Maintenance Manual Edition 10/2012 MAXUMTM edition II Process Gas Chromatograph (Modular Oven Configuration) pro ces s p GAS CHROMATOGRAPHY
Maxum edition II Process Gas Chromatograph (Modular Oven Configuration)
Copyright Notice © 2012 by Siemens All rights reserved. This publication is for information only. The contents are subject to change without notice and should not be construed as a commitment, representation, warranty, or guarantee of any method, product, or device by Siemens. Reproduction or translation of any part of this publication beyond that permitted by Sections 107 and 109 of the United States Copyright Act without the written consent of the copyright owner is unlawful.
A5E31405710001
Safety Practices and Precautions Safety First This product has been designed and tested in accordance with IEC Publication 1010-1, Safety Requirements for Electronic Measuring Apparatus, and has been supplied in a safe condition. This manual contains information and warnings which have to be followed by the user to ensure safe operation and to retain the product in a safe condition.
Safety Practices and Precautions, Continued Grounding the Product A grounding conductor should be connected to the grounding terminal before any other connections are made. Correct Operating Voltage Before switching on the power, check that the operating voltage listed on the equipment agrees with the available line voltage.
Chapter 1 Knowing Your System Introduction Overview The Maxum edition II © system, hereafter referred to as Maxum II, represents a significant advance in process chromatography. This was accomplished by combining the best of the Siemens Advance Maxum and PGC 302 gas chromatographs into a single platform analyzer. Multiple configurations of the Maxum II exist, and each of these configurations may be further customized to meet customer needs.
Introduction, Continued Important Information Included with each analyzer is a custom documentation-drawing package. This package provides drawings and information pertinent only to a specific analyzer. Contents of this package are application dependent and will vary for each analyzer.
Maxum II Specifications Configuration Oven Single isothermal airbath oven or split airbath oven with 2 independent isothermal zones or split airbath oven with one side isothermal and one side programmed temperature. or Single or dual independent airless ovens. Dual version has two distinct oven compartments for complete operating independence. or Modular Oven configuration consisting of any combination of up to two large or small analytical oven units.
Maxum II Specifications, Continued Performance Minimum Range (general)* Thermal Conductivity: 0-500 ppm Flame Ionization: 0-1 ppm FPD: 0-1 ppm (application dependent: some lower ranges may be available) Repeatability (general)* ± 0.5% of full scale for full scale ranges from 2-100%; ± 1% of full scale for full scale ranges from 0.05-2%; ± 2% of full scale for full scale ranges from 50-500 ppm; ± 3% of full scale for full scale ranges from 5-50 ppm; ± 5% of full scale for full scale ranges from 0.
Maxum II Specifications, Continued Communication Options Serial Output RS232, RS485 Airbath/Airless Oven: Port 1 – RS232/RS485 (Modbus) Port 2 – RS232/RS485 (Serial Printer) Port 3 – RS232/RS485 (Modbus) Port 4 – RS232/RS485 (Modbus) Modular Oven: Port 1 – RS232/RS485 (Modbus) Port 2 – RS485 (Modbus) In addition to serial connections, network Modbus and network printers supported on all configurations.
Maxum II Specifications, Continued Input/Output Options Standard I/O Airbath/Airless Oven Configuration: 2 analog outputs; 4 digital outputs (1 indicates system error, 3 are user configurable); 4 digital inputs Modular Oven Configuration: 2 digital outputs (1 indicates system error, 1 is user configurable) Board Slots for Optional I/O Airbath/Airless Oven Configuration: Up to 2 Modular Oven Configuration: Up to 2 2 I C I/O Boards I2C AIO:8 analog inputs, 8 analog outputs, 2 digital inputs I2C DIO: 6
Maxum II Specifications, Continued Gas Sample Requirements Sample Flow 50-200 cc/min (application dependent) Sample Filtration 0.
Maxum II Specifications, Continued Installation Configuration Single unit with multiple enclosures Dimensions Height39 3/4" (1010 mm) [ Modular Oven - 24 11/16 (627 mm) ] Width:26 1/16" (662 mm) Depth: 16 3/16" (411 mm) CAUTION When mounting the analyzer on a wall, care should be taken to ensure that the wall (vertical mounting surface) can withstand four times the minimum weight of the analyzer when mounted with the appropriate hardware.
Installation (continued) Hazardous Class Airbath/Airless Oven Standard Configurations: Certified by CSA C/US for use in Class I, Division 1, Groups A, B,C,D with air or nitrogen purge Certified by CSA C/US for use in Class I, Division 2, Groups A, B,C,D Certified according to ATEX with air or nitrogen purge and purge control for Zone 1 or Zone 2 (II 2 G c Ex py nA nC ib IIB+H2 T4 Gb) Suitable for use in general purpose and non-hazardous areas.
Maxum II Specifications, Continued Installation (continued) DC Power (optional) Modular Oven Configuration Only: 24VDC +/-10%, 10A minimum, with 32V over voltage protection limit (from power source). Power must be regulated, with 100mV max, pk-pk, noise/ripple measured with 20MHZ bandwidth. The power must be limited to 20A by short circuit protection, fusing or circuit breaker. External 24V must be accepting of the negative terminal being grounded to earth potential.
Maxum II Specifications, Continued Calibration Type Manual or automatic Zero Automatic baseline correction Span Standard sample cylinder Notes: Dimensions are shown as millimeters Recommended Clearance Left Side - 460 (18”) Right Side – 460 (18”) Front Side – 654 (25 ¾”) Center to Center – 1120 (44”) A5E31405710001 1-11
About The Maxum II Modular oven Description The Maxum II GC is completely enclosed in an air-purgable, metal cabinet with hinged doors. Mounted above the isothermal oven is the electronics enclosure and regulator panel. The analyzer may be mounted on a wall, in a rack or on a floor stand.
About The Maxum II, Continued Regulator Panel The regulator tower contains space for six gauges and regulators. The base Maxum II Modular Oven includes an electronics enclosure fast purge gauge and regulators to support the configuration. See the custom documentation drawing package that was shipped with the analyzer to see which gauges and regulators are mounted on the analyzer. Isothermal Oven The Maxum ll has a wide variety of oven configurations.
About The Maxum II, Continued Switching and Sample Valves The application modules for the Maxum II Modular Oven use the Siemens Model 50 valve. The Model 50 is a 10-port diaphragm type valve that is suitable for vapor samples. The Model 50 is operated solely by air pressure against the diaphragm, with no moving parts. This unique design allows for easy maintenance, a long operation life, and a very compact size.
About The Maxum II, Continued Work Station The Maxum II uses a PC based network workstation for programming and data processing. Analyzers can be programmed and monitored from a single location, and, like the CIM Display, the workstation includes graphical displays for operation, maintenance, and diagnostics. It also supports PC printers to print chromatograms and alarm logs in order to meet record keeping requirements.
About The Maxum II, Continued Terms The following are new terms that are used in this manual. Application refers to the supporting hardware and software required to perform the analysis. Supporting hardware consists of hardware channels: detector channel (AI), Solenoid Valve Control Module channel (AO), Electronic Pressure Control channel (DI), Temperature Controller (DO). Streams are defined to applications. If there are 3 or 4 simultaneous streams, they are defined as a single group called a Method.
About The Maxum II, Continued Duplicate Modules Parallel Chromatography can reduce the cycle time for complex applications and also increase chromatograph analysis frequency by running duplicate modules in parallel at staggered times. Since times are staggered the system will provide more frequent measurement updates. If similar measurements are performed on different streams, parallel modules can be used for each stream instead of switching the stream to a single module.
About The Maxum II, Continued Intended Use The Maxum edition II gas chromatograph is primarily used in all branches of the fine chemicals, refining and hydrocarbon processing industries. It performs chemical composition analysis of gases and liquids that are present in all phases of production. The Maxum II is built for installation in harsh environments either directly or nearby in at-line process measurement laboratories.
Maxum II Operation Overview Description This section provides an overview of the operation of the Maxum II analyzer. Figure 1-4 is an operational block diagram showing how a sample is processed within the analyzer. For simplicity the block diagram only depicts a single modular oven. The accompanying narrative traces the sample through the Maxum II and how the various modules interact during the analysis.
Maxum II Operation Overview, Continued Analyzer Operation Refer to Figure 1-4 for the following narrative. Power On The Power Entry Control Module-Direct Current (PECM-DC), in response to commands on the internal bus, accepts system primary power and provides switching and control of AC power for oven heaters and other AC powered devices. Sample Conditioning Before being piped to the analyzer, the sample from the process is sent to a sample conditioning system.
Maxum II Operation Overview, Continued Column Valves In most applications, there are multiple columns in use that are typically switched by column valves located in between them. These column valves are not shown in the illustration, but like the sample valves and SSOs described above they are also controlled by the SVCM and EMSNE software located in the electronics control section. The Siemens Model 50 valve is used for any required column valves.
Maxum II Operation Overview, Continued Embedded Sensor Near Electronics The Embedded Sensor Near Electronics (EMSNE) software takes the place of a physical SNE Controller board (SNECON) that is used many configurations of Maxum analyzer. In the modular oven configuration, this function is performed by the processor on the Communication and Control (CAC3) board, which resides on the CIM board.
Functional Tasks Overview This section provides an operational overview of the Real-Time functional tasks of the Maxum II.
Functional Tasks, Continued Cycle Control Flag A check is made to see if the analyzer is to run a diagnostic type cycle. This is for the purpose of validating the analytical hardware, such as solenoid valves, detectors, carrier regulators, etc. This is optional based on a custom application being initiated per the power fail alarm. Cycle control flags are checked to see if any analyzer cycle clocks are to be in RUN mode. If they are not, the analyzer remains in the HOLD mode until operator intervention.
Functional Tasks, Continued Cycle Clock The Analysis Cycle Clock is another clock that provides the time base for all events associated with the actual chromatograph analysis cycle. The cycle clock is maintained by the EMSNE software and can be configured to provide timed event resolutions of 0.1 second, 0.01 second, 0.01 minute, or 0.001 minute. This is the Embedded SNE Event Table Scan Rate, which is independent of detector scan rates.
Analyzer Internal Communications Description The primary internal communication link within the Maxum II Modular Oven analyzer is the I2C bus. This bus is used to provide the communication paths from the CIM to the internal devices including DPMs, EPCs, PECM-DC and I/O boards. Note that the SVCM communications are via the PECM-DC. I2C Internal Bus Physical Connections The Advance Communication System (ACS) Ethernet is accessed via the 10BaseT port on the CAC3 board.
Maxum II Hardware Identification Overview The Maxum II modules located in the electronic enclosure section have their own physical address and communicate via the I2C Internal Bus. Address information is contained in the SYSCON database and identifies modules by their location. Identification Number ALL modules within the Maxum II electronic enclosure have a unique hardware identification number. The first section of the hardware ID is the SNE ID.
Advance Communication System Network Connectivity The Advance Communication System (ACS) uses industry standard protocols and provides high-speed communication among all devices. The ACS can function alone or may be connected to a Distributed Control System (DCS) or plant-wide Local Area Network (LAN). As with other Siemens systems, the network has complete backward compatibility with existing Advance Data Hiway systems.
Chapter 2 Maxum II Modules Overview Description This chapter provides a functional description for each replaceable module installed within the Maxum II Gas Chromatograph Modular Oven configuration. Learning Hint Please read the System Overview section of this manual for a basic understanding of the overall operation of the Maxum II.
Control Interface Module (CIM) Description The Control Interface Module (CIM) is a multipurpose assembly capable of functioning as the control processor, motherboard, peripheral interface, and user interface for the Maxum II analyzer. It may be used in both the Modular Oven and Airbath/Airless Oven configurations of the Maxum analyzer. This section is related to the use of the CIM in the Maxum II Modular Oven configuration.
Control Interface Module, Continued CIM Operation Below is a summary of the basic functions performed by the CIM assembly • Memory storage for the application database, analytical results, programs, etc. • Running Embedded Sensor Near Electronics (EMSNE) software to control the sample analysis, acquire and process data from detectors and control and monitor the analytical operating environment. • Performing data processing and calculations. • Storing and executing MaxBasic programs.
Control Interface Module, Continued CAC3 (continued) The CAC3 utilizes a 32-Bit, 240 MHz microprocessor. The on-board memory for the CAC3 consists of 128 MB SDRAM, 64 MB NOR Flash, and 256 MB NAND Flash. The CAC3 also includes an on-board 10/100 Ethernet controller, used for connection to external Ethernet. The communication backbone between the CAC and the CIMBase is the General Purpose Bus (GP Bus). The GP Bus is a 32 bit, 120 MHz parallel address/data bus with dedicated chip selects and interrupts.
Control Interface Module, Continued LED indicators for the CAC3 are as shown in figure 2-3 and table 2-1 CAC3 LEDs Figure 2-3: LEDs on the CAC3 Board LED LED1 LED2 Description Debug LED1 Debug LED2 LED3 LED4 Power Good Maintenance LED5 LED7 Fault Ethernet Speed Green LED on RJ-45 Link Status Yellow LED on RJ-45 Link Acknowledge Color / Meaning Green – On during normal operation. Green – On during normal operation.
Control Interface Module, Continued CIMBase Board Connections Other than the external Ethernet connection on the CAC3, CIMBase board provides all of the connections for the CIM assembly, External connectors are shown below. Figure 2-4: CIM Connections 2-6 • Debug Connector – This serial RS-232 port is used to interface to the debug function on the CAC3. The debug port has no support for hardware handshake.
Control Interface Module, Continued CIMBase Board Connections (continued) • Reset Switch – This pushbutton switch initiates a hard reset of the CIM (same as initial power up). • CIM Display Backlight – Power/Control connector for the backlight of the color display. • I2C Bus – The I2C connectors are shown on the left side of figure 2-4. Two I2C buses are equipped on the CIM. These are labeled I2C Bus A and I2C Bus B. o I2C Bus A includes the two connectors on the top as shown in figure 2-4.
Control Interface Module, Continued Note: RS-485 serial ports are designed to comply with the Profibus standard. The pin layout is below. DB-9 Pin# 1 2 3 4 5 6 7 8 9 RS-232 RX TX GND RTS CTS - RS-485 Modbus 5 V Pwr Line B (RxD+/TxD+) Common Line A (RxD–/TxD–) - Table 2-2: Serial Port Pin Layouts for CIM • CAUTION 2-8 Intrinsic Safety Grounds – The touch screen display is designed as an intrinsically safe device.
Control Interface Module, Continued CIMBase LEDs and Options The CIMBase is equipped with several LEDs that relate useful information regarding the operating status of different interfaces. These LEDs are shown in figure 2-6 and described in table 2-3. The CIMBase is also equipped with certain option switches, described below, that must be set appropriately for proper operation. Before installation, verify that all switches are set correctly.
Control Interface Module, Continued CIMBase LEDs Table Name Color Description Power Green Is connected directly to 3.3V supply. Should be on at all times. Power Fault Red Power is faulty or hardware reset switch is being pressed. CAC Connection Fault Red Connection from the CIMBase to the CAC3 is faulty or incomplete. After power up, this LED should turn off once CAC3 to CIMBase connection is completely initialized.
I2C Input/Output Boards Description The Maxum II Modular Oven supports three different types of I/O circuit boards that communicate via the I2C bus.
I2C Input/Output Boards, Continued DI Mode Switch Switch SW1 located at the top of the board near the front (connector end) controls the mode setting for the on-board digital inputs. The switch sets the mode for all digital input circuits on the board (mixing of modes on a board is not allowed). The available options are Default/Sink and Legacy. The Legacy option is designed to adjust for a non-standard configuration that may be in use on some systems.
I2C Input/Output Boards, Continued Analog Input/Output Board The I2C AIO board makes available 8 Analog Outputs (AOs), 8 Analog Inputs (AIs), and 2 Digital Inputs (DIs). Figure 2-9: I2C Analog Input/Output Board Analog Outputs There are eight AO circuits available on the AIO board. The AO is able to output currents from 0 to 25mA, although a 4 to 20mA range can be selected in software. The range above 20mA is used to meet Namur compliant out-of-range fault readings. Two pins are used for each AO.
I2C Input/Output Boards, Continued Analog Inputs There are eight AI circuits available on the AIO board. Analog inputs may be either voltage or current based. The I2C I/O boards use two pins for AI circuits. Setting for either voltage or current is accomplished using jumper settings on the board, one jumper per circuit so that AIs on the same board can be set differently. Shorting the jumper across the left two pins engages a 50 ohm resistor across the inputs.
I2C Input/Output Boards, Continued Analog I/O Board (AIO) Connections Circuits on the AIO board are wired as shown in the following table. The table is the view as seen when looking at the connector while the board is installed.
I2C Input/Output Boards, Continued Digital Input/Output Board The I2C DIO board makes available 8 Digital Outputs (DOs) and 6 Digital Inputs (DIs). Figure 2-10: I2C Digital Input/Output Board Digital Outputs There are eight DO circuits available on the DIO board. The DO consists of three pins connected to a relay; Normally Open (NO), Normally Closed (NC), and Common (C). When the relay is not activated (DO has value of zero) then NO is open and NC is connected to C.
I2C Input/Output Boards, Continued Digital I/O Board (DIO) Connections Circuits on the DIO board are wired as shown in the following table. The table is the view as seen when looking at the connector while the board is installed.
I2C Input/Output Boards, Continued Analog and Digital Input/Output Board The I2C ADIO board makes available 4 Digital Outputs (DOs), 4 Digital Inputs (DIs), 4 Analog Outputs (AOs), and 4 Analog Inputs (AIs). Figure 2-11: I2C Analog and Digital Input/Output Board Digital Outputs There are four DO circuits available on the ADIO board. DOs are described in the previous section for the DIO board. Digital Inputs There are four DI circuits available on the ADIO board.
I2C Input/Output Boards, Continued Analog and Digital I/O Board (ADIO) Connections Circuits on the ADIO board are wired as shown in the following table. The table is the view as seen when looking at the connector while the board is installed.
Intrinsically Safe TCD Detector Personality Module (ISTCD DPM) Description Output signals from Thermal Conductivity Detector (TCD) in the Modular Oven are input to the associated Detector Personality Module (DPM). The DPM is mounted inside the Electronics Enclosure (EC) on the floor of the compartment. The DPM digitizes the incoming analog data and then passes it to the CIM via an I2C port. The resulting data is then processed by the Embedded SNE software in the CIM.
ISTCD Detector Personality Module (ISTCD DPM), Continued Connections The connections to the ISTCD DPM are shown in figure 2-13 below. The connections are described below. Figure 2-13: ISTCD DPM Connections and Board ID Orange connectors to detectors: Each ISTCD DPM consist two connections. Each connection is capable of interfacing to two pairs of TCD elements (four total channels, 1 for reference and 3 for signal). Wiring of the connectors to the ovens depends on the configuration.
ISTCD Detector Personality Module (ISTCD DPM), Continued Board ID Switch The Board ID switch shown in figure 2-13 indicates the board number for the I2C bus. A diagram of how to set the switch is shown on the board. Each equipped DPM must have a unique board ID Reference Select Switches A Detector Personality Module is designed to process the signals for two sets of four thermistor beads.
Power Entry and Control Module–Direct Current (PECM-DC) The Power Entry and Control Module – Direct Current (PECM-DC) board contains the electronics that distributes 24V DC power to the various other components in the Maxum II Modular Oven configuration. Input 24V power is received from either the internal 24V Power supply or optionally from an external source. The PECM-DC is mounted on the back inside wall of the EC cabinet.
Power Entry and Control Module–Direct Current (PECM-DC), Continued DC Power Input (Optional) The Maxum II Modular Oven is typically installed with an internal 24V power supply that supports a wide range of AC power input options. In addition to AC input, the PECM-DC allows for power via external 24V DC supply. In this configuration the internal DC power supply is not installed. The requirements for this configuration are detailed in the specification table at the beginning of Chapter 1 of this manual.
Power Entry and Control Module–Direct Current (PECM-DC), Continued Heater Control for Modular Ovens The PECM design provides control for the oven heaters. All oven heaters for a modular oven (left for right) are powered by a single harness. RTDs for temperature sense and over temperature sense for a modular oven (left or right) are connected by a single harness as well. Connector locations are shown in figure 2-16. I2C Bus The PECM-DC has six I2C bus connectors for internal bus distribution.
Solenoid Valves Description The Solenoid Valves provide pneumatic interface to control flow to the oven sampling and column valves as well as optional control for external devices. Solenoid Valves are suitable for air, nitrogen and helium on the pressure side and vacuum on the vent side. The electronic enclosure for the Maxum II Modular Oven configuration has space for three modules, one for the left oven, one for the right oven and one for external devices.
Solenoid Valves, Continued Mechanical The SMC brand solenoid valves used in the Modular Oven are 4-port valves that can optionally be used in 3-port operation. Each type of configuration utilizes both 4-port and 3-port operation via the pre-configured manifold block. • 2 Station: Viewed from front as installed, the left solenoid valve is configured as 4-port and the right solenoid valve is configured as 3-port.
Solenoid Valves, Continued Operation Test Specifications Step Procedure 1. Using a fine pointed object, depress orange button on the solenoid. 2. When depressed, pressure is applied to the piston that moves to either the open or closed position. Resulting pressure is then applied to the column or sample valve. 3. If piston does not operate when the button is depressed, check for correct gas pressure. 4.
Electronic Pressure Control (EPC) Module Description The Electronic Pressure Control (EPC) Module reduces oven set-up time by using precise pressure control without restrictors or needle valves. This module also allows programmed pressure control for faster chromatography and modern applications. It allows for precise resetting of pressures. The EPC can be used for both carrier and fuel gas supply, which eliminates the less reliable mechanical regulation.
Electronic Pressure Control (EPC) Module, Continued Electrical The EPC is made up of a printed circuit board with two pressure transducers, two proportional valves with associated electronic circuitry, manifold for pneumatic connections, PC connector for communication signals and a DC power connector. Refer to Figure 2-20. The EPC provides electrically controlled pressure for helium, hydrogen and nitrogen carriers etc.
Electronic Pressure Control (EPC) Module, Continued Location ID Switch Settings As shown in the figure below, the EPC has a set of four DIP switches. These are used to set the unique location ID for the specific EPC, which is used in software as part of the hardware ID string. The location ID is set using a binary counting of the switches from right to left (as numbered on the board and not on the actual switches).
Electronic Pressure Control (EPC) Module, Continued Specifications The following specifications are applicable to the Electronic Pressure Control Module (EPC): Topic Specification Maximum inlet pressure 120 psig Pressure output range 5-100 psig Minimum differential between EPC inlet and outlet 5 psi Flow range from EPC 5-500 sccm (see note below) Controlled pressure stability over temperature range +/-0.5% of setpoint Short-term pressure stability +/-0.
24 Volt Power Supply Overview The 24V Power Supply for the Maxum II Modular Oven configuration is comprised of a 110/230 VAC power supply manufactured by Delta Electronics. It provides 24 VDC operating system voltages from a wide range of AC inputs. It is mounted on a DIN rail on the back of the EC. Refer to the figure below.
Chapter 3 CIM Display Panel Operation Overview Introduction This chapter is intended for operating and maintenance personnel. All of the Maxum II’s operational and daily routine maintenance tasks can be performed from the CIM color touch screen display. The CIM Display is the physical hardware that is installed in the door of the Maxum II. It is controlled by a processor board called the CIM Board. The combination of board and display is referred to as the CIM (Control Interface Module).
Overview, Continued Emulator A PC-based graphical simulation of the physical CIM Display, known as the HMI emulator, is available using the PC based workstation software. This emulator is capable of performing all of the functions that are available with the physical unit. The emulator is a graphical representation of the physical display. Because of this, some aspects of the emulator appear slightly different than they appear on the physical unit.
CIM Display Hardware Overview The CIM display contains a back-lit color graphic display screen layered with a touch screen sensor. It is part of the Control Interface Module (CIM) assembly that includes the display, the CIM-BASE board, and the Communication and Control (CAC3) board (which is mounted on the CIM-BASE). Refer to chapter 2 of this manual for more information. Figure 3-1: CIM Display Status LEDs The four LEDs next to the screen indicate the analyzer systems status.
Screen Characteristics Description The screen is in color and back-lit for easy reading, and it is divided into several functional areas: • • • • • Main Navigation Bar Status Bar Content Area Toolbar Softkey Bar Main Navigation Bar Status Bar Content Area Toolbar Softkeys Figure 3-2: Screen Layout Main Navigation Bar The main navigation bar allows the user to return to the home menu screen, go back to a previous menu screen, or launch the interactive help function (all denoted by easy to understand i
Screen Characteristics, Continued Status Bar The status bar shows various data about the analyzer, including the name, date and time, and run/hold status. It also shows information about the current application, stream, method, and cycle clock. In addition, the status bar contains gray buttons that permit the user to change the run/hold status or to select the current analyzer, stream, application, and method. Content Area The middle part of the screen is the general content area.
Using the CIM Display Navigating the Menus As mentioned previously, the menu tree of the CIM Display is organized into three functional levels. This structure is used to allow different levels of access to analyzer control and configuration operations. The three functional menu levels are as follows. • Monitor Menu – This menu level allows minimal control of the analyzer and viewing of analyzer status with minimal control of analyzer function. This level is intended for operations personnel.
Using the CIM Display, Continued Entry of Data The original Maintenance Panel for Maxum was equipped with a numeric keypad for data entry. The touch screen function of the CIM Display eliminates the need for this. When data entry is required on the physical CIM Display, a pop-up window with numeric keypad appears on the screen as shown below.
Using the CIM Display, Continued Accessing Help The online help function of the CIM Display represents a large leap forward in usability over the original HMI. It allows the user to obtain a help description for virtually every element displayed on the screen. It also allows the user to obtain detailed descriptions of alarms as well as possible causes and suggested corrective actions.
Using the CIM Display, Continued Alarm Help One useful feature of the online help function of the CIM display is the ability to get detailed descriptions of alarms as well as possible causes and suggested corrective actions. To access alarm help, first load the alarm screen by selecting it from the menu or from the toolbar on the right side of the screen. Next, touch the help icon ( ) on the upper right corner of the CIM display (or click on the icon if using the emulator).
Password Restrictions Description It is possible to configure the CIM Display for different levels of password access. By default, six different levels of password access are available. By default, the display is preset for a “configure” level of access, which allows the user to perform almost all analyzer functions except password administration.
Password Restrictions, Continued Obtaining/Changing a Password Passwords can be modified from the User’s Passwords screen on the Configure menu. To change a password you must be logged on with “Super” level access. To change a password, select the table entry for the user and then tap (click) the “SELECT” softkey. This will display a window to modify the password. Privilege If your password is accepted you can modify any menu items or parameters assigned to your user level (or lower user levels).
Chapter 4 Maintenance Overview Description Procedures in this Chapter are for use by maintenance personnel. Safety First When performing maintenance procedures in this chapter, observe all warnings, cautions and notes to prevent physical injury to yourself or unnecessary damage to the equipment. WARNING Observe all plant safety requirements before performing any repair or maintenance on the Maxum II.
Overview, Continued Help If technical assistance is required during performance of maintenance functions, or if parts are being returned, the customer should contact Siemens at the addresses and/or phone numbers provided at the beginning of this manual. How to Use This Chapter Before performing a procedure first read it through. It is recommended that a regular scheduled daily, weekly or monthly maintenance program be established.
Overview, Continued Note: The tasks described below are provided as a suggested guidleine for routine maintenance. Requirements for a particular analyzer will depend on environment, location of the analyzer, available resources, and the specific characteristics of the application. Task Valve Inspection Frequency Gas Samples – Model 50 – Yearly Routine maintenance schedule for valves will vary greatly depending on sample properties, application (including temperature and pressure) and environment.
General Maintenance Scheduled Maintenance It is important that a preventative maintenance schedule be established to examine the Maxum II for internal and external cleanliness, damage, and proper operation. Refer to Table 4-1 for suggestions regarding maintenance intervals. However, maintenance schedules for a particular analyzer will depend on the application, operating environment, maintenance resources, and geographical location of the analyzer.
General Maintenance, Continued Opening Doors To gain access to the modules, the electronic enclosure door must be opened. It will be necessary to use a #4mm Allen wrench to open the door if the Allen screw on the latch has been tightened. Inspection After Maintenance After performing any maintenance function(s), check to be certain there is no loose hardware left within the electronic enclosure. Such items can create electrical shorts causing damage to internal components.
Control Interface Module (CIM) Description This section presents the procedures for removal and installation of Maxum II door mounted Control Interface Module (CIM). This includes the CAC3 board, the CIM-Base Board, and the CIM Display. Three procedures are presented in this section: • • • • CAC3 Removal and Installation CIM-Base Board Removal and Installation CIM Display/Touchscreen Removal and Installation Battery Replacement WARNING Voltage dangerous to life exists.
Control Interface Module, Continued Step Note: A5E31405710001 Procedure The CAC3 is mounted on the CIM-Base board, which is located on the inside of the Maxum door. The CAC3 is highlighted in the blue box in the image below. 4. Disconnect the Ethernet cable from the CAC3 board. It is not necessary to disconnect the other end of this cable. 5. Remove the CAC3 board by grasping both sides firmly and pulling up. Do not touch board mounted components. 6.
Control Interface Module, Continued CIM-Base Removal and Installation 4-8 Step Procedure 1. Before beginning replacement, if possible, save the current Maxum .amd database file to be reloaded after the CAC3 board is replaced. Note that if the CAC3 is faulty, backup may not function. In this case it will be necessary to use the most recent backup file. 2. Once the database is saved, power off the Maxum. 3. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). 4.
Control Interface Module, Continued Step A5E31405710001 Procedure Note: Cable Routing: When replacing the cables on the CIM-Base in the following step, take note of the routing. The display backlight cable runs behind the board standoff as shown on the left image below. In addition, the display control interface cable is routed behind the board as shown in the right image below. 8.
Control Interface Module, Continued CIM Display/Touch Screen Removal and Installation 4-10 Step Procedure Note: Although the CIM color display and the touch screen are separate parts, they are shipped as one assembly attached to a metal mounting plate. Due to the need for special tools to correctly align the two devices, the display and touch screen should NOT be disassembled on-site. This procedure describes the steps to remove and replace the entire CIM Display assembly. 1.
Control Interface Module, Continued CAUTION When installing the CIM Display assembly, it is necessary to use a torque wrench ensure a proper seal while at the same time preventing damage to the display. Step A5E31405710001 Procedure 7. Before installing the new display, remove the protective film from the display surface. 8. Install the new display on the door. Using a torque wrench (Siemens part number A5Exxxxxxxx), tighten the six nuts to a value between 0.34 to 0.56 NM (3 to 5 in lb).
Control Interface Module, Continued The battery should only be replaced with an approved spare. Contact Siemens for a replacement. IMPORTANT Battery Replacement Step 1. Procedure Power off the Maxum and then open electronic enclosure door, using a 4mm (5/32”) Allen wrench if necessary. Before removal of battery, note location of its positive end when installed in battery holder. The positive and negative terminals are marked on the battery. CAUTION 2.
Power Entry Control Module – Direct Current (PECM-DC) Description This section references procedures for the Power Entry Control Module –Direct Current (PECM-DC), which is specific to the Modular Oven configuration. The PECM-DC is mounted to the back wall of the Electronic Enclosure. The PECM-DC assembly consists of a printed circuit board that controls the distribution of 24V power throughout the EC as well as distributing the internal I2C bus and controlling oven temperature.
Power Entry Control Module – Direct Current (PECM-DC), Continued PECM-DC Removal and Installation 4-14 The following procedure should be used for replacement of the PECMDC in the Maxum II Modular Oven configuration. Step Procedure 1. Turn off power to the Maxum II at the main circuit breaker. 2. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). 3. Remove all other cables connected to PECM-DC.
24V Power Supply Description This section presents the procedures for removal or installation of the 24V Power Supply. This power supply is mounted to the back wall of the Electronic Enclosure on a DIN rail. It provides 24 VDC operating system voltages from a wide range of AC inputs. WARNING Voltage dangerous to life exists. Before performing the removal and installation procedures, it is important that primary AC power to the Maxum II be turned off from the main circuit breaker.
Power Supply, Continued Power Supply Removal and Installation 4-16 Step Procedure 1. Turn off power to the Maxum II at the main circuit breaker. 2. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). 3. Label and disconnect any cables that run from the power supply to other devices. This includes the internal power to the PECM-DC, the internal chassis ground, and the external power from the main. It also includes any other device that may be connected.
Solenoid Valves Description This section presents the procedures for removal or installation of a Solenoid Valve. The valves are mounted on either the floor or back of the electronic enclosure, depending on configuration. Valves are replaced individually using the valve kit noted in the spare parts section of this manual. WARNING Voltage dangerous to life exists.
Solenoid Valves, Continued Step 4-18 Procedure 4. As show below, use a small screwdriver to remove the two screws that fasten the solenoid to the manifold. If the black gasket adheres to the manifold after removing the solenoid, then remove the gasket manually. 5. Install the new solenoid, using a new gasket from the kit. 6. Reattach the cable to the solenoid. 7. Close the door and reapply power to the device.
Model 50 Valve Description This section provides maintenance instructions for the Model 50 Valve. The Model 50 is a pneumatically operated diaphragm valve specifically designed for process gas chromatography. It uses pressure-ondiaphragm activation with no other moving parts. The valve can inject vapor samples and switches columns simultaneously. It is capable of switching gasses up to 75 psig (515 kPa). The Model 50 valve is equipped as part of the Analytical Module that installs in a Modular Oven.
Model 50 Valve, Continued Figure 4-5: Exploded View of Model 50 Valve 4-20 A5E31405710001
Model 50 Valve, Continued Maintenance Personnel If customer maintenance personnel are not technically trained to repair the Model 50 Valve on site, it is recommended that the valve be returned to Siemens for repair or direct replacement. Direct Valve Replacement If it is determined that the problem is directly related to the Model 50 Valve system performance, the customer must make a determination if the valve can be repaired on site or if it should be returned to Siemens for repair or replacement.
Model 50 Valve, Continued Maintenance Procedures Valve Removal and Disassembly (see Figure 4-5) The valve is serviced by disassembling and then thoroughly cleaning the components to remove all particulates. Ultrasonic cleansing with a suitable solvent works very well. During the cleaning and re-assembly process, care must be taken to avoid scratching or damaging the polished surfaces of the valve. After cleaning, the valve is reassembled using new Teflon® coated stainless steel diaphragms.
Model 50 Valve, Continued Step Procedure 5. Place the valve bottom plate on a lint free cloth. Using a 2.5 mm Allen wrench, remove the five component socket head fastening cap screws. Refer to Figure 4-5. 6. Separate valve Top, Center and Bottom plates, placing them on a lint-free cloth. Both diaphragms are visible. Valco & Swagelok Fittings The ports are machined for a 1/16” Valco internal nut. The Valco ferrule or the 2-piece Swagelok ferrule can be used.
Model 50 Valve, Continued Step Replacing Diaphragms 5. Turn the nut ¼ turn (90 degrees) past the point where the ferrule first starts to grab the tubing. 6. Remove the fitting and inspect it. The ferrule may be free to spin axially on the tubing but should have no lateral movement along the tubing. If it does, reinstall the fitting and tighten it another 1/8 turn past finger tight. Remove, re-inspect and repeat if necessary.
Model 50 Valve, Continued Step A5E31405710001 Procedure 6. Repeat steps 3 and 4 with the middle plate. 7. Place the top plate on the valve, verifying alignment using the alignment marks. 8. Install the 5 screws and washers finger tight. 9. Tighten the screws down evenly (2.5mm Allen wrench) to 6 to 8 inch-pounds of torque. (It is recommended to use the torque wrench available from Siemens, PN 1631005-001, which is calibrated at 7.2 inch pounds). Remove the assembled valve from the valve fixture.
Intrinsically Safe Thermal Conductivity Detector (ISTCD DPM) Description This section provides removal and installation procedure for the Intrinsically Safe Thermal Conductivity Detector (ISTCD) Detector Personality Module (DPM). This board is mounted on the floor of the electronics enclosure in the center of the enclosure. WARNING Voltage dangerous to life exists.
ISTCD DPM, continued Step A5E31405710001 Procedure 5. Remove DPM, along with its mounting bracket, using an 8 mm socket wrench or nut driver. There are two nuts securing the metal mounting bracket to the enclosure. One is visible in the front and one is at the back of the module. 6. If required, the DPM board can be removed from the bracket by removing the two screws that mount the board to the bracket (not the screws that connect the black cover together).
Analytical Modules Description This section describes repair procedures for the Analytical Modules for the Modular Oven. The Maxum Modular Oven configuration is designed for ease of repair. The primary aspect of this design is the removable Analytical Module. This design allows the operator to quickly remove the analytics package which is secured with only one or two bolts. The module can then be taken back to a central location for troubleshooting and repair.
Analytical Modules, continued Figure 4-7: Manifold and Pneumatic Diagram of Large Modular Oven (rear view) A5E31405710001 4-29
Analytical Modules, continued Figure 4-8: Manifold and Pneumatic Diagram of Small Modular Oven (rear view) 4-30 A5E31405710001
Analytical Modules, continued Caution Removal of Analytical Module A5E31405710001 It is not required to power down the analyzer to remove an analytical module. However, it is important to place the analyzer in Hold and block gas flows. Step Procedure 1. Place the analyzer in Hold and block gas flows. 2. Open the door to the oven compartment. 3. There will be either one or two ovens installed.
Analytical Modules, continued Replacement of Thermistor Board Step Procedure 1. Making note of the connection location for each wire, remove the wiring that is connected to the Thermistor/Filament Board that is to be removed. Remove the wires by carefully pulling on the end of the metal connector. 2. Remove the Thermistor Board by removing the Button Head Hex Screw, the Lockwasher, and the Flat Washer as shown in figure 4-9. 3. Discard O-rings (13). Do not attempt to reuse old O-rings. 4.
Analytical Modules, continued Figure 4-9: Thermistor Bead Board (Exploded View) Figure 4-10: Proper Alignment of Metal Inserts Step 7. Procedure Install the new O-Rings in hole in the Detector Block. It is also possible to install the O-Rings on the thermistor board instead of in the hole. If installing the O-Rings on the board, be careful not to damage the element. 8. A5E31405710001 Install the Board into the Detector Block.
Analytical Modules, continued Step Procedure 9. Reinstall the Flat Washer, Lock Washer, and Button Head Hex Screw. Do not over tighten the screw as this can damage the Board. 10. Reconnect wiring to the board. Wiring MUST be connected to the same cells as before. Verify all termination points. Note: The length of the wiring is such that color coded wires can connect only to their specified bead. Also note that there are two wires of each color.
Analytical Modules, continued Replacement Thermistor Wiring Harness Step Procedure 1. Making note of the connection location for each wire, remove the wiring that is connected to the Thermistor/Filament Board that is to be removed. Remove the wires by carefully pulling on the end of the metal connector. 2. Remove the wiring harness by removing the 2 mm button head hex screws that secure the 9-pin connector to the manifold. 3. Install the new wiring harness using the 2 mm button head hex screws. 4.
Use of Analytical Module Hardware Test Box Description This section provides describes the Module Hardware Tester device and its use for troubleshooting Modular Oven Analytical Modules. The Module Hardware Tester is used to check for leaks in a module and to test the electrical characteristics of the Thermal Conductivity Detector beads. Requirements for Use The Module Hardware Tester is encased in a hard plastic carrying case for mobility. It requires no outside power source.
Use of Analytical Module Hardware Test Box, continued Figure 4-12: Module Hardware Tester Components A5E31405710001 As shown above, the Module Hardware Tester is equipped with the following components: • Bead Select Switch – Used to choose which TCD bead to test. A single module will have beads 1-4 and a double module will have beads 1-8. Position 9 is used to check for short between beads and ground.
Use of Analytical Module Hardware Test Box, continued Note • Gas Pressure Gauge – Shows the internal pressure of the pneumatic system of the test box. • Vent Line – This connection is used to release pressure from the box when the main valve setting is set to vent. • Valve 1 Switch – This is used to test for leaks on the actuation lines of the Model 50 as well as manifold ports 1 and 2 on the module.
Use of Analytical Module Hardware Test Box, continued Setup of Hardware Tester The following procedure should be used to set up the device for use. Refer back to figure 4-12. Step Procedure 1. Place the test box in a clean dry area that is well ventilated. 2. Set the switches labeled VALVE 1, VALVE 2, and VALVE 3 to OFF. Set switch labeled MAIN VALVE to VENT. 3. For leak checking, connect 1/8” gas supply line to the port labeled GAS SUPPLY. Turn on gas at supply end. 4.
Use of Analytical Module Hardware Test Box, continued Electrical Test The following procedure should be used to test the electrical characteristics of the TCD beads. Refer back to figure 4-12. Bead Select Switch Setting Expected Resistance at 25°C 1-8 27-33 kΩ 9 > 2 MΩ Table 4-2: Module Hardware Tester Step Procedure 1. With the external test meter connected as previously described, set the BEAD SELECT switch to position 1. 2. Read the measurement on the meter.
Use of Analytical Module Hardware Test Box, continued Leak Test The following procedure should be used to test for internal leaks within an analytical module. Refer back to figure 4-12 during this procedure. Checking for leaks using the Module Tester is accomplished by pressurizing different parts of the module to a specific pressure (typically 100 psig) using input gas. Then, the pressurized volume is sealed off and the gas pressure gauge is monitored to determine if there is a pressure loss over time.
Use of Analytical Module Hardware Test Box, continued Step 3. Procedure VALVE 1 pressurizes the control ports for the Model 50 valve(s). Turn VALVE 1 to ON. Wait about 5 seconds for the pressure to stabilize. 4. Set MAIN VALVE to BLOCK. This isolates the pressurized ports. 5. Allow the test to sit for about 1 minute. There should be no pressure drop over this time. If a leak is present, use a leak detector to find the source. Note that there may be more than one leak. 6.
Chapter 5 Parts Introduction Overview This chapter provides maintenance personnel with information concerning parts and assemblies for the Maxum II. Chapter Highlights How to Place an Order Topic Page Introduction 5-1 Maxum II Modular Oven Acronyms 5-2 Available Parts 5-3 Parts can be ordered using the contact information at the beginning of this manual: To ensure an immediate response to your request, you should provide the following: A5E31405710001 • Purchase order number.
Introduction, Continued Maxum II Acronyms Modular Oven ADIO AIO CAC3 CIM DIO DPM EC EPC EmSNE GC NAU PECM-DC SVCM ISTCD 5-2 I2C Combined Analog/Digital Input Output Board I2C Analog Input Output Board Communication and Analytical Control board Version 3 (processor board of SYSCON2, mounts on SIB) Control Interface Module assembly, consisting of CIMBASE, CIMBOARD (CIMBASE + CAC3), and CIM Display (color display with touchscreen interface) I2C Digital Input Output Board Detector Personality Module; ampl
Available Parts Description Part Number 1671004-103 2015946-002 2020164-001 2020165-001 2020166-001 2020176-001 2021185-001 2022021-001 A5E03251957001 A5E03467866001 A5E03467983001 A5E03660721001 A5E03660722001 A5E03660723001 A5E03881071001 A5E03896485001 A5E03896485002 A5E03896485003 A5E03919676001 A5E30174254 A5E30366979 S81804 A5E03959533001 A5E03989070001 A5E03989098001 A5E03989426001 A5E03989448001 A5E03989451001 A5E03989574001 A5E03989577001 A5E03990228001 A5E03990569001 A5E03990579001 A5E03990581001
Available Parts (continued) A5E31277202001 A5E03607125001 A5E03607139002 A5E03607149002 A5E03607150002 A5E31273922001 A5E31273922002 A5E31273922003 A5E31273922004 A5E31273922005 A5E31273922006 A5E31273924001 5-4 KIT, SPARE PARTS, MODULE HARDWARE SINGLE MODULE, PRESSURE TEST, HARDWARE ONLY DOUBLE MODULE REPLACEMENT, 1 M50, HARDWARE ONLY DOUBLE MODULE REPLACEMENT, 2 M50, HARDWARE ONLY DOUBLE MODULE REPLACEMENT, 3 M50, HARDWARE ONLY SINGLE MODULE, PRESSURE TEST, LIGHT GASES 101/102 SINGLE MODULE, PRESSURE TE
10/2012 Edition A5E31405710001 Siemens Industry Inc. 7101 Hollister Road, Houston, TX 77040 United States Phone +1 (713) 939-7400 Fax +1 (713) 939-9050 www.usa.siemens.
