, 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 depressed, 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 depressions. The following specifications are applicable to the SVCM. Function Switching Speed (Maximum response time on/off ms) Specification 4-way 15 ms 3-way non-latching 15 ms Operating Voltage 24 VDC Pressure Range, 3-way 25 to 100 psi Pressure Range, 4-way 25 to 100 psi Maximum PSI 100 psi Vacuum Range 0 to 27" of Hg Ambient Temperature Range -18°C to 65°C -0.4°F to 149°F (dry air) Leakage Not greater than 50 micro Liter/min, air @ 69.8°F (21°C) with 50 psig on the common port. 2000596-001 2-51 Maxum II Module Siemens Liquid Injection Valve Electronic Pressure Control (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 for precise resetting 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, found in Chapter 4 of this manual. There are no other functional differences. Older Version Newer Version (with DIP Switches) Figure 2-43 Pressure Control Module (with Attached Manifold) Mechanical The EPC is mounted to right side wall of the Electronic Enclosure. For mounting location, see Figure 2-44. 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. EPCM Right Side Wall Figure 2-44 2000596-001 EPC Component Location 2-52 Maxum II Module Electrical Siemens Liquid Injection Valve 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 (<100 psi) applications such as flame detector fuel. The EPC operates from +24 VDC at 4 watts. Electrical connections are made using plug type connectors. The EPC receives commands from the Sensor Near Electronics 2 Controller (SNECON) via I C bus regarding timing and pressure setpoint. The timing of messages from the SNECON 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 fieldmounted installations. 2 The EPC communicates with other components via the I C bus and communicates actual pressure back to the SNECON. Regulated pressure range is 5-100 psig. 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 Sensor 2 Near Electronics Controller (SNECON) I C, to the EPC. Status and 2 diagnostic data is available via the SNECON I C. Non-Volatile Memory The initial control parameters and calibration parameters are stored in SYSCON On-Board non-volatile memory. With this type of memory, data is not lost in the event of a power failure or turning system power off. 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. 2000596-001 2-53 Maxum II Module Specifications Siemens Liquid Injection Valve The following specifications are applicable to the Electronic Pressure Control (EPC) Module: Topic Specification Maximum inlet pressure 120 psig Pressure output range 5-100 psig Minimum differential between EPC inlet and outlet 5 psi Flow range from EPC 5-500 cm /s (see note below) Controlled pressure stability over temperature range ±0.5% of setpoint Short-term pressure stability ±0.0005 psi over 30 seconds Typical response time for step change in setpoint. Stable to within 0.1% of final value within 0.5 seconds* 3 * (For hydrogen the response time is ~ 1 second). Note: When running applications with column flow rates of less than 3 5 cm /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 3 cm /s is recommended. 2000596-001 2-54 Maxum II Module Siemens Liquid Injection Valve Power System Module (PSM) 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. Figure 2-45 Power System Module (PSM) Input AC Power 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 input power 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. Circuit Analysis Primary AC power is conditioned and converted to 24 VDC. After conditioning; only one 24 VDC source is supplied to system components. DC to DC converters generate other operating voltages. 24 VDC The PSM provides only one 24 VDC source to operate system components. A blocking oscillator generates the 24 VDC output voltages at 6 amps. Operating voltages for other components within the analyzer are generated by the 24 VDC using DC to DC conversion. 2000596-001 2-55 Maxum II Module Specifications Siemens Liquid Injection Valve The Power Supply Module specifications are presented below. Note that these specifications are specific to the PSM and may differ from the overall Maxum specifications. Voltage Range 115 VAC (85 to 140 VAC) 230 VAC (185 to 264 VAC) Frequency Range 47 to 63 Hz Nominal Input Current 2 amp @ 115 VAC 1 amp @ 230 VAC Output Rating 24 VDC @ 6 amp Nominal Output Voltage 24 VDC ± 3%, 1% ripple plus noise at a bandwidth of 30 MHz Nominal Output Current 6 amps @ <104°F (40°C) 4 amps @ 104 to 158°F (40 to 70°C) Basic Load 0.2 amps/0.0 amps open circuit permitted Dynamic Load Between 0.2 amps to 3 amps in the load range. A maximum load of 2 amps at 1.8 kHz is switched. Switching is controlled by pulse width. Precision range is not exceeded in this operational mode. Current Limitation Start at 6.4 to 7.5 amps. When current drops, device is switched on. Overvoltage Cutoff Starts 27 to 31 VDC. When voltage drops, device is switched on. Over-temperature Cutoff After temperature decreases to specified tolerance, device is switched 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 Size 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 PSM Fuse Replacement 2000596-001 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 250V, 4.0 Amp, “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. 2-56 Maxum II Module Siemens Liquid Injection Valve Siemens Liquid Injection Valve Description 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. See Figure 246 below. Components The Siemens Liquid Injection Valve (SLIV) consists of three components: • • • Temperature-controlled vaporization system Sample flow unit with seals Pneumatic drive (actuator) Figure 2-46 Siemens Liquid Injection Valve Functional Description 2000596-001 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. See Figure 2-47 on the next page. 2-57 Maxum II Module Siemens Liquid Injection Valve Figure 2-47 LIV Sample Injection Specifications 2000596-001 Max. Vaporization temperature 60 - 300°C (140 - 572°F) with explosion-proof analyzers according to the temperature class Injection volume 0.4 to 2.5 µl 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 4 to 6 bars (48 to 87 lb/sq inch) Sample pressure Max. 50 bars (725 lb/sq in), recommended 5 … 10 bars (72.5.145 lb/sq in) Connections For tube with 3 mm (1/8 in.)outer diameter 2-58 Maxum II Module Vaporization system Siemens Liquid Injection Valve 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 (Figure 2-48 below) 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 2-48 Sample Flow Unit 2000596-001 2-59 Maxum II Module Vaporization Temperature Siemens Liquid Injection Valve 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 in Figure 2-49. Figure 2-49 Vaporization Temperature NOTICE Filter Requirements 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. 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: • • 2000596-001 98% for 0.3-µm particles with liquid samples 99.99% for 0.1-µm particles with gaseous samples 2-60 Maxum II Module Flame Photometric Detector Flame Photometric Detector Description The FPD is a selective detector that can detect sulfur based on the emission of light during combustion. It is intended for use only in the Maxum II. Two versions have the FPD have been available for the Maxum II. In 2007, enhancements were made to the original FPD. The enhanced FPD is called FPD II. The original FPD and FPD II are very similar. All information in this section refers to both versions unless otherwise specified. The components leaving the column are combusted in a hydrogen rich flame. They then generate light with wavelengths specific to the material. An interference filter permits only those wavelengths which are characteristic for Sulphur to pass on to the photomultiplier. The photomultiplier generates an electric signal proportional to the amount of material passing through the flame. It is also possible to detect phosphorus in this manner; however, detection of phosphorus would require a different filter and is not supported in the Maxum II at this time. Specifications 2000596-001 -11 Detection limit for sulfur (Original FPD) Detection limit for sulfur (FPD II) 2 x 10 g/s -13 7 x 10 g/s Characteristic for sulfur Quadratic: [S] Operating temperature range 80°C to 150°C Ignition type Glow Plug Electrical Data 2 Volts / 3 Amps (Maximum, only for flame ignition) 2 2-61 Maxum II Module Flame Photometric Detector Below are sample views of the certification labels affixed to the FPD. Labels Original FPD FPD II Figure 2-50 Conditions for Safe Use per ATEX Certificate 2000596-001 Certification Labels • 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. 2-62 Maxum II Module Design Flame Photometric Detector 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 Figure 2-51 Flame Photometric Detector Combustion Chamber • • • Optics • • • • • 2000596-001 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. 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. 2-63 Maxum II Module Heater Flame Photometric Detector The 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. 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. IMPORTANT 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. 2000596-001 2-64 Maxum II Module Flame Ionization Detector Flame Ionization Detector Description The flame ionization detector (FID) is used for measuring hydrocarbons. It responds to most carbon containing compounds. Figure 2-52 Flame Ionization Detector Measurement Principle See Figure 2-53. The output from the separation column is burned in a hydrogen flame. The ions produced are captured by the collector electrode and generate ionization current. This measurement current ID is converted to a measurement signal UA in the amplifier. Within the linearity range, the measurement signal is proportional to the number of hydrocarbon atoms that are burned per time unit. The measurement signal also depends on the bonding types and possible presence of heteroatoms in addition to the carbon. Detector geometry and gas supply are calibrated so that the sensitivity and structural linearity are optimal. Figure 2-53 FID Block Diagram 2000596-001 2-65 Maxum II Module Ignition Spark Flame Ionization Detector The high voltage igniter module is comprised of a switching stage and a high voltage transformer that is used to generate the voltage for the ignition spark. The ignition module is in a separate unit from the detector. A new igniter module has been developed for the FID. Refer to the Maintenance Chapter of this Manual (Chapter 4) for more information regarding the new igniter module. Configurations • • Specifications Detection limit Absolute sensitivity Concentration range Linearity range Basic current at 250 Noise at impedance 0 Noise at impedance 2 Max. operating temperature Ignition type Detector Gas Supply Non Ex Module Explosion Proof (Ex Certified Module -12 Approx. 1 x 10 g C/s -3 Approx. 2 x 10 As/g C 4 Approx. 10 ppb ... 10 ppm -12 -5 10 ... 10 g C/s -12 3 ... 7 x 10 A -13 Approx. 10 A -14 Approx. 4 x 10 A 180 °C (T3), 280 °C (T2) High voltage spark Reaction Gas - The FID requires both hydrogen and combustion air (synthetic air or purified air). Reaction Gas - The FID requires both hydrogen and combustion air (synthetic air or purified air). Carrier Gas - Hydrogen, nitrogen, argon or helium are suitable carrier gases. 2000596-001 2-66 Maxum II Module Flame Ionization Detector Additive/Make-up Gas - To increase the sensitivity of the FID and to improve the structural linearity, air is added to the combustion gas via R02. When operating with Nitrogen as carrier gas this additive is not required. If the Hydrogen carrier gas stream is below 20 ml/min Siemens recommends the addition of Hydrogen combustion gas to achieve a stable flame and, if necessary, air to increase the sensitivity. Pressure reducers R01 to R03 are installed in the combustion gas inputs on the side of the detector. Figure 2-54 FID Gas Supply Maintain a Clean Supply Gas The FID is very sensitive to all types of hydrocarbons and to any contaminates 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 vpm. 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. Sensitivity The temperature of the detector flame and the size of the combustion zone determine the sensitivity of an FID as do the composition and the flow speed of the gas mixture. For an optimum signal/noise ratio use following gas flow rates: Combustion gas Combustion air Additive air Pressure Regulators 2000596-001 20 300 20 to to to 45 500 40 ml/min ml/min ml/min The electronic pressure control modules control the gas flow rate to the detectors. The flow rates can be adjusted. The carrier gas flow rate can be ~20 to 40 ml/min, but it should never exceed 60 ml/min including the additive. 2-67 Maxum II Module Methanator Methanator Description The methanator (Figure 2-55 and Figure 2-56) 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. 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. 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. Methanator Operation In the methanator, CO and CO2 are catalytically reduced to methane under excess hydrogen, which can be detected in the FID. The catalytic reaction can be described as follows. CO + 3 H2 CO2 + 4 H2 CAUTION CAUTION CAUTION 2000596-001 Ru → Ru → CH4 + H2O CH4 + 2 H2O When a purged methanator is installed, if the purge air supply of the Maxum II is interrupted during operation, it is imperative that the analyzer be powered down. Once powered down, the electronics enclosure door must be kept closed for at least 8 minutes. An 8-minute delay is necessary to give the methanator time to cool down sufficiently. If the door to the electronics enclosure is opened prematurely, explosive gas can ignite by entering the electronics enclosure and then entering the methanator through the conduit tube, causing equipment damage and injury. In addition, any time the analyzer is powered down when explosive gases are present, it is necessary to wait at least 8 minutes in order to allow the purged methanator to cool before opening the analyzer door. Failure to observe these precautions may result equipment damage and injury. For an explosion proof methanator, never remove the screw cap of the methanator while it is hot. If the cap is removed while hot, explosive gases can enter the device and ignite, causing equipment damage and injury. Allow at least 30 minutes for the methanator to cool down before opening. 2-68 Maxum II Module Methanator Methanator Parts The methanator is a stainless steel pipe filled with a catalyst. The pipe is heated using heating cartridges. An RTD temperature sensor regulates the heating. The pipe is heated to approximately 400°C, and the sample with hydrogen carrier is passed through the pipe. With the temperature and catalyst, the CO and/or CO2 (depending on the exact temperature) are converted into methane for detection by the FID. Because of the very high operating temperature, various safety protections are built into the design of the purged methanator. First, although the methanator assembly is installed in the detector compartment, it is installed inside a protective cover that limits air passage. The interior of the assembly is connected to the electronics enclosure using a conduit pipe which contains the electrical wiring for the methanator. This pipe and the protective cover over the assembly effectively make the interior assembly part of the purged electronics enclosure. Further explosion protection features of the purged methanator include the gas inlets and outlets that enter and leave the methanator. These are configured as flame arrestors. In addition the protective cover that is installed over the methanator assembly is insulated to prevent the surface temperature from exceeding 180°C. The explosion-proof methanator is protected by enclosing the hardware in an explosion-proof enclosure. Air passage is limited by sealed openings. Gas inlets and outlets are configured as flame arrestors. The device is insulated to prevent the surface temperature from becoming a hazard. Specifications Non-Ex-Methanator Max. Operation Temperature 400 °C Heater 2 cartridges 115 V each Classification none Gas Supply Figure 2-55 2000596-001 Ex-Methanator 400 °C 2 cartridges 115 V each EEx dp IIB+H2 T3 Use H2 (35 to 45 ml/min) as carrier gas. H2 is used as reaction gas in the methanator and as combustion gas in the FID. Combustion air and additive are adjusted the same as with the FID without methanator. Purged Methanator Figure 2-56 Explosion Proof Methanator 2-69 Maxum II Module Thermal Conductivity Detector Thermal Conductivity Detector Description 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 electronic circuits are located on a Detector Personality Module (DPM). (In older analyzers the DPM was mounted as part of an assembly with the SNE). The detector works on the principle that the thermal conductivity of the carrier gas is different (conducts more heat or less from the heated element) than the thermal conductivity of the sample components. The electronic circuits sense the change in heat flow and produce a proportional analog voltage signal. Sensing Elements For varied applications the TCD can use either filaments or thermistors for its sensing element Thermistor Model 8-cell Thermistor TCD: The detector includes six independent measurement cells and two reference cells. There is also a 4-cell version with three independent measurement cells and one reference cell. The 8-cell version has 4 installed thermistor boards and the 4-cell version has two thermistor boards installed. These two versions are otherwise identical. See the Intrinsically-Safe Thermal Conductivity DPM (IS-TCD3) on page 2-32 for a description of the DPM used for this. Filament Model For higher temperature requirements a 2-cell Filament TCD is available. The 2-cell Filament TCD can be used as an Inter-column Detector (ITC) in conjunction with a FPD or FID application. See the Base3 Detector Personality Module (DPM) on page 2- 27 for a description of the DPM used for this. Measurement Principle The TCD is operated in a constant temperature mode. The TCD compares the power required to maintain the measurement element (either thermistor or filament) at a specific temperature versus the power required to maintain the reference element at that same temperature. Thermistor detector beads operate at approximately 135 °C and filaments operate at approximately 325 °C. 2000596-001 2-70 Maxum II Module Thermal Conductivity Detector Detector Gas Supply Carrier Gas Table 2-9 Relative Thermal Conductivity Flow Rates 2000596-001 Hydrogen, helium, nitrogen and argon are suitable carrier gases. In this sequence the thermal conductivity of the gases decreases. The TCD is most sensitive when the gas with the highest thermal conductivity difference is used. Table 2-9 below shows the thermal conductivity (at 0 300 C) of various gases with reference to nitrogen. Gas Type Relative Thermal Conductivity at 3000 C H2 He CH4 O2 N2 CO2 Ar 675 560 170 105 100 90 70 The flow rates through the reference branch and the measurement branch should be 1 to 40 mL/min each. For trace analyses the carrier gas should be selected such that the thermal conductivity difference is highest between the gas and the component of lowest concentration. 2-71 Maxum II Module Pulse Discharge Detector (PDD) by Valco Pulse Discharge Detector (PDD) by Valco Description The Valco Model D-2 Pulse Discharge Detector (PDD) is manufactured by Valco Instrument Co. Inc. Three variations of the PDD are available for use in the Maxum II Process Chromatograph. These are Helium Ionization (PDHID), Photoionization (PDPID), and Electron Capture (PDECD). The PDD uses a stable, low powered, pulsed DC discharge in helium as an ionization source such that the need for a radioactive source is eliminated. Performance of the PDD is comparable to detectors with conventional radioactive sources. In the helium ionization mode (PDHID), the PDD is a universal, nondestructive, high sensitivity detector. The response to both inorganic and organic compounds is linear over a wide range. Response to fixed gases is positive (increase in standing current), with a minimum detectable quantity (MDQ) in the low ppb range. The PDD in helium photoionization (PDPID) mode is a selective detector. When the helium discharge gas is doped with a suitable noble gas, such as argon, krypton, or xenon (depending on the desired cutoff point), the PDD can function as a specific photoionization detector for selective determination of aliphatics, aromatics, amines, as well as other species such as ammonia. In the electron capture mode (PDECD), the PDD is a selective detector for monitoring high electron affinity compounds such as refrigerants, chlorinated pesticides, and other halogen compounds. For this type of -15 -12 compound, the MDQ is at the femtogram (10 ) or picogram (10 ) level. The PDD is similar in sensitivity and response characteristics to a conventional radioactive ECD, and can be operated at temperatures up to 400°C. Figure 2-57 Valco Pulse Discharge Detector (PDD) 2000596-001 2-72 Maxum II Module Pulse Discharge Detector (PDD) by Valco Measurement Principles See the Pulse Discharge Detector (Models D-2 and D-2-I) Instruction Manual available from Valco Instruments Co. Inc. for information regarding the measurement principles of the Valco PDD in its different operating modes. Specifications Refer to the Pulse Discharge Detector Instruction Manual for complete specification information associated with the Valco PDD. Operation and Installation The electronics (Pulse Discharge Controller) of the Valco detector are used to control the pulse discharge and the detector temperature. The Valco electronics is also used to amplify the detector signal. The output of the Valco detector electronics is connected to the Maxum via a Base Detector Personality Module equipped with an Analog Input Mezzanine board. The processing of the Valco detector signal is then handled by the Maxum II electronics. The Valco PDD should be operated in the 1X range with the Maxum detector board set on “low sensitivity”. The PDD 0-10V (un-attenuated) output from the Valco electronics is used. The connection to the detector is critical. The column or a capillary tube must be inserted in the detector as noted in the Column Connection section of the Valco manual. High purity gases together with a high quality gas purification device are required for proper use of the PDD. The quality of the gases is dependent upon the specific application. Refer to the Valco manual for general gas requirements and your custom documentation for specific requirements for your application. Normally an SAES Getters gas purifier is supplied with the system. Refer to the Pulse Discharge Detector Instruction Manual for additional information regarding installation and operation of the Valco PDD. Service 2000596-001 Service of the detector is limited to replacement of the electronics module or the replacement of the detector itself. Repair of these parts requires return to Siemens or Valco. 2-73 Maxum II Module Live Tee Switch Live Tee Switch Description The live tee is a valveless switch that can be used in place of a valve for switching columns. The live tee is virtually maintenance free since it has no moving parts, no temperature limitations and the sample only comes into contact with metal parts in the Live Tee. Figure 2-58 Live Tee Switch Mechanical Description There are two separate inner chambers separated by a polyamide barrier between the upstream column side (pre-column) and the down stream column side (main column). A platinum/iridium capillary tube (tee piece capillary) passes across the barrier. Columns are attached to the live tee by slipping the column end over the tee piece capillary all the way to the barrier, then backing out about 1 mm, and tightening a fitting using a metal sleeved graphite ferrule. Exercise care to avoid puncturing the polyamide barrier or bending the capillary while installing columns. Follow the column manufacturer’s instructions for cutting and handling fused silica columns. 2000596-001 2-74 Maxum II Module Figure 2-59 Inlets & Vents Live Tee Switch Live Tee Switch for Capillary Columns Figure 2-60 Live Tee Switch for Packed Columns The live tee has carrier gas inlets and vents on each of the upstream (Pm(+)) and downstream (Pm(-)) sides. The upstream side vent of the live tee is the heartcut vent (cut vent), and is normally run directly to atmospheric vent or through a monitor detector or ITC. The downstream side vent is called the “purge” vent and is normally connected to the outlet of the downstream column as a make-up or fuel gas just upstream of the main detector. During the flow set up procedure the purge vent can also function as an ITC when connected to the main detector. This is the typical arrangement of these vents. However, in some circumstances it is advantageous to plumb the cut vent to the main detector, and the purge vent to the ITC or directly to atmosphere. Figure 2-61 schematically shows the tee piece with columns and carrier gas connections. Pm (+) PA Pm (-) Injector Pre Column Split and Backflush Vent Main Column NV Cut Cut To Vent or Detector To Detector NV Purge Purge to Vent or Detector Figure 2-61 Typical Configuration 2000596-001 2-75 Maxum II Module Operation Live Tee Switch The following is a list of common terminology and abbreviations used in the following narrative. Pa Sample stream pressure at the inlet to the pre column. Pm Midpoint pressure. The pre-column outlet pressure of the sample stream at the Live Tee, as measured with the cut and purge vents (see below) blocked and the EPC flow through the carrier gas inlets off. This is the basis for determining the set point pressures for the carrier gas inlets, Pm(+) and Pm(-). 2000596-001 Pm (+) Midpoint pressure set point for the upstream carrier gas inlet of the Live Tee. Pm (-) Midpoint pressure set point for the downstream carrier gas inlet of the Live Tee. Cut Vent Vent on the column inlet side of the tee piece, controlled by needle valve 1 (NV1) Purge Vent Vent on the column outlet side of the tee piece, controlled by NV2 Cut Off Straight run flow pre column to main column (heartcut off) Cut On Pre column to cut vent (heartcut on) Back Flush Off Injector to pre column (opposite of the terminology used with valves) Back Flush On Pre column to backflush vent 2-76 Maxum II Module Live Tee Switch How It Works The operation of the Live tee takes advantage of the pressure drop across the tee-piece capillary and the annular spaces between the outside diameter of the capillary and the inside diameter of the column ends. The heartcut and backflush functions of the tee piece are delected by varying the pressures Pa, Pm(-) and Pm(+). Straight Mode To function in the straight-through column mode, pressure on the upstream carrier gas inlet (Pm(+)) of the live tee is set slightly higher than the pre-column outlet pressure (Pm). As shown below, this causes carrier gas entering the Pm(+) inlet of the tee piece to flow through the annular space between the column and the capillary and then through the capillary to the main column, adding a small component to the column flow. Pressure on the Pm(-) inlet of the tee piece is adjusted slightly higher than the pressure at the outlet of the capillary, but slightly lower than Pm(+), causing carrier gas to flow through the annular space between the main column and the capillary, adding another small element of flow to the main column. The small flows introduced to the column at both sides of the live tee effectively serve as make up flows, preventing any peak broadening through the tee piece by eliminating unswept dead volumes. Figure 2-62 Straight – Pa > Pm(+) > Pm(-) Cut On Mode To function in the heartcut mode, as shown below, the pressure at Pm(+) is reduced to slightly below that of Pm(-), causing carrier gas to flow from the Pm(-) side back through the capillary and out to the cut vent, taking with it all flow from the pre-column. It is possible to have this pressure adjusted marginally so peaks are split and flow to both the main detector and out to the cut vent. It is also possible to have the Pm(-) pressure adjusted so peaks partially flow through both the main detector and the purge vent. When either of the two vents is connected to the main detector at the outlet of the main column, the earlier eluting peaks from the vents signal the peak retention time of the pre-column and are useful in determining cut timing. Figure 2-63 Cut On – Pa > Pm(-) > Pm(+) 2000596-001 2-77 Maxum II Module Backflush Mode Live Tee Switch To function in the backflush mode, shown below, pressure at the column inlet Pa is reduced to allow flow of carrier gas from the Pm(+) side of the live tee back through the pre-column and out the backflush vent. The splitter vent will usually double as a backflush vent, but in the case of direct injection, a pneumatic valve can be opened when inlet pressure is reduced. In this mode, Pm(+) is also slightly higher than Pm(-), causing carrier gas to flow through the capillary and out to the downstream column as shown below. Figure 2-64 Backflush – Pm(+) > Pm(-) > Pa 2000596-001 2-78 Chapter 3 Operation of Maxum II User Display Panels Overview Introduction This chapter is intended for operating and maintenance personnel. Two different versions of user display panel are available for the Maxum. The original version is the HMI, also referred to as a Maintenance Panel. This user interface featured a black and white screen and keypad entry. A newer display is also available, the Color Touchscreen Display (CTD). This enhanced interface features a touch screen and color display, with a larger screen than the HMI. Both types of display are installed in the door of the Maxum analyzer. All of the Maxum II’s operational and daily routine maintenance tasks can be performed from either the HMI or from the CTD. See subchapter 3a for information relating to the CTD. See subchapter 3b for information relating to the HMI. 2000596-001 3-1 Chapter 3a Color Touchscreen Display Panel Operation Overview Introduction This chapter is intended for operating and maintenance personnel. All of the Maxum II’s operational and daily routine maintenance tasks can be performed from the Color Touch Screen Display (CTD). Two different hardware configurations are supplied for the CTD. The operation of the two doors is identical. The latest door hardware, supplied in the Maxum II analyzers equipped with single or dual airbath and airless ovens, is called the “TIB Door”. The door has the touch interface mounted on the back of the display panel itself, with LCD control and backlight power cabled from the SYSCON2.1. TIB Door The “CIM Door”, currently supplied in the Maxum II Modular Oven analyzers, is controlled by a processor board called the CIM Board. The combination of board and display is referred to as the CIM (Control Interface Module). Information relating to the Control Interface Module hardware can be found in the Maintenance Manual for the Maxum II Modular Oven Configuration (Siemens Part Number A5E31405710001). CIM Door 2000596-001 3a-1 The CTD runs an enhanced version of the HMI software that is used to control the Maintenance Panel in older versions of Maxum. Because this chapter deals primarily with the operation of the software, the term HMI may be used at times to refer to the software even though the hardware is the CTD or CTD Display. In addition, the display emulator in the workstation software is referred to as the HMI emulator. The HMI software on the CTD utilizes interactive display screens, menus, and icons for common functions. In addition, the software is equipped with context sensitive help for most functions. This makes the device intuitive and simple to use once the user is familiar with the basic operation. Before You Begin The information in this chapter is written for the color touch screen Display running the latest software version. Some versions of Maxum may be equipped with the older Maintenance Panel. Information for that version of the Maintenance Panel can be found chapter 3a of this manual. Since it is also possible to install a CTD display in an existing Maxum (including Airbath/Airless oven configuration), it may be possible that the CTD has a different software version. In this case some screens and menus may appear different. However, all versions of display are designed to look and operate in a similar manner, including both the CTD Display and the Maintenance Panel running the most recent software versions. All versions 4.0 and up have a menu tree of the HMI that is organized into 3 functional levels. These levels allow different levels of access to analyzer control and configuration. 3a-2 2000596-001 Overview, Continued Emulator A PC-based graphical simulation of the physical CTD, known as the HMI emulator, is available using the PC based workstation software. This emulator is capable of performing all of the functions that are available with the physical unit. The emulator is a graphical representation of the physical display. Because of this, some aspects of the emulator appear slightly different than they appear on the physical unit. Chapter Highlights Topic Overview 3-1 Introduction 3-1 Before You Begin 3-2 Emulator 3-3 Color Touchscreen Display Hardware Status LEDs Screen Characteristics 3-4 3-4 3-5 Description 3-5 Main Navigation Bar 3-5 Status Bar 3-6 Content Area 3-6 Toolbar 3-6 Softkey Bar 3-6 Using the CTD 3-7 Navigating the Menus 3-7 Entry of Data 3-8 Accessing Help 3-9 Password Restrictions 2000596-001 Page 3-11 Description 3-11 Checking Your Access 3-11 Password Format 3-11 Obtaining/Changing a Password 3-12 Privilege 3-12 3a-3 Color Touchscreen Display Hardware Overview The CTD contains a back-lit color graphic display screen layered with a touch screen sensor. Figure 3-1: CTD Status LEDs 3a-4 The four LEDs next to the screen indicate the analyzer systems status. Power The green "Power" LED lights when the power supply is on. Warning The yellow "Warning" LED lights when the "Maintenance request" status signal is active. Fault The red "Fault" LED lights when the "Failure" status signal is active. Purge The red "Purge" LED lights when purge pressure is lost as detected by the PECM-DC. 2000596-001 Screen Characteristics Description The screen is in color and back-lit for easy reading, and it is divided into several functional areas: • • • • • Main Navigation Bar Status Bar Content Area Toolbar Softkey Bar Figure 3-2: Screen Layout Main Navigation Bar The main navigation bar allows the user to return to the home menu screen, go back to a previous menu screen, or launch the interactive help function (all denoted by easy to understand icons). The help function on the main navigation bar is an interactive feature that provides context sensitive assistance. It is accessed by clicking the help icon on the far upper right and then clicking the area of the screen for which help is desired. The main navigation bar also contains information regarding the current level of password access (default is “configure”). This information is located next to the help icon in the far right side of the bar. 2000596-001 3a-5 Screen Characteristics, Continued Status Bar The status bar shows various data about the analyzer, including the name, date and time, and run/hold status. It also shows information about the current application, stream, method, and cycle clock. In addition, the status bar contains gray buttons that permit the user to change the run/hold status or to select the current analyzer, stream, application, and method. Content Area The middle part of the screen is the general content area. It contains menu lists or parameters with the applicable values, as well as alarm messages and operator hints. The content area is where the primary information for a selected screen is displayed. The top left of the content area is usually a general name or description of the screen. Toolbar The toolbar allows the user to navigate directly to commonly used screens. This includes access to the alarm screen as well as settings for valves, temperature, pressure and streams. It also allows the user to navigate to the different menu levels (monitor, maintenance, and configure). The Softkey Bar The softkey bar appears at the lower edge of the screen. Its gray background distinguishes it from the content area. The softkey bar associates different actions with the softkeys located below the screen. The actions vary depending on the screen shown. 3a-6 2000596-001 Using the CTD Navigating the Menus As mentioned previously, the menu tree of the CTD is organized into three functional levels. This structure is used to allow different levels of access to analyzer control and configuration operations. The three functional menu levels are as follows. • Monitor Menu – This menu level allows minimal control of the analyzer and viewing of analyzer status with minimal control of analyzer function. This level is intended for operations personnel. All password levels have access to the Monitor Menu; however, higher access is necessary for some functions. • Maintenance Menu – This menu level allows detailed application and stream control and is intended for engineering personnel. A password with “Maintain” level access is needed to access the Maintenance Menu and all of its functions. • Configure Menu – This menu level allows system configuration control and is intended for use of system administrators and engineers. A password with “Configure” level access is needed to access the Maintenance Menu. Higher (“Super”) access is needed to access user and password functions. These different menu levels can be selected using the tool bar icons. The three options show up anytime any one of the main three menus is displayed. Select the Home icon in the far upper right corner of the CTD in order to display the default menu, which will display the menu icons. The Toolbar The Softkey Bar The toolbar allows the user to navigate directly to commonly used screens. In addition to selections described above, this includes access to the alarm screen as well as settings for valves, temperature, pressure and streams. To navigate to a screen using the toolbar, simply tap on the desired icon (or click if using the HMI emulator). At the bottom of the screen, below the content area, is the softkey bar. When a menu is displayed, a series of softkeys appears on the softkey bar. As the user navigates through the different screens, the softkeys that appear will depend on the particular screen being displayed. The function of each softkey is identified by a label on the softkey. To operate a softkey, simply touch it on the display screen (or click on it if using the HMI emulator). 2000596-001 3a-7 Using the CTD, Continued Entry of Data The original Maintenance Panel for Maxum was equipped with a numeric keypad for data entry. The touch screen function of the CTD eliminates the need for this. When data entry is required on the physical CTD, a pop-up window with numeric keypad appears on the screen as shown below. Figure 3-3: Window for Data Entry on CTD When the HMI emulator is used, the data entry window does not appear because the numeric keys on the computer keyboard can be used. 3a-8 2000596-001 Using the CTD, Continued Accessing Help The online help function of the CTD represents a large leap forward in usability over the original HMI. It allows the user to obtain a help description for virtually every element displayed on the screen. It also allows the user to obtain detailed descriptions of alarms as well as possible causes and suggested corrective actions. Context Sensitive Screen Help To access help touch the help icon ( ) on the upper right corner of the CTD (or click on the icon if using the emulator). This puts the software in an interactive help mode. This mode is context sensitive. This means that for the next item you touch (or click), the software will display a help window for that item. In the figure below, the help icon was selected and then the “Temp” icon on the toolbar. This displayed the help text window in the middle of the screen. Figure 3-4: Window for Data Entry on CTD Click OK to remove the window and continue. Note that once the window is removed, the software is no longer in the help mode. Clicking a selection will have the normal effect. 2000596-001 3a-9 Using the CTD, Continued Alarm Help One useful feature of the online help function of the CTD is the ability to get detailed descriptions of alarms as well as possible causes and suggested corrective actions. To access alarm help, first load the alarm screen by selecting it from the menu or from the toolbar on the right side of the screen. Next, touch the help icon ( ) on the upper right corner of the CTD (or click on the icon if using the emulator). This puts the software in the interactive help mode. To see help for an alarm, click the “Description” field for that alarm. This will display the alarm help screen. In the figure below, the help icon was selected and then the “Description” field for the first alarm on the list. This displayed the help text window in the middle of the screen. Figure 3-4: Window for Data Entry on CTD Note that this help box is displayed only when the “Description” field is selected while in help mode. Selecting other fields for the alarm provides help information describing what the field is used for (context sensitive help described on the previous page), rather than information about the alarm. 3a-10 2000596-001 Password Restrictions Description It is possible to configure the CTD for different levels of password access. By default, six different levels of password access are available. By default, the display is preset for a “configure” level of access, which allows the user to perform almost all analyzer functions except password administration. If the access level of the current active password is not sufficient for a requested operation, a screen will appear stating that the required level of password must be entered. By default, when a password is entered, the session remains active for 60 minutes unless a different time period has been set; see description of “SET TIME” softkey below. Checking Your Access To see if you are authorized to perform a specific function, use the appropriate menu path to navigate to that function. If the following screen appears, then password entry is necessary to perform that function (i.e. the current level of access is not sufficient to perform the function). Select the “LOGIN” softkey and then enter the appropriate password and press OK. If the password is correct and has sufficient access, access level will change (seen in the upper right corner of the display next to the help icon). You are now logged on and can execute the required function. If the password is incorrect, the screen will revert back to the home menu and the access level will not change. Password Format 2000596-001 A password consists of one to six numerical digits and is entered via the numeric keypad. 3a-11 Password Restrictions, Continued Obtaining/Changing a Password Passwords can be modified from the User’s Passwords screen on the Configure menu. To change a password you must be logged on with “Super” level access. To change a password, select the table entry for the user and then tap (click) the “SELECT” softkey. This will display a window to modify the password. Privilege If your password is accepted you can modify any menu items or parameters assigned to your user level (or lower user levels). There are six predefined user levels (levels 0-4 and 99). The items that can be modified at these user levels are predefined and cannot be changed by the user. By default six users are defined. These are “public”, “operate”, “calibrate”, “maintain”, “configure”, and “super”. The default access level for each of these users matches their names. In addition, multiple individual users may be defined. These users must have unique names and they can be created with either “operate”, “calibrate”, “maintain”, or “configure” access levels. Creation and deletion of users must be performed using the workstation software. (Refer to the Gas Chromatograph Portal (GCP) chapter of this manual for instructions on creating and deleting users). The change privilege remains in effect if the user presses any key before the timeout limit (default 60 minutes). In this manner the user does not have to re-enter a password repeatedly while browsing through menu screens. However, the analyzer automatically logs out (back to the default user), if the user has not pressed a key within the timeout limit. 3a-12 2000596-001 Chapter 4 Maintenance Overview Description Procedures in this Chapter are for use by maintenance personnel. Note: Some hardware modules have been updated. See Chapter 2 for information on the latest hardware. Safety First When performing maintenance procedures in this chapter observe all warnings, cautions and notes to prevent physical injury to yourself or unnecessary damage to the equipment. WARNING Observe all plant safety requirements before performing any repair or maintenance on the Maxum II. Chapter Highlights The following maintenance information is provided: Topic 2000596-001 Page Overview 4-1 General Maintenance 4-6 SYSCON2 4-9 SYSCON2.1 4-16 Power Entry Control Module Version 2 (PECM2) 4-17 Power Supply (PS) 4-21 Solenoid Valve Control Module (SVCM) 4-24 Solid State Relay Module 4-31 Electronic Pressure Control Module (EPCM) 4-38 Purge Control Module (PCM) 4-41 Wiring Distribution Board 4-45 Air Circulating Fan (ACF) 4-47 Model 50 Valve 4-49 Maintenance • 4-1 Overview, Continued Topic Page Model 20 Valve 4-56 Model 20 High Temperature Valve (HTV) 4-69 Model 11 and Model 11 Low Dead Volume (LDV) Valves 4-85 Liquid Injection Valve 4-101 Live Tee Switch 4-113 Live Tee Switch Example Application 4-115 Flame Photometric Detector (FPD) 4-126 Flame Ionization Detector (FID) 4-131 Thermal Conductivity Detector (TCD) 4-138 Miscellaneous Maxum II Procedures 4-143 Troubleshooting 4-144 Help If technical assistance is required during performance of maintenance functions, or if parts are being returned, the customer should contact Siemens at the addresses and/or phone numbers provided at the beginning of this manual. How to Use This Chapter Before performing a procedure first read it through. It is recommended that a regular scheduled daily, weekly or monthly maintenance program be established. By doing so, the Maxum II’s downtime will be reduced and the system will operate at optimum analytical efficiency. Siemens recommendations for routine maintenance are listed in table 4-1 on the following page. These recommendations are intended as a guideline. Actual maintenance may change depending on application and the environment in which the Maxum II operates. 2000596-001 Maintenance • 4-2 Overview, Continued Note: The tasks described below are provided as a suggested guidleine for routine maintenance. Requirements for a particular analyzer will depend on environment, location of the analyzer, available resources, and the specific characteristics of the application. Task Frequency Backup of database Weekly as well as before performing any maintenance that requires the analyzer to be powered down. Status Check – Includes checking alarms, utility bottle pressures, flow rates, and oven temperature. Daily. Visual Inspection (walk by) Daily or weekly (may vary depending on location, application and. environment) Interior Electronic Enclosure Visual Inspection (open cabinet and check for moisture and/or contamination) Monthly (may vary depending on location, application and environment) Valve Inspection Gas Samples – Model 11 – 6 months Model 20 – 6 months Model 50 – Yearly Liquid Injection Samples All valve types 6 weeks Routine maintenance schedule for valves will vary greatly depending on sample properties, application (including temperature and pressure) and environment. In addition, for liquid injection applications, valve seals may need to be replaced on a regular basis. The interval could range from 4 weeks to a few months depending on the sample properties. Table 4-1: Recommended Routine Maintenance 2000596-001 Maintenance • 4-3 Overview, Continued Note: The tasks described below are provided as a suggested guidleine for routine maintenance. Requirements for a particular analyzer will depend on environment, location of the analyzer, available resources, and the specific characteristics of the application. Task Frequency Verification of Calibration Monthly (may vary greatly depending on application). When validation is included automatically as part of the method, the results should be checked daily if possible. Sample Transport Filters Replace as necessary. Note that wet/dirty samples require more frequent attention than dry/clean samples. Lithium Battery on SYSCON Replace every 5 years Table 4-1 (Continued): Recommended Routine Maintenance 2000596-001 Maintenance • 4-4 Overview, Continued Figure 4-1: Electronics Enclosure Wiring Harness Diagram 2000596-001 Maintenance • 4-5 General Maintenance Scheduled Maintenance It is important that a preventative maintenance schedule be established to examine the Maxum II for internal and external cleanliness, damage, and proper operation. Refer to Table 4-1 for suggestions regarding maintenance intervals. However, maintenance schedules for a particular analyzer will depend on the application, operating environment, maintenance resources, and geographical location of the analyzer. Even though the Maxum II is tightly sealed against moisture and foreign contamination, it is recommended that the electronic enclosure door be opened periodically and internal components examined for moisture and/or contamination. If contamination is found, the system should be shutdown and corrective procedures performed. If such contamination is not removed, it could render the Maxum II inoperable. Component Interface Cabling and Connectors Modular components within the Maxum II are interfaced together via miniature ribbon cables, miniature wiring and connectors. It is therefore important that maintenance personnel follow the information presented in the following sections to prevent their damage. Ribbon Cable Therefore, when opening and closing electronic enclosure door for maintenance and/or inspection, care must be exercised so as not to place a sharp bend or crimp in the cable when the door is closed. Removing Connectors Internal components and modules are interfaced together using miniature wiring and associated connectors. It is therefore important that when a module and/or component is to be removed and replaced, that the connector be grasped and gently rocked, back and forth. DO NOT REMOVE A CONNECTOR BY PULLING ON ASSOCIATED CONNECTOR WIRING. Nut and Bolt Mounting Hardware With very few exceptions, nut and bolt hardware used to secure modules and/or components in their mounting locations are in metric. WARNING Observe all plant safety requirements before performing any repair or maintenance on the Maxum II. 2000596-001 Maintenance • 4-6 General Maintenance, Continued Opening Doors To gain access to the modules, the electronic enclosure door must be opened. It will be necessary to use a #4mm Allen wrench to open the door if the Allen screw on the latch has been tightened. APU Maintenance Switch When an analyzer is equipped with an Automatic Purge Unit (APU), the APU is designed to cut power to the analyzer when the Electronics Enclosure Door is opened (disrupting purge). Maxum II analyzers with APU are equipped with a key operated Maintenance Switch that allows a user to perform maintenance on the analyzer while powered. WARNING The Maintenance Switch on a Maxum II analyzer that is equipped with Automatic Purge Unit (APU) should ONLY be used when it has been verified that the analyzer location is safe. “Hot Work” permits may be required depending on the location. All work must be with the approval of local safety personnel. Inspection After Maintenance After performing any maintenance function(s), check to be certain there is no loose hardware left within the electronic enclosure. Such items can create electrical shorts causing damage to internal components. This increases system downtime for performing of corrective maintenance. Field Tool Kit Recommended tools for performing maintenance are as follows: • Maxum II Tool Kit or • Set of metric Allen wrenches • Set of metric wrenches or nut drivers Note: Special tools required for specific procedures within this section are noted within the procedure (example: torque wrenches required for valve assembly). 2000596-001 Maintenance • 4-7 General Maintenance, Continued Use of Solvents and Detergents 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 also 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. 2000596-001 Maintenance • 4-8 SYSCON2 Description This section presents the procedures for removal or installation of the SYSCON2 boards, SIB and CAC3. The SYSCON2 is mounted in the upper center section of the electronic enclosure with the SIB being mounted within the bottom of the SYSCON cage and the CAC3 being mounted on the SIB. • • • CAC3 Removal and Installation SIB Removal and Installation Battery Replacement NOTE The steps to install expansion boards in the SYSCON2 are the same as for the legacy SYSCON. The procedure for installation of expansion boards is detailed in the previous section WARNING Voltage dangerous to life exists. 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. CAUTION To remove the SIB from the SYSCON assembly, the assembly must be completely removed from the electronic enclosure. When removing the assembly, exercise care so as not to drop the assembly. Doing so could seriously damage sensitive components. When removing any SYSCON2 components, service personnel should either wear a wrist type grounding strap with the other end connected to the SYSCON frame or personally ground themselves to the chassis. Even a small static discharge could cause permanent damage to the sensitive electronic components. Procedures The following procedures should be followed for removal and installation SYSCON2 related hardware. CAC3 Removal and Installation 2000596-001 Step Procedure 1. Before beginning replacement, if possible, save the current Maxum .amd database file to be reloaded after the CAC3 board is replaced. Note that if the CAC3 is faulty, backup may not function. In this case it will be necessary to use the most recent backup file. 2. Once the database is saved, power off the Maxum. 3. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. Maintenance • 4-9 SYSCON2, Continued Step NOTE Procedure 4. Using a 5/16” wrench or Phillips screwdriver (depending on assembly type), loosen the topmost SYSCON assembly fastening nuts that secure the assembly to electronic enclosure mounting bracket. 5. Pull the SYSCON assembly cage forward so it rests on the rubber mounting foot, being careful not to damage any connected cables. Refer to figure 4-7 In the following step only remove expansion boards that would prevent removal of the CAC3 board. Verify each expansion board interface cable is labeled with its mounting location. 6. If boards are installed in the PCI slots that block removal of the CAC3, those boards must be unplugged at this time. Disconnect interface cables for any board that must be removed and then remove the board (make note of which cables are connected to which board before removing). Figure 4-7: Positional Location of SYSCON2 in Electronic Enclosure 2000596-001 Maintenance • 4-10 SYSCON2, Continued Step 2000596-001 Procedure 7. Disconnect the Ethernet cable from the CAC3 board. It is not necessary to disconnect the other end of this cable. 8. Remove the CAC3 board by grasping both sides firmly and pulling up. Do not touch board mounted components. 9. Place the CAC3 in an anti-static bag for return to Siemens. 10. Install the new CAC3 board by pressing it firmly into the connectors, taking care not to touch any components or connections on the board. Then, reconnect the Ethernet cable to the CAC3. 11. If any boards were removed from PCI slots, reinstall them at this time and reconnect their cables. Verify that all boards and cables are in their correct locations. 12. Repeat previous steps in reverse order to slide the SYSCON assembly cage back into place, tighten the fastening nuts, and close the analyzer door. 13. Apply power to the Maxum and allow it to boot. 14. Restore the analyzer database using the .amd file that was saved before beginning the procedure. 15. When the CAC3 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. Maintenance • 4-11 SYSCON2, Continued SIB Removal and Installation 2000596-001 Step Procedure 1. Before beginning replacement, if possible, save the current Maxum .amd database file. Note that if the SIB is faulty, backup may not fuction. 2. Once the database is saved, power off the Maxum. 3. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 4. Using a 5/16” wrench or Phillips screwdriver (depending on assembly type), loosen the topmost SYSCON assembly fastening nuts that secure the assembly to electronic enclosure mounting bracket. 5. Pull the SYSCON assembly tray forward so it rests on the rubber mounting foot, being careful not to damage any connected cables. 6. Pull the SYSCON assembly cage forward so it rests on the rubber mounting foot, being careful not to damage any connected cables. Refer back to figure 4-7 in the previous procedure. 7. Note the connection locations of all interface cables, labeling them if necessary. Then unplug each external interface cable. This includes any cables connecting to boards in the PCI slots, any serial cables, HMI ribbon cable, and any external Ethernet cables (including the Ethernet cable running to the SNECON). Any orange I/O connectors should be labeled and unplugged from their respective locations (do not disconnect the I/O wiring from the connectors). 8. From rear left side of the SYSCON cage, remove the two external PECM Power Cables. To remove cables, press in the connector locking tabs and pull connector outward. These two cables have different connectors preventing cabling errors during reinstallation. Maintenance • 4-12 SYSCON2, Continued Step Procedure 7. Remove the SYSCON cage tray by lifting the tray upwards and pull forward from its mounting rail assembly. It is recommended that the assembly be lifted by one hand and supported by the other. Place assembly on a clean dirt free work surface. 8. The oldest version of SYSCON assembly tray must be partially disassembled in order to remove the SIB board. This version of tray can be identified by the perforated panels that surround it. If this type of assembly is in use, remove the perforated panel on the left side of the tray as shown in the picture below. If this type of tray is not in use, skip to the next step. Figure 4-8: Partial Disassembly of Original Version SYSCON tray 2000596-001 9. Note the locations of any boards mounted in the PCI slots and any cables connected internally to the SIB board. Temporarily label cables and boards if necessary. 10. Remove any boards that are plugged into the PCI slots of the SIB. Also, disconnect the internal Ethernet cable and remove the Ethernet Switch board from the far right slot. Set Ethernet Switch and any other installed boards on a clean dry surface. 11. Remove all internal cables that are connected to the SIB. The plug in locations of these cables should have been noted in the previous steps. Maintenance • 4-13 SYSCON2, Continued 2000596-001 Step Procedure 12. Remove the CAC3 board by grasping both sides firmly and pulling up. Do not touch board mounted components. Set the CAC3 aside on a clean dry surface. 13. Remove the six Allen screws that secure the SIB to the SYSCON assembly tray. Screws are located in each corner and in the center of the SIB. 14. To remove the SIB, lift-up the right side and carefully slide the board out the right side of the SYSCON assembly. Carefully guide the SIB over and around any connector hardware that is attached to the inside of the SYSCON assembly. When removing motherboard, lift by the board by the edges. DO NOT touch board mounted components. 15. Place the SIB in an anti-static bag for return to Siemens. 16. To reinstall new SIB, repeat previous steps in reverse order. When reinstalling CAC3 board and any other electronic boards, handle by the edges to prevent damage to components. 17. Verify that all hardware is installed securely and in the correct locations. 18. Reinsert the SYSCON assembly tray into the analyzer and leave it in the pulled-out dropped-down position. 19. Reconnect all external cables to their correct locations. Verify that all connections are secure and correct. 20. Slide the SYSCON assembly cage back into place, tighten the fastening nuts, and close the analyzer door. Then, apply power to the Maxum analyzer and allow it to boot. 21. Since the CAC3 board was not replaced, it should NOT be necessary to reload the analyzer database. 22. When the CAC3 is disconnected from the SIB, 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. Maintenance • 4-14 SYSCON2, Continued IMPORTANT Battery Replacement The battery should only be replaced with an approved spare. Contact Siemens for a replacement. Step Procedure 1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 2. Using appropriate tools, loosen the topmost SYSCON Assembly fastening hardware that secures the assembly to electronic enclosure mounting bracket. 3. Pull the SYSCON assembly forward and lower so it rests on the electronic enclosure bottom frame rubber mounting feet. For battery location, refer to Figure 4-9. 4. Remove defective battery from its mounting bracket located at the rear of the module. Refer to picture below. 5. When installing Lithium Battery in its holder, place the positive (+) side so it installs per marking on the holder. 6. After installation, push the SYSCON assembly back into its mounting facility and secure assembly in place with the fastening hardware. 7. Before closing door and reapplying AC power, be certain the battery is securely installed in its holder and polarity, within holder, is correct. 8. When the battery is disconnected, 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. Battery Figure 4-9: SYSCON Board 2000596-001 Maintenance • 4-15 SYSCON2.1 Maintenance for the SYSCON2.1 is largely the same as for the SYSCON2. 2000596-001 Maintenance • 4-16 Power Entry Control Module (PECM2) - New Version Description This section presents the procedures for removal or installation of the newest version of the Power Entry Control Module (PECM2). The PECM2 is also covered in detail in the PECM Installation Manual (Siemens part number 2000687-001). When replacing the original version of the PECM it should be upgraded to the PECM2. This will require additional cabling. If upgrading from original PECM to PECM2, refer to the procedure in the Maxum II Extended Service Manual (Siemens part number A5E02220441001). New two-part PECM WARNING Voltage dangerous to life exists. 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. WARNING 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. The PECM2 assembly is mounted to the left wall of the Electronic Enclosure. The PECM2 assembly consists of a base board with attached temperature controller board. The temperature control board mounts directly on the base board. This section covers replacement of both the base board and the temperature control board. 2000596-001 Maintenance • 4-PAGE48 Power Entry Control Module (PECM2), Continued PECM2 Removal and Installaton The following procedure should be used for replacement of the PECM2 in the Maxum II. If upgrading from original PECM to PECM2, refer to the Maxum II Extended Service Manual (part number A5E02220441001). Step Procedure 1. Turn off power to the Maxum II at the main circuit breaker. 2. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 3. Remove power connections from PECM2. Secure and lable these connections for reattachment later. 4. Remove cables connected to PECM2. Label each cable when it is removed. 5. Unplug the atmospheric reference tube from the purge switch. (connection SW1, tubing connection on the bottom board of the PECM2, middle right side, back). Refer to Figure 4-15. 6. Use a 5mm nut driver or socket to loosen the two hex nuts at the top of each side of the base plate of the PECM2. Do not remove the nuts completely. 7. Slide the PECM2 up and then lift it off of the mounting bolts. 8. On the replacement PECM2 perform the following: • • • • 2000596-001 Verify that the Purge Disable jumper JP2 is set correctly. Ensure the TL/OT boards are moved to the replacement PECM2 (J15 & J16) to maintain the same T-rating of the GC. Install the appropriate fuses for either 115VAC or 230VAC in Fuse locations F1 and F2 and install covers. Refer to the table on the following page for fuse assignments). Be sure to replace the fuse cover over the fuses once the fuses are installed. Move jumper cables or termination plugs to the replacement PECM2. Maintenance • 4-PAGE48 Power Entry Control Module (PECM2), Continued Step Fuse F1 F5 F2 F4 F3 Procedure 9. Making sure there are no wires behind the mounting position of the PECM2, install the replacement PECM2 on the mounting bolts. 10. Reattach the atmospheric reference tube from the purge switch. (SW1, tubing connection on the bottom board on the PECM2, middle right side, back). 11. Starting at the back of the PECM2, plug in all cables. Make sure that plug in locations and labels match. Refer to Figure 4-15. 12. Reattach power connections and apply power to the analyzer. Function Fuses for 115VAC Fuses for 230VAC AC Power Circuit 1 16A 10A (1901693-001) (1901694-001) 6.3A 6.3A (1901695-001) (1901695-001) 16A 10A (1901693-001) (1901694-001) LWH 1-5 (low wattage heaters) 10A 10A (1901694-001) (1901694-001) Power Supply (24V out) 3.15A 3.15A (1302004-033) (1302004-033) Heater Channel 6 AC Power Circuit 2 Table 4-2: PECM2 Fuse Assignments 2000596-001 Maintenance • 4-PAGE48 Power Entry Control Module (PECM2), Continued Figure 4-15: PECM2 Assembly Layout 2000596-001 Maintenance • 4-PAGE48 Power Supply Description This section presents the procedures for removal or installation of the Power Supply. The Power Supply is mounted to the top of the electronic enclosure. Location is to the left side of the SYSCON Assembly. WARNING Voltage dangerous to life exists. 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. Procedure The following procedures should be followed for removal and installation of power supply. Refer to Figure 4-16. CAUTION Before loosening, but not removing, the four mounting screws that secure power supply to inside top of enclosure, firmly grasp the power supply so it does not fall onto components mounted in bottom of enclosure. Power Supply Removal and Installaton 2000596-001 Step Procedure 1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 2. Remove the power entry control module power cable connector from front of power supply. Maintenance • 4-PAGE48 Power Supply, Continued Power Connections to Syscon 115/230 VAC Selector Switch 24 VDC Connected to WDB/PECM PECM Power Connector GND Wire Connected to Chassis GND Enclosure Slotted Mtg. Screw Locations (2) Figure 4-16: Power Supply Mounting Configuration Step 2000596-001 Procedure 3. Disconnect and label any cables that run power supply to other devices. 4. Unplug the power supply chassis ground wire from its spade plug on the analyzer chassis. This plug is located on the back wall of the analyzer behind the power supply. 5. Loosen but do not remove the two #5 mounting nuts from left side of power supply. 6. Firmly grasp the power supply, slide it forward until it touches the front frame of electronic enclosure upper frame. This should clear mounting bolts and release the right side of supply from SYSCON mounting bracket. Maintenance • 4-PAGE48 Power Supply, Continued Step CAUTION 7. Rotate the lower left side downward to clear mounting hardware then remove the power supply by lifting it out to the left. 8. To reinstall the power supply, perform steps 1 to 7 in reverse order. 9. After installation of power supply, reconnect all power cables to the WDB and SYSCON. Connect green ground wire to electronic enclosure chassis. Before applying primary AC power to the power supply after installation, be certain the power supply red 115/230 VAC selector switch is set to the input primary AC power source voltage. 10. 2000596-001 Procedure Before closing electronic enclosure door and reapplying AC power, be certain all interface cables are correctly connected from the power supply to other modules within the analyzer. Maintenance • 4-PAGE48 Solenoid Valve Control Module (SVCM) This section presents the procedures for removal or installation of the Solenoid Valve Control Module (SVCM). The SVCM is mounted on the back wall of the electronic enclosure; depending upon your installation you can have up to three modules. 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 PECM module. Also, the old version uses a Parker brand solenoid, and the new version uses an SMC brand solenoid. Description IMPORTANT If the old configuration is in use, it is necessary that the valve driver circuit board be removed in order to remove the bank of eight latching solenoids. This allows access to the module mounting hardware. The screws securing the module to the rear of the electronic enclosure wall are captive and cannot be fully removed. The screws are removed with the SVCM assembly. WARNING Voltage dangerous to life exists. 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. CAUTION There are 15 Viton O-rings installed in each latching solenoid bank. After removal of a solenoid bank, the assembly should be inspected to be certain all O-rings have remained installed. These O-rings must be in place when the bank assembly is reinstalled. For their location, refer to Figure 4-20. Old SVCM New SVCM Figure 4-17: Old and New SVCM Assemblies 2000596-001 Maintenance • 4-PAGE48 Solenoid Valve Control Module (SVCM), Continued Procedures Procedures are presented for removal of the circuit board and then the latching solenoids. Refer to Figures 4-17 through 4-20. IMPORTANT Depending on the configuration of the Maxum II, it may be necessary to remove an SNE assembly in order to properly access the SVCM assembly for removal. Refer to the SNE maintenance section of this manual for instructions on removing an SNE assembly. Removal SVCM Electronics Controller (Old SVCM Only) 2000596-001 Step Procedure 1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 2. Disconnect both solenoid cables J10 and J11 connected to circuit board. Also disconnect J1, J2 and J3. Refer to Figure 4-18. 3. Remove three 5mm Allen mounting screws securing SVCM to relay bank mounting standoffs. These are not captive screws and MUST BE completely removed. 4. Remove circuit board from mounting standoffs. To remove, grasp board by its sides to prevent static discharge which could damage components. 5. To reinstall a new circuit board, perform steps 1 to 4 in reverse order. To prevent damage to SVCM, DO NOT over tighten mounting screws (screws should be tightened firmly but not torqued down). Maintenance • 4-PAGE48 Solenoid Valve Control Module (SVCM), Continued CAUTION SVCM Solenoid Assembly Removal and Installation In the following procedure, when removing the older configuration SVCM assembly, DO NOT remove connectors from individual relays. The connectors should remain connected to each relay. Step 1. Procedure Remove the tubing from each right angled elbow fitting. These fittings are located on the left and right side of SSR mounting assembly. Refer to Figures 4-19 and 4-20. (Old SVCM) To remove hose from fitting, pushup on fitting collar then pull tubing from fitting. After tubing is removed, collar will return to its original position. (New SVCM) To remove hose from fitting, pull tubing from fitting while pushing in on orange fitting collar. Note: For ease in removing tubing from collar, the right angled fittings can be rotated for easier access to collar. 2. (Old SVCM) DO NOT remove cables from installed relays. (New SVCM) Verify the labeling on the individual cables from the relays. Then, remove the cables from the relays. Do not disconnect the cables at the PECM end. 2000596-001 3. Remove the six 5mm allen head assembly mounting screws. These are captive screws that stay with the assembly. Do NOT remove the six nuts next to the SVCM assembly. These connect the SVCM tubing manifold to the back of the Electronics Assembly 4. Slowly pull the solenoid assembly from its mounting assembly. The mounting standoffs will be removed with the assembly. Maintenance • 4-PAGE48 Solenoid Valve Control Module (SVCM), Continued Step 5. Procedure After the assembly has been removed, examine its electronic enclosure mounting surface to be certain all 15 O-rings are still installed. Check O-rings to be certain they are not damaged or cut. Any defective O-ring MUST BE replaced. “O” RING PART REPLACEMENT: • • 6. CAUTION 2000596-001 Install right angled fittings on both the left and right sides of the replacement assembly. Before installation of a SVCM, check enclosure mounting surface to be certain all 15 O-rings are installed. If any O-ring is lost or damaged, replace it with a new one. Never install assembly with a defective O-ring. Any contaminants not removed from mating surfaces will allow pressure losses resulting in inaccurate analytical analysis results. 7. IMPORTANT QTY 12: #039006-1/8” QTY 3: #039008-3/16” To reinstall a new SVCM relay assembly, perform steps 1 to 7 in reverse order. To reinstall tubing on right angled fittings, simply push tubing into collar as far as it will go. Collar will automatically move with tubing. When installed, pull on tubing to be certain it is securely fastened in fitting. 8. (Old SVCM Only) After reinstalling assembly, reinstall the circuit board by performing the removal procedures 1 to 5 in reverse order. 9. Before reapplying AC power, be certain the SVCM assembly is securely fastened to its electronic enclosure mounting surface, hoses are tightly fastened to right angled fittings and assembly wiring harness connectors are connected to correct SVCM connectors. Maintenance • 4-PAGE48 Solenoid Valve Control Module (SVCM), Continued Figure 4-18: Old SVCM Installation and Removal Diagram 2000596-001 Maintenance • 4-PAGE48 Solenoid Valve Control Module (SVCM), Continued Figure 4-19: New SVCM Installed 2000596-001 Maintenance • 4-PAGE48 Solenoid Valve Control Module (SVCM), Continued Figure 4-20: Old SVCM Assembly Removal and Installation 2000596-001 Maintenance • 4-PAGE48 Solid State Relay Module Description This section presents the procedures for removal or installation of the solid state relay module. The module is mounted behind a protective cover plate located on the left side of enclosure back wall. WARNING Voltage dangerous to life exists. 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. CAUTION To ensure correct replacement of all removed wires, label each wire as to which relay connector it is connected. For example connector SSR-2 is connected to relay SSR2 terminal 2. Also note the relay connection points for the jumper wires. Installation Note Two different configurations of Solid State Relay Module are available, the SSR and the Medium Wattage SSR. Procedures for both configurations are given in this section. It is not possible to replace a single relay on the Medium Wattage SSR 2000596-001 Maintenance • 4-PAGE48 Solid State Relay Module, Continued Procedures Solid State Relay Module Removal and Installation (Not the Medium Wattage SSR) IMPORTANT 2000596-001 The following procedures should be followed for removal and or installation of solid-state relay module. Also included are procedures to replace a single relay on the SSR module or to replace the Medium Wattage SSR assembly. Refer to Figure 4-21. Step Procedure 1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 2. Disconnect PECM to SSR Power connector. This allows for easier removal of the module. For ease in removing relay cover, extend right side of cover outward, lift up on PECM power cable, and then extract cover. 3. Remove the two cover plate spring loaded retaining captive screws, and then remove cover. The cover plate is mounted on standoffs and retaining screws are removed when cover is removed. 4. Remove the plastic shield (if installed) that covers the relays on the SSR module. 5. Before removal of each cable harness connector from its relay termination, label the harness connector with its relay connection point. For example, connector SSR-2 is connected to relay SSR2 terminal 2. 6. Loosen cable harness clamp and remove clamp from around harness. 7. Remove all the cable harness connectors connected to the SSR module. DO NOT disconnect the other internal connectors on the SSR module. Maintenance • 4-PAGE48 Solid State Relay Module, Continued Figure 4-21: Solid State Relay Module 2000596-001 Maintenance • 4-PAGE48 Solid State Relay Module, Continued IMPORTANT Although each cable is identified, it is recommended that you identify each cable as to its relay termination point. Step Procedure 8. Remove the two ground connection lugs from each cover standoff. Depending on configuration standoffs may not need to be removed. If the lugs are a “spade” type then the standoffs will only need to be loosened. If the lugs have a closed hole, then the standoffs must be removed. To loosen or remove standoffs, use a 5mm nut driver. 9. Using a 5mm Allen wrench, remove the six mounting screws securing relays to electronic enclosure back wall standoffs. Remove the solid-state relay module. Relays are mounted to heat sink assembly. IMPORTANT IMPORTANT When the solid-state relay module is removed, the rear mounted heat sink is also removed as part of the relay mounting assembly. 10. Remove solid-state relay module assembly. 11. To reinstall the solid-state relay module, repeat steps 1 to 10 in reverse order. When reinstalling relay cover, lift up on PECM power cable and insert left side of cover at an angle. Before securely tightening fastening screws, be certain wiring harness is installed within cover cutout opening. DO NOT pinch wiring harness. 12. 2000596-001 Before closing electronic enclosure door and reapplying AC power, be certain all cable harness connectors are connected to their correct relay terminations. Maintenance • 4-PAGE48 Solid State Relay Module, Continued Removal and Installation of a Single Relay Step Procedure 1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 2. Disconnect PECM to SSR Power connector. This allows for easier removal of the module. 3. Remove the two cover plate spring loaded retaining captive screws, and then remove the cover. The cover plate is mounted on standoffs and retaining screws are removed when cover is removed. 4. Remove the plastic plate (if installed) that covers the relays on the SSR module. 5. Before removal of each cable harness connector from its relay termination, label the harness connector with its relay connection point. Remove each connector from the relay that is to be replaced as well as any other connectors for wires that would prevent the removal of the relay. 2000596-001 6. Remove the screws that secure the relay to the module. Since the heat sink compound on the back of the relay acts as an adhesive, the relay will remain secured to the module. 7. Break the relay free from the adhesive by pulling firmly, and then remove the relay from the enclosure. 8. Install the new relay by applying the heat sink compound and repeating steps 1 to 7 in reverse order. 9. Before closing electronic enclosure door and reapplying AC power, be certain all cable harness connectors are connected to their correct relay terminations. Maintenance • 4-PAGE48 Solid State Relay Module, Continued Note Refer to Figure 4-22 on the next page when executing the following procedure. . Medium Wattage Solid State Relay Module Removal and Installation Step Procedure 1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 2. Unplug the power cable and the control cable from the Medium Wattage Solid State Relay Module. Unplug the cables only at the SSR end. Leave them plugged in at their opposite ends. 3. Remove the Medium Wattage SSR by unscrewing the Allen head screws that secure it to the enclosure. Note: There is a gasket located between the SSR and the enclosure back wall. Set this gasket aside for use in reinstalling the new SSR. 4. 2000596-001 Install the new Medium Wattage SSR by executing steps 1 to 3 in reverse order. Maintenance • 4-PAGE48 Solid State Relay Module, Continued Figure 4-22: Medium Wattage Solid State Relay Module 2000596-001 Maintenance • 4-PAGE48 Electronic Pressure Control Module Description This section presents the procedures for removal or installation of Electronic Pressure Control (EPC) Module. The Module is located on the upper right side wall of the electronic enclosure directly behind the Air Circulating Fan. Two different versions of the EPC exist. These versions are functionally the same. The primary difference is in the way that the board identification is set. This difference is described in detail at the end of this procedure. WARNING Voltage dangerous to life exists. 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. CAUTION The EPC Module and the attached manifold are one assembly. This assembly is critical to safety certification and as such must not be disassembled. Replacement of the EPC includes replacement of the manifold. Procedures The following procedures should be followed for removal and installation of the EPC. Refer to Figure 4-23. Step 2000596-001 Procedure 1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon 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. Maintenance • 4-PAGE48 Electronic Pressure Control Module, Continued CAUTION 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. CAUTION The ferrules connected on the gas supply side of the EPC manifold are composed of vespel-graphite. To prevent damage, these ferrules must NOT be over-tightened. Proper tightness is typically ½ turn past fingertight. Step Procedure 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 new EPC is not equipped with a module ID jumper, move the jumper that is connected to location J2 from the old module to the new module. or, 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” on the next page). IMPORTANT 2000596-001 6. To reinstall the new EPC, perform steps 1 to 4 in reverse order. Use caution when reconnecting gas lines. Do not over-tighten. 7. 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. After replacing the EPC assembly it is necessary to inspect the system for leaks. Maintenance • 4-PAGE48 Electronic Pressure Control Module, Continued Original EPC Connectors DIP Switches on New EPC Figure 4-23: EPC Connector Locations Setting Location ID As shown above, 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 in the older version EPC. Location ID #1 Plugs Location ID #2 Location ID #3 Second switch / connector pin set (binary 2) 1 & 2 switch / connector pin set (binary 3) Location ID #4 Switches st 1 switch / connector pin set (binary 1) 2000596-001 st nd rd 3 switch / connector pin set (binary 4) Maintenance • 4-PAGE48 Purge Control Module (PCM) Description This section presents the procedures for removal or installation of the Purge Control Module (PCM). The PCM is located on lower right side wall of the electronic enclosure. WARNING Voltage dangerous to life exists. 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. Procedures The following procedures should be followed for removal and installation of PCM pressure switch. Refer to Figures 4-24 and 4-25. IMPORTANT The pressure switch can be removed and replaced without having to remove the PCM module. PCM Pressure Switch Step Procedure 1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 2. Note: In order to replace the solenoid pressure switch, it should NOT be necessary to remove the PCM assembly from the enclosure. Unplug the connector to the faulty solenoid pressure switch. Grasp connector from bottom section and pull straight out from mating section. IMPORTANT 2000596-001 Before removal of pressure switch connecting wires, note pressure switch pin location that wires are connected to. It is recommended that each wire be labeled with its pin connector. Wires MUST NOT be interchanged. Maintenance • 4-PAGE48 Purge Control Module (PCM), Continued Step 3. Procedure Using the appropriate size wrench, unscrew the faulty pressure switch from the PCM pressure switch control mounting assembly. Figure 4-24: Purge Control Pressure Switch and Orifice Locations 4. To reinstall PCM pressure switch, repeat steps 1 to 3 in reverse order. CAUTION DO NOT over tighten pressure switch during installation. Proper tightness should be approximately 1/4 turn past finger tight. 5. 2000596-001 Before applying AC power, be certain the PCM pressure switch is securely installed. Maintenance • 4-PAGE48 Purge Control Module (PCM), Continued .021-inch Orifice The Orifice is located on the upper right side of the the PCM pressure switch control mounting assembly. The following procedures should be followed for removal and installation of PCM pressure switch .021-inch Orifice. The Orifice should be replaced if it becomes blocked-off or fails to perform its system function. Refer to Figure 4-24. Step 1. Procedure Note: In order to replace the Orifice, it should NOT be necessary to remove the PCM assembly from the enclosure. Unscrew the Orifice assembly then remove from the PCM assembly. 2. Screw the new orifice assembly into the PCM assembly. 3. Before reapplying AC power, be certain the Orifice is securely installed. DO NOT over tighten Orifice during installation. Proper tightness should be approximately 1/4 turn past finger tight. PCM Assembly Removal The following procedures should be followed for removal and installation of PCM Assembly. Refer to Figure 4-25. Step 1. Procedure Disconnect tubing connected to assembly front and rear mounted right angled elbow fittings. To remove tubing from fitting, push up on fitting collar then pull tubing from fitting. After tubing is removed, collar will return to its original position. 2. IMPORTANT 2000596-001 Remove wires connecting to the solenoid pressure switch. Note pressure switch pin locations where wires are connected. It is recommended that each wire be labeled with its pin connector. Wires MUST NOT be interchanged. Maintenance • 4-PAGE48 Purge Control Module (PCM), Continued Step Procedure 3. Remove the four PCM assembly 5mm Allen mounting screws. 4. Remove the PCM assembly from the electronic enclosure. When assembly is removed, the installation gasket should also be removed. 5. To reinstall PCM assembly, repeat steps 1 to 4 in reverse order. DO NOT over tighten pressure switch during installation. Proper tightness should be approximately 1/4 turn past finger tight. IMPORTANT To reinstall tubing on right angled fittings, simply push tubing into collar as far as it will go. Collar will automatically move with tubing. When installed, pull on tubing to be certain it is securely fastened in fitting. 6. Before applying AC power, be certain PCM assembly is correctly installed, tubing is tightly installed in right angled fittings and interface wiring is correctly connected to PCM switch pins. Figure 4-25: PCM Assembly Removal 2000596-001 Maintenance • 4-PAGE48 Wiring Distribution Board Description This section presents the procedures for removal or installation of the Wiring Distribution Board. The board is located on lower rear wall of the electronic enclosure. WARNING Voltage dangerous to life exists. 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. CAUTION Exercise caution when removing the Wiring Distribution Board. The board is secured in place by two 5mm captive screws located in the upper left and lower right corners with the other two corners secured by push-on fasteners. Procedures The following procedures should be followed for removal or installation of Wiring Distribution Board. Refer to Figure 4-26. Step Procedure 1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 2. Disconnect all interface cables from connectors J100 to J110. Label each connector with its terminating location for reinstallation. 3. Disconnect air circulating fan connector J5. Label function of connector for reinstallation. 4. Disconnect power supply voltage connector J1. Label function of connector for reinstallation. 5. Note: This step is only applicable if connected to a network. Unplug connection to 10Base2 connector. Unplug connectors from J3 and J4. Label each connector with its termination point. 2000596-001 Maintenance • 4-PAGE48 Wiring Distribution Board, Continued Step CAUTION Procedure 6. Remove the upper left and lower right board mounting screws. 7. To remove the board, place two fingers from each hand on back of lower left and upper right connectors and pull forward. Because the fasteners are a push-on type, the board will pop-off with little exertion. Do not extract Wiring Distribution Board from push-on fasteners by grasping board by its sides. This will cause breakage of board or damage components. 8. To reinstall a new Wiring Distribution Board, perform steps 1 to 7 in reverse order. Note: The switch setting S1 is not used in Maxum II and should be left at the default setting of 1. 9. Before reapplying AC power, be certain all interface cables and network cables are connected to their correct Wiring Distribution Board terminations. Figure 4-26: WDB Interface Connection Locations 2000596-001 Maintenance • 4-PAGE48 Air Circulating Fan Description This section presents the procedures for removal or installation of the Air Circulating Fan located on the lower right front side wall of the electronic enclosure. WARNING Voltage dangerous to life exists. 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. Procedures The following procedures should be followed for removal and installation of ACF. Refer to Figure 4-27. Step 2000596-001 Procedure 1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When door is open DO NOT place tension on the Maintenance Panel interface ribbon cable. 2. Disconnect interface cable from Wiring Distribution Board (WDB) connector J5. 3. Remove Air Circulating Fan interface cable from wiring harness bundle. 4. Remove the four 5mm long Allen screws from each corner of Air Circulating Fan. 5. Remove Air Circulating Fan. 6. To reinstall a new Air Circulating Fan, perform steps 1 to 5 in reverse order. 7. Before reapplying AC power, be certain fan power cable is securely connected to WDB connector J5 and power cable is reinstalled in wiring harness bundle. Maintenance • 4-PAGE48 Air Circulating Fan, Continued Figure 4-27: Electronic Enclosure Fan Location 2000596-001 Maintenance • 4-PAGE48 Model 50 Valve Description This section provides maintenance instructions for the Model 50 Valve. The Model 50 is a pneumatically operated diaphragm valve specifically designed for process gas chromatography. It uses pressure-ondiaphragm activation with no other moving parts. The valve can inject vapor samples and switches columns simultaneously. It is capable of switching gasses up to 75 psig (515 kPa). Figure 4-28: Model 50 Valve Repair Kits & Fixtures 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 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 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. 2000596-001 • 4-49 Model 50 Valve, Continued Figure 4-29: Exploded View of Model 50 Valve 2000596-001 • 4-50 Model 50 Valve, Continued Maintenance Personnel 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 repair or direct replacement. Direct Valve Replacement If it is determined that the problem is directly related to the Model 50 Valve system performance, the customer must make a determination if the valve can be repaired on site or if it should be returned to Siemens for repair or replacement. Repair of Valve 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. Maintenance Facility 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. If Model 50 Valve maintenance is to be performed on site, the area must be clean and free of foreign 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 components, shake or blow with clean air the excess cleaning fluid from the individual components. Ensure that the components are air dry before reassembling. CAUTION 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. WARNING Voltage dangerous to life exists. 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. Only maintenance personnel with proper authorization should open the electronic enclosure. 2000596-001 • 4-51 Model 50 Valve, Continued Maintenance Procedures Valve Removal and Disassembly (see Figure 4-29) The valve is serviced by disassembling and then thoroughly cleaning the components to remove all particulates. Ultrasonic cleansing with a suitable solvent works very well. During the cleaning and re-assembly process, care must be taken to avoid scratching or damaging the polished surfaces of the valve. After cleaning, the valve is reassembled using new Teflon coated stainless steel diaphragms. DO NOT attempt to reuse old diaphragms. Notice the alignment marks on the three sections of the valve near the actuation ports. The valve should be reassembled so that these marks line up. If the marks to not line up it is possible that the center plate is upside down. The screws should be tightened evenly to 6-8 inch pounds using the appropriate torque screwdriver with an allen head bit. Step Procedure 1. From primary AC circuit breaker, turn analyzer AC primary power OFF. 2. Shut off the air to the oven heater. 3. Open Maxum II’s oven door using a 4mm (5/32’”) Allen wrench. 4. To remove Model 50 Valve from the oven, first disconnect all tubing to the valve. CAUTION 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. CAUTION 2000596-001 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 4-29 for port locations. 6. Place the valve on a clean dust and lint free cloth within a clean work environment. 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. • 4-52 Model 50 Valve, Continued Step Procedure 7. Place the valve bottom plate on a lint free cloth. Using a 2.5 mm Allen wrench, remove the five component socket head fastening cap screws. Refer to Figure 4-29. 8. Separate valve Top, Center and Bottom plates, placing them on a lint free cloth. Both diaphragms are visible. Valco & Swagelok 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. Valco & Swagelok Assembly Instructions Use a wheel-cutting tool (Supelco 58692-U) to score the tubing, and then with a pair of straightening pliers (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 (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. Step 2000596-001 Procedure 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. • 4-53 Model 50 Valve, Continued Step Replacing Diaphragms 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. Use the Valve Assembly Fixture, Siemens PN 2020281-001, properly align the Diaphragms when rebuilding the Model 50 Valve. The fixture consists of a base (1), 2 guide pins (2) and a diaphragm placement disc (3). 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. Step 2000596-001 Procedure Procedure 1. Remove the old diaphragms from the plates. DO NOT attempt to reuse the old diaphragms. 2. With the pins installed in the fixture base, place the bottom plate of the valve on the base. The pins should fit in the mounting holes on the bottom plate and hold it in place. 3. Position the placement disc on the bottom plate and set the diaphragm in place . 4. 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. 5. 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. • 4-54 Model 50 Valve, Continued Step 2000596-001 Procedure 6. Repeat steps 3 and 4 with the middle plate. 7. Place the top plate on the valve, verifying alignment using the alignment marks. 8. Install the 5 screws and washers finger tight. 9. 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 1631005-003, which is calibrated at 7.2 inch pounds). Remove the assembled valve from the valve fixture. 10. Reinstall the valve in the oven and connect all tubing. 11. Power up and check for leaks. Verify valve operation by running chromatograms. • 4-55 Model 20 Valve Description This section presents information to perform fault diagnostic testing, maintenance and repair and installation of the Model 20 Valve. To assure optimum valve operation, a clean contaminant free operating environment is required at all times. 1. 2. 3. 4. 5. 6. Valve Cap Allen Screws (3 total) Belleville Washers (6 total) Teflon Disc Seal Diaphragm Dacron Cushion Diaphragm Plungers (6 total) 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) Figure 4-30: Model 20 Valve Components Maintenance Procedures Maintenance procedures are divided into three phases as presented below. The type of maintenance procedure to be performed is determined by the type of fault, availability of spare parts, experience of maintenance personnel and availability of tools and work place facilities. The description accompanying each type of procedure will guide the user in the type of maintenance procedure to be performed. Within the procedures, the numbers in parenthesis denote parts referenced in the list contained in Figure 4-30 above; refer back to the list for locations. Diagnostic: These can determine problems by a visual examination of valve. Mini-Maintenance: Mini-Maintenance procedures should be performed with the Model 20 Valve installed in the analyzer. These procedures are the first logical step for maintenance personnel if they are not sure of what the problem is. 2000596-001 • 4-56 Model 20 Valve, Continued If these procedures fail to correct problem with a faulty valve, or visual inspection detects an appreciable amount of foreign contamination on the diaphragm, it is recommended that the valve be returned to Siemens for repair. Procedures include the following: • • • Valve Cap Disassembly Cleaning Fittings and Tubing Valve Cap Assembly Maxi-Maintenance: These are procedures which may be performed if the valve fault cannot be corrected using Mini-Maintenance procedures. The valve can either be replaced or the following procedures can be performed. This includes completely disassembling, cleaning, and rebuilding of the entire valve. Procedures include the following: • • • • • Valve Cap Disassembly Cleaning Fittings and Tubing Valve Cap Assembly Actuator Disassembly Actuator Assembly Visual Valve Inspection If system operational performance or a visual inspection of the Model 20 Valve indicates a real or potential problem with the valve, the following information will assist maintenance personnel in determining whether the valve can be repaired on site or whether it should be returned to Siemens for repair or replacement. Maintenance Personnel 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. Direct Valve Replacement If it is determined that the problem is directly related to Model 20 Valve system performance, the customer must make a determination if the valve can be repaired on site or if it should be returned to Siemens for repair or replacement. Repair of Valve 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. 2000596-001 • 4-57 Model 20 Valve, Continued 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 comtaminating 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. CAUTION 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. Diagnostic Procedures Depending on the installation, the following tests can be performed with the valve mounted within 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 Pressure: Leakage may be from a carrier 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. Sample Pressure Higher Than Carrier: 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. Refer to Figure 4-31. 2000596-001 • 4-58 Model 20 Valve, Continued 1. 2. 3. 4. 5. 6. Valve Cap Allen Screws (3 total) Belleville Washers (6 total) Teflon Disc Seal Diaphragm Dacron Cushion Diaphragm Plungers (6 total) 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 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) Control Port (Upper, Middle, or Lower depending on location) Figure 4-31: Section View of Model 20 Valve 2000596-001 • 4-59 Model 20 Valve, Continued Slow or Erratic Piston Switching Improper lubrication and/or contamination of Bal-Seal (18) will increase friction on valve-actuating piston. This causes valve switching to be erratic, slow or inoperative. Refer to Figure 4-31. To correct the conditions causing slow or erratic piston switching, perform the following: • • • • • • Additional Faults Disassemble valve body Discard old O-ring Thoroughly clean all components Lubricate components per specifications Install new O-ring Reassemble the valve The following additional conditions can be visually observed without the valve being removed or disassembled: • • • • Port-to-Port Leakage Low Flow Rate (plugging) Double Sampling and other Sample Flow Problems More serious conditions do require the valve to be disassembled. Procedures for disassembling the Valve are presented in the following sections. Mini-Maintenance Procedures 2000596-001 The following procedures should be followed for performing MiniMaintenance on the Model 20 Valve. Refer to Figures 4-31 and 4-32. • 4-60 Model 20 Valve, Continued 1. 2. 3. 4. 5. 6. Valve Cap Allen Screws (3 total) Belleville Washers (6 total) Teflon Disc Seal Diaphragm Dacron Cushion Diaphragm Plungers (6 total) 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 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) Control Port (Upper, Middle, or Lower depending on location) Figure 4-32: Exploded View of Model 20 Valve 2000596-001 • 4-61 Model 20 Valve, Continued Valve Cap Disassembly and Cleaning Step 1. Procedure 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. CAUTION 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). Do not place polished valve cap (1) 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). NOTE If seal disc diaphragm (4) is brittle and dirty but not ruptured, or if it is ruptured but clean, DO NOT disassemble the rest of the valve. 5. Cleaning Fittings & Tubing 2000596-001 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, perform the following procedures. All fittings and tubing must be cleaned and valve diaphragms inspected for cleanliness, and for catalyst or polymer buildup in the valve cap. Plunger valve body faces should be wiped clean using hexane, acetone, or methanol and a lint free cloth. If port-to-port leakage or blockage exists when a valve flow passage is switched open, then contamination of flow passages or excessive friction in the lower section of the valve may exist. This impedes valve operation and the valve must be thoroughly flushed clean. • 4-62 Model 20 Valve, Continued Step 6. NOTE Procedure Prepare a large syringe with a Tygon tubing adapter installed. Fill syringe with a recommended cleaning solvent. An ultrasonic cleaner filled with a recommended cleaning solvent is recommended for cleaning all components. Solvent must not leave any residue on evaporation. If solvent becomes contaminated during cleaning, it must be replaced with a clean supply. 7. CAUTION Valve Cap Assembly 2000596-001 Clean valve cap while it is disassembled. Using syringe, flush solvent through each port in the valve cap. 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. 8. Place the actuator assembly upright on a clean lint free cloth surface. Refer to Figures 4-31 and 4-32. 9. Position the Dacron cushion disc diaphragm (5) between the three alignment pins on the plunger valve body (13). 10. Using tweezers, hold 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. 11. Install Teflon seal disc diaphragm (4) over the Dacron diaphragm disc cushion (5). • 4-63 Model 20 Valve, Continued Step NOTE Procedure 12. Align valve cap (1) over the three guide pins of the valve plunger body (13). Port 1 must be placed toward the upper control port. 13. Lower valve cap (1) over plunger valve body plunger guide pins (13) then install valve cap (1) onto the plunger valve body. 14. Install, but do not securely tighten, the three Allen screws (3) each with two Belleville lock washers (2). 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. 15. 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. b. c. d. 16. Finger tighten 20 inch pounds (2.3 Nm) 40 inch pounds (4.5 Nm) 60 inch pounds (6.8 Nm) 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 THREE ALLEN SCREWS ARE SECURELY TIGHTENED. DO NOT OVERTIGHTEN. 2000596-001 • 4-64 Model 20 Valve, Continued Maxi-Maintenance Procedures Actuator Disassembly The following procedures should be followed for performing MaxiMaintenance on Model 20 Valve. Maxi-Maintenance procedures include the Mini-Maintenance procedures in addition to the disassembly, inspection and assembly of the valve Actuator presented in this section. Refer to Figures 4-31 and 4-32. Step 1. Procedure Perform the following Maxi-Maintenance procedures in the order presented. • • • • • NOTE 2000596-001 Valve Cap Disassembly (Mini-Maintenance) Cleaning Fittings and Tubing (Mini-Maintenance) Actuator Disassembly (Maxi-Maintenance) Actuator Assembly (Maxi-Maintenance) Valve Cap Assembly (Mini-Maintenance) 2. Check valve plungers (6) for sticking. 3. 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. 4. 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. 5. 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 be thoroughly cleaned with a recommended cleaning solvent, repaired, or the entire actuator must be replaced. 6. Turn actuator on its side. Remove the three screws (16) which secure the plunger valve body (13) to the cylinder valve base (14). When performing the following procedure, DO NOT allow actuator plungers to fall from plunger valve body (13). • 4-65 Model 20 Valve, Continued Step NOTE NOTE Procedure 7. With plunger valve body (13) in the horizontal position, remove the assembly. Carefully remove all six plungers (6). 8. 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). An alternate method for removing the actuator piston assembly is presented in step 9. If this method is not used, proceed to step 10. 9. 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. DO NOT USE MORE THAN 30 PSIG (210 KPA) OF AIR PRESSURE WHEN USING THIS METHOD. 10. 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. 11. 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. It is extremely important that, when reassembling the actuator, the assembly area be clean and dust free. Hands of maintenance personnel must be clean and not oily and tools must also be clean. 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. 2000596-001 • 4-66 Model 20 Valve, Continued Actuator Assembly 2000596-001 Step Procedure 12. 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 4-31 and 4-32. 13. Apply a bead of Krytox 240 AC lubricant, or equivalent; in "O" ring grooves of spring-loaded piston (15). 14. Install new silicon O-rings (18 and 19) in spring loaded pistion (15) and apply a coating of lubricant over each "O" ring. 15. Apply bead of lubricant in upper groove of air loaded piston (12a). 16. Install a new silicon "O" ring (19) in the upper air loaded piston (12a) and apply a coating of lubricant over the "O" ring. 17. Place upper piston (12a) over the small diameter of lower piston (15). Position pistons using guide pin (12b) for proper orientation. 18. 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). 19. Position the valve upright with its three ports on the left. Install a #6-32 screw in the center-threaded hole of air loaded piston assembly (12) and bottom spring-loaded piston (15). 20. Lift the combined assembly (12 and 15), and orient it with the upper piston guide pin (12b) facing toward maintenance person. 21. Press the piston assembly into the cylinder base (14). After installation, remove the #6-32 screw. 22. Align plunger valve body (13) and insert the piston guide pin (12b) into one of the three bottom holes of plunger valve body (13). 23. Rotate plunger valve body (13) to align body screw holes with cylinder base (14) threaded holes. 24. Install three #10-32 7/8" socket head screws (16) and Belleville washers (17). • 4-67 Model 20 Valve, Continued Step NOTE 2000596-001 Procedure 25. Hand tighten screws. DO NOT compress the Belleville washers (20) into the cylinder base (14). 26. 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. 27. Place a small drop of Krytox 143 AY or equivalent oil on each plunger. 28. Using a pair of tweezers, lift each plunger up and down to allow the oil to flow around a plunger. 29. Refer back to the previous procedure for reassembly of the valve cap. • 4-68 Model 20 High Temperature Valve (HTV) Description This section presents the user with the necessary information to perform fault diagnostic testing, maintenance and repair, and installation of the Model 20 High Temperature Valve (HTV). The valve is actuated by air pressure. To assure optimum valve operation, a clean contaminant free operating environment is required at all times. 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 Control Port (Upper, Middle, or Lower depending on location) 32. 33. 34. 35. 36. Valve Cap Teflon Disc Seal Diaphragm Nomex Cushion Diaphragm Allen Screws (6 total) Belleville Washers (12 total) Figure 4-33: Model 20 High Temperature Valve (HTV) Components Maintenance Procedures Maintenance procedures are divided into three phases as presented below. The type of maintenance procedure to be performed is determined by the type of fault, availability of spare parts, experience of maintenance personnel and availability of tools and work place facilities. The description accompanying each type of procedure will guide the user in the type of maintenance procedure to be performed. Within the procedures, the numbers in parenthesis denote parts referenced in the list contained in figure 4-33 above; refer back to the list for locations. Diagnostic: These can determine problems by a visual examination of the valve. 2000596-001 • 4-69 Model 20 High Temperature Valve (HTV), Continued Mini-Maintenance: Mini-Maintenance procedures should be performed with the Model 20 High Temperature Valve (HTV) installed in the analyzer. These procedures are the first logical step for maintenance personnel if they are not sure of what the problem is. If these procedures fail to correct problem with a faulty valve, or visual inspection detects an appreciable amount of foreign contamination on the diaphragm, it is recommended that the valve be returned to Siemens for repair. Procedures include the following: • • • Valve Cap Disassembly Cleaning Fittings and Tubing Valve Cap assembly Maxi-Maintenance: These are procedures, which may be performed if the valve fault cannot be corrected using Mini-Maintenance procedures. The valve can either be replaced or the following procedures can be performed. This includes completely disassembling, cleaning, and rebuilding of the entire valve. Refer to Figure 4-33. Procedures include the following: • • • • • Valve Cap Disassembly Cleaning Fittings and Tubing Valve Cap Assembly Actuator Disassembly Actuator Assembly Visual Valve Inspection If system operational performance or a visual inspection of the Model 20 High Temperature Valve (HTV) indicates a real or potential problem with the valve, the following information will assist maintenance personnel in determining whether the valve can be repaired on site or whether it should be returned to Siemens for repair or replacement. Maintenance Personnel 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. Direct Valve Replacement If it is determined that the problem is directly related to Model 20 High Temperature Valve (HTV) system performance, the customer must make a determination if the valve can be repaired on site or if it should be returned to Siemens for repair or replacement. Repair of Valve 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 HTV repair kit (PN K21021), can be obtained from Siemens. 2000596-001 • 4-70 Model 20 High Temperature Valve (HTV), Continued 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 installation. All foreign contamination adhering to valve must be removed quickly using a dust/lint free cloth and a cleaning solvent, such as hexane, acetone or methanol. After cleaning valve cap and tubing, shake excess cleaning fluid from tubes and let valve cap air dry before reassembling. CAUTION 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 methane. Diagnostic Procedures Depending on the installation, the following tests can be performed with the valve mounted within 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 Sample Pressures Lower Than Carrier Pressure: Leakage may be from a carrier 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. Sample Pressures Higher Than Carrier: 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 (33), which must be replaced. Check for liquid substances escaping from the vent hole. Refer to Figure 4-34. Slow or Erratic Piston Switching Improper lubrication and/or contamination of Bal-Seals will increase friction on valve-actuating piston. This causes valve switching to be erratic, slow or inoperative. Refer to Figure 4-34. 2000596-001 • 4-71 Model 20 High Temperature Valve (HTV), Continued 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 Control Port (Upper, Middle, or Lower depending on location) 32. 33. 34. 35. 36. Valve Cap Teflon Disc Seal Diaphragm Nomex Cushion Diaphragm Allen Screws (6 total) Belleville Washers (12 total) Figure 4-34: Section View of Model 20 HTV 2000596-001 • 4-72 Model 20 High Temperature Valve (HTV), Continued Additional Faults The following additional conditions can be visually observed without the valve being removed or disassembled: • • • • Port-to-Port Leakage Low Flow Rate (plugging) Double Sampling and other Sample Flow Problems More serious conditions do require the valve to be disassembled. Procedures for disassembling the Valve are presented in the following sections. Mini-Maintenance Procedures Valve Cap Disassembly and Cleaning The following procedures should be followed for performing MiniMaintenance on the Model 20 HTV. Refer to Figure 4-34 and 4-35. Step 1. Procedure 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. CAUTION 2000596-001 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). Do not place polished valve cap (32) against any abrasive surface. Place it on a lint free cloth free of foreign contaminants. • 4-73 Model 20 High Temperature Valve (HTV), Continued 13. Outer (Large) Bal-Seals (2 total) 14. Plungers (6 total) 15. Spring Loaded (Lower) Piston 16. Cylinder Base 17. Valve Plunger Body 18. Air Loaded (Upper) Piston 19. Large Belleville Washers (3 total) 20. Inner (Small) Bal-Seal 21. Control Port (Upper, Middle, or Lower depending on location) 32. 33. 34. 35. 36. Valve Cap Teflon Disc Seal Diaphragm Nomex Cushion Diaphragm Allen Screws (6 total) Belleville Washers (12 total) Figure 4-35: Exploded View of Model 20 HTV 2000596-001 • 4-74 Model 20 High Temperature Valve (HTV), Continued Step 4. Procedure Inspect the Teflon seal disc diaphragm (33) and the Nomex cushion diaphragm (34). Examine valve cap base seal (33) and cushion diaphragm (34) subassembly's 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 seal disc diaphragm (33) is brittle and dirty, but not ruptured or if it is ruptured but clean, DO NOT disassemble the rest of the valve. 5. Cleaning Fittings & Tubing All fittings and tubing must be cleaned and valve diaphragms inspected for cleanliness, and for catalyst or polymer buildup in the valve cap. Plunger valve body faces should be wiped clean using hexane, acetone, or methanol and a lint free cloth. If port-to-port leakage or blockage exists when a valve flow passage is switched open, then contamination of flow passages or excessive friction in the lower section of the valve may exist. This impedes valve operation and the valve must be thoroughly flushed clean. For cleaning parts, an ultrasonic cleaner is recommended. 6. NOTE Prepare a large syringe with a Tygon tubing adapter installed. Fill syringe with a recommended cleaning solvent. If solvent becomes contaminated during cleaning, it must be replaced with a clean supply. 7. 2000596-001 Visually inspect the rest of valve. If it is clean and in good condition, install a new seal disc diaphragm (33) and a Nomex cushion diaphragm (34). To reassemble the valve cap, perform the following procedures. Clean valve cap while it is disassembled. Using syringe, flush solvent through each port in the valve cap. • 4-75 Model 20 High Temperature Valve (HTV), Continued Valve Cap Assembly Step 8. CAUTION 2000596-001 Procedure Place the actuator assembly upright on a clean lint free cloth surface. Refer to Figures 4-34 and Figure 4-35. 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. 9. Position the Nomex cushion disc diaphragm (34) between the three alignment pins on the plunger valve body (17). 10. Using tweezers, hold 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. 11. Install Teflon seal disc diaphragm (33) over the Nomex disc cushion diaphragm (34). 12. Align valve cap (32) over the three guide pins of the valve plunger body (17). Port 1 must be placed toward the upper control port. 13. Lower valve cap (32) over valve plunger body guide pins (17) then install valve cap (32) onto the plunger valve body. 14. 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). • 4-76 Model 20 High Temperature Valve (HTV), Continued 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. Step 15. Procedure 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. b. c. d. Finger tighten 20 inch-pounds (2.3 N•m) 40 inch-pounds (4.5 N•m) 60 inch-pounds (6.8 N•m) BE CERTAIN ALL THREE ALLEN SCREWS ARE SECURELY TIGHTENED. DO NOT OVERTIGHTEN. 16. Tighten the three Allen screws (35) that secure the plunger valve body (17) to the cylinder base (16) to approximately 30 to 40 inch-pounds (3.4 to 4.5 N•m). Maxi-Maintenance Procedures The following procedures should be followed for performing MaxiMaintenance on Model 20 HTV . Maxi-Maintenance procedures include the Mini-Maintenance Procedures in addition to the disassembly, inspection and assembly of the valve Actuator presented in this section. CAUTION The Model 20 HTV Repair Kit (PN K21021) available from Siemens includes adapters required for use during actuator reassembly. Failure to use the proper tools may cause damage to the Bal-Seals. Actuator Disassembly Step 1. Procedure Perform the following Maxi Maintenance procedures in the order presented: • • • • • 2000596-001 Valve Cap Disassembly (Mini-Maintenance) Cleaning Fittings and Tubing (Mini-Maintenance) Actuator Disassembly (Maxi-Maintenance) Actuator Assembly (Maxi-Maintenance) Valve Cap Assembly (Mini-Maintenance) • 4-77 Model 20 High Temperature Valve (HTV), Continued Step NOTE NOTE Procedure 3. Check valve plungers (14) for sticking. 4. 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. 5. 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. 6. 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 be thoroughly cleaned with a recommended cleaning solvent such as hexane, repaired, or the entire actuator must be replaced. 7. Turn actuator on its side. Remove the three socket head screws (35) which secure the plunger valve body (17) to the cylinder valve base (16). When performing the following procedure, DO NOT allow actuator plungers to fall from plunger valve body (17). 7. With plunger valve body (17) in the horizontal position, remove the assembly. Carefully remove all six plungers (14). 8. 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). An alternate method for removing the actuator piston assembly is presented in step 9. If this method is not used, proceed to step 10. 9. Carefully apply 10 psig (70 kPa) 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. DO NOT USE MORE THAN 30 PSIG (210 KPA) OF AIR PRESSURE WHEN USING THIS MEHOD. 2000596-001 • 4-78 Model 20 High Temperature Valve (HTV), Continued Step Procedure 10. 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. 11. 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. CAUTION Replace all Bal-Seals (20) if they have any nicks, scratches or any other type of deformations. NOTE It is extremely important that, when reassembling the actuator, the assembly area be clean and dust free. Hands of maintenance personnel must be clean and not oily and tools must also be clean. 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. Actuator Assembly CAUTION 2000596-001 12. 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 4-34 and 4-35. 13. Apply a bead of Krytox 240 AC lubricant, or equivalent, in BalSeal grooves of spring loaded piston (15) 14. Lubricate outside diameter of assembly tool (Part Number A00145). Be certain spring-loaded Bal-Seal (13) is properly oriented with the associated spring facing up. 15. 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 4-36. When installing Bal-Seals, handle them with extreme care, do not remove Bal-Seal springs for installation and do not nick or scratch BalSeals. • 4-79 Model 20 High Temperature Valve (HTV), Continued Figure 4-36: Assembling Bal-Seal (13) on Piston (15) 2000596-001 • 4-80 Model 20 High Temperature Valve (HTV), Continued Step 2000596-001 Procedure 16. Apply a bead of Krytox 240 AC lubricant, or equivalent, in both Bal-Seal grooves of air-loaded piston (18). 17. Using pad of fingers or "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 4-37. 18. Push spring loaded Bal-Seal (20) to the bottom of groove. 19. Apply small bead of Krytox 240 AC lubricant, or equivalent, on the small Bal-Seal sealing surface of lower spring loaded piston (15). 20. Place upper air loaded piston (18) over the small diameter of lower piston (25). Position pistons using guide pin for proper orientation. 21. 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. 22. 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). 23. 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 4-38. 24. Lift piston and Bal-Seal assembly and orient assembly with the upper piston index guide pin towards the maintenance person. 25. Firmly, but evenly, press the piston and Bal-Seal assembly through the assembly guide tool into the cylinder valve base (16). Refer to Figure 4-39. 26. Remove guide tool assembly stud and lock washer. 27. Align plunger valve body (17) and insert piston index guide pin into one of the three bottom plunger valve body holes. • 4-81 Model 20 High Temperature Valve (HTV), Continued Figure 4-37: Installing Bal-Seal (20) in Piston Groove (18) A. B. Figure 4-38: Placing Assembly Guide Tool on Valve Base (16) 2000596-001 • 4-82 Model 20 High Temperature Valve (HTV), Continued Figure 4-39: Inserting Piston Assembly (15 and 18) into Base (16) 2000596-001 • 4-83 Model 20 High Temperature Valve (HTV), Continued Step 2000596-001 Procedure 28. Rotate plunger valve body (17) to align the plunger valve body screw holes with cylinder valve base (16) threaded holes. 29. 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. 30. With the recess 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. 31. Place a small drop of Krytox 143 AY or equivalent oil on each plunger. Using a pair of tweezers lift each plunger and move it up and down to allow lubricating oil to flow around the plunger. 32. Refer back to the previous procedure for reassembly of the valve cap. • 4-84 Model 11 and Model 11 Low Dead Volume Valves Description This section presents the user with the necessary information to perform fault diagnostic testing, maintenance and repair and installation of the Model 11 Valve and the Model 11 Low Dead Volume Valves. These valves are actuated by air pressure. To ensure optimum valve operation, a clean contaminant free operating environment is required at all times. Refer to Figure 4-40. 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 4-40: Model 11 (or Model 11 LDV) Valve Without Valve Cap 2000596-001 • 4-85 Model 11 and Model 11 LDV Valves, Continued Valve Types This Model 11 valve is broken down into two primary types, the standard Model 11 Valve and the Model 11 Low Dead Volume (LDV) valve. Within this section, maintenance procedures for these two types of valve are the same except where noted. Further maintenance procedures for these valves, including port-to-port leak tests, are available in the Model 11 Valve Repair Manual (PN M06115) and the Model 11 LDV Valve Repair Manual (PN 2015584-001). Figure 4-41: Model 11 LDV Valve NOTE 2000596-001 Figure 4-42: Model 11 Valve For maintenance purposes, the primary difference between the Model 11 and the Model 11 Low Dead Volume (LDV) valves is the sample ports on the valve cap. This can be seen in the figures above. There is an adapter tube (available from Siemens) that can be useful for some maintenance procedures involving the Model 11 LDV. None of the procedures in this section require the use of the adapter tube. For more information on the adapter tube, refer to the Model 11 LDV Repair Manual (PN 2015584-001). • 4-86 Model 11 and Model 11 LDV Valves, Continued Maintenance Procedures Maintenance procedures are divided into three phases as presented below. The type of maintenance procedure to be performed is determined by the type of fault, availability of spare parts, experience of maintenance personnel and availability of tools and work place facilities. The description accompanying each type of procedure will guide the user in the type of maintenance procedure to be performed. Within the procedures, the numbers in parenthesis denote parts referenced in the lists contained in the figures within this section; refer back to the lists for locations. Diagnostic: These can determine problems by a visual examination of valve. Mini-Maintenance: Mini-Maintenance procedures should be performed with the valve installed in the analyzer. These procedures are the first logical step for maintenance personnel if they are not sure of what the problem is. The valve should be returned to Siemens for repair if procedures fail to correct problem of a faulty valve or a visual inspection detects an appreciable amount of foreign contamination on the diaphragm. Valve cap maintenance procedures are as follows: • • • Valve Cap Disassembly Cleaning, Fittings and Tubing Valve Cap Assembly Maxi-Maintenance: These procedures may be performed if the valve fault cannot be corrected using Mini-Maintenance procedures. The valve can either be replaced or these procedures can be performed. This includes completely disassembling, cleaning and rebuilding the entire valve. Procedures include the following: • • • • • • Visual Inspection 2000596-001 Valve Cap Disassembly Cleaning Fittings and Tubing Valve Cap Assembly Valve Body Disassembly Valve Body Cleaning Valve Body Assembly If system operational performance or a visual inspection of the Model 11 or Model 11 Low Dead Volume Valve indicates the real or potential problem with the valve, the following information will assist maintenance personnel in determining the problem. Information will indicate whether the valve can be repaired on site or whether it should be returned to Siemens for repair or replacement. • 4-87 Model 11 and Model 11 LDV Valves, Continued Maintenance Personnel If customer 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. Direct Valve Replacement If it is determined that the problem is directly related to Model 11 or Model 11 Low Dead Volum (LDV) Valve system performance, the customer must make a determination if the valve can be repaired on site or if it should be returned to Siemens for repair or replacement. Repair of Valve 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. If the Valve shows evidence of poor switching conditions, the following procedures should be performed. • • • • • • Maintenance Facility Disassemble the valve body Discard the old O-rings Install new O-rings Thoroughly clean all the components Lubricate components Reassemble the valve 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. If valve maintenance is to be performed on site, the area must be clean and free of foreign 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. CAUTION 2000596-001 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. • 4-88 Model 11 and Model 11 LDV Valves, Continued 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 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. Very small sample pressures 1 to 10 oz. (0.4 to 4.3 kPa) may be insufficient to open the flow path 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. 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. Slower Erratic Piston Switching 2000596-001 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. • 4-89 Model 11 and Model 11 LDV Valves, Continued Mini-Maintenance Procedures Valve Cap Disassembly The following procedures should be followed for performing MiniMaintenance on Model 11 or Model 11 Low Dead Volume (LDV) Valve. Figures are of the Model 11 but are also applicable to the Model 11 LDV. Step 1. Procedure Relieve the pressure on the base Allen Set Screw (21) by turning it counterclockwise until it turns easily. Refer to Figure 4-40. 1. 2. 3. 4. 5. 6. 7. Screw (3 total) Belleville Washer (6 total) Valve Cap Teflon Seal Disc Dacron Cushion Disc O-Ring Plungers (6 total) Figure 4-43: Model 11 Valve Cap Exploded View VALVE CAP SEAL DISK (CLEAR) (C04200) CUSHION DISK (W HITE) PLUNGER (6 X) O- RING BODY W ITH BASE ASSEMBLY INSTALLED 627- 11C Figure 4-44: Model 11 Valve Major Components 2000596-001 • 4-90 Model 11 and Model 11 LDV Valves, Continued Step 2. Procedure 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 4-43 and 4-44. • • • 3. Teflon Sealing disc (4) [clear] Dacron Cushion disc (5) [white] and "O" ring (6) Inspect the Teflon sealing disc (4), Dacron cushion disc (5) and silicon rubber "O" ring (6) for dirt or breaks. If damage is evident, discard damaged part(s) and replace with new component(s). 4. If Teflon sealing disc (4), Dacron cushion disc (5) and "O" ring (6) 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, install new Teflon sealing disc (4), Dacron cushion disc (5) and "O" ring (6) and reassemble the cap. Otherwise, either continue with valve disassembly or replace the valve. 5. 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 4-45. 6. To reassemble the valve cap (3), refer to section Valve Cap Assembly. If the valve actuating piston assembly is contaminated or malfunctioning, refer to Valve Body disassembly. PLUNGER ORIENTATION THIS END TOWARD VALVE CAP THIS END TOWARD PISTONS 62711E Figure 4-45: Model 11 Plunger Orientation 2000596-001 • 4-91 Model 11 and Model 11 LDV Valves, Continued Cleaning Fittings and Tubing 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. If port-to-port leakage or blockage exists when a valve flow passage is switched open, then contamination of flow passages or excessive friction in the lower section of the valve may exist. This impedes valve operation and the valve must be thoroughly flushed clean. 1/4" SHORT SCREW LOCATION FOR SERIAL NUMBER 1/2" Figure 4-46: Manifold Tube NOTE If solvent becomes contaminated during performance of the following steps, it must be replaced with a clean supply from a clean beaker. Clean solvent must be used for each of the following steps. Step 2000596-001 Procedure 7. (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 solvent such as hexane is recommended. 8. (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. • 4-92 Model 11 and Model 11 LDV Valves, Continued Valve Cap Assembly CAUTION Step 9. Place the actuator assembly upright on a clean lint free cloth surface with the two valve cap guide pins facing upwards. 10. Using a syringe with Krytox 143 AY lubricating oil, place a drop of oil on sidewall of each valve body (8) plunger hole. 11. 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 4-45 for plunger orientation. 12. Using clean lint free cloths wetted with acetone, remove excess lubricating oil from top of valve body (8). 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. 13. NOTE Install silicon "O" ring (6), Dacron cushion disc (5) and clear Teflon seal disc (4). Do not lubricate "O" ring (6). Clear Teflon seal disc (4) MUST BE mounted on top of Dacron cushion disc (5). Refer to Figure 4-44. Align discs over plungers (7). 14. 2000596-001 Procedure Securely holding valve cap (3), blow out each port and/or tube with compressed air to remove all acetone and foreign matter. • 4-93 Model 11 and Model 11 LDV Valves, Continued CAUTION Do not use grease when installing O-ring. Step 15. 16. Maxi-Maintenance Procedures Procedure 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 4-43. • 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). Valve is now ready for reinstallation and placing into operational service. The following procedures should be followed for performing MaxiMaintenance on the Model 11 Valve or the Model 11 Low Dead Volume Valve. Maxi-Maintenance procedures include the Mini-Maintenance procedures in addition to the disassembly, inspection and assembly of the valve plunger presented in this section. Refer to Figure 4-47. Step 1. Procedure Perform the following Maintenance Procedures in the order presented: • • • • • 2000596-001 Valve Cap Disassembly (Mini-Maintenance) Cleaning Fittings and Tubing (Mini-Maintenance) Valve Body Disassembly (Maxi-Maintenance) Valve Body Assembly (Maxi-Maintenance) Valve Cap Assembly (Mini-Maintenance) • 4-94 Model 11 and Model 11 LDV Valves, Continued Valve Body Disassembly Step 2. Procedure Remove the six plungers (7) by inverting valve body (8) and then shaking it. Plungers should fall into the palm of 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. CAUTION 2000596-001 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. 3. Examine plungers for damage. Any plunger showing defects, such as nicks, must be discarded and replaced with a new part. 4. 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. 5. Use the plier tool supplied with the repair kit to remove the retaining ring clip (19). 6. From bottom of valve body, remove retaining base (18), compression plate (17), compression spring (16) and compensation plate (15) from bottom of valve body (8). Refer to Figure 4-47. 7. Use the plier tool supplied with the repair kit to remove springloaded piston (14) from valve body (8). Insert the tips of the plier nose into the holes in the underside of the piston and pull slowly. 8. Remove air-loaded piston (11) from valve body (8) 9. Using care to catch plungers (7), as presented in step 2, remove any stuck plunger using retaining ring pliers. • 4-95 Model 11 and Model 11 LDV Valves, Continued 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” Figure 4-47: Valve Body Exploded View Step Procedure 10. Examine plungers (7) for damage. Any plunger showing defects, such as nicks, must be discarded and replaced with a new part. 11. 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 reinstall any defective component. 2000596-001 • 4-96 Model 11 and Model 11 LDV Valves, Continued Valve Body Cleaning To clean the valve body after it has been disassembled, perform the following procedures. Step 12. Procedure To clean the valve body, the following components are recommended: • Ultrasonic cleaner recommended • Cleaning solution such as strong detergent solution, hexane, acetone or methanol. Where indicated, use only Krytox Flourinated Grease (Siemens part number G87004). If a strong detergent solution is used, all cleaned parts must be thoroughly rinsed with a solvent to remove detergent residue before reassembling of valve body. NOTE If cleaning solvent becomes contaminated during performance of the following steps, replace it with a clean supply of cleaning solvent. CAUTION 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-ring in any type of cleaning solvent. 2000596-001 13. Fill Ultrasonic cleaner with cleaning solvent. 14. Before placing valve body parts in Ultrasonic cleaner, wipe off all grease and foreign contaminants from valve parts. 15. Place valve body parts on a lint free cloth in ultrasonic cleaner. 16. Turn Ultrasonic cleaner ON and allow to run for 10 minutes. 17. Remove parts and shake cleaning solvent from tubes. Let parts air dry before reassembling. • 4-97 Model 11 and Model 11 LDV Valves, Continued Valve Body Assembly CAUTION 2000596-001 Step Procedure 18. Before reassembling valve body parts, clean hands, tools and perform reassembling procedures in a clean dust free area. 19. Apply KRYTOX 240 AC in both "O" ring grooves of springloaded piston (14) 20. Install silicon rubber O-rings (12 and 13) and apply KRYTOX 240 AC grease to their outer surfaces. 21. Apply KRYTOX 240 AC grease to each of the fingers of the finger spring (10) of air-loaded piston (11). 22. Place air loaded piston (11) over the small diameter of springloaded piston (14) with finger springs (10) outside. Align piston with guide pin. Refer to Figure 4-50. 23. Apply a bead of KRYTOX 240 AC grease to the "O" ring airloaded piston (11) groove. Refer to Figure 4-49. 24. Install silicone "O" ring (9) and apply grease to the "O" ring outer surface. 25. Apply a thin film of KRYTOX 240 AC grease to inside of valve body (8) where the pistons (14 and 11) will be sliding. 26. 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 4-50. Exercise care not to damage the O-rings when sliding them past the lower retaining ring groove. 27. Apply KRYTOX 240 AC grease to the compression plate (17) beveled cone. Insert the ball (20) into the greased cone. 28. Insert both the compression plate (17) and ball (20) into retaining base (18). Refer to figure 4-48. 29. 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. 31. Place compression spring (16) on compression plate (17). 32. Place compensation plate (15) over the compression spring (16). • 4-98 Model 11 and Model 11 LDV Valves, Continued P49510 S52000 P49500 V1605 B0006 H1064 Figure 4-48: Assembly of Air Loaded and Spring Loaded Pistons V16022 SPRING PISTON Figure 4-49: Greasing of Spring Pressure Points 2000596-001 • 4-99 Model 11 and Model 11 LDV Valves, Continued 627- 11D ALIGN PIN W ITH INDEX HOLE V16022 V16023 (AIR LOADED) (SPRINGLOADED) Figure 4-50: Valve Base Alignment Pin Step CAUTION 2000596-001 Procedure 33. 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). 34. 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). 35. Use the plier tool supplied with the repair kit to reinstall the retaining ring (19). Be certain the retaining ring (19) sets into its mounting groove. 36. Prepare to 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). 37. Align and install manifold (23) onto valve body (26) with two 832 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 4-47. 38. If necessary, bend the top two manifold (23) tubes straight up ¼" from base of tube. Refer to Figure 4-46. Bend lower middle tube straight up ½" from manifold tube base. 39. Reassemble valve cap (3) using the procedure provided earlier in this section. • 4-100 Liquid Injection Valve Description 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 Figure 4-51. Refer back to Figure 4-51 for part locations. 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. Teflon and Rulon made gaskets 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. Refer to Figure 4-51 for part locations. • 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. 2000596-001 • 4-101 Liquid Injection Valve, Continued Fault/Remedy Troubleshooting Chart Fault Cause Remedy All peaks appear smaller Sample flow unit (15) or injection blocked. Buildup of material on injection stem. Clean injection hole, stem (6), vaporizer (16) and sample flow unit (15). Peaks are becoming wide and shifted to longer times. Baseline becomes negative before injection 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 getting injected. Leaky pneumatic actuator, grease used up, O-rings (4) damaged, control pressure too low. Clean pneumatic actuator, replace Orings, and grease sliding surfaces 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). Worn gaskets (14) and/or stem (6). Replace gaskets (14) or stem (6). Poor peak form, platform following peak. Increase in baseline. Visible discharge of sample. 2000596-001 • 4-102 Liquid Injection Valve, Continued Fault Cause Remedy 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 magnifying glass. The effect is significantly less on the rest of the stem. Corrosive sample Possibly replace injection stem (6) by version made of another material (e.g. 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 (most frequent case). The particles get lodged in the gasket and scratch the stem during injection. Check filter from sample system and replace if necessary. 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 and other non-volatile materials. The deposits in the vaporizer (16) may be removed mechanically (drill/reamer with 3.3 mm diameter), or the part may be replaced. Replace stem (6) and gasket (14). 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. 2000596-001 • 4-103 Liquid Injection Valve, Continued Maintenance Procedures Figure 4-51 is an exploded view of the valve. Use this figure to aid you in removal and replacement of parts. Parts shown for the heater and sensor area may vary depending upon the valve type. Removing 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. WARNING 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. Step NOTE 2000596-001 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. 5. Unscrew the sample line and pneumatic actuation control lines from the liquid injection valve. Depending on the type of service being performed, it may not be necessary to remove the vaporizer and flange. 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. • 4-104 Liquid Injection Valve, Continued CAUTION All work should be performed on a clean dry surface. Parts should be placed on a clean lint free cloth and hands should be clean. Disassembling Valve Refer to Figure 4-51 for the following procedure. Step 1. Procedure If vaporizer (7)and flange (8) were not removed from the analyzer, then skip this step. Unscrew the valve body (7) from the flange (17) and vaporizer (16) and separate the components. 2000596-001 2. Remove the 2 hex set screws (2) and remove the control cylinder (1). 3. Lift off the sample flow unit (15) and adjustment assembly (13) from the injection stem (6). 4. 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. 5. 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. • 4-105 Liquid Injection Valve, Continued 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Control Cylinder Hex Set Screws Control Piston Large O-Rings Guide Pin (Only on Cross-Hole) Injection Stem (tappet) Valve Body Small O-Ring and Piston Guide Hole Label Indicating Injection Volume Belleville Washer Plate Springs (approx. 8) Adjustment Nut Adjustment Counter Nut Adjustment Assembly Gaskets (2) Sample Flow Unit Vaporizer Flange Carrier Gas Inlet Tube Note: The guide pin (5) is only applicable to pistons with the “crosshole” type stem. Pistons with the much more common “groove/notch” stem are not equipped with a guide pin.. Figure 4-51: Liquid Injection Valve Exploded View Figure 4-52: Liquid Injection Valve Body 2000596-001 • 4-106 Liquid Injection Valve, Continued Replacing the Teflon Gasket Refer to Figure 4-51 for the following procedures. Step O-ring Replacement 1. Replace the Teflon gaskets if they show any signs of wear or contamination. 2. 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. 3. Insert new gaskets (14) into the adjustment assembly (13) and vaporizer (16). Use the correct type gasket according to the application and temperature class. 4. There should be no play between the new gasket and the injection stem. It should be extremely difficult to move the gasket. Refer to Figure 4-51 for the following procedures. The silicone O-rings of the pneumatic drive should be regularly greased with Dow Corning Grease 111, 44 or equivalent. Step 2000596-001 Procedure 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. Liberally grease the new O-rings and the sliding surfaces of the control cylinder (1) and the piston guide (2 & 8). Siemens recommends using Dow Corning 111 with a temperature range from –40 to +260°C or Dow Corning 44 grease with a temperature range from –40 to +200°C • 4-107 Liquid Injection Valve, Continued 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). Step Procedures 1. Procedure Before assembling the valve, apply a thin film of Dow Corning 44 grease to the following parts. Use Dow Corning 111 or 44 or any grease that has a temperature rating of –40 to +260°C • • • • 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). Refer to Figure 4-53 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). Refer to Figure 4-54. 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. Refer to Figure 4-54. Newer sample flow units have this orientation marked with an arrow. 2000596-001 • 4-108 Liquid Injection Valve, Continued Bevel Up Bevel Down Bevel Up Figure 4-53: Belleville Washer Orientation Figure 4-54: Orientation of Sample Flow Unit Hole 2000596-001 • 4-109 Liquid Injection Valve, Continued Step Belleville Washer Spring Adjustment Procedure 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. 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. Step 2000596-001 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. • 4-110 Liquid Injection Valve, Continued Step 3. Procedure 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. Dosing Stem Replacement 2000596-001 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. Refer to Figure 4-52. 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). 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. • 4-111 Liquid Injection Valve, Continued Temperature and Heating Components To be supplied. CAUTION For 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. 2000596-001 • 4-112 Live Tee Switch Description Critical to the operation of the Live Tee Switch valve operation is the correct pressure and flow rates. This section provides procedures for setting the pressure and flow adjustments. Procedure for Pressure and Flow Adjustments To establish the operating pressures first ensure that the columns are not leaking and that the oven is at its operating temperature. 1. Shut off vent flows at the splitter/backflush vent, the cut vent and the purge vent. 2. Establish the desired forward column flow by adjusting the inlet pressure, then read and record the midpoint pressure at the live tee. This can be read directly from the EPC outputs. 3. Adjust the Pm (-) and Pm (+) EPC setpoint to a pressure slightly below the recorded midpoint pressure. 4. Re-establish flows at the vents, nominally 40 to 175 cc/min at the splitter vent, 10 to 70 cc/min at the cut vent and 10-30 cc/min at the purge vent. Optimum flow at the cut vent is approximately 5 times column flow. Flow instructions below 5 times column flow assume that the cut vent is connected to an ITC detector and that the purge vent is connected to the main detector downstream of the main column. Notes Concerning Pressure and Flow Adjustments 2000596-001 When flows have been established at the cut vent and purge vent, the pressure at the midpoint is reduced, and flow through the pre-column increases. When the pressures at Pm(-) and Pm(+) are adjusted, flow in both columns is influenced, and peak retention times change slightly. It is better to start pressure adjustment of Pm(-) and Pm(+) at pressures slightly below the recorded midpoint pressure since the differential pressures required to operate the tee piece will be kept small and influence on the peak retention times will be minimized. • 4-113 Live Tee Switch, Continued Cut On (Pa > Pm(-) > Pm(+)) The first adjustment is made in the cut on mode (Pa > Pm(-) > Pm(+)) by reducing the Pm (+) pressure by 20 mbar (0.3 psi) via adjustment of the Pm (+) EPC setpoint. Since two peaks can appear at the main detector from one component, one through the purge vent, and one through the main column, inject a single component test sample to prevent confusion resulting from multiple peaks. A third peak may also appear on the ITC from the cut vent if an ITC is used. A multiple component sample may easily lead to confusion of the identity of various peaks. If two peaks appear at the main detector, the earlier eluting “pre-peak” has eluted through the purge vent at the retention time of the precolumn. If a third peak has also appeared at the ITC from the cut vent, first address the ITC peak by increasing pressure at Pm (+) (or decrease the pre column inlet pressure, Pa) by 0.1 psi increments until that peak disappears on subsequent injections. Then increase Pm (+) by 0.05 psi increments until the pre-peak just disappears. If no pre-peak appears at the main detector from the purge vent, further decrease Pm (+) in increments of 0.1 psi until a pre-peak appears at the main detector. Once a pre-peak is obtained, increase Pm (+) until it just disappears. If no ITC is used, the Pm (-) pressure must be adjusted. Reduce the Pm (-) pressure (or increase the Pa pressure) by increments of 5 mbar or 0.1 psi until the main peak at the main detector is noticeably reduced in size, and then increase the Pm (-) pressure (or decrease the Pa pressure) until the size of the peak at the main detector is maximized. Reappearance of a pre-peak at the main detector will require additional adjustment of Pm (+). Cut Off (Pa > Pm(-)