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Process Gas Chromatograph
MicroSAM
Operating Instructions · 03/2012
Process Gas Chromatography
Process analytics
Process Gas Chromatograph
MicroSAM
Purpose of this
documentation
1
General information
2
Description
3
Mounting
4
Commissioning and
operation
5
Service and maintenance
6
Spare parts/accessories
7
Examples
8
Technical data
9
Operating Instructions
Dimension drawings
Appendix
7KQ3101
06/2012
C79000-G5376-C560-07
10
A
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the relevant information is not taken into account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: C79000-G5376-C560
Ⓟ 07/2012 Technical data subject to change
Copyright © Siemens AG 2012.
All rights reserved
Table of contents
1
Purpose of this documentation .................................................................................................................. 7
2
General information ................................................................................................................................... 9
3
2.1
Intended use ..................................................................................................................................9
2.2
Safety information ..........................................................................................................................9
2.3
Transportation ..............................................................................................................................11
2.4
2.4.1
2.4.2
Protection against explosion ........................................................................................................12
General regulations......................................................................................................................12
Directives for operation ................................................................................................................15
2.5
Qualified personnel ......................................................................................................................17
2.6
Limitation of liability for external accessories...............................................................................17
2.7
Final shutdown and disposal........................................................................................................17
Description............................................................................................................................................... 19
3.1
Applications..................................................................................................................................19
3.2
Product features...........................................................................................................................20
3.3
MicroSAM design.........................................................................................................................21
3.4
Rating plate design ......................................................................................................................22
3.5
Functional description of the electronics......................................................................................23
3.6
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
3.6.5.1
3.6.5.2
3.6.5.3
3.6.5.4
3.6.5.5
3.6.5.6
3.6.5.7
3.6.5.8
3.6.6
3.6.7
3.6.8
3.6.9
Functions......................................................................................................................................25
Gas flow charts ............................................................................................................................26
Analysis module ...........................................................................................................................28
Example of time switching commands.........................................................................................32
Thermal release in the analysis module ......................................................................................33
Measuring sequence....................................................................................................................33
Preparation of measurement .......................................................................................................35
Purge sample loop .......................................................................................................................39
Injecting........................................................................................................................................41
Empty sample loop completely ....................................................................................................43
Purge sample loop with sample ...................................................................................................44
Cut - start .....................................................................................................................................45
Cut - end ......................................................................................................................................46
Backflushing.................................................................................................................................47
Cut - check ...................................................................................................................................49
Backflushing - check ....................................................................................................................50
Monitoring of the chromatograph functions .................................................................................51
Temperature control systems ......................................................................................................53
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
3
Table of contents
4
5
6
7
Mounting.................................................................................................................................................. 55
4.1
On-site requirements................................................................................................................... 55
4.2
Space requirement...................................................................................................................... 55
4.3
Fixing........................................................................................................................................... 56
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.8
4.4.9
4.4.10
4.4.11
4.4.12
4.4.13
Mounting and connecting ............................................................................................................ 57
Requirements for mounting:........................................................................................................ 57
Gas lines ..................................................................................................................................... 58
Sample lines................................................................................................................................ 59
Exhaust gas lines ........................................................................................................................ 60
Equipotential bonding cable/grounding....................................................................................... 60
Lightning protection..................................................................................................................... 60
Installing the communications cable ........................................................................................... 61
Breathing device ......................................................................................................................... 62
Power switch and fuse ................................................................................................................ 63
Fitting the power cable ................................................................................................................ 64
Connecting of digital outputs and digital inputs........................................................................... 65
Connecting the HMI device ......................................................................................................... 66
Connecting the HMI device on site (only for servicing purposes)............................................... 66
Commissioning and operation ................................................................................................................. 71
5.1
Connection of gas lines............................................................................................................... 72
5.2
Activating the gas supply ............................................................................................................ 72
5.3
Switching on the chromatograph ................................................................................................ 73
5.4
Starting the PC and operating software ...................................................................................... 74
5.5
Shutting down ............................................................................................................................. 75
Service and maintenance ........................................................................................................................ 77
6.1
6.1.1
6.1.2
Maintenance of analysis module................................................................................................. 77
Removal of analysis module ....................................................................................................... 77
Installing the analysis module ..................................................................................................... 84
6.2
Replacing the carrier gas cylinders............................................................................................. 87
6.3
6.3.1
6.3.2
Installing and removing electronic components .......................................................................... 87
Removal of electronic modules................................................................................................... 88
Installation of electronic modules................................................................................................ 92
6.4
6.4.1
6.4.2
6.4.3
Conversion of MicroSAM basic device AS09.............................................................................. 94
Preparation for use of analysis modules of type A ..................................................................... 94
Restoring of data for AS09 type A .............................................................................................. 96
Returning for use of analysis modules of type D ........................................................................ 98
Spare parts/accessories ........................................................................................................................ 101
7.1
Spare parts list .......................................................................................................................... 101
7.2
Accessories ............................................................................................................................... 102
MicroSAM
4
Operating Instructions, 06/2012, C79000-G5376-C560-07
Table of contents
8
Examples............................................................................................................................................... 103
9
Technical data ....................................................................................................................................... 105
10
Dimension drawings .............................................................................................................................. 111
A
Appendix................................................................................................................................................ 113
A.1
A.1.1
A.1.2
Principle of live column switching ..............................................................................................113
Advantages of live switching......................................................................................................114
Live switching function ...............................................................................................................115
A.2
ESD guidelines ..........................................................................................................................120
A.3
EC Declaration of Conformity ....................................................................................................122
A.4
A marking in accordance with KC (Korea).................................................................................122
A.5
Service and Support ..................................................................................................................123
A.6
List of abbreviations ...................................................................................................................124
Glossary ................................................................................................................................................ 127
Index...................................................................................................................................................... 133
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
5
Table of contents
MicroSAM
6
Operating Instructions, 06/2012, C79000-G5376-C560-07
1
Purpose of this documentation
These instructions contain all information that you will require to commission and use the
device.
It is aimed at persons who install the device mechanically, connect it electrically,
parameterize and commission it, as well as at service and maintenance engineers.
Note
Please read the operating instructions before you use this device. The operating
instructions contain all important information for the device.
Observation of the information:
– Guarantees correct device functioning
– Provides reliable results
– Saves you servicing costs
Information
The contents of these instructions are neither part of an earlier existing agreement,
statement or legal commitment nor do they change this. All obligations on the part of
Siemens AG are contained in the respective sales contract which also contains the complete
and solely applicable warranty conditions. Any statements contained herein do not create
new warranties or modify the existing warranty.
The content reflects the technical status at the time of printing. We reserve the right to make
technical changes in the course of further development.
History
The following table shows the most important changes in the documentation compared to
each previous edition:
Issue
Comment
Firmware
04
Revision of contents and editing
FW: 3.10
Revision of contents and editing
FW: 3.00
Revision of contents and editing
FW: 02.08.00
First edition
FW: 01.17.00
03/2012
03
02/2010
02
09/2008
01
08/2006
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
7
Purpose of this documentation
MicroSAM
8
Operating Instructions, 06/2012, C79000-G5376-C560-07
General information
2.1
2
Intended use
● This gas chromatograph is used to separate and quantitatively determine components in
a gaseous sample.
● The device may only be used for the purposes specified in these instructions.
● Modifications to the device which are not expressly referred to in these instructions
therefore result in an application which is not in accordance with the intended use. Such
modifications to the device are then the exclusive responsibility of the user.
2.2
Safety information
The gas chromatograph complies with the applicable safety standards. If the handling
instructions and safety information are observed, no dangers exist when using the device
which could endanger the health of personnel or result in damage to property.
You will find the safety information:
● In these operating instructions and in the manual
● On the gas chromatograph
● On the chromatograph components
WARNING
Only appropriately qualified persons are permitted to make interventions on this device.
These persons must be thoroughly familiar with all sources of danger and service
activities in accordance with these operating instructions.
For trouble-free and safe operation of this device, the following requirements must be
met:
Transportation in accordance with proper procedures
Proper storage
Proper installation and assembly
Careful operation and maintenance
To avoid injury to persons and damage to the device, please observe the information in
the manual.
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
9
General information
2.2 Safety information
WARNING
Dangerous gases
The gas chromatograph requires various gases for operation which have different
danger potentials.
The gas chromatograph may require gases for operation which produce an explosive
mixture with air.
Route all exhaust gases out of the gas chromatograph and away from the position of
use using a common line.
Always provide sufficient ventilation as soon as you allow the sample gas line to run
empty and the sample gas contains corrosive or toxic components.
CAUTION
Corrosion danger
The housing and the pipelines are resistant to solvents as well as weak alkalis and
acids.
Check the resistance of the housing and the pipelines when using in an environment
with strong alkalis or acids and/or at higher temperatures.
Avoided corrosion and damage of the connection lines resulting from permanent contact
with the following substances:
Nitric acid
Hydrochloric acid
Carbon bisulfide
Ethanol
Formic acid
Petroleum spirit
Hydraulic oil
Isopropanol
MicroSAM
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Operating Instructions, 06/2012, C79000-G5376-C560-07
General information
2.3 Transportation
CAUTION
Electrostatic sensitive devices
This device contains electrostatic sensitive devices. Electrostatic sensitive devices may
be destroyed by voltages that are undetectable to a human. Voltages of this kind occur
as soon as a component or an assembly is touched by a person who is not grounded
against static electricity. The damage to a module as a result of overvoltage cannot
usually be detected immediately. It may only become apparent after a long period of
operation.
Protective measures against discharge of static electricity:
Before you work with modules, first discharge any static charges from your body, for
example by touching a grounded object.
Devices and tools used must be free of static charge.
Always pull the mains connector and disconnect the battery before installing or
removing modules.
Hold modules only by their edges, and do not touch pins or printed conductors.
2.3
Transportation
The gas chromatograph is supplied in various designs, and can also include a metal bracket
as a protective unit for the connection pipes (see ⑦, Fig. 3.1). If the chromatograph is
supplied with this metal bracket, it must only be transported or shipped together with it.
Furthermore, we also recommend operation of the chromatograph with the metal bracket
fitted.
If the chromatograph is transported or shipped without this metal bracket, the warranty is
nullified.
Exception: The metal bracket is not required if the chromatograph is mounted in a protective
casing approved by Siemens. In this case, transportation or shipping of the chromatograph is
only permissible in this protective casing.
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
11
General information
2.4 Protection against explosion
2.4
Protection against explosion
2.4.1
General regulations
The installation and operation of electrical equipment in potentially explosive atmospheres
are regulated by the directive RL 99/92/EU (ATEX 137). This directive refers to the generally
recognized process engineering regulations.
WARNING
Cancellation of the explosion protection
The test certificate for your explosion-proof gas chromatograph only applies to the original
configuration as well as to connection and installation according to the switching and piping
plans of Siemens AG. Changing one or more components will void the explosion protection
for your device.
Conditions
The test certificate and any supplements contain all conditions and regulations specified for
installation and operation of the device.
MicroSAM
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Operating Instructions, 06/2012, C79000-G5376-C560-07
General information
2.4 Protection against explosion
WARNING
Explosion hazard
The device is designed to analyze flammable and non-flammable gaseous media.
Hydrogen or inert gases are used as auxiliary gases.
For the analysis of flammable gases or use of hydrogen as a carrier gas, oxygen may
only be present in concentrations ≤ 2% in the sample.
Oxygen at concentrations up to 21% and pressure up to 1.1 bar (110 kPa) is permissible
for operation only if an additional constructive explosion protection measure is
implemented, for example, installation of a flame arrester between the process
connection and gas chromatograph.
Oxygen at concentrations up to 21% and pressure > 1.1 bar (110 kPa) is not allowed
under normal operating conditions for explosive mixtures.
The pneumatic conditions for the sample and the auxiliary gas must be strictly observed:
– Sample gas ≤ 1.6 bar (160 kPa) absolute pressure
– Auxiliary gas ≤ 8 bar (800 kPa) absolute pressure
If flammable gases are connected at a pressure > 1.1 bar (110 kPa), the chromatograph
and the gas line must be purged with process gas prior to analysis.
Flammable gases which are explosive under the analysis conditions even with the
exclusion of oxygen (acetylene and ethylene oxide), may only be present in the
analyzed mixture in concentrations that are uncritical for safety-related engineering.
Acetylene and ethylene oxide can be present in a concentration up to 100%.
The permissible ambient temperature range is -30° to +55° C.
The temperature range for continuous operation is -20 °C to +50 °C.
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
13
General information
2.4 Protection against explosion
Table 2- 1
Case examples for explosion protection
MicroSAM
(7KQ3101)
Case
no.
Concentration of
oxygen
in normal
operation
Transient
concentration of
oxygen
(not normal
operation)
Permis Sample
pressure
sible
carrier (absolute)
gases
External
flame
arrester
Substances
that are
explosive
under
exclusion of
oxygen
Process
medium
zone x
1
0 ... 2 %
0 ... 2 %
H2, He, 1.0 ... 1.6 bar
N2, Ar
Not
required
Not allowed
Not
x
explosive
2
0 ... 2 %
0 ... 21 %
H2, He, 1.0 ... 1.6 bar
N2, Ar
Not
necessary
Zone 1
x
3
0 ... 21
%
0 ... 21 %
H2, He, 1.0 ... 1.1 bar
N2, Ar
Required
Not allowed;
with the
exception of
acetylene
and ethylene
oxide up to
100%
Zone 0
x
4
0 ... 4 %
0 ... 4 %
He, N2, 1.0 ... 7 bar
Ar
Not
necessary
Not allowed
Zone 1
SITRANS
CV
(7KQ3105)
x
x
x = applies to the product
Identification of explosion protection
The gas chromatograph has a flameproof enclosure. With the flameproof enclosure, the
housing resists an internal explosion pressure.
The housing of your gas chromatograph has a rating plate which identifies the explosion
protection.
This device is approved for a sample gas inlet pressure of 1.6 bar absolute (160 kPa) in
accordance with ATEX II 2 G Ex d IIC T4.
MicroSAM
14
Operating Instructions, 06/2012, C79000-G5376-C560-07
General information
2.4 Protection against explosion
Release version base device and the associated explosion protection
Release
version
base
device
New features of the basic device
Protection against explosion
Explosion protection certificate
Supplements
AS 08
Live dosing, range of supply
voltage extended:
ATEX II 2 G EEx d IIC T4
ATEX
DMT 03 ATEX E 069 X
Supplement 1 to 3
FM
Class I, Div 1, Groups A, B, C, D T4
Class I, Zone 1, Group IIC T4
FM
Certificate 3017424
Date Issued 2005/12/14
CSA
Class I, Div 1, Groups B, C, D T4
CSA
Certificate 1915614
Date Issued 2007/06/07
24 V DC (18.5 V ... 30.2 V)
Enclosure Type 4X
AS 09
eLive injection: Introduction of a
5th solenoid valve, modification
of the micro-diaphragm valve
ATEX II 2 G EEx d IIC T4
ATEX
DMT 03 ATEX E 069 X
Supplement 1 to 3
FM
Class I, Div 1, Groups A, B, C, D T4
Class I, Zone 1, Group IIC T4
FM
Certificate 3017424
Date Issued 2005/12/14
CSA
Class I, Div 1, Groups B, C, D T4
CSA
Certificate 1915614
Date Issued 2007/06/07
Enclosure Type 4X
AS 10
Modified 3rd temperature control
system (model with temperature
protection)
Modified 4th temperature control
system (model with temperature
protection)
ATEX
II 2G Ex d IIC T4 Gb
DMT 03 ATEX E 069 X
ATEX
DMT 03 ATEX E 069 X
Supplement 1 to 4
FM Certificate canceled
CSA
CSA
CLASS I, DIVISION 1 GROUPS B, C, Certificate 1915614
D T4
Date Issued 2009/11/13
CLASS I, ZONE 1 GROUPS IIC T4
ENCLOSURE TYPE 4X / IP65
2.4.2
Directives for operation
Switching on the chromatograph
Only switch on the power supply to the device if this has been closed correctly.
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
15
General information
2.4 Protection against explosion
Opening the housing with the power supply switched off
WARNING
Explosions
If you open the housing prematurely, explosions may occur due to hot components and
residual electrical charges in the gas chromatograph. A corresponding label informing you
of this is present on the device.
Before opening the housing in a hazardous area, disconnect the device from the power
supply.
It is essential that you wait for 60 minutes following switching off of the power supply.
WARNING
Fire permission certificate
Replacement of the backup battery is only permissible if you have a fire permission
certificate. This instruction applies regardless as to whether the gas chromatograph is
switched on or off.
Opening the housing with the power supply switched on
A diagnostics connector is located behind the status display panel. You must open the
housing in order to access it.
WARNING
Fire permission certificate
Opening the housing in the hazardous area with the power supply switched on is only
permissible if you have a fire permission certificate.
Maintenance and repair of components
WARNING
Observe the directive
Observe the regulations of directive RL 99/92/EU (ATEX 137) when carrying out
maintenance and repairs on parts associated with the explosion protection.
MicroSAM
16
Operating Instructions, 06/2012, C79000-G5376-C560-07
General information
2.5 Qualified personnel
2.5
Qualified personnel
CAUTION
Qualified personnel
Only qualified personnel are authorized to install and use the process gas
chromatograph.
Insufficient knowledge of the operating instructions, or the complete absence thereof,
result in the deletion of all liability claims with regard to Siemens AG.
We therefore recommend owners to have the instruction of personnel confirmed in
writing.
Qualified personnel are people who are familiar with the installation, mounting,
commissioning, and operation of the product. These people have the following qualifications:
● They are authorized, trained or instructed in operating and maintaining devices and
systems according to the safety regulations for electrical circuits, high pressures and
aggressive as well as hazardous media.
● For explosion-proof devices: they are authorized, trained, or instructed in carrying out
work on electrical circuits for hazardous systems.
● They are trained or instructed in maintenance and use of appropriate safety equipment
according to the safety regulations.
2.6
Limitation of liability for external accessories
If you wish to use or connect accessories in the chromatograph which are not specifically
recommended by Siemens AG, please first obtain confirmation from Siemens AG that the
operational safety of the chromatograph is not influenced by the external accessory. Without
this confirmation, Siemens AG excludes all liability for the operational safety.
2.7
Final shutdown and disposal
It is essential to observe the environmental protection guidelines at the location of the
operating company for the final shutdown and disposal of the process gas chromatograph!
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
17
General information
2.7 Final shutdown and disposal
MicroSAM
18
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.1
3
Applications
The process gas chromatograph is used in various industry sectors, for example:
● Chemical industry
● Oil & gas
● Iron & steel
● Pharmaceuticals
● Metals, basic materials, cement
● Glass
The process gas chromatograph is a device for determining the concentration of selected
components in a process gas, and is used for measuring and analysis methods associated
with process analysis.
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
19
Description
3.2 Product features
3.2
Product features
Functions:
● Analysis using a micro electromechanical system (MEMS).
● Precision due to valveless live injection.
● High-resolution capillary columns.
● Very good detection limits due to high-performance detectors.
● Very good linearity throughout the complete measuring range; expensive calibration
gases can therefore be saved. Reason: several calibration gases must be used if the
linearity is poor.
● Operation:
– Using Ethernet and a PC
– Using the built-in control panel (MMI) of a MAXUM chromatograph
– Using a network access unit (NAU)
● Device can be mounted directly at the sampling point, since it has a rugged and compact
design and only a carrier gas supply and little power are required.
● Modular design and low energy consumption, thus low operating costs.
MicroSAM
20
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.3 MicroSAM design
3.3
MicroSAM design
The following illustration provides an overview of the most important MicroSAM modules.
①
②
③
④
⑤
⑥
⑦
MicroSAM housing
Main cover
Analysis module
Lock nut
Insulating cover
Earthing connection
Metal bracket
Figure 3-1
⑧
⑨
⑩
⑪
⑫
⑬
⑭
Gas connections with blanking plugs
Pressure controller
RSP module
EPC module
Spacer
Side cover
Communications and power supply cable
MicroSAM design
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
21
Description
3.4 Rating plate design
3.4
Rating plate design
The rating plate is located on the housing and contains the Order No. and other important
product information.
①
②
③
④
Vendor
CE marking
Ex marking with Ex data
⑤
⑥
⑦
CSA marking with CSA data
IEC marking
Serial number and release version (RV)
Consult operating instructions
Figure 3-2
Rating plate
MicroSAM
22
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.5 Functional description of the electronics
3.5
Functional description of the electronics
Overview
The following block diagram shows the basic design of the electronics:
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MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
23
Description
3.5 Functional description of the electronics
RSP (real-time signal processing) and CAC (communication and analytical control)
563
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Figure 3-3
RSP and CAC
EPC (electronic pressure control)
Figure 3-4
EPC
MicroSAM
24
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
3.6
Functions
Predefined analysis modules are used in your gas chromatograph.
The main feature of the analysis module is the in-line detection. With the in-line detection,
columns and thermal conductivity detectors (TCD) are connected in series so that
measurements are carried out at the points where the separation of components is optimum.
The thermal conductivity detectors are half-bridges without an actual reference. Pairs of
thermal conductivity detectors are combined into a complete bridge circuit such that signals
are never superimposed.
The type and serial number of the analysis module are engraved on the rating plate on the
breathing connector, e.g. A01 124 ES04 or higher. The supplement ES04 identifies product
version 4 of the analysis module.
From release version 9 (AS09) onwards of the MicroSAM basic unit, the version eLive is
produced. In this case the basic unit has an additional membrane valve function 5 for
purging the sample loop. This extension improves control of the injection pulse position.
The following diagrams show permissible combinations of basic devices and types of
analysis modules.
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*) Modules of type A can also be used. It is necessary to modify the basic device in this
case. The corresponding procedure can be found in Section Conversion of MicroSAM basic
device AS09 (Page 94).
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
25
Description
3.6 Functions
3.6.1
Gas flow charts
As of AS09, the MicroSAM gas chromatograph is manufactured as two versions: Live and
eLive.
Solenoid valves control the respective functions in the multi-membrane valve.
Gas flow chart for analysis modules A01 - A11 (live injection)
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Solenoid valve 2 (MV2)
Membrane valve function 2: "Purge sample loop with sample"
Solenoid valve 3 (MV3)
Membrane valve function 3: "Empty sample loop completely"
Solenoid valve 4 (MV4)
Membrane valve function 4: "Inject"
EPC
Electronic pressure control
TCD
Thermal conductivity detector
Figure 3-5
Analysis module of type A with live injection
MicroSAM
26
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
Gas flow chart for analysis modules D01 - D11 (eLive injection)
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Solenoid valve 2 (MV2)
Membrane valve function 2: "Purge sample loop with sample"
Solenoid valve 3 (MV3)
Membrane valve function 3: "Empty sample loop completely"
Solenoid valve 4 (MV4)
Membrane valve function 4: "Inject"
Solenoid valve 5 (MV5)
Membrane valve function 5: "Purge sample loop"
EPC
Electronic pressure control
TCD
Thermal conductivity detector
Figure 3-6
Analysis module of type D with eLive injection
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
27
Description
3.6 Functions
3.6.2
Analysis module
Analysis module
● All analysis modules contain live injection (Live-D) and live column switching (Live-T).
● The analysis modules of series D have eLive injection.
● From product version 05 (ES05) onwards, the system for numbering the columns has
been changed.
Analysis modules up to ES04
The analysis modules up to ES04 are suitable for separating the following components:
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MicroSAM
28
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
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Analysis modules A04 to A10 up to ES04
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
29
Description
3.6 Functions
Analysis modules from ES05 onwards
The analysis modules from ES05 onwards are suitable for separating the following
components:
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MicroSAM
30
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
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Analysis modules A06/D06 to A11/D11 from ES05 onwards
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
31
Description
3.6 Functions
3.6.3
Example of time switching commands
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09
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t4 , t5
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Figure 3-11
Example of time switching commands
MicroSAM
32
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
3.6.4
Thermal release in the analysis module
A thermal release is fitted in the analysis module. This switches off the power supply for the
complete device as soon as the maximum permissible temperature of the analysis module of
155 °C is exceeded.
Note
The thermal release used cannot be reset or replaced. If the thermal release is triggered,
you must replace the analysis module.
3.6.5
Measuring sequence
The measuring sequence for live and eLive injection is always as follows:
1. Preparation of measurement (Page 35)
2. Purge sample loop (Page 39)
3. Injecting (Page 41)
4. Empty sample loop completely (Page 43)
5. Purge sample loop with sample (Page 44)
6. Cut - start (Page 45)
7. Cut - end (Page 46)
8. Backflushing (Page 47)
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
33
Description
3.6 Functions
The terms in the following table have been taken from the original English versions of the
operating software 'Maxum System Manager' and 'EZChrom'. They are used throughout the
Section 'Measuring sequence'.
Abbreviatio Original English term
n
Further clarification
MV1
Solenoid Valve 1 – "Flush loop" or "Flush
loop_1"
Solenoid valve 1 for the function: "Bring
sample loop to pressure of EPC 1"
MV2
Solenoid Valve 2 – "Sample"
Solenoid valve 2 for the function: "Purge
sample loop with sample"
MV3
Solenoid Valve 3 – "Back flush"
Solenoid valve 3 for the function: "Empty
sample loop completely"
MV4
Solenoid Valve 4 – "Injection"
Solenoid valve 4 for the function: "Inject"
MV5
Solenoid Valve 5 – "Flush loop_2"
Solenoid valve 5 for the function: "Purge
sample loop"
Column
Capillary Column
Column
CG
Carrier gas
Carrier gas
EPC
Electronic Pressure Control
Electronic pressure control
TCD
Thermal conductivity detector
Thermal conductivity detector
1)
Live injection
Live injection
Live switching
Live column switching
Pulse
Pulse duration in seconds for switch status
ON
ON
ON - switch status on membrane valve 1)
OFF
OFF - switch status on membrane valve 1)
Logic values used in the operating software.
The following table lists the significance of the colors for the gas lines used in the Section
"Measuring sequence".
Color of gas line
Assignment
Red
Sample gas
Blue
Carrier gas
Violet
Mixture of sample gas and carrier gas
MicroSAM
34
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
Note
Types of solenoid valves
The membrane valve functions are controlled by solenoid valves. Two types of solenoid
valves are used: open when deenergized and closed when deenergized.
Closed when deenergized: MV2 - Sample, MV4 - Injection
Open when deenergized: MV1 - Flush loop, MV3 - Back flush
Open when deenergized: MV1 – Flush loop_1, MV5 – Flush loop_2
Result
The result of the measurement is e.g. a chromatogram with time switching points on detector
TCD 2. This chromatogram shows the difference in the two procedures (live and eLive)
between the switching points t4 and t6.
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3.6.5.1
Example: chromatogram with time switching points
Preparation of measurement
Note
Time switching points
The time switching points shown on the following pages all depend on the type of
application. Only the time switching point t6 for the injection is always zero.
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
35
Description
3.6 Functions
Purging of membrane valve
Time switching point t1 = -20 s
Live
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MicroSAM
36
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
Backflushing of system
Time switching point t2 = -19 s
Live
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MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
37
Description
3.6 Functions
Backflushing of system finished
Time switching point t3 = -13 s
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MicroSAM
38
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
3.6.5.2
Purge sample loop
Live
Time switching point t4 = -10 s. The contents of the sample loop are transferred to the outlet
"Backflush" by means of the live injection.
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MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
39
Description
3.6 Functions
eLive
In this version, the procedure is carried out in two steps at different times:
Step - 1 - time switching point t4= - 10 s: The contents of the sample loop are set to the
pressure level of the carrier gas via MV1.
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ON
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OFF
Step 2 - time switching point t5 = -4 s: The contents of the sample loop are transferred to the
outlet "Backflush" by means of MV5 and the live injection.
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MicroSAM
40
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
3.6.5.3
Injecting
Injection time switching point t6 = 0 s: A small quantity from the sample loop is directed onto
the column system. This quantity can be changed by varying the pulse duration of the
injection valve.
Live
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MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
41
Description
3.6 Functions
eLive
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MicroSAM
42
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
3.6.5.4
Empty sample loop completely
Time switching point t7 = 1.5 s: Following an injection, the injection loop is briefly emptied via
membrane valve function 3 (Backflush).
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ON
ON
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OFF
ON
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
43
Description
3.6 Functions
3.6.5.5
Purge sample loop with sample
Time switching point t8 = 1.7 s: The sample loop is filled with a new sample.
Live
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OFF
OFF
OFF
OFF
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MicroSAM
44
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
3.6.5.6
Cut - start
The time switching point t9 depends on the application: By reducing the pressure on the
electronic pressure control EPC 3, the sample components are transferred by live switching
into column 3.
Live with pressure EPC 3 < pressure EPC 2
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eLive with pressure EPC 3 < pressure EPC 2
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Flush loop_2
OFF
OFF
OFF
OFF
OFF
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
45
Description
3.6 Functions
3.6.5.7
Cut - end
The time t10 depends on the application: By increasing the pressure on the electronic
pressure control EPC 3, the gas components still present on column 2 are not transferred by
live switching into column 3 but are purged via TCD 2B to the outlet of the analysis.
Live with pressure EPC 3 > pressure EPC 2
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OFF
OFF
OFF
OFF
OFF
MicroSAM
46
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
3.6.5.8
Backflushing
The time switching point t11 depends on the application: The contents of columns 1-2 are
purged backwards via the outlet "Backflush". This step continues until the gas components
which are still present are purged out of columns 1-2.
Live
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OFF
OFF
ON
ON
OFF
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
47
Description
3.6 Functions
The measuring cycle is finished when all components have left the column system.
Note
Check that all components which have been backflushed have left the column system.
MicroSAM
48
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
3.6.6
Cut - check
During the cut (t10 to t11), part of the sample is transferred from column 2 to column 3, e.g. in
the period from 29 s to 37 s (dashed line in the illustration).
The following illustration shows the signal response at the detectors TCD 4B, TCD 1B and
TCD 2B.
The components still present in column 2 are purged following the cut via TCD 2B to the
outlet.
You can check the setting of the live column switching at TCD 1B and TCD 2B during the
cut.
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Figure 3-13
Cut - check
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
49
Description
3.6 Functions
3.6.7
Backflushing - check
The components which are still present in columns 1 and 2 are removed from the analytical
system by the backflush process. Checking of the backflushed components is carried out at
TCD 2A.
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;
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Backflushing - check
MicroSAM
50
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
3.6.8
Monitoring of the chromatograph functions
The gas chromatograph is a measuring instrument for determining the concentration of
selected components in a process gas. The intended use of the device includes checking of
correct functioning at regular intervals.
Display
Up to release version 4, the display consists of 8 LEDs. From release version 5 onwards, the
display consists of an alphanumeric display and 6 LEDs.
9'&
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Display up to and including release version 4
6DPSOHIORZ
Display from release version 5 onwards
Note
Release version
You can find the release version of your gas chromatograph on the rating plate under "AS".
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
51
Description
3.6 Functions
The LEDs behind the inspection window of your chromatograph provide you with an initial
overview of the status of your gas chromatograph. They have the following meanings:
LED
Meaning if the LED lights up
Power
24 V supply voltage present.
Heartbeat
Software sign-of-life
Ready
Chromatograph is ready.
Maint. Req.
Chromatograph has a maintenance request.
Failure
Chromatograph has an alarm.
Sample flow
No sample flow
Health status (left)
Ethernet connection has been established.
Health status (right)
Communication is taking place.
The text box displays the following information:
1. Sample stream: S1, S2, S3, S4
2. Sample components: e.g. CO2, propane etc.
3. Measured value of sample as numeric value
MicroSAM
52
Operating Instructions, 06/2012, C79000-G5376-C560-07
Description
3.6 Functions
3.6.9
Temperature control systems
Previously available temperature control systems
The device previously featured three temperature control systems:
● Two temperature control systems heated the column and the detectors. They are located
in the analysis module.
● The third temperature control system heated the pneumatic connectors.
Additional fourth temperature control system
The fourth temperature control system is located on devices as of release version 10 at the
sample inlet of the MicroSAM:
①
②
③
Fourth temperature control system at the sample inlet
Sample path in the heated copper tube
Access to the pneumatic connector
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
53
Description
3.6 Functions
①
②
Fourth temperature control system at the sample inlet
Sample path in the heated copper tube
Why an additional temperature control system?
Depending on the dew point of the process sample, condensate can form in the sample
path. This can result in destruction of the analysis module.
From the entrance to the enclosure of MicroSAM, the preheated sample is thermostatically
controlled to the correct temperature by the additional temperature control system. The
sample path is heated by the additional temperature control system.
MicroSAM
54
Operating Instructions, 06/2012, C79000-G5376-C560-07
4
Mounting
4.1
On-site requirements
WARNING
Explosion hazard
Only make the terminal connections and only close the device when it is disconnected from
the supply.
Only start up the device when it has been correctly connected and when the housing has
been closed.
WARNING
Use in non-hazardous areas
Make the Ex symbol permanently illegible if the device is used in non-hazardous areas.
It is essential to observe the following conditions:
● Permissible ambient temperature from -20 to +55 °C
● Maximum permissible relative humidity 90%
● 24 V DC supply voltage
● Use of appropriate lightning protection equipment
● Grounding must be possible
● Use of gas connections and the gas purity requirements as described in sections Gas
lines (Page 58) and Sample lines (Page 59).
● Protection against direct solar radiation, even when the sun is low
4.2
Space requirement
The spacing from a wall or the next chromatograph must be at least 300 mm on both sides.
The spacing from the ceiling and floor must be at least 200 mm.
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
55
Mounting
4.3 Fixing
4.3
Fixing
The gas chromatograph is supplied preassembled on a metal bracket.
The device is:
● Secured using four screws through four holes in the metal bracket.
● Secured using two screws through the two elongated holes in the metal bracket to allow
simple removal.
NOTICE
Note the correct mounting position
The chromatograph must always be mounted horizontally with the analysis module at
the top. When mounted correctly, the technical specifications are guaranteed, and the
text can be read in the inspection window.
If you wish to mount the chromatograph in a different position, please first contact
Siemens AG servicing personnel.
1
5
2
6
3
7
4
8
/ PP
[
Figure 4-1
Gas chromatograph mounting
MicroSAM
56
Operating Instructions, 06/2012, C79000-G5376-C560-07
Mounting
4.4 Mounting and connecting
4.4
Mounting and connecting
4.4.1
Requirements for mounting:
The following are essential for mounting:
● Gas lines, sample lines, exhaust gas lines
● Power switch, line fuse, power cable
● Equipotential bonding cable
● Communications cable
CAUTION
Do not remove the dummy plug prior to startup
Leave the dummy plugs on the gas inputs until you start up the chromatograph.
Check the correct functioning of the gas lines before you connect them to the
chromatograph!
CAUTION
Destruction of the thermal conductivity detectors
Only use the carrier gas specified in the device documentation! The thermal
conductivity detectors could be destroyed.
Do not operate the thermal conductivity detectors with bridge voltages higher than
those specified in the application data. The bridge voltages must be optimized at
minimum values in order to guarantee a long service life for the thermal conductivity
detectors The maximum bridge power is 70 mW for helium.
Note
Increasing the detection limit
If you are satisfied with a shorter service life for a thermal conductivity detector, you can
increase the maximum bridge power to more than 70 mW for helium.
Before increasing the bridge power, please first contact Siemens AG servicing personnel.
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
57
Mounting
4.4 Mounting and connecting
4.4.2
Gas lines
The gas lines are made of stainless steel with a 3 mm ∅ (1/8'').
● Use only very clean gas lines suitable for chromatography.
● Connect the gas lines to the gas chromatograph according to the piping diagram.
● Connect a stop valve upstream of each gas input to the gas chromatograph.
Gas connections on the gas chromatograph
● All gas inlets and outlets: Swagelok 1/8''.
● The gas inlets and outlets are numbered.
Figure 4-2
1
5
2
6
3
7
4
8
Gas connections
Number
Description
Comment
1
Analysis module output
Heated
2
Analysis module output
Heated
3
Sample
Heated
4
Sample
Heated
5
Carrier gas input
Not heated
6
Output from pneumatic connectors
Not heated
7
Discharge of control medium for solenoid valves and EPC
flow inserts
Not heated
8
Reserved
Unheated, closed
MicroSAM
58
Operating Instructions, 06/2012, C79000-G5376-C560-07
Mounting
4.4 Mounting and connecting
Note
All device-specific piping and wiring diagrams are enclosed with the device in accordance
with the order.
NOTICE
Shortening the preassembled gas lines between the housing and the mounting bracket will
void the explosion protection for the gas chromatograph.
CAUTION
Do not remove the adapters
Filters are integrated in the connections for the sample stream and carrier gas.
The adapters at gas connections 3, 4, 5 and 8 contain a R60 filter (order no. C70211A1677-C56) pressed into the screwed gland, and must not be removed.
4.4.3
Sample lines
● Fit the sample preparation equipment as close as possible to the chromatograph so that
the connection lines are short.
● The sample line to the chromatograph must have a downward gradient.
NOTICE
Filter for microdiaphragm valves
The microdiaphragm valves have a shorter life if the sample contains particulates.
In such cases, a filter is required as part of the sample preparation equipment.
We recommend a filter with a degree of separation for a gaseous sample of 99.99% for
1.0 μm particles.
The sample preparation equipment from Siemens AG contains such filters.
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
59
Mounting
4.4 Mounting and connecting
4.4.4
Exhaust gas lines
All exhaust gases from the chromatograph must be routed into a common line. The
individual exhaust gas lines must have a downward gradient to the common line. They must
not have a diminishing diameter.
Material of the common exhaust gas line
Stainless steel piping:
● Inner diameter of at least 12 mm (1/2")
● With welded stubs and screwed glands
● With a gradient of at least 10%.
4.4.5
Equipotential bonding cable/grounding
An equipotential bonding cable is required for explosion-proof chromatographs irrespective
of the local installation guidelines. Independent thereof, the chromatograph housing must be
grounded for electromagnetic compatibility reasons.
Procedure
1. Connect the grounding screw (symbol ) at the bottom right on the chromatograph to a
central grounding point. The permissible cable cross-section is 2.5 mm2 to 6 mm2.
2. It is essential to provide a contact washer between the cable lug and housing. The
connection must be made in the following sequence:
– Housing
– Contact washer
– Cable lug
– Washer
– M6 screw
4.4.6
Lightning protection
We recommend the installation of appropriate lightning protection equipment for the
protection of personnel and devices!
MicroSAM
60
Operating Instructions, 06/2012, C79000-G5376-C560-07
Mounting
4.4 Mounting and connecting
4.4.7
Installing the communications cable
Type of cable
Siemens AG recommends twisted-pair cables, 0.14 mm2 (AWG 26).
CAUTION
Protection against explosion
All cores must be connected in the terminal box.
Core color
Description
Comment
Mounting with
Violet
hub1)
Mounting without hub2)
RS232 RxD / RS485 B+
Black
RS232 TxD / RS485 A-
Gray/pink
RS232 / RS485 shield
Red/blue
RS232 / RS485 GND
Brown/green
Ethernet 10BaseT TX+
Ethernet cable:
Orange/white
Ethernet cable:
Green/white
White/green
Ethernet 10BaseT TX-
Ethernet cable:
Orange
Ethernet cable:
Green
White/yellow
Ethernet 10BaseT RX+
Ethernet cable:
Green/white
Ethernet cable:
Orange/white
Yellow/brown Ethernet 10BaseT RX-
Ethernet cable:
Green
Ethernet cable:
Orange
1)
Standard EIA/TIA-T568A assignment
2)
Standard EIA/TIA-T568B assignment
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
61
Mounting
4.4 Mounting and connecting
4.4.8
Breathing device
The breathing device is used for pressure compensation during operation. Pressure
compensation is required due to temperature variations during operation
①
Breathing connector
Figure 4-3
Breathing device
Danger
DANGER
Danger of explosion through discharged gases
In the event of a fault, all gases supplied to the chromatograph (also samples and hydrogen
as carrier gas) can be discharged via the breathing connector or a connected line. In such a
case, there is a danger to personnel, equipment and the environment!
For this reason, take appropriate measures to prevent this.
Never connect the breathing connector to the exhaust gas system.
WARNING
Do not close off the breathing device
Ensure that the breathing device is not closed during operation, otherwise:
Pressure compensation is no longer carried out.
Ex protection is no longer guaranteed.
Housing protection IP65 is only guaranteed if the pipeline connected to ① ends in a
room which contains neither splashing water nor dust.
MicroSAM
62
Operating Instructions, 06/2012, C79000-G5376-C560-07
Mounting
4.4 Mounting and connecting
DANGER
Danger of explosion through discharged gases
In the event of a fault, all gases supplied to the chromatograph (also samples and hydrogen
as carrier gas) can be discharged via the breathing connector or a connected line. In such a
case, there is a danger to personnel, equipment and the environment!
For this reason, take appropriate measures to prevent this.
Never connect the breathing connector to the exhaust gas system.
4.4.9
Power switch and fuse
The gas chromatograph does not have a power switch. Therefore install an external power
switch with a switching capacity of min. 2.5 A and a slow-blow fuse with a rating of 2.5 A.
Note
Fit the power switch such that it is readily accessible during operation.
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
63
Mounting
4.4 Mounting and connecting
4.4.10
Fitting the power cable
The chromatograph is supplied with a 4-m long cable. The cable has a diameter of 18 mm.
Connect all cores of the power supply in accordance with the following table since one single
core is insufficient for the maximum current. The cable must be securely routed and
terminate in a terminal box with approved type of protection.
Appropriate cable gland: M32 with a terminal areas from 13 to 21 mm.
Core color
Description
White
+24 V DC
Brown
+24 V DC
Green
+24 V DC
Yellow
+24 V DC
Gray
GND 24 V DC
Pink
GND 24 V DC
Blue
GND 24 V DC
Red
GND 24 V DC
Black
Permissible cable length
The power supply on the chromatograph must be
● up to AS07: 24 V DC (-15 ... +10%)
● from AS08 onwards: 24 V DC (18.5 ... 30.2 V)
If the power supply delivers exactly 24 V DC, and if only one chromatograph is connected,
the following cable lengths are permissible between the power supply and the
chromatograph depending on the cable cross-section (distance = half the cable length):
Core cross-section
Distance
1.5
mm2
40 m
2.5
mm2
70 m
4.0 mm2
110 m
mm2
170 m
6.0
10.0 mm2
280 m
mm2
450 m
16.0
MicroSAM
64
Operating Instructions, 06/2012, C79000-G5376-C560-07
Mounting
4.4 Mounting and connecting
4.4.11
Connecting of digital outputs and digital inputs
The following table is valid for devices from release version 4 onwards.
Core color
Description
Usage
Comment
White/gray
Digital input 1+
Sample flow,
24 V DC = OK,
0 V = too low
24 V DC to optocoupler
Gray/brown
Digital input 2+
Application programmable
White/red
Digital input 3+ or
SSSI* SCL-Rx
Application programmable
Brown/red
Digital input 4+ or
SSSI* SDA-Rx
Application programmable
Brown/blue
Digital output 1+
Application programmable
White/blue
Digital output 2+
Application programmable
White/pink
Digital output 3+ or Application programmable
SSSI* SCL-Tx
Pink/brown
Digital output 4+ or Application programmable
SSSI* SDA-Tx
Circuit diagram
Second connection to
+24 V DC
9
Relay contact
0.5 A / 100 V / 10 W
Second connection to
+24 V DC
9
* The SSSI signals from devices are available with release version 10. The signals are used,
for example, to connect an IO extender (order no. A5E01494354). Refer to the
documentation of the IO extender for more on this. If SSSI is not used, the lines are available
for their original function as digital inputs and outputs.
The following table is valid for devices up to and including release version 3.
Core color
Description
White/gray
Digital output 1+
Gray/brown
Digital output 1-
White/red
Digital output 2+
Brown/red
Digital output 2-
Brown/blue
Digital input 1+
White/blue
Digital input 1-
White/pink
Digital input 2+
Pink/brown
Digital input 2-
Usage
Comment
Relay contact
0.5 A / 100 V / 10 W
Sample flow,
24 V DC = OK,
0 V = too low
24 V DC to optocoupler
Arc-suppression diode with inductive loads
If you connect inductive loads (e.g. valves) for digital outputs, you must connect the arcsuppression diodes in parallel.
Type of cable
Siemens AG recommends twisted-pair cables, 0.14 mm2 (AWG 26).
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
65
Mounting
4.4 Mounting and connecting
4.4.12
Connecting the HMI device
The gas chromatograph is operated using a PC or laptop.
WARNING
Protection against explosion
You require a fire permission certificate if you transport a PC or laptop through the
hazardous zone.
Opening the gas chromatograph in the hazardous area with the power supply switched
on is only permissible if you have a fire permission certificate.
Connect the Ethernet port of the PC to the corresponding leads of the gas chromatograph
(see table Installing the communications cable (Page 61)).
4.4.13
Connecting the HMI device on site (only for servicing purposes)
You must open the chromatograph in order to connect the HMI device for servicing
purposes.
Procedure
WARNING
Hazardous area
You require a fire permission certificate in order to carry out servicing work on the gas
chromatograph in a hazardous area.
Due to the hot components and residual electrical charges in the gas chromatograph,
explosions may occur if you open the housing prematurely. A corresponding warning
label is present on the device.
It is therefore essential that you wait for at least 65 minutes every time before you open
the chromatograph!
Breathing device
The breathing device must not be closed!
Only use tool to open the cover.
The directives for explosion protection specify that the cover of the chromatograph may
only be opened using a tool. These directives are complied with using the hexagon sockethead bolt ②!
1. Loosen the hexagon socket-head bolt SW 1.5 ② on the securing ring of the inspection
window.
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Mounting
4.4 Mounting and connecting
2. Unscrew the securing ring. If the ring cannot be opened by hand, extend the lever arm.
To do this, insert e.g. two appropriate screwdrivers into the holes on the edge of the ring
①.
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Mounting
4.4 Mounting and connecting
3. Then carefully lever the insert out of the chromatograph as shown in the following picture.
A 25-contact Sub-D socket becomes visible.
4. Connect the Ethernet connection of the HMI PC to the corresponding pins of the
chromatograph according to the following table. If the display board is removed, the
Ethernet connection via the standard cable is interrupted.
Pin No.
Description
Comment
Mounting with hub1)
Mounting without hub2)
22
Ethernet 10BaseT TX+
Ethernet cable:
Orange/white
Ethernet cable:
Green/white
23
Ethernet 10BaseT TX-
Ethernet cable:
Orange
Ethernet cable:
Green
24
Ethernet 10BaseT RX+
Ethernet cable: Green/white
Ethernet cable:
Orange/white
25
Ethernet 10BaseT RX-
Ethernet cable:
Green
Ethernet cable:
Orange
1)
Standard EIA/TIA-T568A assignment
2)
Standard EIA/TIA-T568B assignment
Following completion of on-site operation
1. Screw in the securing ring as far as possible.
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Mounting
4.4 Mounting and connecting
2. Carefully rotate the 1.5 mm hexagon socket-head bolt ② in the ring in the clockwise
direction as far as possible.
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Mounting
4.4 Mounting and connecting
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Commissioning and operation
5
The following description includes the procedures for starting up and shutting down the
device, and the safety aspects which must be observed.
CAUTION
Observe the commissioning sequence!
To avoid damage to the gas chromatograph, carry out all work in the sequence given in
these instructions.
Procedure
1. Connection of gas lines (Page 72)
2. Activating the gas supply (Page 72)
3. Switching on the chromatograph (Page 73)
4. Starting the PC and operating software (Page 74)
WARNING
Explosion hazard
If you commission a gas chromatograph in an environment with an explosive
atmosphere, you must observe the directives for explosion protection.
Switch off the gas chromatograph when carrying out repairs or maintenance as soon
as atmospheric air penetrates into it, in other words:
– When the device is opened.
– When work is carried out on carrier gas lines and sample gas lines.
Also disconnect other energy sources, e.g. Ethernet and Modbus, if these do not
have an appropriate explosion-proof design.
You require a fire permission certificate if you transport a PC or laptop through a
hazardous zone and/or if you wish to open a chromatograph in zone 1.
It is essential to observe the information in Section General regulations (Page 12).
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Commissioning and operation
5.1 Connection of gas lines
5.1
Connection of gas lines
Procedure
1. Remove the dummy plugs from the gas inlets and outlets "1" to "7" of the chromatograph.
2. Connect the exhaust and gas lines according to the piping diagram.
5.2
Activating the gas supply
Requirement
All gas lines are connected and leakproof.
Procedure
1. Turn the carrier gas up to a pressure of 600 to 700 kPa.
2. Turn the sample gas up to an absolute pressure of ≤ 160 kPa.
3. If applicable, turn the calibration gas up to an absolute pressure of ≤ 160 kPa.
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Commissioning and operation
5.3 Switching on the chromatograph
5.3
Switching on the chromatograph
Requirement
The external power switch is fitted and connected as described in Section "Power switch and
fuse (Page 63)".
Procedure
Switch on the external power switch.
Response on the display up to release version 4:
Response
LED
1.
24 V DC lights up.
2.
Health Status on the right and Health Status on the left light up.
3.
Sample flow and Maint.Reg. flash together until the MicroSAM is ready.
4.
Heartbeat starts to flash when the MicroSAM is ready.
5.
Failure lights up until the temperature and pressure have reached their operating values
and any alarms have been acknowledged.
6.
Ready lights up at the end of the switch-on procedure as soon as the chromatograph is
ready.
Response on the display from release version 09 onwards:
The gas chromatograph starts. The message "Starting... " is output in the text box of the
display. When starting-up has been completed, the message disappears.
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Commissioning and operation
5.4 Starting the PC and operating software
5.4
Starting the PC and operating software
The factor setting for the IP address of the gas chromatograph is 161.218.51.xx. The subnet
mask is always set to 255.255.255.0.
Requirement
● Manually set the IP address of the PC to a value between 161.218.51.0 and
161.218.51.255 with the subnet mask 255.255.255.0.
The PC must not have the same IP address as the gas chromatograph.
We therefore recommend the IP address 161.218.51.254.
● The connection between the PC and gas chromatographs has been made, and the
Windows XP operating system has been started.
Procedure
Start the program "Maxum System Manager" (start bar Start ➜ Programs ➜ Maxum System
Tools ➜ Maxum System Manager).
Start the function "Add Unit" (Menu "System" ➜ Menu command "Add Unit") and enter the
new gas chromatographs.
Note
Operating software
The following are described in detail in the Maxum System Manager manual:
Installation of the Maxum System Manager and EZChrom operating software.
Establishment of connection between PC and gas chromatographs.
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Commissioning and operation
5.5 Shutting down
5.5
Shutting down
WARNING
Explosion hazard
Switch off the gas chromatographs when carrying out repairs or maintenance as soon
as atmospheric air penetrates into it, in other words:
– When the device is opened.
– When work is carried out on carrier gas lines and sample gas lines.
Before switching the device on again, flush the gas lines again with inert gas following
completion of the repair or maintenance work.
Note
The column system and the detector are contaminated least if the chromatograph remains in
operation. Do not shut down the device if the system is only stationary for a short time, e.g. 3
weeks. Only switch off the output devices.
If you wish to shut down the gas chromatograph, Siemens AG recommends the following
sequence:
1. Shut off all sample streams.
2. Switch off the power supply.
3. Allow the device to cool down for 65 minutes.
4. Shut off the carrier gas.
5. If you switch off the gas chromatograph for a longer period, close all outlets and inlets
with the supplied blanking plugs. Sealing prevents oxygen or water from diffusing into the
columns.
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Commissioning and operation
5.5 Shutting down
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Service and maintenance
6.1
Maintenance of analysis module
6.1.1
Removal of analysis module
6
Procedure
WARNING
Explosion hazard
If the gas chromatograph is mounted in a hazardous area, observe the explosion
protection regulations.
Before opening the housing in the hazardous area, switch off the power supply and then
always wait for at least 65 minutes.
Following the waiting time:
– When the surface temperatures inside the gas chromatograph have cooled down to
a temperature corresponding to temperature class T4.
– When the electric charge on the internal components has dropped to a voltage
permissible for explosion protection.
1. Loosen the 1.5-mm hexagon socket-head bolt ③ in the top cover ② by two complete
turns.
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Service and maintenance
6.1 Maintenance of analysis module
2. Unscrew the top cover ②. If the cover ② cannot be opened by hand, extend the lever
arm. Insert e.g. two appropriate screwdrivers into the holes ① on the edge of the cover.
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Service and maintenance
6.1 Maintenance of analysis module
3. Pull out the insulating cover using the handle.
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Service and maintenance
6.1 Maintenance of analysis module
4. Loosen the M14 nut ① using the supplied ring spanner A/F 21.
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Service and maintenance
6.1 Maintenance of analysis module
5. Unscrew the M14 nut until it is flush ① as shown below.
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Service and maintenance
6.1 Maintenance of analysis module
6. Loosen the M6 lock nut using a ring spanner A/F 10 ①.
7. Completely unscrew the M14 nut.
8. Unscrew the screw on the pulling tool as shown below.
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Service and maintenance
6.1 Maintenance of analysis module
9. Insert the dovetail of the pulling tool behind the hexagon screw head on the analysis
module.
10.Lock the pulling tool by rotating clockwise.
11.Hold the bottom part of the pulling tool tight, and rotate the screw clockwise until the
analysis module is released.
12.Remove the analysis module from the guide pin.
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Service and maintenance
6.1 Maintenance of analysis module
6.1.2
Installing the analysis module
Procedure
CAUTION
Identical type
The type of new analysis module must be identical to that of the previous module. If the
type is not identical, the device will malfunction.
You can find the type ID:
On the white sticker of the analysis module.
On the rating plate on the ventilation opening of the device.
Example: A05-126 ES02. The first block (A05 in this case) corresponds to the module type.
1. Slide the new analysis module onto the guide pin such that the three electric plugs on the
bottom fit into the corresponding sockets.
2. Press the analysis module tight by hand.
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Service and maintenance
6.1 Maintenance of analysis module
3. Adjust the M14 nut flush as shown in the following photo at ①.
4. Screw the M14 nut by hand onto the guide pin. Make sure that the adjustment is retained.
CAUTION
Damage to the connection
When installing the analysis module, the packing glands of the module are sealed by the
pneumatic connector. Only use the supplied ring spanner. If you apply too much force
by using a different ring spanner with a longer lever arm, the connection will be
damaged.
5. Tighten the M10 lock nut using the ring spanner A/F 10.
6. Rotate the M14 nut clockwise using the A/F 21 ring spanner until the 2.0 mm thread ②
becomes visible.
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Service and maintenance
6.1 Maintenance of analysis module
7. Attach the insulating cover.
8. Carefully screw in the cover as far as possible.
9. Rotate the 2.0 mm hexagon socket-head bolt ② in the cover ① in the clockwise
direction until it is closed.
WARNING
Tightening the locking screw
According to the explosion protection regulations, all housing covers which have to be
unscrewed to open the housing must each be secured against unintentional opening by
a locking screw. This is achieved for this device using the hexagon socket-head bolt ②.
Before opening, loosen this hexagon socket-head bolt ②.
Following closing, tighten this hexagon socket-head bolt ②.
10.Restart the device. During the startup process, the analysis parameters are reestablished
by downloading the individual setups supplied with the analysis module.
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Service and maintenance
6.2 Replacing the carrier gas cylinders
6.2
Replacing the carrier gas cylinders
Procedure
1. Save the operating data before switching off;
refer to the software description "Maxum System Manager".
2. Switch the MicroSAM off.
3. Switch off the 24 V DC power supply.
4. Close the main cylinder valve.
5. Replace the cylinder.
6. Purge the pressure reducer several times.
7. Open the main cylinder valve.
8. Switch on the 24 V DC power supply.
9. Carry out the calibration.
6.3
Installing and removing electronic components
WARNING
Observe waiting time
Observe the regulations for explosion protection if the chromatograph is installed in a
hazardous area.
Before opening the housing in the hazardous area, switch off the power supply and then
always wait for at least 65 minutes.
Following this time, the surface temperatures within the chromatograph have cooled down
to a temperature corresponding to temperature class T4, and the electric charge of internal
components has dropped to a noncritical value.
CAUTION
Electrostatic-sensitive device
Before touching such components or devices:
Switch the chromatograph off.
Remove all static from yourself by touching an earthed object or by using an ESD
bracelet.
Only use tools free of static charges.
Do not touch pins or printed conductors. Hold modules only by their edges.
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Service and maintenance
6.3 Installing and removing electronic components
6.3.1
Removal of electronic modules
Replacing the backup battery
The gas chromatograph has a backup battery for the built-in clock.
WARNING
Explosion hazard
Observe the regulations for explosion protection if the chromatograph is installed in a
hazardous area. Replacement of this backup battery is only permissible in the hazardous
area if you have a fire permission certificate. This applies whether the gas chromatograph
is switched on or off.
Procedure
1. Remove the connector ② on the battery module.
2. Loosen the screw T30 ①.
3. Remove the backup battery ③.
4. Install the new backup battery in the reverse order.
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Service and maintenance
6.3 Installing and removing electronic components
Removing the CAC module
Procedure
1. Hold the CAC module on the long side, and carefully lever out.
2. Make sure you do not bend the connector pins.
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Service and maintenance
6.3 Installing and removing electronic components
Removing the RSP module
Procedure
1. Disconnect all electric connections.
2. Loosen the six screws ① T30.
3. Carefully remove the RSP module ②.
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Service and maintenance
6.3 Installing and removing electronic components
Removing the EPC module
Procedure
1. Loosen the three connectors ①.
2. Loosen the four screws T10 ②.
3. Carefully remove the EPC module ③.
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Service and maintenance
6.3 Installing and removing electronic components
6.3.2
Installation of electronic modules
CAUTION
Note the correct mounting position
Make sure that the modules are correctly positioned when installing:
The EPC module has three plug connectors. The side on which the plug connector is
"missing" must point toward the cable gland of the chromatograph.
The RSP module has one cutout. This cutout must point toward the cable gland of the
chromatograph.
Installing the EPC and RSP modules
● Install the two modules in the reverse order to that when removing.
Installing a new CAC module
● Position the CAC module correctly above the connectors, and push in uniformly. Only
press on the two short sides (above the connectors).
Closing the housing
1. Carefully screw in the cover as far as possible.
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Service and maintenance
6.3 Installing and removing electronic components
2. Rotate the 1.5 mm hexagon socket-head bolt in the cover ② in the clockwise direction as
far as possible.
WARNING
Tightening the locking screw
According to the explosion protection regulations, all housing covers which have to be
unscrewed to open the housing must each be secured against unintentional opening by
a locking screw ②.
Before opening, loosen this hexagon socket-head bolt ②.
Following closing, tighten this hexagon socket-head bolt ②.
3. The system parameters must be downloaded when the device is switched on again. The
procedure is described in the "Maxum System Manager" operating software manual.
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Service and maintenance
6.4 Conversion of MicroSAM basic device AS09
6.4
Conversion of MicroSAM basic device AS09
A solenoid valve MV5 is fitted in the MicroSAM basic device of release version 09 (AS09).
You can also prepare the MicroSAM basic device as a GC which can be operated with
analysis modules of type A.
6.4.1
Preparation for use of analysis modules of type A
Procedure
1. Terminate measuring mode of the device.
2. Deactivate the detectors using the operating software.
3. Save the configuration in the flash memory.
4. Switch off the device.
5. Shut off the carrier gas and sample gas supplies.
6. Open the two housing covers.
7. Deinstall the analysis module type D.
8. Install the analysis module type A.
9. Remove the RSP module.
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Service and maintenance
6.4 Conversion of MicroSAM basic device AS09
10.Interchange the plugs to the solenoid valves MV3 and MV5.
Procedure: Preparation for use of analysis modules of type A
View of EPC module
① Disconnect the solenoid valve MV5 (plug number 5).
① Disconnect the solenoid valve MV3 (plug number 3).
③ Connect the cable number "3" to the solenoid valve MV5. The cable number "5" is not
required in the configuration of type A.
11.Reinsert the RSP module.
12.Close the housing.
The basic device AS09 is now prepared for use of analysis modules of type A.
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Service and maintenance
6.4 Conversion of MicroSAM basic device AS09
6.4.2
Restoring of data for AS09 type A
Requirement
Knowledge of the Maxum EZChrom und Maxum System Manager operating software.
Procedure
1. Start up the device.
2. Start the EZChrom program (start bar Start ➜ Programs ➜ Maxum System Tools ➜
Maxum EZChrom).
3. Start the "Open" function (menu "File" ➜ Menu command "Method" ➜ "Open").
4. Download the AXX.met file from the CD "Parameter Backup CD".
5. Click in the toolbar of Maxum EZChrom on the "Instrument Setup" symbol, and select the
"Valves" menu.
6. Click on "FlushLoop" in the "Name" column, and change the name in the drop-down list to
"FlushLoop_1".
7. Repeat step 6 for all other entries with the name "FlushLoop".
8. Change the remaining parameters according to your application.
9. Save the configuration (menu "File" ➜ Menu command "Method" ➜ "Save As").
10.Export the saved data to the GC (menu "File" ➜ Menu command "Method" ➜ "Export...").
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Service and maintenance
6.4 Conversion of MicroSAM basic device AS09
The gas chromatograph has now been configured for type A analysis modules.
Note
Parameter settings
The parameters on the CD are appropriate for basic devices up to AS08. The parameters
include the settings for the solenoid valves MV1 to MV4. MV1 is preset in the software to
"FlushLoop".
From AS09 onwards, the basic device contains an additional solenoid valve MV5, and MV1
and MV5 are preset to "FlushLoop_1" and "FlushLoop_2" respectively.
When reconfiguring to a gas chromatograph with type A analysis modules, you must
therefore rename "FlushLoop" to "FlushLoop_1".
You do not require "FlushLoop_2" for a gas chromatograph with a type A analysis modules.
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Service and maintenance
6.4 Conversion of MicroSAM basic device AS09
6.4.3
Returning for use of analysis modules of type D
Procedure
1. Terminate measuring mode of the device.
2. Deactivate the detectors using the operating software.
3. Save the configuration in the flash memory.
4. Switch off the device.
5. Shut off the carrier gas and sample gas supplies.
6. Open the housing.
7. Deinstall the analysis module type A.
8. Install the analysis module type D.
9. Remove the RSP module.
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Service and maintenance
6.4 Conversion of MicroSAM basic device AS09
10.Connect the plugs to the solenoid valves MV3 and MV5.
Procedure: Returning for use of analysis modules of type D.
View of EPC module
① Connect the plug number "3" to the solenoid valve MV3.
② Connect the plug number "5" to the solenoid valve MV5.
11.Reinsert the RSP module.
12.Close the housing.
13.Using the Maxum EZChrom and Maxum System Manager operating software, download
the standard methods for the analysis modules of type D.
The basic device AS09 has now been returned and parameterized for use of analysis
modules of type D.
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Service and maintenance
6.4 Conversion of MicroSAM basic device AS09
MicroSAM
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Spare parts/accessories
7.1
Spare parts list
6,(0(16
Item
Designation
Order No.
10
Main cover
A5E00117263
20
Insulating cover
A5E00146499
30
Side cover
A5E00117261
520
Inspection window, complete
A5E00481197
50
NPT cable gland, potted with cable
A5E00839837
60
RSP module
A5E00315395
70
CAC module
A5E00794337
280
Battery module
A5E00713507
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Spare parts/accessories
7.2
Item
Designation
Order No.
100
O-ring set with 2 units each 200x2 and 63x1.5 as
well as 6 units M3x6 threaded pin
A5E00209858
110
Solenoid valve 3/2-way "D"
A5E00162568
120
Solenoid valve 3/2-way "C"
A5E00105041
250
Swagelok 1/8" screwed gland with safety filter for
sample input, sample output, carrier gas
A5E00198331
260
Swagelok 1/8" screwed gland for gas connection,
with dummy plug
A5E00198046
290
Flow insert, type 1
A5E00146507
300
Flow insert, dummy
A5E00177777
310
Flow insert, type 2
A5E00191739
500
Sealing cap 1/8", brass
A5E00391322
Item
Designation
Order No.
130
Pulling tool for analysis module
A5E00209905
140
Conical pressure nut, complete
A5E00160856
160
Analysis module type A01
A5E00209700
170
Analysis module type A02
A5E00209753
180
Analysis module type A03
A5E00209756
190
Analysis module type A04
A5E00209765
200
Analysis module type A05
A5E00209774
210
Analysis module type A06
A5E00209800
220
Analysis module type A07
A5E00209802
230
Analysis module type A08
A5E00209808
235
Analysis module type A09
A5E00505612
240
Analysis module type A10
A5E00497962
245
Analysis module type A11
A5E00885119
600
Analysis module type D01
A5E02048228
580
RSP service cable
A5E00362332
590
MicroSAM basic device without analysis module,
with rating plate and MicroSAM software package
A5E00881520
Accessories
Item
Designation
Order No.
151
Set of screwed glands for MicroSAM
A5E00399237
152
Carrier gas drying filter (1/8")
GWK-CHRTSCP17971
570
Filter support for carrier gas drying filter (1/8")
GWK-CHRFICP7988
MicroSAM
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Operating Instructions, 06/2012, C79000-G5376-C560-07
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1% of full-scale value (application-dependent)
Smallest measuring range
1000 ppm (application-dependent)
Linear range
Typically ≥ 104
Cycle time
Typically 30 … 240 s
Ambient temperature influence
Negligible
Influence of vibrations
Negligible
Mean time to repair (MTTR)/
Mean time between failures (MTBF)
< 1 hour/3 years (without consumables)
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Technical data
Permissible bridge power
Carrier gas
Permissible bridge voltage
Permissible bridge power
Argon (Ar)
700 mV
25 mW
Nitrogen (N2)
700 mV
30 mW
Helium (He) / hydrogen (H2)
1100 mV
70 mW
Electronics: Communication and analytical controller (CAC)
Microprocessor
Intel 586 architecture
Flash EEPROM
128 MB
Dynamic RAM
64 MB
Operating system
Windows CE 3.0/5.0
Software
Preinstalled. Modifications or upgrades for operation PC locally
or downloadable via network
Electronics: Real-time signal processor (RSP)
Microprocessor
Motorola 68376, 20 MHz
Flash EPROM
1 MB
Static RAM
1 MB
Operating system
Forth
Software
Preinstalled. Modifications or upgrades downloadable via
internal service interface
Interfaces
Communication
1 x Ethernet 10BaseT / TCP/IP
Control system coupling
1 x RS485 or RS232 / MODBUS RTU,
OPC (ODPC) over Ethernet (only MicroSAM)
Inputs/outputs: Basic equipment
Digital outputs (relay contact 0.4 A / 24 V DC)
For devices of release version 4 onwards: 4, freely-usable *)
For devices up to release version 3: 2, freely-usable *)
Note:
The release version is present on the rating plate at "AS".
Digital inputs (24 V to optocoupler)
For devices of release version 4 onwards: 4, of which 3 freely-usable *)
For devices up to release version 3: 2, of which 1 freely-usable *)
*) Extendable by NAU or I/O extender (only MicroSAM, SITRANS CV preassigned)
MicroSAM
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109
Technical data
Status display
Display up to and including release version 4
LED displays for
Supply voltage
Software sign-of-life
Ready for operation
Maintenance demanded
Fault
Sample flow
Ethernet connection status
Communication status
Supply voltage
Software sign-of-life
Ready for operation
Maintenance demanded
Fault
Sample flow
Display from release version 5 onwards
LED displays for
Recommended operator panel
See documentation of supplied software
MicroSAM
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10
Dimension drawings
①
②
Mounting holes for MicroSAM
Electric cable with a length of 4000 mm.
Figure 10-1
Dimension drawing of MicroSAM
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111
Dimension drawings
MicroSAM
112
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A
Appendix
A.1
Principle of live column switching
Two columns are connected in sequence with the live T-piece in between. The columns
have different separating properties, for example. The three operating states of the live
switching are selected by changing the pressure in the gas lines of the live T-piece:
● Straight
● Backflushing
● Cut.
To achieve this, the electronic pressure controllers are programmed at the factory using a
time function.
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The components pass through the two
columns in succession.
Once some of the components have
passed through the first column, the flow
direction in it is reversed. The components
still present in the first column are returned
to the beginning of it, and flushed into the
atmosphere via the backflushing output.
This means that the analysis cycle can be
drastically shortened: for example, if the
components are only transported slowly
through the first column, those of higher
boiling point need not be heated up, which
is time-consuming.
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113
Glossary
&XW
Once the components have passed
through the first column, a number of them
are flushed through the cut output. They
never reach the second column. This
operating state is used in the following
cases:
To keep components which cannot be
backflushed away from the second
column, because these are followed by
further components which are to be
measured.
If components would falsify the result or
damage the second column.
In order to directly pass components to
a further detector, e.g. to shorten the
duration of the analysis.
A.1.1
Advantages of live switching
● The sample only comes into contact with parts of the live T-piece, but not with valves.
● No switching valves are required in the oven, and the column switching does not result in
any temperature limitations.
● The live switching is maintenance free since there are no moving parts.
● The live switching has a minimum dead volume, and is therefore particularly suitable for
capillary columns.
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Glossary
A.1.2
Live switching function
Pressures and flows
3
Two columns are connected in succession.
Pressure P1 is initially applied. The final
pressure is the atmospheric pressure P0.
This results in pressure distributions and
flows as shown on the left.
3
Conclusion:
with the "straight operation" shown in the
graphic, the pressure P2 is produced in the
middle between the two columns.
3
Note
In real processes, the curve for the pressure drop is nonlinear.
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115
Glossary
A thought experiment
3
3
The pressure P2 from the previous figure is
read on the y-axis. This pressure P2 is then
applied between the two columns. The input
of the first column is left open. This results in
a pressure distribution with the flows as
shown on the left.
Conclusion:
the first column is now operated in
backflushing mode.
3
MicroSAM
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Glossary
What hasn't been possible yet ...
If a particular peak must not reach the second column once it has left the first column, an
output is required between the two columns (cut output). Furthermore, a connection is
required for the pressure P2 from the "thought experiment" above. The solution to the
problem is the live T-piece.
The two columns are connected in the live T-piece via a capillary ①. This coupling capillary
has a flow resistance; two pressures must be considered:
● P3 downstream of the capillary
● P2 upstream of the capillary.
In "straight operation", everything remains as described in the section "Pressures and flows".
Only the pressure P3 must be additionally considered.
3
3
3
3
3
3
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117
Glossary
Time for the cut
The pressure P2 is set a little lower than
pressure P3.
3
The result:
- the components are flushed into the
atmosphere as soon as they leave the first
column.
3
3
3
Since the pressure on the left of the coupling
capillary is lower than that on the right, the
gas present in the first column is transported
to the cut output!
MicroSAM
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Glossary
If everything were that simple ...
... then the process would now be finished. However, the live switching must first be
adjusted. Adjustment of the live switching has already been carried out by Siemens AG.
Description of the adjustment function for live switching:
The live T-piece has six connections, of which the three right-hand ones can be outputs. This
means that a peak can also simultaneously leave the device via two or even three outputs.
This state is not desired during operation! You must therefore inject a test mixture, and
observe the detector signals at the three outputs. You must then decide on how to change
the pressures P2 and P3 such that unambiguous flow conditions exist for "straight operation"
and "cut":
Straight
3
6DPSOH
3
Everything from the first column must enter
the coupling capillary, and everything from
the coupling capillary must enter the second
column. This functions reliably if the "center"
flow (sample) is supplemented by the flows
of the auxiliary inputs P2 and P3. The flow in
the coupling capillary is from left to right.
Cut
3
6DPSOH
3
Everything from the first column must pass
to the cut output. This functions reliably if the
"center" flow (sample) is supplemented by a
sufficiently large flow of the auxiliary input
P3, which must now also supply power to the
second column. The flow in the coupling
capillary is now reversed from right to left.
The flow of P2 automatically becomes
correspondingly smaller.
Backflushing
Backflushing functions exactly as described earlier in the section "A thought experiment".
This is irrespective of the position in which the live T-piece is currently being operated.
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119
Glossary
A.2
ESD guidelines
Definition of ESD
All electronic modules are equipped with large-scale integrated ICs or components. Due to
their design, these electronic elements are highly sensitive to overvoltage, and thus to any
electrostatic discharge.
The electrostatic sensitive components/modules are commonly referred to as ESD devices.
This is also the international abbreviation for such devices.
ESD modules are identified by the following symbol:
CAUTION
ESD devices can be destroyed by voltages well below the threshold of human perception.
These static voltages develop when you touch a component or electrical connection of a
device without having drained the static charges present on your body. The electrostatic
discharge current may lead to latent failure of a module, that is, this damage may not be
significant immediately, but in operation may cause malfunction.
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Glossary
Electrostatic charging
Anyone who is not connected to the electrical potential of their surroundings can be
electrostatically charged.
The figure below shows the maximum electrostatic voltage which may build up on a person
coming into contact with the materials indicated. These values correspond to IEC 801-2
specifications.
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6\QWKHWLFPDWHULDO
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$QWLVWDWLFPDWHULDOIRUH[DPSOHZRRG
RUFRQFUHWH
Figure A-1
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Electrostatic voltages on an operator
Basic protective measures against electrostatic discharge
● Ensure good equipotential bonding:
When handling electrostatic sensitive devices, ensure that your body, the workplace and
packaging are grounded. This prevents electrostatic charge.
● Avoid direct contact:
As a general rule, only touch electrostatic sensitive devices when this is unavoidable (e.g.
during maintenance work). Handle the modules without touching any chip pins or PCB
traces. In this way, the discharged energy can not affect the sensitive devices.
Discharge your body before you start taking any measurements on a module. Do so by
touching grounded metallic parts. Always use grounded measuring instruments.
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121
Glossary
A.3
EC Declaration of Conformity
The original of the EC Declaration of Conformity be seen at:
Siemens AG
I IA SC PA RD
Karlsruhe
A.4
A marking in accordance with KC (Korea)
KC marking for use in Korea only
Device version
Operating instructions
A급 기기
이 기기는 업무용(A급) 전자파 적합기기로서 판매자 또는 사용자는 이 점을
주의하시기 바라며 가정 외의 지역에서 사용하는 것을 목적으로 합니다.
Class A device
This device is classified as having electromagnetic resistance suitable for
industrial use (Class A) and may be used universally, apart from in domestic
use.
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Glossary
A.5
Service and Support
Worldwide contact partners
If you have any further questions relating to the products described in this documentation,
contact your local representative at the Siemens office nearest you.
You will find information on whom to contact at this Internet address
www.siemens.com/automation/partner (http://www.siemens.com/automation/partner).
Product information on the Internet
The instructions are included on the CDs which are already supplied or may be ordered. In
addition, the instructions are available on the Internet on the Siemens homepage.
A signpost to the range of technical documentation, the online catalog, and the online
ordering system for individual SIMATIC products and systems is available at
www.siemens.com/processanalytics (http://www.siemens.com/processanalytics)
Here you will find:
● Products & solutions, including our newsletter containing up-to-date information on your
products.
● Electronic trading over the Internet.
● Support with e.g. instructions and manuals, certificates, brochures and catalogs.
Training center
Siemens offers corresponding courses for newcomers to process gas chromatography.
Please contact the central Training Center in Karlsruhe.
Training Center Europe
Process Instrumentation and Analytics
Siemensallee 84
D-76181 Karlsruhe, Germany
Internet: www.sitrain.siemens.com (http://www.sitrain.siemens.com/index_en.html)
Technical support
● You can reach the "Technical Support" for all A&D products using:
– the Web form for "Support Request" at www.siemens.com/automation/support-request
(http://www.siemens.com/automation/support-request) .
– Phone: +49 180 5050 222
– Fax: +49 180 5050 223
(0.14 € / min from German landline, mobile charges may differ)
● You can find the latest information concerning your device on the Internet at
www.siemens.com/automation/ (http://www.automation.siemens.com/).
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123
Glossary
A.6
List of abbreviations
Abbreviation/symbol
Description
°
Degrees
°C
Degrees Celsius
Ar
Argon
AS
Release version
ATEX
Atmosphère explosible (French for explosive atmosphere)
AWG
American Wire Gauge
Bit
binary digit
ca.
approx.
CAC
Communication and Analytical Control
CD
Compact Disk
CE
Communautés Européenes (French for European Community)
CH4
CH4 = methane
cm²
Square centimeter
CO2
CO2 = carbon dioxide
CS2
Carbon bisulfide
CSA
Canadian Standards Association
DC
Direct Current
DIN
Deutsches Institut für Normung e. V. (German standards association)
DVD
Digital Versatile Disk
DVGW
Deutsche Vereinigung des Gas- und Wasserfaches e. V. (German
technical/scientific association)
EEPROM
Electrically Erasable Programmable Read Only Memory
e.g.
For example
EIA
Electronic Industries Alliance
eLive
enhanced Live injection
EMC
Electro Magnetic Compatibility
EN
Europäische Norm (European standard)
EPC
Electronic pressure controller (
ES
Product version
ESD
Electrostatic Discharge
FM
Factory Mutual, USA certification organization
GC
Gas Chromatograph
H2
H2 = hydrogen
H2O
H2O = water
H2S
H2S = hydrogen sulfide
He
Helium
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Glossary
Abbreviation/symbol
Description
IEC
International Electrotechnical Commission
IEEE
Institute of Electrical and Electronics Engineers
IP
Internet Protocol
ISO
International Standards Organization (from Greek: "isos": "equal")
kPa
Kilopascal
kg
Kilogram
l
Liter
LED
Light emitting diode
m
Meter
m3
Cubic meter
max.
Maximum
MB = Mbit
106 bits
MEMS
Micro electromechanical system
MHz
Megahertz
min
Minute
ml
Milliliter
MMI
Man-Machine Interface
MPa
Megapascal
MTBF
Mean operating Time Between Failures
MTTR
Mean Time To Recover
MV
Solenoid valve
N2
N2 = nitrogen
NAU
Network Access Unit
NEMA
National Electrical Manufacturers Association
PC
Personal Computer, a stationary single-user computer
Porabond Q
Name of a type of column
ppm
parts per million (≙ 10-6)
PTB
Physikalisch-Technische Bundesanstalt (German technical inspectorate)
PWM
Pulse width modulation
RAM
Random Access Memory
ROM
Read Only Memory
RS
Recommended Standard
RS -232
(also EIA-232) Identifies an interface standard for a sequential, serial data
transmission
RS-485
(also EIA-485) Identifies an interface standard for a differential, serial data
transmission
RSP
Real Time Signal Processing
s
Second
Sil5
Name of a type of column
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125
Glossary
Abbreviation/symbol
Description
t
time
T
Temperature
TCD
Thermal Conductivity Detector
TCP/IP
Transmission Control Protocol/Internet Protocol; a reference module for
communication on the Internet
TS
Column
V
Volt
VDE
Verband der Elektrotechnik, Elektronik und Informationstechnik (German
Association for Electrical, Electronic and Information Technologies)
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Glossary
Glossary
Aldehyde
Aldehydes are chemical compounds containing a terminal carbonyl group (or more exactly
an aldehyde group, CHO) as the functional group. The series of aldehydes derived from the
alkanes form the homogenous series of alkanals.
Aliphatic hydrocarbons
Aliphatic hydrocarbons (Greek: aleiphar, fatty) are organic hydrocarbon chains. Aliphatic
compounds are "acyclic or cyclic, saturated or unsaturated carbon compounds except
aromatic compounds". The simplest group of aliphatic hydrocarbons are the alkanes. Like all
pure hydrocarbons, aliphatic hydrocarbons are nonpolar, lipophilic compounds.
American wire gauge (AWG)
American Wire Gauge is a specification for wire diameters, and mainly used in North
America. It identifies electric cables made of stranded or solid wire and is used in electrical
engineering to identify the cross-section of conductors.
Analog
Continuous representation of a variable, e.g. voltage, using a scale, in contrast to "Digital".
Aromatic compounds
Aromatic compounds, or also arenes, are an important class of compounds in organic
chemistry. They feature a specific bonding structure.
ATEX
ATEX is the abbreviation of the French term "Atmosphère explosible". ATEX stands for both
the directives of the European Community for the field of explosion protection: the ATEX
product directive 94/9/EC and the ATEX operation directive 1999/92/EC.
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127
Glossary
Breathing device
The breathing device is used for pressure compensation during operation. This pressure
compensation is required due to temperature variations during operation
Carbon bisulfide
Carbon bisulfide (trivial name: bisulfide of carbon) is a colorless liquid with the total formula
CS2. Carbon bisulfide is a highly refracting and extremely flammable liquid which is as
pleasant as ether when pure, but which almost always smells extremely unpleasant due to
contamination.
Chromatography
Chromatography or Chromatografie (Greek) is a procedure used in chemistry which allows a
mixture to be separated as a result the different distribution of its individual components
between a stationary phase and a mobile phase.
Cut
Two columns are connected in sequence with a live T-piece in between. The columns have
different separating properties, for example. The three operating states of the live switching
are selected by changing the pressure in the gas lines of the live T-piece:
● Straight
● Backflushing
● Cut.
Cut is the name of the process where the components have passed through the first column
and some of them are flushed through the cut output. They never reach the second column.
Detection limit
The detection limit refers to the extreme value of a measuring method down to which the
variable can just still be reliably detected.
The measured value at the detection limit has an increased inaccuracy which, however,
does not exceed a defined statistical confidence interval. Measured values with an
inaccuracy greater than the defined confidence interval are outside the detection limit, and
are referred to as immeasurable or nondetectable in the sense of the measuring method.
The criterion for "reliable detection" generally refers to the precision of the measuring
method for a zero or blank measurement. This therefore means the statistical error or the
variation in the measured signal if a sample is not present (e.g. the standard deviation of
background signal, noise, blank value, zero value etc.).
A measured value is frequently considered as valid or detected if the inaccuracy of the value
is less than three times the standard deviation of the zero measurement.
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Glossary
Digital
Representation of a variable, e.g. time, in the form of characters or numbers. In its digital
representation, this variable can be changed only in pre-defined steps, in contrast to
"Analog".
EEPROM
Electrically Erasable Programmable Read Only Memory
EEPROMs are often used where individual bytes of data (e.g. configuration data or runtime
meters) change over time and must be stored safely in the event of a mains power failure.
ElectroMagnetic Compatibility
Definition as per the EMC law:
EMC is the capability of a device to operate satisfactorily in an electromagnetic environment
without itself emitting electromagnetic signals which interfere with other devices in that
environment.
eLive
As of release version 09, MicroSAM features the eLive injection, which controls the position
of the injection content, prevents the mixing with carrier gas, and prevents the influences of
viscosity during injection in the case of certain gas compositions.
Ethane
Ethane is a chemical compound belonging to the group of alkanes (saturated hydrocarbons).
Ethane is a colorless and odorless gas with the formula C2H6. Ethane is primarily used for
heating and combustion purposes. Ethane is a main component of natural gas, in addition to
methane.
Ethine
Ethine (or acetylene) is a colorless gas with the formula C2H2. Ethine is the simplest
representative from the group of alkines.
Firmware
Firmware (FW) is software which is embedded in a chip in electronic devices – unlike
software that is stored on hard drives, CD ROMs, or other media. These days, the firmware
is mostly stored in a flash memory or an EEPROM.
The firmware mostly contains elementary control functions of the device, as well as input and
output routines.
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129
Glossary
Gas chromatography (GC)
Gas chromatography is an analytical method used worldwide to separate mixtures into
individual chemical compounds. GC can only be used for components which are gaseous or
can be vaporized. With this type of chromatography, an inert gas is used as the mobile
phase, usually nitrogen, helium or hydrogen. The carrier gas is passed through a tube or
capillary with a defined internal diameter, the so-called "Column". Older columns are made
of metal, newer columns of quartz glass which are coated to increase the resistance to
breakage. The column is internally lined with a defined stationary phase, frequently with
viscous polysiloxanes.
Ketones
Ketones are chemical compounds containing a non-terminal carbonyl group (>C=O) as the
functional group. Ketones are oxidation products of secondary alcohols. The ketones derived
from the alkanes are also referred to as alkanones. The simplest ketone is acetone
(propanone or dimethyl ketone).
MEMS: Micro Electro-Mechanical System
MEMS is a combination of:
● mechanical elements,
● sensors,
● actuators,
● electronic circuits
on a substrate or chip.
Modbus
The Modbus protocol is a communications protocol based on a master/slave or client/server
architecture. The Modbus protocol was defined by Modicon in 1979 for communication with
its programmable controllers. Modbus is a de facto standard in industry, since it is an open
protocol.
Modbus is used to connect a master (e.g. a PC) and several slaves (e.g. measuring and
control systems). There are two versions of Modbus: one for the serial interface and one for
Ethernet.
Molecular filter
Molecular filter (or also molecular sieve) is the term for naturally occurring and synthetic
zeolites which have a strong adsorption capacity for gases, vapors and dissolved materials
with certain molecular sizes. Appropriate selection of the molecular sieve permits molecules
of different sizes to be separated.
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Glossary
Nonpolar
A nonpolar molecule does not have a permanent dipole moment. Nonpolar compounds are
highly soluble in nonpolar solvents. The solubility increases along with the similarity of the
interacting forces between the particles of the solvent and between those of the dissolved
compound.
Polarity
Polarity with regard to chemical compounds refers to the generation of separate charge
centers produced by the shifting of charges in groups of atoms, the result being that a group
of atoms is no longer electrically neutral. The electrical dipole moment is a measure of the
"polarity" of the molecule.
Process Gas Chromatography
Process gas chromatography:
● Is one of the most powerful measuring and analysis methods for process analytics.
● Is a procedure that is both discrete and extractive.
● Is frequently used for online monitoring of processes since the sequences are easy to
automate and a large number of components can be measured simultaneously.
● Can be used to separate and quantify the components of almost all homogenous
gaseous or liquid mixtures. It must be possible to vaporize the liquid components without
decomposition.
The individual components of a discrete sample pass through the column system at
different velocities, and are recorded in succession by a detector.
The time between sample introduction and recording of a substance at the detector (the
retention time) is characteristic of the substance and is used to identify it. The magnitude
of the detector signal is a measure of the volume concentration of the component in the
gas.
Propanone
Propanone (also acetone) is the simplest ketone. Acetone is a colorless liquid used as an
aprotic solvent and as an educt for organic syntheses.
Real-time
Real-time is the time which sequences require in the real world. The term defines that a
system must respond to an event within a defined time. The term does not provide any
information on the speed or processing performance of a system.
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131
Glossary
RS 232
A recognized industrial standard for serial data transmission, and applies to cable lengths up
to 15 m. Differential evaluation is not possible with RS 232. The sending and receiving of
data take place on different lines.
RS 485
RS 485 is an interface standard for line-based, differential, serial data transmission. RS 485
uses a pair of cables in order to transmit one inverted version and one non-inverted version
of the data signal. The original data signal is reconstructed at the receiver from the difference
between these two signals. It is then possible to use significantly longer transmission links
and higher speeds than with RS 232. Furthermore, several transmitters and several
receivers can be connected to one pair of conductors.
Silanes
The name silanes refers to a group of chemical compounds consisting of a silicon matrix and
hydrogen. Silanes can have a branched (iso- and neo-silanes) or unbranched (n-silanes)
structure. The general total formula of these compounds combined under the generic term
catena silanes is SinH2n+2. Ring-shaped hydrosilicon compounds are referred to as
cyclosilanes (general total formula: SinH2n).
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Index
A
Accessories, 17
Adapter, 59
Adjustment
Live switching, 119
Analysis module, 25
Analysis modules A01 to A03, 28
Analysis modules A04 to A10, 28
Applications, 19
Arc-suppression diode, 65
Assembly
At electrostatic risk, 11
ATEX guideline, 12
B
Backup battery, 88
Battery module, 88
Bridge power, 57
Bridge voltages, 57
C
Cable cross-section, 64
Cable lug, 60
CAC
Communication and analytical control, 24
CAC module, 89
Calorific value measuring instrument, 51
Capillary column, 20
Carrier gas, 57
Carrier gas cylinder, 87
CE marking, 22
Climatic conditions, 105
Column, 113
Column system, 75
Columns and gases, 107
Common exhaust gas line, 60
Contact partner, 123
Core cross-section, 64
Corrosion danger, 10
Coupling capillary, 117
CSA marking, 22
D
Dangerous gases, 10
Detector, 75
Detectors, calibration and performance data, 108
Digital input, 65
Digital output, 65
Dimensions and weights, 105
Display, 51
Disposal, 17
Distance, 64
Dovetail, 83
Dummy plug, 57
E
EC Declaration of Conformity, 122
Electromagnetic compatibility, 106
Electronics:Communication and analytical controller
(CAC), 109
Electronics:Real-time signal processor (RSP), 109
Electrostatic sensitive device, 11
Electrostatic-sensitive device, 87
eLive injection, 27
Environmental protection guidelines, 17
EPC
Electronic pressure control, 24
EPC module, 91
Equipotential bonding, 60
ESD guidelines, 120
Ethernet cable, 61, 68
Ex marking, 22
Explosion hazard, 13
Explosion protection, 77
Explosion protection certificate, 15
Supplements, 15
F
Filter, 59
Final shutdown, 17
Fire permission certificate, 16
Firmware ID, 7
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133
Index
G
M
Gas composition measuring instrument, 51
Gas connection
Gas inlet, 58
Gas outlet, 58
Gas flow charts, 26
Gas line
Material, 58
Piping diagram, 58
Gradient, 60
Guide pin, 83
Guidelines
ESD guidelines, 120
Maintenance, 9
Maintenance engineers, 7
MEMS, 20
Metal bracket, 11, 56
Module
CAC, 89
EPC, 91
RSP, 90
Modules, 21
Mounting, 105
Communications cable, 57
Equipotential bonding, 57
Exhaust gas lines, 57
Gas lines, 57
Line fuse, 57
Power cable, 57
Power switch, 57
Sample lines, 57
Mounting position, 56
Multi-membrane valve, 26
H
Hexagon socket-head bolt, 66
I
IEC marking, 22
Industry
Chemical industry, 19
Iron & steel, 19
Metals, aggregates, cement, 19
Oil & gas, 19
Pharmaceuticals, 19
Injection
eLive, 27
Live, 26
Inputs/outputs, 109
Inspection window, 56
Installation and assembly, 9
Insulating cover, 79
Intended use, 51
Interfaces, 109
IP address, 74
L
Label, 16, 66
Laptop, 66
LED, 51
Linearity
Measuring range, 20
Live injection, 26, 30
Valveless, 20
Live switching, 30, 113, 114
Locking screw, 86
N
Natural gas, 9
Non-intended use, 9
O
Operating software, 74
Operational safety, 17
Optocoupler, 65
Order No., 22
Oven, 107
P
PC, 66
Power supply, 64
Power supply, 105
Power switch, 63
External, 73
Pressure controller, 113
Process analysis, 19
Process Gas Chromatography, 19
Product information on the Internet, 123
PTB, 9
Pulling tool, 82
MicroSAM
134
Operating Instructions, 06/2012, C79000-G5376-C560-07
Index
Q
Qualified personnel, 9, 17
R
W
Waiting time, 87
Warranty conditions, 7
Recommended operator panel, 110
Relay contact, 65
Release version, 51
Ring spanner, 80
RSP
Real-time signal processing, 24
RSP module, 90
S
Safety, 106
Safety equipment, 17
Safety regulations, 17
Sample and injection, 108
Sample gas, 10
Sample line, 59
Serial number, 22
Service technicians, 7
Shipping, 9
Status display, 110
Storage, 9
Stream sampling point, 20
Sub-D socket, 68
Subnet mask, 74
Surface temperature, 77
Swagelok, 58
Switching capacity, 63
T
Technical support, 123
Temperature control systems, 53
Terminal area, 64
Terminal box, 61
Text box, 51
Thermal conductivity detector, 25, 57
Thermal fuse, 107
Training center, 123
Transportation, 11
Type of cable, 65
Type of protection, 64
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07
135
Siemens AG
Industry Sector
Sensors and Communication
Process Analytics
76181 KARLSRUHE
GERMANY
www.siemens.com/automation
Subject to change without prior notice
C79000-G5376-C560-07
© Siemens AG 2012