Maxum II Maintenance Manual 2015 en-US PDF
Maxum II Maintenance Manual 2015 en-US PDF
Maxum II Maintenance Manual 2015 en-US PDF
System Functions 2
General Maintenance and
Troubleshooting 3
Component Descriptions and
Maintenance Procedures 4
PD
Maxum II Maintenance Manual
Specifications 5
Manual
10/2015
2000596-001
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in
this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
1 Analyzer Overview........................................................................................................................................7
1.1 Introduction..............................................................................................................................7
1.2 Parts of the Maxum II...............................................................................................................8
1.3 Isothermal Oven.......................................................................................................................9
1.4 Switching and Sampling Valves.............................................................................................10
1.5 Operator Controls...................................................................................................................11
2 System Functions.......................................................................................................................................13
2.1 Chromatography Overview....................................................................................................13
2.2 Intended Use and Personnel Qualifications...........................................................................14
2.3 Functions................................................................................................................................15
2.4 Analyzer Operation................................................................................................................19
2.5 Data Communication..............................................................................................................23
3 General Maintenance and Troubleshooting...............................................................................................25
3.1 General Analyzer Shutdown Procedure.................................................................................25
3.2 General Analyzer Startup Procedure.....................................................................................25
3.3 Troubleshooting.....................................................................................................................27
3.4 Alarm Codes, Descriptions, and Suggested Actions..............................................................29
3.4.1 Alarms 5.2 301 - 324.............................................................................................................29
3.4.2 Alarms 5.2 330 through 359 SNE Communication................................................................31
3.4.3 Alarms 5.2 360 - 399..............................................................................................................33
3.4.4 Alarms 5.2 400 - 562..............................................................................................................35
3.4.5 Alarms 5.2 671 - 699..............................................................................................................38
3.4.6 Alarms 5.2 700 - 736..............................................................................................................40
3.4.7 Alarms 5.2 801 - 999..............................................................................................................42
3.4.8 Alarms 5.2 1002 - 1096..........................................................................................................43
3.4.9 Alarms 5.2 1617 - 1697 Pecm Errors.....................................................................................49
3.4.10 Alarms 5.2 1917 - 2005 DPM TCD........................................................................................51
3.4.11 Alarms 5.2 2217 - 2306 DPM FID..........................................................................................54
3.4.12 Alarms 5.2 2500 - 2577 Access Bus Driver Errors.................................................................58
3.4.13 Alarms 5.2 2817 - 2904 DPM Temperature...........................................................................63
3.4.14 Alarms 5.2 3117 - 3204 EPC.................................................................................................65
3.4.15 Alarms 5.2 3401 - 3454 TFTP................................................................................................66
3.4.16 Alarms 5.2 3500 - 3528 Advance...........................................................................................67
3.4.17 Alarms 5.2 3718 - 3804 SNE I/O............................................................................................68
3.4.18 Alarms 5.2 4001 - 4124 EZChrom.........................................................................................71
3.4.19 Alarms 5.2 4217 - 4320 CAN Bridge......................................................................................73
3.4.20 Alarms 5.2 4525 - 5220 Advance TC.....................................................................................75
3.4.21 Alarms 5.2 10000 - 11536 MicroSAM....................................................................................77
4.2.2.5 Figure...................................................................................................................................159
4.2.2.6 Model 50 Valve Maintenance Procedure.............................................................................160
4.2.3 Liquid Injection Valve...........................................................................................................162
4.2.3.1 Description...........................................................................................................................162
4.2.3.2 Maintenance Overview.........................................................................................................166
4.2.3.3 Liquid Injection Valve Component Locations.......................................................................167
4.2.3.4 Troubleshooting...................................................................................................................168
4.2.3.5 Service Procedures..............................................................................................................169
4.2.4 Model 20 Valve....................................................................................................................173
4.2.4.1 Basic Maintenance...............................................................................................................173
4.2.4.2 Disassembly and Cleaning...................................................................................................178
4.2.5 Model 20 HT Valve...............................................................................................................186
4.2.5.1 M20HT Description..............................................................................................................186
4.2.5.2 M20HT Intended Users........................................................................................................187
4.2.5.3 M20HT Safety and Certification Information........................................................................187
4.2.5.4 M20HT Procedure - Overview..............................................................................................187
4.2.5.5 M20HT Procedure - Maintenance Facility............................................................................187
4.2.5.6 M20HT Procedure - Figures.................................................................................................188
4.2.5.7 M20HT Procedure - Cleaning of Parts.................................................................................191
4.2.5.8 M20HT Procedure - Valve Cap Disassembly.......................................................................191
4.2.5.9 M20HT Procedure - Actuator Disassembly..........................................................................192
4.2.5.10 M20HT Procedure - Actuator Re-assembly.........................................................................193
4.2.5.11 M20HT Procedure - Valve Cap Re-assembly......................................................................197
4.2.6 Model 11 Valve....................................................................................................................198
4.2.6.1 M11 Description...................................................................................................................198
4.2.6.2 M11 Intended Users.............................................................................................................200
4.2.6.3 M11 Safety and Certification Information.............................................................................200
4.2.6.4 Diagnostic Procedures.........................................................................................................200
4.2.6.5 M11 Procedure - Maintenance Facility.................................................................................201
4.2.6.6 M11 Procedure - Figures.....................................................................................................202
4.2.6.7 Mini-Maintenance Procedures (Valve Cap and Fittings)......................................................205
4.2.6.8 Maxi-Maintenance Procedures (Valve Body).......................................................................208
4.2.7 Live T Switch........................................................................................................................211
4.2.7.1 Live T Switch........................................................................................................................211
4.3 Detectors..............................................................................................................................212
4.3.1 Detector Introduction............................................................................................................212
4.3.2 Thermal Conductivity Detector.............................................................................................213
4.3.2.1 Thermal Conductivity Detector (TCD)..................................................................................213
4.3.2.2 Replace TCD Thermistor Beads/Filaments Introduction......................................................213
4.3.2.3 Figures.................................................................................................................................214
4.3.2.4 Procedure to Replace Beads/Filaments...............................................................................215
4.3.3 Flame Ionization Detector....................................................................................................216
4.3.3.1 Flame Ionization Detector (FID)...........................................................................................216
4.3.3.2 Replacing the FID Mesh Filter..............................................................................................216
4.3.3.3 Replacing the FID Quartz Jet...............................................................................................220
4.3.3.4 Replacing the FID Igniter.....................................................................................................222
4.3.4 Flame Photometric Detector................................................................................................234
4.3.4.1 Flame Photometric Detector (FPD)......................................................................................234
4.3.4.2 Upgrade Description............................................................................................................238
4.3.4.3 Intended Users.....................................................................................................................239
4.3.4.4 Safety and Certification Information.....................................................................................239
4.3.4.5 Procedure - Upgrade FPDI to FPDII....................................................................................239
The Maxum edition II system, also called the “Maxum II”, represents a significant advance in
process chromatography. The Maxum II combines the best of the Siemens Advance Maxum
and PGC 302 gas chromatographs into a single platform analyzer. From oven and electronic
components to software and communication networks, the system is modular. Pre-configured
application modules are available for many common measurements.
A Maxum II system offers a wide range of detector modules including Thermal Conductivity,
Flame Ionization, Flame Photometric, and the Pulsed Discharge Detector (which can operate
in Helium Ionization, Photoionization, and Electron Capture modes). All detector modules are
available for both air bath and airless ovens. The Maxum II oven is designed so it can be
divided into two independently heated isothermal ovens for parallel chromatography
applications.
The Maxum II Maintenance Panel provides maintenance personnel with access to all
maintenance functions and data. In addition, the Maintenance Panel displays both real time
and archived chromatograms. A PC-based network workstation runs the Gas Chromatograph
Portal software.
Overview
The Maxum II Gas Chromatagraph is completely enclosed in an air-purgable, metal cabinet
with hinged doors. Mounted above the isothermal oven is the electronics enclosure and
regulator panel. The analyzer may be mounted on a wall, in a rack or on a floor stand.
Electronics Regulator
Enclosure Panel
Color
Touchscreen
Detector
Compartment
Isothermal
Oven
Electronics Enclosure
The Electronics Enclosure houses all the electronics and pneumatic modules required for
performing all temperature, valve control and analysis functions. The Electronics Enclosure
modules are interconnected using simple cable connections made to each module. All modules
can be easily removed and replaced. The Maxum II software recognizes each Maxum II’s
application, hardware components and network configurations.
Solid
State
Relay 8-Channel Electronic
Module Pressure Control. Up
To 4 Modules. 2
Channels Each For
Control Of Carrier
Gas Pressure
Power
Entry
Control
Module
(PECM)
Regulator Panel
The regulator panel contains space for seven gauges and regulators. The base Maxum II
comes with two standard regulators and an electronics enclosure fast purge. See the custom
documentation drawing package that was shipped with the analyzer to see which gauges and
regulators are mounted on the analyzer.
The Maxum ll has a wide variety of isothermal oven configurations. Both air bath and airless
ovens are available. All air bath configurations are available with Vortex cooling for sub-
ambient temperature operation. A program temperature oven option is available for Maxum II
applications where isothermal, multi-dimensional chromatography is not practical. Typically
the program temperature Maxum II is used for Motor Gasoline (ASTM 3710) & Simulated
Distillation (ASTM 2887) applications.
Oven Configurations
Vapor or High Pres‐ Model 20 The air-pressure actuated, diaphragm valve provides uniform sample volume, low
sure Liquid Samples internal volume, high pressure up to 1500 psi, 10350 kPa, fast switching (millisec‐
onds), reliability, and durability. It functions equally well as a liquid or vapor sample
valve, column switching valve, or column back flush valve.
Liquid Sample LIV The liquid injection valve can be used to automatically inject a constant quantity of
liquid sample followed by fast, complete vaporization. Small gas quantities can also
be injected using the valve.
Vapor Valveless The device has no parts to fail or wear out and exhibits essentially zero dead volume
Live Column for fast column switching and sample injection with capillary columns.
Switching
Color Touchscreen
The color touchscreen displays all maintenance functions and data in a graphical display. In
addition it eliminates the need for a chart recorder because it can also display both real-time
and stored chromatograms. The stored chromatograms include voltages and cycle times for
future comparison as well as zoom and pan features. Operational and routine maintenance
tasks for the analyer can be performed from the color touchscreen interactive display screens
and menus. System security is assured with multiple levels of password protection for all
analyzer-operating functions. A color touchscreen emulator (also called a Human Machine
Interface, or HMI, emulator) is available from the Maxum Gas Chromatograph Portal (GCP)
software. This emulator allows a user to perform color touchscreen tasks without being located
at the unit.
Workstation
The Maxum II uses a PC based network workstation for programming and data processing.
Analyzers can be programmed and monitored from a single location, and, like the color
touchscreen, the workstation includes graphical displays for operation, maintenance, and
diagnostics. It also supports PC printers to print chromatograms and alarm logs in order to
meet record keeping requirements.
The Maxum II workstation software, Gas Chromatograph Portal (GCP), is designed for PCs
with Microsoft® Windows operating systems. PC workstations can be connected through
existing LANs for wide access to monitoring or maintenance tasks. The graphical interface
recognizes and displays all network hardware. The system monitors the alarm status of all
analyzers connected to the network to centralize system maintenance. More information can
be found in the Release Notes file supplied with the GCP Software.
Chromatography Software
EZChrom© industry specific software is incorporated in the GCP software. This is a laboratory
quality application builder developed by Scientific Software, Inc. and includes custom features
for the Maxum II. Using EZChrom, it is possible to set up methods and component peak
identification. More information can be found in the Release Notes file supplied with the
EZChrom software (under the Maxum EZChrom directory).
EZChrom allows a user to choose the best peak gating and basing methods automatically. It
is also possible to:
● Re-process captured chromatograms with different methods
● Measure unknown component peaks automatically
● Record multiple detector measurements simultaneously.
Parallel Chromatography
With the Maxum II hardware and software, it is possible to take a complex single-train
chromatograph analysis and break it into multiple simple trains. Each simple train is then run
simultaneously – in parallel. Not only does this procedure simplify the overall analysis, but also
it is performed faster and more reliably.
Redundant Measurements
Using parallel chromatography can reduce calibration requirements by running two identical
modules in parallel on the same stream to obtain redundant measurements. As long as the
results remain the same within a predefined error limit, the analysis is known to be accurate.
Deviations outside the error limit can trigger notification or activate analyzer calibration.
Overall, the Maxum II calibration requirements are significantly lower because of the parallel
measurement configurations and standard modular applications.
Personnel Qualifications
Only suitably qualified personnel may operate or perform maintenance on the Maxum II. For
the purposes of safety, qualified personnel are defined as follows:
● Those who have been appropriately trained for the tasks which they are performing (for
example, commissioning, maintenance, or operation).
● Those who have been appropriately trained in the operation of automation technology
equipment and are sufficiently acquainted with Maxum II documentation.
● Those who are familiar with the safety concepts of automation technology and are
sufficiently acquainted with Maxum II documentation.
● Those who are authorized to energize, ground and tag circuits and devices in accordance
with established safety practices may perform the tasks for which they are trained.
WARNING
Operation or Maintenance is performed in the presence of dangerous voltages and potentially
hazardous materials, and must be performed by qualified Personnel.
Operation or Maintenance of the Maxum II by unqualified personnel or failure to observe the
warnings in this manual or on the device may lead to severe personal injury and/or extensive
property damage.
2.3 Functions
Overview
This section provides an operational overview of the real-time functional tasks of the Maxum
II.
Startup Tasks
On start-up, when primary AC power is applied to the analyzer, the analyzer first processes
whatever electronic self-tests and diagnostics are required such as PROM, RAM, A/D, and
communication ports. This processing occurs within 5 seconds.
System-related initial messages are generated and output to the network ports. Appropriate
initial messages are then displayed on the Maintenance Panel and completed within 20 to 25
seconds. If the analyzer cycle clock is in RUN or CAL mode, an appropriate alarm may be
generated during this internal test and the following startup period.
Self Test
After the self-test, the following conditions occur:
● Installed hardware is initialized.
● Interrupts are enabled.
● Oven temperatures and carrier pressure default set points are output.
● Analog input system(s), associated with detector inputs, are initialized and begin scanning.
The SYSCON verifies that a valid database is resident, then ouputs the appropriate
temperature and carrier set points. If a valid database is not verified, default set points are left
in place.
Oven Temperature
The analyzer monitors the oven temperature to ensure that it has stabilized at the set point
before automatically proceeding. Depending on how long primary AC power has been off, this
may take from 2 seconds to 45 minutes.
Description
A schedule event can be for instrument calibration and special calibrations. Special calibrations
include daily or shift averages, report logging to a printer or Host computer. When these tasks
are scheduled by the TOD clock, they are put into queue. This allows them to be performed
at the next appropriate time. Typically, this is after completion of current analysis cycle.
If a calibration is scheduled, it is put in queue. The calibration then initiates after completion
of the current cycle, and when the appropriate time has passed for the calibration blend to flow
through the sampling valve. If shift average reports are to be calculated and printed, the report
should include all cycles, which started, or sampled, during the specified shift. To have data
available for calculation, a wait period may occur for completion of the current sample analysis.
Accessing SYSCON
The clock cycle RUN mode is controlled by the SYSCON upon command from SNE. When a
clock cycle is started, the associated SNEs, for that method, initiate a mirror of the cycle clock.
The SNE clock is the true basis of timed events relating to the Gas Chromatograph oven valve
timing, detector digitization and peak integration.
Note
Scheduled solenoid valve events cause Solenoid Valve Control Module (SVCM) hardware to
be activated within 5 milliseconds of stated cycle time. Any scheduled pressure set-point
adjustments are transferred to the actual Electronic Pressure Control Module (EPCM)
hardware within 5 milliseconds.
Manual Operations
Manually controlled functions can be initiated through the color touchscreen. A manually-
controlled event can occur asynchronously with any event and control some of the analyzer
operations. Controlled items include:
This section provides an overview of the operation of the Maxum II analyzer. The operational
block diagram shows how a sample is processed within the analyzer. The SNE functions are
performed in software in new systems; older systems still have hardware versions.
Electronics Enclosure
Oven
Temperature
Heater
Control
Control
DPM DPM DPM
(A/D) (A/D) (A/D)
Detector Compartment
(Mezannine)
FID FPD
Feedthroughs
Atmosphere Vents
Sample Sample In
Conditioning
Columns
Columns
Columns
Sample
Valve
Oven
Regulated Carrier Gas
Power On
The Power Entry Control Module (PECM), in response to commands on internal bus, accepts
system primary power and provides switching and control of AC power for oven heaters and
other AC powered devices.
Sample Conditioning
Before being piped to the analyzer, the sample from the process is sent to a sample conditioner
system. The sample conditioner ensures that the process sample is compatible with the
requirements of the analyzer. That is, it assures that the phase, pressure, temperature and
flow rate to the analyzer are suitable, that the sample is filtered, that condensates are removed
and other treatments are carried out. The resultant conditioned sample is typically piped via
1/8-inch stainless steel tubing to the sample valve(s) located in the oven of the Maxum II.
Sample Valve
The type of sample valve used in a Maxum II is application dependent. Five primary types of
sample valves are available.
● The first is the 10-port Model 50 valve that is designed for vapor sample only.
● The second is the Model 11 valve for vapor or liquid samples.
● Third is the Model 20 valve for liquid high-pressure samples.
● The fourth type is the set of Valco valves that are designed for high temperatures and very
low sample volumes.
● The fifth is the independently-heated Siemens Liquid Injection Valve.
The sample valve(s) and any column valves are controlled by a Solenoid Valve Control Module
located in the Maxum II’s electronic enclosure section. There can be up to three SVCMs
installed in an electronics enclosure (EC).
Columns
Samples are injected by the sample valves into the chromatograph columns where the samples
are separated into individual components. Many different types of columns may be used
including 1/16-inch micro-packed, 1/8-inch packed and fused silica or metal capillaries. The
columns used are dependent on the requirements of the application.
Column Valves
In most applications, there are multiple columns in use that are typically switched by column
valves located in between them. These column valves are not shown in the illustration, but like
the sample valves described above they are also controlled by the Solenoid Valve Control
Module and SNE software module.
Oven Heaters
For the columns and detectors to work correctly, they must usually be operated at elevated
temperatures. The Maxum II uses electrical heater(s) to elevate the temperature. These
heaters (not shown in block diagram) are connected to relays in the Electronic Enclosure
section and, like the valves and the Electronic Pressure Control Module(s), are controlled by
the SNE software module.
Detector
The sample eluted from the columns is transported to the associated detector that senses the
presence of the sample and converts it to an electrical signal. Depending upon the application,
the Maxum II can include up to three detector modules. Each detector module can have
multiple detector sensor elements. Several detector module types are available including
Thermistor, Filament, Flame Ionization, Flame Photometric, and Pulsed Discharge. The
resulting electrical signal from the detector is then connected to the Detector Personality
Module (DPM) located in the EC.
Internal Communication
An I2C Internal Bus provides communication between the SYSCON, SVCM, EPC, PECM and
to the I/O bus. External communication is through an Ethernet link. The interface for each type
of module is described in the Component Descriptions and Maintenance Procedures section.
Color
Touch
I2C Sampling
Display
System
GCP
Ethernet
Switch
Analyzers
(optional)
Ethernet
I2C I2C I2C
Module Addressing
The Maxum II modules located in the electronic enclosure section have their own physical
address and communicate via the I2C Internal Bus, shown in the diagram below. Address
information is contained in the SYSCON database and identifies modules by their location.
Each DPM is associated with a software SNE module that appears in the list as a separate
device.
Identification Number
All modules within the Maxum II electronic enclosure have a unique identification number as
related to the software SNE module which controls them. The identification relationship
between the SNE and the modules it controls is referred to as the SNE ID String.
11 : 1 - 1 . 1 - 1 . 1 . 129
Channel Number
Channel Type
PIC Index
Module Number (Location ID)
Sub Module Type & Description
Module Type
SNE ID
Address information is located in the analyzer local I/O Table. The I/O points are identified by
module type, mounting location within the electronic enclosure and channel number. This
allows module addressing from either the SYSCON database, SNE Tables or from Advance
Database.
1. Put the Maxum II in Hold and wait for the cycle to complete. This will provide the quickest
restart of the application when power is restored.
2. Once the cycle is completed and the Maxum II is holding, then remove power from the unit.
WARNING
Voltage dangerous to life exists. Failure to follow appropriate safety procedures may result
in severe injury or death.
Before beginning to work inside the electronics enclosure, the power must be externally
removed from the GC. AC power comes directly into the electronics enclosure, so power must
be removed and secured/tagged to prevent inadvertent application while work is being
performed.
WARNING
Voltage dangerous to life exists. Severe injury or death can result if precautions are not
observed.
When the Electronic Enclosure door is open, voltage dangerous to life exists. These
procedures will involve operation of the unit with the electronics door open, which will require
a “hot work permit” in some locations to ensure that there are no hazards for the personnel
working in the area.
Before proceeding with these procedures, make sure the unit is installed correctly in
accordance with these instructions and local and national codes. See the custom
documentation package for particular Maxum II details and procedures for the particular unit.
1. Ensure that the AC (Mains) power is off to the Maxum II.
2. Open the electronic enclosure door and inspect all connections.
3. If appropriate permits have been obtained to meet area classification requirements
necessary to operate with the door open, then apply power to the unit. No intervention
should be necessary for the unit to begin to operate after a few minutes. If normal operation
is not achieved, refer to the section on troubleshooting to resolve the issue. The
Troubleshooting section defines the normal LED operating modes for this assembly. Close
the electronics door and secure it per the applicable safety codes.
4. If the area classification does not permit the unit to be operated with the door open, then
close the door, secure it per the applicable safety codes, and apply power to the unit. Correct
operation can be determined through the interface on the door or a remote interface if one
is not included in the door of the electronics enclosure.
5. Follow the procedure for restart of the specific unit.
15.Enter the correct subnet mask. Press the “Home” key to return to the menu.
16.Press the 9 key to change the Default Gateway address.
17.Enter the Default Gateway address. Press the “Home” key to return to the menu.
18.Press the 0 key to select “No” to the question “Change the DNS?”
19.Press any key to continue.
20.Press the Back key to return to the bootloader menu.
21.Press the 9 key to reset the device.
The external Ethernet cable may now be reconnected to the network, and the analyzer should
be visible in the GCP Network list.
3.3 Troubleshooting
The LEDs on the PECM board can help with LEFT Heater Status RIGHT Heater status
troubleshooting problems. There are two
sets of LEDs: one on each side of the front Heater 1 Air Pressure Heater 2 Air Pressure
board as shown in the diagram to the right. Heater 1 Power Activate Heater 2 Power Activate
The bottom set of three LEDs is the same as
PECM-CTRL PCB
PECM LEDs
State 1
GCP 5.2 Alarm Descriptions 1002 - 1128 SNE Common Module Errors
The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm
text, description, and actions.
GCP 5.2 Alarm Descriptions 2500 - 2577 Access Bus Driver Errors
The following tables list the alarm number (#), type (+ information, ? warning, ! error) alarm
text, description, and actions.
Overview
The Power System Module (PSM) is a 110/230 VAC switching power supply that provides 24
VDC operating system voltages. It also provides 110/220 VAC conditioning. The 24 VDC power
supply provides high speed switching with power factor correction and universal input. The
PSM is a stand-alone system consisting of a power supply, filtering, circuit fuse protection and
a power monitor board.
AC Line Input
AC power input to the power supply is from the Power Entry Control Module. A line cord from
the PECM plugs into the front AC receptacle of the power supply. A primary Line Voltage
Selector selector switch (located above the AC receptacle) must be set to match the primary
AC voltage input from the Power Entry Control Module.
Output Connections
Output 24 VDC is supplied to components within the Maxum II via a cable harness that exits
the backside of the PSM. The cable terminates in quick disconnect connectors. Typically, a
white connector supplies 24 volts to the SYSCON2.1 cage and an orange connector supplies
24 volts to the PECM, where it is distributed to various modules in the EC. DC/DC converters
in the modules generate the other voltage levels needed by various circuits.
Fuse Replacement
The Power System Module is equipped with a fuse (Siemens Part Number A6X19905350).
This fuse is located on the front of the PSM just above the power cord plug. The fuse is a 250
V, 4.0 A, “slow-acting” type. Although this fuse rarely fails, replacement is simple (disconnect
power to the analyzer first). To remove the fuse, unplug the power cable that comes from the
PECM. Access the fuse by removing the fuse cap with a large blunt screwdriver.
Specifications
Voltage Range 115 VAC (85 to 140 VAC), 230 VAC (185 to 264 VAC)
Line Frequency Range 47 to 63 Hz
Nominal Input Current 2 amp @ 115 VAC, 1 amp @ 230 VAC
Nominal Output Voltage 24 VDC ±3%, 1% ripple plus noise at a bandwidth of 30 MHz
Nominal Output Current 6 A @ < 104°F (40°C)
4 A @ 104° to 150°F (40° to 70° C)
Static Load 0.2 A; 0.0 A open circuit permitted
Dynamic Load Between 0.2 A to 3 A in the load range. A maximum load of 2 A at 1.8 kHz is
switched. Switching is controlled by pulse width. Precision range is not exceeded
in this operational mode.
Overcurrent Cutoff Cutoff starts at 6.4 to 7.5 amps. When current drops, device switches on.
Overvoltage Cutoff Cutoff starts at 27 to 31 VDC. When voltage drops, device switches on.
Overtemperature Cutoff After temperature decreases to specified tolerance, device switches on.
Power Fail Transitions Occurs 20 ms after a primary power failure. Should a power failure occur, a low
20 ms signal is generated.
Electric Isolation Input/Output: 3.7 kV
Dimensions Length: 10.24 inches (260 mm)
Width: 2.36 inches (60 mm)
Depth: 3.54 inches (90 mm)
Cooling Convection and conduction through aluminum mounting plate.
Output Wiring Cable harness
Note
This procedure assumes that power is off in the analyzer.
The 24V power supply is easily accessed at the top of the electronics enclosure.
Replacement Steps
WARNING
Voltage dangerous to life exists in the electronics enclosure. Failure to follow proper safety
procedures may result in injury or death.
Turn off line votage to the analyzer before disassembling power-supply components. Even
though nothing appears to be operating, AC voltage can still be present on many of the
components in the enclosure.
NOTICE
Obtain all permits that may be required to perform this work.
Observe local codes and obtain any required permits before starting the work.
The power supply has an integral bracket that slips under flanges in the top of the enclosure
on the right side, and by two muts on threaded studs on the left side. Slots in the bracket allow
removing the supply without completely removing the nuts.
2
1
3 4 6
5
7 7
A. B. C.
Line-voltage
To PECM power connector To safety
selector switch
ground lug
on back wall
Fuse holder
To SYSCON
power connector Line-cord connector
on bottom-left of cage
Note
Verify proper position of line-voltage selector switch and fuse value. Incorrect settings can
damage the equipment.
See the information packet that was shipped with the analyzer for information on the individual
analyzer.
Overview
The PECM3-CTL board mounts on the PECM-SSR board. This assembly provides a variety
of power and control functions. The connections are shown below.
AC in MWH out
LWH1 - LWH5
out HWH SSR
power out
Optional
UPS input Purge Air
for 24vdc Switch
supply
24v in
Fan
HWH SSR
power
control out
Temp RTD in
F1
u les
I2C bus
mo d t
F5
TL/
OT
tr o l ou MW
H Air bath heater
on in
F2 Hc trol monitor in
cov
er) H W H co n Solenoid
i th out HW
(w control out
F4 ver)
t co
w i th ou
( Atmospheric
F3
pressure sensor
PECM-SSR Board i n
on trol Purge disable jumper
WHc
Filtered H/M Purge signal out
LW
AC out I2C bus (Ribbon-cable
to 24v connector to
supply L1 MMI PECM-SSR)
PECM3-CTRL Board LED out
The PECM3 assembly part number is 2021828-002. An upgrade kit, part number 2022019-001
is available to replace earlier units.
Note
The power switching circuit is designed for either 115 VAC or 230 VAC. For safety reasons,
the PECM is not designed to convert DC to AC. Attempted operation from a DC source will
damage or destroy the PECM. To generate and control 115 VAC from a DC voltage system,
the customer must use components external to the PECM.
3
2
1
2
3
2
1
N1
N2
L1
L2
Filtered AC
F3
3A
Holder
J1 Low Wattage
Hot
H 1 Heater Relays 1- 5
Hot
G 2
N 3 F4 10A
F5 6A
Hot Hot
F1
Holder
Holder
F2
16A 16A
ABH2 ABH1
TB9
1
2
3
Fuses
● F1-ABH2: 16A 115 VAC or 10A, 230 VAC
● F2-ABH1: 16A 115 VAC or 10A 230 VAC
● F3-FLT AC: 3A 115 VAC or 230 VAC
● F4-LWH1-LWH5: 10A 115 VAC or 230 VAC
● F5 LWH6, MWH
I2C PECM
PWM
SSR Pair High-Wattage
Airflow
Heater
Loss
Shutdown
Digital Air Pressure
Switch
AC
Line Heater
SSRa SSRb
The 24V power supply connects to one of two parallel power connectors, TB1 and TB2 on the
PECM-CTL board. Another module can be powered from the other connector.
Each of the 7 I2C connectors also provides 24VDC power to the connected module.
A separate connector powers a 24V fan.
TB2
AC Power Input
R47 10kΩ
LWH 4A On
5V J6 10kΩ 5A
1 DET/CTRL A
2
SSR EN A R54
LWH 4B On 3 4 2
DET/CTRL B
4 4 2
LWH 4 Plug Det SSR EN B
5
Plug Detect
6
GND TB5
LWH4 CTRL PLUG 5V 1
3
1 Line
LWH 4B Enabled
SSR4B
2 Neutral
LWH4
Jumper
A&B Common Unused
Jumper
AC Hot
Solid
State SSRA Hot SSRA Load Hot
Relay
AC Neutral A Unused SSRA Load Neutral
SSRB Hot To LWH Hot Load SSRB Load Hot
Oven Functions
SYSCON PECM
I2C
PWM
SSR Pair High-Wattage
Airflow
Heater
Loss
Shutdown
Digital Air Pressure
Switch
AC
Line Heater
SSRa SSRb
Each circuit consists of two series-connected solid-state relays. One of these relays controls
the 1400-Watt AC heater to maintain the set point temperature by monitoring the air bath RTD
and heater pressure switch. The second relay is used for safety purposes. It performs an
emergency analyzer heater shutdown if an over-temperature condition is detected. Both relay
circuits are completely independent of each other. However; in order for the power circuit to
be energized, both relays must be enabled. Temperature controls are monitored by the
Detector Personality Module and routed to the PECM via a dedicated cable and connector, or
by the temperature-control circuits on the PECM-CTL board itself. No other functions are
connected to the temperature control circuit. The connections are EMC filtered. When over
temperature is detected the PECM over temperature circuit inhibits the SSR from powering
the heater.
Alarm conditions are reported to the SYSCON over the I2C link.
Solenoid Control
Includes solenoid valve control which eliminates the need for individual SVCM controller
boards. When converting older design and eliminating original SVCM controller boards,
additional long cables are required.
Purge Monitoring
The PECM monitors the state of the purge condition for the analyzer. If a loss of purge is
detected the purge switch is enabled. The purge control alarm signal is controlled by the
SYSCON. The purge signal cable from SYSCON to PECM plugs into connector J1302 on the
PECM2. Connection SW1 on the PECM2 is used to connect atmospheric reference for the
purge switch.
When a purged enclosure is not required per the safety codes, connector J2 on the PECM2
can be used to disable the purge alarm. See the PECM3 I/O Connections diagram in PECM
Overiew for connector locations.
L1 MMI LEDs
Maintenance Panel Level 1 consists of LEDs on the outside of the analyzer door. It is intended
for use in GCs that are not equipped with the full feature Maintenance Panel. The PECM
supplies the control signals for Maintenance Panel Level 1, if equipped. For PECM-1, the
Maintenance Panel Level 1 connects to position J17. See the PECM3 I/O Connections
diagram in PECM Overiew for the location of connector J17.
Physical Location
The PECM is mounted to the left inside wall of the EC cabinet. All fuses and electrical
connections are readily accessible.
Overview
General Precautions
The PECM is the entry point for the line voltage for the entire analyzer.
Note
Specific additional instructions are provided with tags placed on the Maxum II and in the custom
application drawing package noted below. Installation must include all of the items noted in
both of these as well as the manuals. The tagging and custom application drawing package
are unique to the particular Maxum II.
● This procedure must be performed by a user who has detailed knowledge of the Maxum.
If a customer does not have the knowledge required for this procedure, then it is
recommended that Siemens Field Service personnel be contracted to assist.
● A tool kit including both standard and metric wrenches, Hex wrenches, and nut drivers is
required to perform this procedure.
● Before beginning replacement, be sure to save a current database of the application to be
reloaded after the PECM is replaced in case this becomes necessary.
WARNING
Voltage danerous to life is present on the PECM. Failure to observe proper safety measure
can cause severe injury or death.
Before beginning to remove or install the PECM assembly, the power must be externally
removed from the GC. AC power comes directly into this board for regulation and distribution
in the electronics enclosure, so power must be removed and secured/tagged to prevent
inadvertent application while this procedure is being performed.
Troubleshooting
The alarm system can also provide direct information on alarms for an error. Review the alarms
to see if they provide an indication of the problem. Each alarm has a written description that
may provide an indication of the problem area.
The LEDs on the PECM board can help with LEFT Heater Status RIGHT Heater status
troubleshooting problems. There are two
sets of LEDs: one on each side of the front Heater 1 Air Pressure Heater 2 Air Pressure
board as shown in the diagram to the right. Heater 1 Power Activate Heater 2 Power Activate
The bottom set of three LEDs is the same as
PECM-CTRL PCB
Heater 1 Temp Limit Heater 2 Temp Limit
used on other boards (described below.) The Heater 1 Overtemp Heater 2 Overtemp
left set is for the PECM software. (The other
LEDs are not used for PECM1 replacement.)
The corrective action to take for each of the Normal Normal Temperature
LED indications is noted below with a correc‐PECM Status Fault Fault Controller
tive action reference number on the diagram Warning Warning
Status
at the right. The normal state indication is
shown in the diagram below.
PECM LEDs
State 1
State 3
State 2 - Self test
Precautions
Before starting this procedure, follow the steps in the General Analyzer Shutdown Procedure.
WARNING
Voltage dangerous to life exists. Failure to follow proper safety procedures may result in
severe injury or death.
Before beginning to remove or install the PECM assembly, the power must be externally
removed from the GC. AC power comes directly into this board for regulation and distribution
in the electronics enclosure, so power must be removed and secured/tagged to prevent
inadvertent application while this procedure is being performed.
WARNING
High-voltage circuitry. Failure to follow proper procedures may result in equipment damage,
personal injury or death.
The cable harness connectors and the chassis plugs associated with the Heater circuits are
marked with orange identifier tags. Before reconnecting any connector or plug to a Heater
circuit, ensure that the orange identifier tag on the connector or plug reads identical to the
orange identifier tag on its mating connector.
CAUTION
Observe proper fuse values to prevent equipment damage or personal injury.
The PECM1 is used in applications with both 115VAC and 230VAC power. Before installing
a replacement assembly, ensure that the correct fuses for the particular application are
installed in the replacement PECM3.
Procedure
1. Open electronics door. If the latch is locked, use 4mm (5/32’”) Allen wrench to unlock.
2. Label all cable connections before disconnecting if they are not already labeled. Be sure
to read the Warning below concerning those tagged with orange labels.
3. Unplug cables from all PECM connectors.
4. Unplug the atmospheric reference tube from the purge switch. (labelled “Purge SW”, tubing
connection next to the back wall of the EC, on the PECM1.
5. Use a 5mm nut driver to loosen two hex nuts at the top of each side of base plate of the
PECM.
6. Slide the PECM up and then lift the PECM off of the mounting bolts.
See also
General Analyzer Shutdown Procedure (Page 25)
Procedure
1. On the replacement PECM3 assembly do the following:
– Set the Purge Disable jumper JP2 to the same setting as the PECM being replaced.
– Install the appropriate fuses for either 115VAC or 230VAC in Fuses F1 and F2 and install
fuse covers.
– Move jumper cables or termination plugs to the replacement PECM.
– Move the TL/OT modules from the old PECM to the replacement PECM, in the mounting
locations marked “TEMP CONTROL 1” and TEMP CONTROL 2”. These are required
to avoid false alarm codes.
– If Heater Termination Plugs are installed in the old PECM instead of cables at the
positions marked “TEMP RTD 1” and “TEMP RTD 2”, move these to identical locations
on the replacement PECM. The plugs disable the PECM temperature circuits, including
the LEDs.
2. Ensure that there are no wires behind the mounting position of the PECM.
3. Because the atmospheric Purge switch SW1 is near the back wall after the PECM is
installed, if desired, the Purge tube may be installed on SW1 before mounting the PECM
in the next step.
4. Install the replacement PECM on the two mounting bolts.
5. Tighten the two 5mm hex nuts.
6. Start at the back of new controller and plug in the following cables (see the connector
identification illustrations)
– If not already connected in step 12, connect the Purge switch SW1 (tubing connection)
– Relay power plug TB9 and Heater Relay Control cable
– Fan power cable plug J18, and 24VDC power cables to the orange TB1 and TB2 on top
board (there are TB1 and TB2 AC connectors on the bottom board as well - see
illustration at right.)
– I2C connections (J24 - J26, J30 - J33)
– Low wattage heater connections (TB8, TB3 to TB5, and LWH1 to LWH6)
– AC inputs (TB1, TB2, & TB10.)
– Heater pressure switch (J10) (If no cable, then a jumper is needed.)
7. When replacing in a unit that has a MMI-1, then connect the MMI LED cable to J17.
8. Connect the Purge Signal cable to J1302.
9. Move 24V cable (from power supply) from WDB J1 to PECM3 TB1.
10.Add 24V power cable, 2021837-001 from PECM3 TB2 to WDB J1.
11.Ensure the correct fuses are in the correct positions, as shown in PECM AC Power
Distribution illustration.
12.When the procedure is completed, follow the steps in the General Analyzer Startup
Procedure.
See also
General Analyzer Startup Procedure (Page 25)
4.1.3.1 Description
Overview
The System Controller (SYSCON2.1) is a combination of two interconnected boards that
together function as the control processor and motherboard for the Maxum analyzer.
The SYSCON2.1 consists of two boards, the Communication and Analytical Control (CAC3)
board and the SYSCON Interface Board (SIB3). The CAC3 contains the processor and
memory functions for the SYSCON2.1 as well as control of external Ethernet communications
(via the Ethernet Switch Board). The CAC3 is mounted on and operates in conjunction with
the SIB3. With the exception of external Ethernet, the SIB3 contains all interfaces provided by
the SYSCON2.1.
The CAC3 on the SYSCON2.1 stores the analyzer application database, combines all data
results, and performs additional high-level data processing and calculations. All network
communications, maintenance panel and analyzer functions are also coordinated by the
SYSCON2.1. The SYSCON2.1 provides communication between the Controller Board, I/O
Boards and the EC operating modules.
More information about the SYSCON can be found in the System Controller version 2
(SYSCON2.1) Installation Manual (Siemens part number A5E02643617001).
Additional Functions
Software Support
The SYSCON2.1 is supported only by software version 5.2 or greater.
4.1.3.2 Mechanical
Overview
The SYSCON2.1 board pair resides in the SYSCON assembly. This assembly is a pullout,
drop-down drawer located on a slide rail assembly mounted to the upper wall of the Electronic
Enclosure. The SYSCON assembly is a card cage housing the SYSCON2.1 boards, the
Ethernet Switch Board, and any other associated hardware such as I/O boards.
Serial
SYSCON2.1 External
Ethernet
Intrinsic-Safety Ground Connection Points Ports Cage Ports
SYSCON2.1 Drawer
Overview
The Communication and Control board (CAC) is a standardized, single-board central
processing unit for intended for use in Siemens products. For the Maxum family of products
the third generation of the CAC board (CAC3) is used.
The CAC3 includes an on-board 10/100 Ethernet controller, used for connection to external
Ethernet. This is connected via a short RJ-45 patch cable to the Ethernet Switch Board, which
resides in a card slot on the SIB3.
More information and details pertaining to the CAC3 can be found in the System Controller
version 2.1 (SYSCON2.1) Installation Manual (Siemens part number A5E02643617001).
CAC3 LEDs
The CAC3 is equipped with several LEDs that communicate useful information about the
operating status of the CAC3.
Link Status
Link Acknowledge
LED7
SIB3
Compared to the SYSCON2 in previous Maxum II analyzers, the SIB3/CAC3 together with the
Color Touchscreen equipped with a TIB module replaces the SIB2/CAC3 and Color
Touchscreen equipped with a CIM module. This simplifies the internal cabling in the electronics
enclosure.
The SYSCON Interface Board version 3 (SIB3) is a board, with the CAC3 mounted on it,
performs the function of the SYSCON2.1. Unlike the CAC3, the SIB3 is specific to the Maxum
family of products (including the Maxum, the Maxum II, NAU). The combined SIB3 and CAC3
are an electrically and mechanically compatible replacement for the legacy SYSCON board
in the Maxum.
SIB3 LEDs
LED Locations
The SIB3 has several LEDs that indicate useful information about the operating status of
various interfaces.
Internal
Ethernet I2C LEDs
Power LEDs to SNECON
LEDs
I2C-Pullup
Active LEDs
CAC3
CAN
Bridge
LEDs
0 1 2 3
DI Mode
Switch
(Set to Mode 2)
Power LEDs
Located at the back of the board near the RJ 45 connector
SIB3 Connectors
Overview
Other than external Ethernet, the SIB3 provides all interfaces for the SYSCON2.1. The
connections are described below. All connectors in the SYSCON2.1 have the same pin
assignments as the corresponding connectors in the original SYSCON, except where noted
below.
42
3
5
Ethernet
Ethernet (to Ethernet Maintenance I2C B
Reset
to SNECON Switch) Panel (Legacy)
(Legacy)
(if used)
I2C A
CAC3 Power
Purge
SYSCON
Debug CAN
Internal
Serial Port 2
Color
Touchscreen
0 1 2 3
I/O Mode
Switch
Note
Only use cards specified and sold by Siemens for the SYSCON2.1. Installation of a card that
is not approved by Siemens into a SYSCON2.1 PCI slot, may damage both the card and the
SYSCON2.1.
Serial Ports
● SYSCON Debug – This serial RS-232 port provides the SYSCON2.1 debug function on
the CAC3. The debug port has no support for hardware handshake. The debug port is
accessed via a DB9 connector on the front of the SYSCON assembly cage.
● Serial Ports 1 and 2 – The SYSCON2.1 is equipped with two serial ports, each ground-
isolated and configurable for RS-232 or RS-485. Both ports support RTS/CTS hardware
handshake. Maximum supported data rate on the serial ports is 115200 bits/second. Serial
Port 1 supports Modbus and Serial Port 2 may be used to support a printer.
Note
RS-485 Operation
When configured for RS-485 operation, the serial ports are designed to comply with the
Profibus standard. This results in a different pinout than for the previous version of SYSCON
(pins 8 and 2 reversed). For backward Modbus RS-485 compatibility when replacing a
SYSCON+ with a SYSCON2.1, an adapter cable (part number A5E02283873001) is
available.
● Serial Ports 3 and 4 – These two serial ports, equipped on the same slot connector as the
SYSCON Debug port, are not active in software release 5.0.
I2C Bus
The I2C connectors are shown in the upper right corner of the SYSCON2.1 Connections photo.
Two I2C buses are equipped on the SYSCON2.1. These are labeled I2C Bus A and I2C Bus B.
● I2C Bus A includes the two connectors on the right as shown in the SYSCON2.1
Connections photo. I2C Bus A is dedicated and hard wired to the CAN Bridge function. This
allows the new SYSCON2.1 to interface with legacy CAN I/O cards in the PCI slots.
● I2C Bus B includes the three I2C connectors on the left as shown in the SYSCON2.1
Connections photo. I2C Bus B is supports2 future configuration changes in the Maxum II.
Resets
The SYSCON2.1 has a pushbutton reset switch at the front of the board. This switch may be
accessed via the front of the newest version SYSCON assembly cage. The second connection
consists of two pin connections at the back of the board (top left of the SIB3 connections photo)
second connection operates using a simple loop closure, and supports legacy SYSCON
assembly cages that provide a separate wired pushbutton reset. Both connections allow the
user to initiate a hard reset of the SYSCON (same as initial power up).
Purge
The purge detect signal is received from the PECM and handled by the SYSCON as a digital
input to generate a purge alarm.
Display Connectors
Interface and power for the Color Touchscreen connect to the SYSCON2.1 using a cable
assembly. This cable runs directly from two connectors on the SIB3, out through tthe back of
the SYSCON cage, to the Color Touchscreen panel.
Power
The 24 V power supply mounted beside the SYSCON cage powers the SYSCON2.1 directly
through a cable that plugs into the bottom of the cage. On-board power conversion derives
the other voltages needed for operation.
Note
Battery
The real-time clock on the CAC3 board is powered by a long-life 3v cell mounted on the SIB3.
This battery should last at least 5 years under normal operation. Because the battery is located
on the SIB3 board while the real time clock is on the CAC3 board, if the CAC3 board is
disconnected from the SIB3, then battery backup is lost. The time and date must then be set
on the analyzer.
The ports on the ESB are auto-negotiating for either 10Base or 100Base operation. The
Ethernet Switch is plug-and-play as it does not require initial setup or configuration.
Configuration of the ESB is not supported at this time.
The ESB is equipped with a jumper setting, R2, located in the lower right portion of the board.
For proper field operation this jumper should be set to default position, 2-3 (or the jumper can
be removed for default operation as well). There are several LEDs equipped on the Ethernet
Switch. These identify the operating speed of each port as indicated in the following table.
LEDs for external connectors count from the bottom up (e.g. bottom LED is for top connector).
Figure 4-17 Ethernet Switch Board with Fiber (ESBF, Part Number A5E02555919001)
Board Replacement
A failure in the SYSCON2.1 will generally interrupt communication between the GCP
networkbased software and the detectors. A simplified view of the system is shown below.
120/240VAC
Heaters
120/240VAC PECM
SSR
Board 120/240VAC 24 V
Supply
24VDC
Color
Touch I2C I2C
Display SYSCON DPMs
24VDC
(SIB3)
PECM I2C
RS232 EPCs
Controller 24VDC
RS485
24VDC Board
CAN CAC3 I2C
SVCMs
Ethernet 24VDC
GCP
AC Supply
GCP
Ethernet I/O
Switch Boards DC Supply
Analyzers (I2C)
(optional)
Ethernet Digital Communication
Most problems can be resolved by checking interconnects between cable, boards, and
connectors. If a component must be replaced, the following sections give detailed procedures.
See also
General Analyzer Startup Procedure (Page 25)
General Analyzer Shutdown Procedure (Page 25)
Replacing A CAC3
The CAC3 memory content depends on backup-battery voltage from the SIB3. When the CAC3
is removed from the SIB3, the memory content is lost. Observe safe ESD handling procedures.
Early SIB3s
with nuts on Current SIB3s have screws
threaded studs in nuts swaged into the board
securing the CAC3 to secure the CAC3
Removing a SIB3
1. As each cable is disconnected, move it clear of the SIB so it can be removed.
2. Make note of
– I/O board positions
– I/O cable location
– All cable positions to the SIB3
– SIB3 I/O Mode switch
3. Disconnect
– I/O cables from SIB3 and I/O boards
– Display cables
– Ethernet cable from CAC3
– Internal ethernet cable to SNEs if used
4. Remove ESB
5. Remove I/O boards
6. Disconnect from the SIB3
– I2C cables
– Purge cable
– Power cable
– Serial cables
– CAN bus cable if present
7. If the existing CAC3 will be reused, remove it following the procedure in the preceding
section and place in a static-protected area.
8.
Remove 6 mounting screws from
the locations shown in the illustra‐
tion at right.
9. Remove the SIB, rear edge first to pull the I/O connectors from the SYSCON cage opening.
Installing a SIB3
1. Set the I/O mode switch on the SIB3 to the same position as the board that was removed.
2. Install a CAC3 using the procedure described earlier. The two boards together are called
the SYSCON2.1.
3. Install the SYSCON2.1 in the tray and secure with the 6 mounting screws removed earlier.
4. Install these cables to the SIB3:
– I2C cables
– Purge cable
– Power cable
– Serial cables
– CAN bus cable if present
5. Install the ESB and reconnect the Ethernet cable from the rear RJ-45 connector to the
horizontal RJ-45 conncector on the CAC3.
6. Install the I/O boards.
7. Reconnect these cables:
– I/O cables from SIB3 and I/O boards
– Display cables
– Ethernet cable from CAC3
– Internal ethernet cable to SNEs if used
See also
General Analyzer Shutdown Procedure (Page 25)
General Analyzer Startup Procedure (Page 25)
NOTICE
Observe battery polarity. Reversing the battery can damage the board.
Before removal of battery, note location of its positive end when installed in battery holder.
The positive and negative terminals are marked on the battery. For the 3.6 V version (original
SYSCON), note that the physical shape of the Positive and Negative terminals on the battery
are NOT STANDARD.
4.1.3.7 Procedure
Follow this procedure to replace the battery.
1. Power down the analyzer using standard procedures.
2. Open electronic enclosure door (using a 4 mm (5/32 inch) Allen wrench if necessary). When
door is open DO NOT place tension on the Maintenance Panel interface ribbon cable.
3. Using appropriate tools, loosen the topmost SYSCON Assembly fastening hardware that
secures the assembly to electronic enclosure mounting bracket.
4. Pull the SYSCON drawer out and lower it so that it rests in the tilted-out position.
5. The battey holder is located on the left side of the SIB3 board. (Near the back on the original
SYSCON board) Remove battery from its holder.
6. When installing the lithium battery in its holder, place the positive (+) side following the
marking on the holder. Refer to the applicable picture in the previous step.
Note that for the original SYSCON (3.6 V tube shaped battery) the physical shape of the
positive and negative terminals on the battery are NOT like a standard battery.
7. After installation, push the SYSCON assembly back into its mounting facility and secure
assembly in place with the fastening hardware.
8. Before closing door and reapplying AC power, be certain the battery is securely installed
in its holder..
9. When the battery in a SYSCON is removed, current date and time information is lost. If the
analyzer is configured to obtain date and time information from a central server, then it will
update automatically. If no time server is set, it will be necessary to manually set the date
and time on the analyzer.
4.1.4.1 Overview
SIB3-Based I/O
The SYSCON2.1 has ten on-board inputs/outputs. The connectors for these are wired from
two orange connectors on the front of the SYSCON assembly cage. Switch SW3 selects sink
(Mode 2) or source (Mode 1) for the digital inputs.
I2C Bus
I/O Board
LEDs
CAN Bus
I/O Board LEDs
In the illustration above, one I2C I/O board is shown on the right. Two legacy CAN boards are
shown to the left. These boards have a number of additional status LEDs, described in the
section on CAN I/O Board Information.
Location
ID Switch
Signal Cable
from Detector
Part Number
The Base3 DPM (Part Number A5E02645925001) is shipped with current analyzers. It can
be used as a replacement part for earlier DPMs in Maxum I analyzers using an adapter, part
number A5E34938458001.
Color
Touch
Display
Figure 4-27 FID, FPD, or Analog Input Detector Input Signal Path
Color
Touch
Display
Digital
(Range
Network I2C I2C Select) Mezzanine
BaseDPM
GCP SYSCON PECM Module
A/D
(signal conditioning)
Location ID Switch
The Location ID Switch, shown previously in the photograph, selects the DPM location that is
incorporated in the address, to be reported in the results.
The DPM I2C port is connected directly to the system controller via the PECM or a wiring
distribution board. In this scenario, the following values are applied:
NOTE:
If the DPM I2C port is connected to an SNE, the value is always set to “1”. The actual location
value is determined by the SNE.
I2C PECM
PWM
SSR Pair High-Wattage
Airflow
Heater
Loss
Shutdown
Digital Air Pressure
Switch
AC
Line Heater
SSRa SSRb
A mounting location and connector are provided for two Temperature Setpoint Modules. The
modules are installed on the left side (back) of the DPM, shown below. This same position is
used in the Temperature Control DPM.
Location ID Switch
I2C
Status
LEDs
Figure 4-31 Temperature Setpoint Modules Installed on Left Side of Base3 DPM
Mezzanine Modules
A mezzanine module conditions the signal from a non-conductivity detector. The mezzanine
plugs into the Base3 DPM in order to tailor the DPM for a specific measurement.
Three primary types of mezzanine are available to accommodate FID and FPD detectors, and
various detectors that produce a scaled analog output (AI) mezzanine. Some of the
mezzanines have a dual range function for maximum flexibility. See the table below for details
relating to the various mezzanine options.
The AI mezzanine can be used for reading a detector voltage signal from a specialized or third
party detector, such as the Valco PDD, where the device only supplies a scaled voltage output.
The AI signal will be treated like a normal detector signal, with a 50% balance range.
Overview
Output signals from Thermal Conductivity Detector (TCD) in the Modular Oven are input to the
associated Detector Personality Module (DPM). The DPM is mounted inside the Electronics
Enclosure (EC) on the floor of the compartment. The DPM digitizes the incoming analog signal
and then passes the data to the SYSCON via an I2C port. The resulting data is then processed
by the Embedded SNE software. Results can then be viewed on the maintenance panel or the
workstation.
Color
Touch
Display
The IS-TCD3 DPM is an enclosed unit that is not field repairable. Opening the case may violate
the safety protection of the device. Service is limited to replacement of the entire DPM.
Part Number
The IS-TCD3 DPM (part number A5E02645923001) is shipped with current analyzers. It can
be used as a replacement part for earlier DPMs in Maxum I analyzers using an adapter, part
number A5E34938550001.
Intrinsic Safety
The intrinsic safety feature of this module is only used in the Maxum II Modular Oven. The
following two paragraphs apply only if this feature are used.
The TCD DPM in the Maxum II, as well as the actual detector controlled by the TCD, is
protected by intrinsic safety. Intrinsic safety is a method of protection where a circuit is designed
such that it will not create a spark or other condition capable of causing ignition of flammable
vapors or gases, even under fault conditions. Various circuits in the Maxum analyzer use this
form of protection, including the IS-TCD3.
Note
To preserve the intrinsically safe design protection of the IS-TCD3, certain measures are
required. Failure to adhere to all requirements for use of the IS-TCD3 in the Maxum II could
violate the safety protections of the analyzer. See the Maxum II Explosion Protection Safety
Standards Manual (A5E02220442001) for more information on the safe use of intrinsically safe
circuitry in the Maxum II.Maxum II Explosion Protection Safety Standards Manual
(A5E02220442001) for more information on the safe use of intrinsically safe circuitry in the
Maxum II.
Connections
The connections to the IS-TCD3 DPM are shown below.
I2C Connector
DPM
Mounting
Screw
Intrinsic Safety Ground
DPM Connection Lugs
Cage
Inputs from
DPM Detector
Mounting
Screw
Position
ID Switch
Reference
Selector
Switches
Orange connectors to detectors: Each IS-TCD3 DPM consists of two connections. Each
connection is capable of interfacing to two pairs of TCD elements (four total channels, 1 for
reference and 3 for signal).
Intrinsic Safety Grounds: The intrinsically safe design of the IS-TCD3 DPM (not normally used
with airless or airbath ovens) requires two ground connections to the chassis terminated to
two different terminals. The Maxum II Modular Oven is shipped with these grounds connected
correctly. Refer to the Maxum II Explosion Protection Safety Standards Manual
(A5E02220442001) for more information on the safe use of intrinsically safe circuitry in the
Maxum II.
I2C Bus Connection: The white connector on the reverse side of the DPM connects to the I2C
Bus on the PECM.
Overview
The Temperature Control DPM is identical to the Base3 DPM except that it includes only the
temperature-control components. This is useful when extra temperature-control functions are
needed.
A Location ID Switch is also included, and functions as described in Location ID Switch in the
Base3 DPM section.
Location ID Switch
I2C
Status
LEDs
7. Reconnect the I2C/power cable and temperature control output cables from the rear edge
of the board.
8. Reconnect the RTD temperature input cables (top rear of unit, if present).
9. Follow the steps in the General Analyzer Startup Procedure.
Configuration
The SNE is configured by the System Controller (SYSCON) and periodically reports analysis
results. It can be interactively controlled for Real-Time decisions on operation scenarios. The
SNE software controls all sampling relating to its internal configuration and sensor setup.
Components
The major SNE software components are as follows:
Data Manager
The Data Manager maintains configuration data that controls hardware sequence of events
and controls what manipulation is performed on sampled data.
The Data Manager also provides results and status information to externally connected devices
via the Communication Manager. This data is organized as a set of Sensor Analyzer Module
(SAM) structures. The data represents the unit as a standard sensor to external host.
Communication Manager
The Communication Manager acts as a central point of control for communication links
attached to the Sensor Near Electronics (SNE). This allows Internal SNE software to function
regardless of which communication link is being used to communicate with the system.
Hardware Manager
The Hardware Manager provides scheduling and communication services for the hardware in
the analysis zone. These include devices such as the following:
Computational Engine
The Computational Engine takes acquired chromatography data and performs system
calculations. Most of these calculations are performed by functions contained in the EZChrom
method, which provides all peak identifications and integration and response factors.
The SSR module assembly is mounted to the left side of the EC back wall. A metal cover not
shown in the photograph above protects the relays for the standard version of the SSR. The
standard version of the SSR is equipped with heat dissipating fins that extend through the back
of the enclosure wall to dissipate generated heat to the outside atmosphere. The medium
wattage version dissipates heat to the interior of the electronics enclosure using heat sinks.
The standard SSR, also called high wattage, can provide switching for two heater elements
of up to 1400 watts each. The medium wattage version can control two heater elements of up
to 500 watts each. Relays for both the original and new standard SSR versions are available
as spare parts. For the medium wattage SSR, individual relays cannot be replaced.
NOTICE
The SSR module supports either 115 VAC or 230 VAC power. For 115 VAC power the in-line
fuses to the SSR should be rated at 16 A. For 230 VAC, the fuses must be rated at 10 A. DO
NOT use a 16 A rated fuse for 230 VAC primary AC power. This could result in overheating
and equipment damage.
Schematic A
3
1 4
2 3 Rc 1 Load
3 Zero
Snubber
1 4 Control voltage AC
Voltage LED or Line
2 detect
4 2 Load
SVCM Versions
There are two configurations of SVCM. The old version, which is still supported as a spare
part, is equipped with a valve driver circuit board. For the newer version of the SVCM, this
valve drive circuitry has been moved to the PECM2 module. The newer version has a lower
cost and is more reliable and robust.
The SVCM electronics, whether onboard for the old version or on the PECM for the new
version, receives commands from the SYSCON module (via the I2C bus). Pulse timing is
controlled from the SVCM electronics.
Solenoids
Test Buttons
(bottoms of solenoids)
Mechanical
Each SVCM incorporates 8 solenoid valve circuits for driving 3-way and 4-way solenoid valves.
The SVCM is mounted in the Controller Enclosure on the manifold block. It can also be mounted
in a Division 2 purge enclosure. Up to 3 SVCM assemblies can be mounted in the Maxum II.
This allows for up to twelve 3-way solenoids and twelve 4-way solenoids. SVCM-1 is mounted
in the lower right portion of the back wall. SVCM-2 is mounted in the lower left portion of the
back wall. SVCM-3 is mounted (vertically) in the upper right portion of the back wall. The
original SVCM is equipped with Parker solenoids. The newer SVCM is equipped with SMC
solenoids. Manifold in/out SST tubing connections incorporate one touch push type tubing
connectors.
Function Specification
Switching Speed (Maximum response time on/off ms)
4-way 15ms
3-way non-latching 15ms
Operating Voltage 24VDC
Pressure Range, 3-way 25 to 100psi
Pressure Range, 4-way 25 to 100psi
Vacuum Range 0 to 27" of Hg
Ambient Temperature Range -18°C to 65°C
-0.4°F to 149°F (dry air)
Leakage ≤ 50 microLiter/min, air @ 69.8?F (21°C) with 50psig on the
common port.
Operation Test
1. Using a fine-pointed object, press Solenoid Valve red button.
2. When pressed, pressure is applied to the piston that moves to either the open or closed
position. Resulting pressure is then applied to the column or sample valve.
3. If piston does not operate when the button is pressed, check for correct gas pressure.
4. If piston does not operate and pressure is 75 psig, Solenoid Valve is defective and must
be replaced.
5. Repeat for each valve operating on and off. Allow at least 1 second between button presses.
WARNING
Voltage dangerous to life exists. Failure to follow proper procedures may result in equipment
damage, personal injury or death.
Before performing the removal and installation procedures, turn off primary AC power to the
Maxum II from the main circuit breaker. Observe all site safety requirements before
performing any repair or maintenance on the Maxum II.
Procedure
1. Back up and shut down the unit using the General Analyzer Shutdown Procedure.
2. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary).
3. Unplug the cable to the solenoid to be replaced.
4. As show below, use a small screwdriver to remove the two screws that fasten the solenoid
to the manifold. If the black gasket adheres to the manifold after removing the solenoid,
then remove the gasket manually.
5. Install the new solenoid, using a new gasket from the kit.
6. Reattach the cable to the solenoid.
7. Follow the steps in the General Analyzer Startup Procedure.
The Electronic Pressure Control (EPC) Module reduces oven set-up time by using precise
pressure control without restrictors or needle valves. This module also allows programmed
pressure control for faster chromatography and modern applications. It allows precise control
of pressures. The EPC can be used for both carrier and fuel gas supply, which eliminates the
less reliable mechanical regulation. Four independent EPCs can be installed in one Maxum II.
Each EPC provides two independently regulated pressures for use on carrier and flame fuel
sources in the oven. Gas connection is located in the regulator section. Regulated pressure
range is 5-100 psig. Two slightly different versions of the EPC are available. The primary
difference between the two versions is that the newer version is equipped with DIP switches
that identify the location ID of the module. The older version uses a jumper plug to identify the
ID. The differences between these methods of identification are described fully in the procedure
to replace the EPC. There are no other functional differences.
Tubing Manifold
Ch2
Ch1
Location ID
Selector Switches
Low Pressure
Switch Inputs I2C Connector
Mechanical
Electrical
The EPC is made up of a printed circuit board with two pressure transducers, two proportional
valves with associated electronic circuitry, manifold for pneumatic connections, PC connector
for communication signals and a DC power connector. See Figure 2-44.
The EPC provides electrically controlled pressure for helium, hydrogen and nitrogen carriers
etc., as well as low flow and low pressure (<100psi) applications such as flame detector fuel.
The EPC operates from 24VDC at 4 watts. Electrical connections are made using plug type
connectors.
The EPC receives commands from the SYSCON via I2C bus regarding timing and pressure
setpoint. The timing of messages from the SYSCON controls timing within the EPC. There is
no time base in the EPC. Module control is established by sending parameters, such as
setpoint pressures and ramp rates to the EPC. The EPC is used in the Maxum II to control the
carriers and/or fuels for the detector modules. The EPC can also be used in field-mounted
installations.
The EPC communicates with other components via the I2C bus and communicates actual
pressure back to the SYSCON. Regulated pressure range is 5-100psig.
Channels
Each EPC channel consists of a pressure sensor amplifier and analog filter followed by an A/
D Converter. The converter is read by the local controller that calculates a new control value
used to control the proportional solenoid valve.
Control parameters, such as set-point pressures are sent via the I2C bus to the EPC. Status
and diagnostic data is available via software.
Diagnostics
EPC diagnostics are read-back of setpoint pressure via the software, DC power within
operating limits, monitoring of line and short-term pressure variations with respect to the
setpoint regulation, out of range pressure alarm and a diagnostic failure.
Specifications
Parameter Value
Maximum inlet pressure 120psig
Pressure output range 5-100psig
Minimum differential between EPC inlet and outlet 5psi
Flow range from EPC (see note below) 5-500cm3/s
Controlled pressure stability over temperature range ±0.5% of setpoint
Short-term pressure stability ±0.0005 psi over 30s interval
Typical response time for step change in setpoint. Stable to within 0.1% of final value with‐
in 0.5 seconds (For hydrogen the re‐
sponse time is approximately 1 second).
Note
When running applications with column flow rates of less than 5 cm3/s, a separate bleed flow
path is recommended in order to reduce the time required to achieve pressure stability when
variable setpoints are used. Depending on the volume involved, a bleed flow rate of 5-10
cm3/s is recommended.
Procedure
WARNING
Voltage dangerous to life exists. Failure to follow proper procedures may result in equipment
damage, personal injury or death.
Before performing the removal and installation procedures, it is important that primary AC
power to the Maxum II be turned off from the main circuit breaker. Observe all plant safety
requirements before performing any repair or maintenance on the Maxum II.
Note
Do not over-tighten ferrules. Oertightening may damage the ferrules.
The ferrules connected on the gas supply side of the EPC manifold are composed of vespel-
graphite. To prevent damage, these ferrules must NOT be over-tightened. Proper tightness
is typically ½ turn past finger-tight.
Note
Do not disassemble the EPC.
The EPC is made up of a manifold that is mounted to the electronic enclosure wall on standoffs
and the module itself. Due to safety and certification issues, it is necessary to replace both the
EPC and manifold as one assembly.
1. Open electronic enclosure door (using a 4mm (5/32”) Allen wrench if necessary). When
door is open DO NOT place tension on the display panel interface cable.
2. Disconnect any external interface connectors to EPC. It is recommended that all cables be
identified with their EPC connector location.
3. Remove the external gas connections from the EPC, labeling each if necessary.
4. Remove the four 4mm Allen screws that secure the manifold to the Electronics Enclosure
and then remove the assembly. These are captive screws and will be completely removed
with module.
5. If the replacement EPC a module ID jumper, move the jumper that is connected to location
J2 (bottom side of PC board) from the old module to the new module.
6. If the EPC is equipped with ID switches, set the switches on the replacement EPC to match
the ID of the EPC that was removed (see Setting Location ID).
7. To reinstall the new EPC, perform steps 1 to 4 in reverse order. Use caution when
reconnecting gas lines. Do not over-tighten.
8. Before applying AC power, be certain the gasket between the manifold and the Electronics
Enclosure is properly seated and interface cable connectors are correctly connected.
9. Inspect the system for leaks.
1st switch / connector Second switch / connec‐ 1st & 2nd switch / con‐ 3rd switch / connector
pin set (binary 1) tor pin set (binary 2) nector pin set (binary 3) pin set (binary 4)
4.1.10.1 Description
Overview
The color touchscreen display is a convenient tablet-like panel that combines a high-resolution
color LCD display with an intuitive touch interface.
TIB
Touch Interface (Touch Interface
Data, Power Board)
SIB3
(in SYSCON2.1)
Display Panel
Components
The LCD display panel controller and power supply are integrated into the SIB3 board in the
SYSCON2.1. The touch interface board (TIB) is mounted directly to the LCD panel /
touchscreen as a single assembly. The TIB and LCD panel are individually replaceable.
Overview
Replacing the color touchscreen panel requires removal and disassembly of the door.
WARNING
Follow Safety Precautions. Failure to follow proper procedures may result in equipment
damage, personal injury or death.
Full safety precautions must be followed throughout all sections of this procedure to prevent
possible injury, equipment damage, or death. Verify that the area is clear of flammable gases
and vapors and that appropriate authorization is obtained to do the work (hot work permits).
NOTICE
Electrostatic Discharge Precautions.
The TIB can be damaged by electrostatic discharge (ESD). Take appropriate precautions
when unpacking and handling these components to avoid ESD damage.
ESD
Ground
Connection
7. Pull out the SYSCON2.1 drawer and disconnect the display cables from the SIB3 as shown
below. The cables can then be pulled out through the rear of the cage.
Display
Cable
Connections
8. Remove door by lifting it out of its hinge sockets and place on work surface.
Display
panel to
TIB cable
LCD
from
SIB3
Intrinsic safety D
ground wires
E
B
E Backlight
Connector
E
E Hole for
wire-tie
E
Wire-tie
anchors, ESD
E insertion ground
points connection
points
Hole for
wire-tie
D
9. Remove the TIB protective cover by removing the 4 screws. (A in exploded view) This
allows access to two of the 6 mounting studs for the LCD assembly. (E in exploded view)
10.Disconnect the three connectors of the display cable assembly; the backlight connector,
the TIB cable connector, and the LCD connector. (B in exploded view)
11.Disconnect the two cables from the display panel to the TIB
12.Unscrew the four standoffs and remove the TIB. (C in exploded view)
Keep touch screen surfaces clean and free of any dust and dirt because small particles
could scratch the touch screen.)
13.Cut the three wire ties securing the cable assemblies to the display assembly. (In small slot
on panel steel slab adjacent to cutout for LCD connector, small hole near corner of slab for
backlight connector, and TIB lower standoff) (D in exploded view)
14.Unplug the two wire-tie anchors by compressing the nylon anchor as shown below. (The
cable assembly and anchors may be left in place if desired.)
Assembly Considerations
Reassembly of the TIB door is generally the reverse order of the disassembly steps given
above.
Display Panel
The replacement display panel has a protective plastic sheet on the glass surface. Remove
this prior to mounting on the door.
When replacing the mounting nuts, use between 3 and 5 inch-pounds of torque. Do not
overtighten.
Wire Ties
Three wire ties are required on the display steel slab. See the exploded view above and the
illustration below for installation locations.
When installing the wire tie for the LCD connector, orient the head flat to keep it clear of the
protective cover when it is reinstalled.
Install wire tie for the LCD connector Install wire tie on the lower Install wire tie for backlight connector
through hole adjacent to the cutout. TIB standoff near the through small hole at the corner of the
intrinsic safety ground lugs. panel plate.
Assembling Fittings
The ports are machined for a 1/16” Valco internal nut. The Valco ferrule or the 2-piece
Swagelok ferrule can be used. It is important to follow the manufacturer’s procedures when
cutting tubing and seating ferrules to ensure that the fitting does not leak.
Pilot
Use a wheel-cutting tool (such as Supelco 58692-U) to score the tubing, and then with a pair
of straightening pliers (such as Supelco 58646) and a pair of needle nose pliers snap the tubing
at the score line. Make certain that all tubing ends are cut square with the tube axis, and that
both the ID and the OD are thoroughly deburred, use a deburring tool (such as Supelco 58804).
Inspect the end of the tubing where the ferrule will seat for scratches along its length. Visible
scratches along the tubing where the ferrule will seat are not acceptable, but those behind the
front edge of the ferrule will not interfere with the integrity of the fitting.
1. Slide the nut and ferrule onto the tubing.
2. Insert this assembly in the fitting detail (valve body), screwing the nut 2 or 3 turns by hand.
3. Push the tubing all the way forward into the details so that it seats firmly.
4. Manually turn the nut until it is finger tight.
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.
components, shake or blow with clean air the excess cleaning fluid from the individual
components. Ensure that the components are air dry before reassembling.
Note
Do not allow Model 50 valve polished surfaces to rest on any surface other than a lint free
cloth. Clean sample flow openings in top plate, center plate, bottom plate and Valco fitting nuts
using a syringe filled with cleaning solvent such as hexane, acetone, or methanol.
CAUTION
Potential burn hazard. Handling hot components may result in personal injury.
Before servicing the Model 50 valve, it is important that primary AC power to the Maxum II
be turned off from the main circuit breaker, and the oven be allowed to cool. Only maintenance
personnel with proper authorization should open the electronic enclosure. Failure to observe
safety precautions can result in personal injury.
4.2.2.5 Figure
Refer to figure 6-2 during the procedures for disassembling and cleaning the Model 50 valve.
2 (50)
1 1/2 (38)
1 5/16 (33)
1 1/8 (29)
Washer
Top Plate
Sample Gas &
Carrier Gas Diaphragm
Connections (10)
Flow Path in Off Position Center Plate
Ferrule
Nut
Valve Removal
1. From primary AC circuit breaker, turn analyzer AC primary power OFF.
2. Shut off the air to the oven heater.
3. Open door to the Maxum II oven using a 4mm (5/32’") Allen wrench.
4. To remove Model 50 valve from the oven, first disconnect all tubing to the valve.
Note
When disconnecting Valco fastening nuts from Model 50 valve, exercise caution not to bend
or crimp the stainless steel tubing.
Note
Before removing Model 50 valve from oven, make note of its orientation within the oven.
5. Remove the valve from the oven by unscrewing the two M3 x 35 socket head cap screws
securing the Model 50 valve. These mounting screws are located between ports 2 and 3
and ports 8 and 9. Refer to Figure 6-2 for port locations.
Note
If the valve is to be sent back to Siemens for service, then skip to the "Valve Reinstallation"
portion of this procedure to install the replacement valve.
2. Place the valve bottom plate on a lint free cloth. Using a 2.5 mm Allen wrench, remove the
five socket head fastening cap screws. Refer to Figure 6-2.
3. Separate Top, Center and Bottom plates of the valve, placing them on a lint free cloth.
Both diaphragms are visible.
4. Remove the old diaphragms from the plates. DO NOT attempt to reuse the old diaphragms.
5. Clean the valve parts by wiping with a dust/lint free cloth and a cleaning solvent (or clean
using an ultrasonic cleaner) as described at the beginning of this chapter. After cleaning,
shake excess cleaning fluid from all parts and allow to air dry before reassembling.
Note
Use the Valve Assembly Fixture, Siemens Part Number 2020281-001, to properly align the
diaphragms when rebuilding the Model 50 valve. The fixture consists of a base, two guide
pins, and a diaphragm placement disc. This fixture will allow the user to place the diaphragm
in the center of the valve. If the diaphragm is not in the center, it may leak.
6. With the pins installed in the base of the assembly fixture, place the bottom plate of the
valve on the center of the base. The pins should fit in the mounting holes on the bottom
plate and hold it in place.
7. Position the placement disc on the bottom plate and set the diaphragm in place .
8. Carefully remove the placement disc without moving the diaphragm. Inspect the diaphragm
for proper alignment. If the diaphragm is not in the center of the plate, repeat the placement
procedure using the placement disc.
9. Place the middle plate on the valve taking care to use the correct holes. Check the alignment
mark on the side of the plate. It should align with the mark on the bottom plate. If not, the
middle plate is upside down and must be removed, turned over, and reinstalled correctly.
10.Repeat steps 7 and 8 with the middle plate.
11.Place the top plate on the valve, verifying alignment using the alignment marks.
12.Install the 5 screws and washers finger tight.
13.Tighten the screws down evenly (2.5mm Allen wrench) to 6 to 8 inch-pounds of torque. (It
is recommended to use the torque wrench available from Siemens, PN 1631005-001, which
is calibrated at 7.2 inch pounds). Remove the assembled valve from the valve fixture.
Valve Reinstallation
1. Reinstall the valve in the oven and connect all tubing.
2. Power up and check for leaks. Verify valve operation by running chromatograms.
4.2.3.1 Description
Overview
The Siemens Liquid Injection Valve (SLIV) is used to automatically inject a fixed quantity of
liquid sample followed by fast, complete vaporization. Small gas quantities can also be injected
using the valve.
Components
The Siemens Liquid Injection Valve (SLIV) consists of three components:
● Temperature-controlled vaporization system
● Sample flow unit with seals
● Pneumatic drive (actuator)
Functional Description
The SLIV uses a moving injection tappet attached to a piston actuator. Sample is injected via
a groove or cross hole in the tappet. In the filling position, the sample flows continuously
through the cross hole or the ring groove of the injection tappet. When injecting, the tappet is
pushed pneumatically into the heated vaporization area. The liquid in the cross hole or ring
groove is vaporized and flushed by the carrier gas into the column. The tappet is then shifted
pneumatically, via the piston actuator, back into its original position. Sample then passes
through the injection hole again.
Parameter Value
Maximum vaporization temperature 60 - 350°C (140 - 622°F) with explosion-proof analyzers ac‐
cording to the temperature class
Injection volume 0.1 to 9.5μl
Ambient temperature -20 to150°C (-4 to 302°F)
Material of parts in contact with the sample V4A, mat. No. 1.4571 Hastelloy, Monel or special
Control pressure 400 to 600 hPa
Maximum sample pressure 6000 kPa, recommended 50 to 100 kPa
Connections For tubing with 3.14 mm (1/8 in.) outer diameter
Vaporization System
The vaporization tube is inserted with an aluminum sleeve into the heating mushroom plate
whose temperature is regulated by a heating cartridge. In addition to the standard vaporization
tube, a version of the SLIV is offered with a glass lined vaporization tube.
The carrier gas is routed via tube into the vaporizer and heated up to the vaporization
temperature in the process.
Vaporization Temperature
The vaporization temperature can be set independent of the oven temperature. It is selected
according to the sample and the boiling point of the sample. The optimum vaporization
temperature must be determined experimentally. The amount by which the vaporization
temperature should be above the sample’s boiling point depends on the heat of vaporization
of the sample. Samples with a high heat of vaporization, such as aqueous samples, only
vaporize sufficiently fast for chromatographic purposes at high temperatures (above 200?C),
as shown below.
Note
Ex units: To comply with electrical hazardous area requirements ensure that:
● The sensor of the temperature sensor is fully inserted into the heating plate.
● The purge tube vent is not being obstructed.
Filter Requirements
The tappet and gaskets will wear faster if the sample contains solid particles. In these cases,
a filter is required upstream of the injection. Siemens recommends a filter with the following
characteristics:
● 98% for 0.3-μm particles with liquid samples
● 99.99% for 0.1-μm particles with gaseous samples
Schedule
This section provides routine maintenance and repair procedures for the liquid injection valve.
A 6-week preventive maintenance schedule is recommended for servicing the valve; however,
the schedule you choose will depend upon the:
● Sample properties
● Vaporization temperature
● Ambient temperature
● Sample pressure
● Analysis Duty Cycle
Part Locations
Throughout this section, the numbers located next to part names, such as “Flange (17)”, refer
to callouts listed in the Liquid Injection Valve Exploded View.
Operational Notes
● If the sample has a corrosive effect on the surface of the injection stem (also called a tappet),
the stem must be replaced with a different material type (e.g. Hastelloy).
● Over time, particles from the sample build up on the gaskets and will eventually obstruct
the sample flow. Gaskets made of Teflon and Rulon are less subject to build up, but are
not suitable for all applications. In addition, if the gaskets are subjected to temperatures
outside of their rating they will loose their shape and reduce the service life of the valve.
● A sample that contains non-volatile or easily polymerized components (salts, proteins,
monomers etc.) can deposit residues in the vaporizer (16), in the injection hole, on the
sample flow unit (15), and on the injection stem (6). Therefore, these parts should be
cleaned regularly if the sample contains materials which are not vaporized.
● The sample flow unit (15) should be oriented vertically when the valve is installed. This is
so that the sample will flow vertically through the valve to prevent air bubbles from forming
in the valve. Make note of this when reinstalling the valve after service.
Bevel up
Bevel down
1. Control Cylinder
2. Hex Set Screws Bevel up
3. Control Piston
4. Large O-Rings
5. Guide Pin (Only on Cross-Hole) Belleville Washer Orientation
6. Injection Stem (tappet)
7. Valve Body
8. Small O-Ring and Piston Guide Hole
9. Label Indicating Injection Volume
10. Belleville Washer Plate Springs (approx. 8)
11. Adjustment Nut
12. Adjustment Counter Nut
13. Adjustment Assembly
14. Gaskets (2) Note: The guide pin (5) is only applicable
15. Sample Flow Unit to pistons with the “cross-hole” type stem.
16. Vaporizer Pistons with the much more common
17. Flange “groove/notch” stem are not equipped
18. Carrier Gas Inlet Tube with a guide pin.
Groove for
sample-flow
unit
Label for
Dosing
Volume
Alignment Groove
for attaching to
Groove for Control Cylinder
O-ring using hex set
screws
4.2.3.4 Troubleshooting
Overview
These procedures refer to the Liquid Injection Valve Component Locations and Liquid Injection
Valve Exploded View illustrations.
CAUTION
Temperature and Heating Components in Explosion Proof analyzers
If the heating assembly is removed, exchanged or retrofitted, the assembly must be tested
and certified in accordance with appropriate regulations before the analyzer can be placed
back in service.
CAUTION
Potential burn hazard. Handling hot components may result in personal injury.
To prevent injury from burns always switch off the oven and valve heaters and allow the oven
and liquid injection valve to cool down before touching the valve.
Procedure
1. Switch off oven and valve heaters and allow oven and valve to cool down.
2. Switch off sample flow at the sample conditioning system and allow sample line to empty.
3. Shut off power to the chromatograph.
4. Shut off carrier gas and control air supplies.
Note
Before doing the next step, purge the sample line including the valve with Nitrogen to avoid
exposure to hazardous substances.
5. Unscrew the sample line and pneumatic actuation control lines from the liquid injection
valve.
6. (If removing entire valve) Disconnect the carrier gas inlet line from the carrier inlet tube (18),
and disconnect the column from the vaporizer (16) outlet inside the oven and then remove
the valve.
7. (If not removing vaporizer and flange) Do not disconnect carrier gas or column. Unscrew
the valve body (7) from the flange (17) and pull out.
NOTICE
Clean Work Area Required
Perform all work on a clean dry surface to avoid contamination. Parts should be placed on a
clean lint free cloth and hands should be clean.
1. If vaporizer (7) and flange (8) were not removed from the analyzer, then skip this step.
2. Unscrew the valve body (7) from the flange (17) and vaporizer (16) and separate the
components.
3. Remove the 2 hex set screws (2) and remove the control cylinder (1).
4. Lift off the sample flow unit (15) and adjustment assembly (13) from the injection stem (6).
5. Remove the sample flow unit and the lens shaped gasket (if the gasket is not present it is
stuck in the vaporizer) to allow the Belleville washer plate springs (10) to drop out.
6. Pull the control piston (3) with stem (6) out of the valve body (7). Do NOT use any tools
such as a screwdriver as a wedge between the piston and the valve body. This would
damage the valve body and control piston.
Procedure
1. Remove the gaskets (14) from the adjustment assembly (13) and vaporizer (16). To do this,
gently insert the tip of the stem (6) approx. 5 mm into the gasket and then tip to the side
until the gasket is loose and can be pulled out with the stem.
2. Insert new gaskets (14) into the adjustment assembly (13) and vaporizer (16). Use the
correct type gasket according to the application and temperature class.
3. There should be no play between the new gasket and the injection stem. It should be
extremely difficult to move the gasket.
O-Ring Replacement
The silicone O-rings of the pneumatic drive should be regularly greased with a high-quality
lubricant such as DuPont Krytox EG2000 or equivalent (Siemens part number G87004).
Procedure
1. Carefully remove the two large O-rings (4) and the small O-ring (8) out of the valve body
(7) and control piston (3) using a small screwdriver or a needle. Only use silicone O-rings,
temperature class -40°C to 200°C.
2. Insert new O-rings in all three locations (4 & 8).
3. Apply a thin film of grease to the new O-rings and the sliding surfaces of the control cylinder
(1) and the piston guide (2 & 8).
Valve Assembly
Read the following notes before performing the assembly procedure. Refer to Figure 4-51 for
the following procedures.
Notes
• The screw threads on the flange plate (17) must move freely. Grease if necessary.
• The diameter of the piston guide hole (8) should be 5.7 mm and be smooth. Replace the
part if there are traces of wear on the piston shaft.
• The adjustment assembly (13) must slide smoothly down inside the valve body (7).
Procedure
1. Before assembling the valve, apply a thin coat of grease (discussed in O-Ring
Replacement above) to the following parts.
– Internal wall of control cylinder (1)
– Shaft of Control Piston (3)
– Piston Guide hole/small O-ring (8)
– Outside of Large O-rings (4)following reassembly of valve body (7) and piston (3)
2. Insert the piston (3) with stem (6) into the valve body (7) such that the stem does not become
greasy.
3. Drop the Belleville washer plate springs next to one another over the stem into the valve
body. Washers must be positioned in an alternating bevel up/bevel down manner (to form
a spring). See Liquid Injector Valve Exploded View for washer orientation.
4. Slide the adjustment assembly (13) with nut (11), counternut (12) and Teflon gasket (14)
onto the stem.
5. Insert the sample flow unit (15) into the valve body (7) over the stem (6). See the Liquid
Injection Valve Body illustration.
Note that the stem hole through the sample flow unit is tapered. This tapering is not readily
apparent when looking at the uninstalled sample flow unit, but it will be visible when it is
installed on the stem. The narrowest side of the hole in the valve body should face outward
(toward the vaporizer). The narrowest side of the hole will be apparent because it will have
the least spacing between the stem and the side of the hole. Newer sample flow units have
this orientation marked with an arrow.
6. Move stem (6) into filling position. This means that the stem should be “pushed in” towards
the control cylinder (1)
7. If you have completely removed the liquid injection valve, fit the flange (17) over the
vaporizer (16), and screw the valve body (7) and the flange together.
8. If the the flange plate (17) and vaporizer (16) were not removed from the analyzer, screw
the partially reassembled valve onto the already installed flange plate.
Procedure
1. Check the spring travel and correct using the adjustment assembly (13) if necessary. The
spring travel is correctly set if the flange (17) can be rotated a further 2.5 rotations starting
with the first pressing of the Belleville washer plate springs until the flange rests on the
valve body. The plate springs can be viewed through a hole when pressing together. If the
flange is tightened firmly, there should be a gap of 0.3 to 0.5 mm between the plate springs.
2. If the adjustment is necessary, loosen the flange from the valve body again, and screw the
nut and counternut in or out as necessary. Then repeat the preceding step.
3. This step is only necessary if using the less common cross-hole stem and should only be
executed if the entire valve including the vaporizer is removed from the analyzer.
Rotate the vaporizer (16) using a 6mm wrench until the carrier gas inlet (18) is parallel to
the sample flow unit (15). The carrier gas should flow through the hole in the stem when
injecting.
4. If the entire valve was completely removed from the analyzer (including the flange and
vaporizer), reinstall it at this time, but do not connect control lines, sample lines, or carrier
gas.
When installing the valve, adjust the valve body (7) so that sample will flow vertically through
the valve. This is necessary to prevent bubbles from forming in the valve.
5. Position the control cylinder (1), and tighten the two hex set screws (2) on the side. The
screws must firmly grip the groove in the valve body (5) wall. See the Liquid Injection Valve
Body illustration.
6. Connect the control lines.
7. Activate the actuator pneumatically. Check that you can hear the switching and movement
noises.
8. Connect the sample lines. After connecting the sample lines inspect that they are not
subjected to any strain and that sample will flow through the valve vertically (to prevent
bubbles from collecting in the valve).
9. Complete re-installation of valve into analyzer including reconnection of carrier gas and
column tubing (if these were disconnected during removal).
See also
Liquid Injection Valve Component Locations (Page 167)
Maintenance Considerations
If customer maintenance personnel are not technically trained to repair the Model 20 valve on
site, it is recommended that the valve be returned to Siemens for service, repair, or direct
replacement.
To repair the valve on site, the customer must have the necessary maintenance tools and
replacement parts. Recommended valve spare parts, including the Model 20 repair kit (PN
K21000), can be obtained from Siemens.
When cleaning the Model 20 valve components, it is imperative that the maintenance be
performed in a clean and contaminant free facility. Components should be placed on a lint free
cloth to prevent impurities from contaminating the valve and its components. Hands should be
clean and free of contaminants. Presence of any foreign contamination can cause additional
valve problems after reinstallation.
All foreign contamination adhering to valve components must be removed using cleaning
solvent, such as hexane, acetone, or methanol and a dust/lint free cloth. After cleaning valve
cap and tubing, shake or blow with clean air the excess cleaning fluid from the individual
components. Ensure that the components are air dry before reassembling.
It is possible to remove the valve cap of the Model 20 valve while the valve is installed in the
Maxum oven. However, there may be situations where the user wishes to remove the valve
from the oven. While this is not described in this manual, it is a straightforward process to
detach air connections, loosen the mounting clamp, and remove the valve.
Note
Do not allow polished face of valve cap to rest on any surface other than a lint free cloth. Clean
metal parts using only a syringe and a cleaning solvent such as hexane, acetone, or methanol.
CAUTION
Potential burn hazard. Handling hot components may result in personal injury.
Before servicing the Model 20 valve, it is important that primary AC power to the Maxum II
be turned off from the main circuit breaker, and the oven be allowed to cool. Only maintenance
personnel with proper authorization should open the electronic enclosure. Failure to observe
safety precautions can result in personal injury.
Figure
19
3 12c
16
12
2 12b
432
12. Air Loaded (Upper)
Piston
15
6 13. Valve Plunger Body
5 61 14. Cylinder Base
15. Spring Loaded (Lower)
Piston
16. Allen Screws (3 total)
17. Belleville Washers
20
(6 total)
CAP BODY 18. Inner (small) O-Ring
19. Outer (large) O-Rings
20. Large Belleville
Washers (3 total)
21. Control Port (Upper,
Middle, or Lower
depending on
21 14 location)
BASE
Diagnostic Procedures
Depending on the installation, the following tests can be performed with the valve mounted in
the analyzer. Other tests require the analyzer to be shut down and valve ports disconnected.
These diagnostic tests indicate specific areas of the fault or trouble.
Valve Leakage
Sample Pressures Lower Than Carrier Gas Pressure: Leakage may be from a carrier-gas port
to a sample port within the valve regardless of whether valve is actuated or deactivated. With
sample inlet flow turned off, sample outlet should be zero. Check carrier and sample gas for
leakage.
Carrier and Sample Gas Leakage: Bubbles indicate internal leakage. For a liquid carrier, check
for liquid dripping from sample outlet tube.
Sample Pressure Higher Than Carrier Gas: Leakage between ports is visually displayed on
analyzer recorder as a baseline shift when sample pressure is removed from valve.
Plugged Valve
If the valve is plugged, plungers are pressed upward by air pressure or spring action and will
not release to their open position when sample pressure drops.
Ruptured Diaphragm
Escaping air from valve vent hole indicates a ruptured diaphragm (4), which must be replaced.
Check for liquid substances escaping from the vent hole.
Slow Erratic Piston Switching
Improper lubrication and/or contamination of O-rings will increase friction on valve-actuating
piston. This causes valve switching to be erratic, slow or inoperative.
This condition requires disassembly of the entire valve (maxi-maintenance). It is recommended
that the valve be returned to Siemens for service.
NOTICE
Do not place polished valve cap (1) against any abrasive surface. Place it on an
uncontaminated lint free cloth.
1. Inspect the valve cap Teflon® base seal disc diaphragm (4) and the Dacron® disc cushion
diaphragm (5) for dirt, contamination or breaks.
Regardless of whether damage or contamination is evident, discard old seal and cushion,
and replace them with new component(s).
Note
If Teflon® sealing disc and Dacron® cushion disc are brittle or dirty, but not ruptured, or
they are ruptured but clean, visually inspect the rest of the valve. If it is clean and in good
order, it is possible to continue with this procedure.
If ruptured discs appear to have caused contamination of the valve, it will need to be
disassembled in order to be cleaned. It is recommended that the valve be returned to
Siemens for service.
Note
All valve fittings and tubing must be clean and valve diaphragms inspected for cleanliness,
catalyst or polymer buildup. Valve cap or plunger valve body faces should be wiped clean
using hexane, acetone or methanol and a lint free cloth.
2. Prepare a large syringe with a Tygon® tubing adapter installed. Fill syringe with a
recommended cleaning solvent.
3. An ultrasonic cleaner filled with a recommended cleaning solvent is recommended for
cleaning all components. Solvent must not leave any residue on evaporation.
Clean valve cap while it is disassembled.
After cleaning of cap, using syringe, flush solvent through each port in the valve cap.
NOTICE
When reassembling the valve cap, always install a new Teflon® Seal Disc diaphragm (4)
and Dacron® Cushion Disc (5). DO NOT install the previously used Seal and/or Cushion
Disc.
4. Position the Dacron® cushion disc diaphragm (5) between the three alignment pins on the
plunger valve body (13).
5. Using tweezers, hold Teflon® seal disc diaphragm (4) by its edges. Before installing disc,
remove lint, dust and oils by sliding disk between your index and middle fingers.
6. Install Teflon® seal disc diaphragm (4) over the Dacron® diaphragm disc cushion (5).
7. Align valve cap (1) over the valve body three-plunger guide pins (13). Port 1 must be placed
toward the upper control port.
8. Lower valve cap (1) over plunger valve body plunger guide pins (13) then install valve cap
(1) onto the plunger valve body.
9. Install, but DO NOT securely tighten, the three Allen screws (3) each with two Belleville
lock washers (2).
Note
To assure proper tightness in the following two steps, it is recommended to use the torque
wrench available from Siemens, PN 1631005-002, which can be adjusted over the range
of torque measurements listed below.
10.Referring to the following screw tightening rotation sequence, securely tighten the three
Allen screws (3) that connect the valve cap (1) to the valve plunger body (13). One at a
time, tighten each screw to first torque. Then continue with the next torque value until the
final value is reached.
– Finger tighten
– 20 inch pounds (2.3 Nm)
– 40 inch pounds (4.5 Nm)
– 60 inch pounds (6.8 Nm)
11.Tighten the three Allen screws (16) that secure the plunger valve body (13) to the cylinder
base (14) to approximately 30 to 40 inch-pounds (3.4 to 4.5 Nm).
NOTICE
Be certain all Allen screws are securely tightened. DO NOT overtighten.
M20 Description
This section presents information to disassemble, clean, and rebuild the Model 20 Valve.
Maintenance procedures for the Model 20 valve are grouped into two types, Mini-Maintenance
procedures and Maxi-Maintenance procedures. Mini-Maintenance procedures involve
working on the valve while it is still installed in the analyzer. Maxi-Maintenance procedures
may be used when Mini-Maintenance does not correct a valve fault. However, it is often
cheaper and easier to replace the valve or return it to Siemens for service. This manual covers
the Maxi-Maintenance procedures in the following order.
● Valve Cap Disassembly
● Actuator Disassembly
● Cleaning Actuator, Fittings, Tubing, etc.
● Actuator Assembly
● Valve Cap Cleaning and Assembly
To assure optimum valve operation, a clean contaminant free work environment is required
for this procedure. To repair the valve on site, the customer must have the necessary
maintenance tools and replacement parts. Recommended valve spare parts can be obtained
from Siemens. Recommended tools will include an ultrasonic cleaner and a clean workstation
with lint-free cloth.
It may be easier and less expensive to replace a valve or return it to Siemens for service rather
than perform Maxi-Maintenance.
In addition to training, the customer must have a clean work environment available for
rebuilding and cleaning the valve. Performing the work in a contaminated environment, or
performing the work incorrectly may damage the valve.
Note
This procedure must only be executed with the consent and approval of all applicable local
safety personnel and/or the local authority having jurisdiction.
NOTICE
Do not allow polished face of valve cap to rest on any surface other than a lint free cloth.
Clean metal parts using a syringe or ultrasonic cleaner and an appropriate cleaning solution
as described in this procedure.
1. Valve Cap
2. Allen Screws (3 total)
3. Belleville Washers (6 total)
4. Teflon Disc Seal Diaphragm
5. Dacron Cushion Diaphragm
6. Plungers (6 total)
7. Ferrule Top
8. Ferrule Bottom
9. Connector
10. Port Tubing
1. Valve Cap
2. Belleville Washers (6 total)
3. Allen Screws (3 total)
4. Teflon Disc Seal Diaphragm
5. Dacron Cushion Diaphragm
6. Plungers (6 total)
7. Ferrule Top
8. Ferrule Bottom
9. Connector
10. Port Tubing
It is important for proper procedures to be used when cleaning valve and detector parts. All
foreign contamination adhering to the part should be removed using an appropriate cleaning
solvent, such as hexane, acetone, or methanol and a dust/lint free cloth. Use of an ultrasonic
cleaner is often helpful. After cleaning, it is necessary remove excess cleaning fluid from the
components by blowing with clean air or shaking. Components must be air dry before
reassembling.
It is possible and often better to use an appropriate detergent, such as Alconox® for cleaning
instead of solvent. However, after cleaning with a detergent, it is necessary to rinse the part
thoroughly with deionized water (distilled water is also acceptable) in order to remove detergent
residue. All water must then be removed by blowing with clean air or shaking. Components
must be completely dry before reassembling.
NOTICE
To prevent damage to the valve cap (1), do not place polished surface of the valve cap
against any abrasive surface. Place it on a lint free cloth free of foreign contaminants.
4. Inspect the valve cap Teflon base seal disc diaphragm (4) and the Dacron disc cushion
diaphragm (5) for dirt, contamination or breaks.
Regardless of whether damage or contamination is evident, discard old seal and cushion,
and replace them with new component(s).
5. Visually inspect the rest of valve. If it is clean and in good condition, install a new disc seal
diaphragm (4) and cushion diaphragm (5).
To reassemble the valve cap, refer to the applicable steps later in this chapter.
Note
The valve cap and fittings will be cleaned before reassembly. This step will be executed
later in this chapter.
Note
In the next three steps, valve plungers (6) are checked for sticking.
1. Using even finger pressure around edges of plunger valve body (13), push valve plunger
body against cylinder valve base (14). All six plungers should rise.
2. Release plunger valve body (13). The six plungers should drop. If plungers do not drop,
check for oil film on plungers. This can prevent plungers from dropping.
3. Apply gentle pressure to the top of each of the six plungers. If plungers drop, without
excessive pressure, the valve is operating normally and does not require additional
disassembly. If plungers stick or are sluggish in their operation, they must either be
thoroughly cleaned with a recommended cleaning solution, repaired, or the entire actuator
must be replaced.
4. Remove all connections from the valve and remove the entire valve from the oven. While
removing the valve, hold it upright to prevent plungers from falling out.
Additional work should be on a clean workspace.
5. Turn actuator on its side. Remove the three screws (16) which secure the plunger valve
body (13) to the cylinder valve base (14).
Note
When performing the following step, DO NOT allow actuator plungers to fall from plunger
valve body (13).
6. With plunger valve body (13) in the horizontal position, remove it from the cylinder base
(14). Carefully remove all six plungers (6).
Note
Perform EITHER step 7 or step 8 to remove the actuator piston from the cylinder base.
7. Place cylinder valve base (14) in upright position. Insert a 6-32 hex threaded standoff screw
into the center-threaded hole and pull to remove air loaded piston (12) and spring-loaded
piston (15).
Note
In the following step, DO NOT use more than 30 psig (210 kPa) of air pressure when using
this method.
Note
It is extremely important that, when reassembling the actuator, that the assembly area be clean
and dust free. Hands of maintenance personnel must be clean and not oily and tools must also
be clean.
Note
Be certain valve cap (1) does not rest on abrasive surface and valve cap has completely air
dried before reassembly. Rest valve cap on a clean lint free cloth.
1. Install the three large Belleville washers (20) in cylinder valve base (14). Washers must be
positioned in an alternating bevel up, bevel down manner (to form a spring). Refer to Figures
5-1 and 5-2.
2. Apply a bead of Krytox 240 AC lubricant, or equivalent; in "O" ring grooves of spring-loaded
piston (15).
3. Install new silicon O-rings (18 and 19) in spring loaded piston (15) and apply a coating of
lubricant over each "O" ring.
4. Apply bead of lubricant in upper groove of air loaded piston (12a).
5. Install a new silicon "O" ring (19) in the upper groove of air loaded piston (12a) and apply
a coating of lubricant over the "O" ring.
6. Place upper piston (12a) over the small diameter of lower piston (15). Position pistons using
guide pin (12b) for proper orientation.
7. Apply Krytox 240C lubricant to each of the six finger spring (12c) pressure points. This is
the point where the spring fingers contact the plunger body (13).
8. Position the valve upright with its three ports on the left. Install a #6-32 screw in the center-
threaded hole of air loaded piston assembly (12) and bottom spring-loaded piston (15).
9. Lift the combined assembly (12 and 15), and orient it with the upper piston guide pin (12b)
facing toward maintenance person.
10.Press the piston assembly into the cylinder base (14). After installation, remove the #6-32
screw.
11.Align plunger valve body (13) and insert the piston guide pin (12b) into one of the three
bottom holes of plunger valve body (13).
12.Rotate plunger valve body (13) to align body screw holes with cylinder base (14) threaded
holes.
13.Install three #10-32 7/8" socket head screws (16) and Belleville washers (17).
14.Hand tighten screws. DO NOT compress the Belleville washers (20) into the cylinder base
(14).
15.Install six plungers (6) into the plunger valve body (13). Plunger recess must face up.
A clean plunger will fall with its own weight, and, when dropped into the valve body (13), it
will bounce.
16.Place a small drop of Krytox 143 AY or equivalent oil between each plunger.
17.Using a pair of tweezers, lift each plunger up and down to allow the oil to flow around a
plunger.
Note
Before reassembling the valve cap, clean it as described below.
1. Prepare a large syringe with a Tygon tubing adapter installed. Fill syringe with a
recommended cleaning solvent.
2. Using syringe, flush solvent through each port in the valve cap.
Note
When reassembling the valve cap, always install a new Teflon Seal Disc diaphragm (4)
and Dacron Cushion Disc (5) on plunger valve body (13). Do not install the previously used
Teflon Seal (4) and/or Dacron Cushion Disc (5). Before reinstalling seal and cushion on
plunger valve body, remove lint and any dust particles.
3. Place the actuator assembly upright on a clean lint free cloth surface. Refer to Figures 5-1
and 5-2.
4. Position the Dacron cushion disc diaphragm (5) between the three alignment pins on the
plunger valve body (13).
5. Using tweezers hold the Teflon seal disc diaphragm (4) by its edges. Before reinstalling
disc, remove lint, dust and oils by sliding disk between your index and middle fingers.
6. Install Teflon seal disc diaphragm (4) over the Dacron diaphragm disc cushion (5).
7. Align and lower valve cap (1) over the three guide pins of the valve plunger body (13). Then
install valve cap (1) onto the plunger valve body.
8. Install, but do not securely tighten, the three Allen screws (3) each with two Belleville lock
washers (2).
Note
To assure proper tightness in the following two steps, it is recommended to use the torque
wrench available from Siemens, part number 1631005-002, which can be adjusted over
the range of torque measurements listed below.
9. Referring to the following screw tightening rotation sequence, securely tighten the three
Allen screws (3) that connect the valve cap (1) to the valve plunger body (13). One at a
time, tighten each screw to first torque. Then continue with the next torque value until the
final value is reached.
a. Finger tighten
b. 20 inch-pounds (2.3 Nm)
c. 40 inch-pounds (4.5 Nm)
d. 60 inch-pounds (6.8 Nm)
10.Tighten the three Allen screws (16) that secure the plunger valve body (13) to the cylinder
base (14) to approximately 30 to 40 inch-pounds (3.4 to 4.5 Nm).
BE CERTAIN ALL ALLEN SCREWS ARE SECURELY TIGHTENED. DO NOT
OVERTIGHTEN.
It may be easier and less expensive to replace a valve or return it to Siemens for service rather
than perform Maxi-Maintenance.
NOTICE
Obtain appropriate permits.
This procedure must only be executed with the consent and approval of all applicable local
safety personnel and/or the local authority having jurisdiction.
All foreign contamination adhering to valve must be removed quickly using a dust/lint free cloth
and a cleaning solvent such as hexane. After cleaning valve cap and tubing, shake excess
cleaning fluid from tubes and let valve cap air dry before reassembling.
NOTICE
Do not allow polished face of valve cap to rest on any surface other than a lint free cloth.
Clean metal parts using a syringe or ultrasonic cleaner and an appropriate cleaning solution
as described in this procedure.
NOTICE
To prevent damage to the valve cap (32), do not place polished surface of the valve cap
against any abrasive surface. Place it on a lint free cloth free of foreign contaminants.
4. Inspect the Teflon seal disc diaphragm (33) and the Nomex cushion diaphragm (34).
Examine valve cap base seal (33) and cushion diaphragm (34) subassemblies for dirt,
contamination or breaks.
Regardless of whether damage or contamination is evident, discard old seal and cushion,
and replace them with new component(s).
5. Visually inspect the rest of valve. If it is clean and in good condition, install a new disc seal
diaphragm (33) and cushion diaphragm (34).
To reassemble the valve cap, refer to the applicable steps later in this chapter.
Note
The valve cap and fittings will be cleaned before reassembly. This step will be executed
later in this chapter.
Note
In the next three steps, valve plungers (14) are checked for sticking.
1. Using even finger pressure around edges of plunger valve body (17), push valve plunger
body against cylinder valve base (16). All six plungers should rise.
2. Release plunger valve body (17). The six plungers should drop. If plungers do not drop,
check for oil film on plungers. This can prevent plungers from dropping.
3. Apply gentle pressure to the top of each of the six plungers. If plungers drop, without
excessive pressure, the valve is operating normally and does not require additional
disassembly. If plungers stick or are sluggish in their operation, they must either be
thoroughly cleaned with a recommended cleaning solution, repaired, or the entire actuator
must be replaced.
4. Remove all connections from the valve and remove the entire valve from the oven. While
removing the valve, hold it upright to prevent plungers from falling out.
Additional work should be on a clean workspace.
5. Turn the actuator on its side. Remove the three socket head screws (35) which secure the
plunger valve body (17) to the cylinder valve base (16).
Note
When performing the following step, DO NOT allow actuator plungers to fall from plunger
valve body (17).
6. With plunger valve body (17) in the horizontal position, remove the assembly. Carefully
remove all six plungers (14).
Note
Perform EITHER step 7 or step 8 to remove the actuator piston from the cylinder base.
7. Place cylinder valve base (16) in upright position. Insert a 6-32 hex threaded standoff screw
into the center-threaded hole and pull to remove air loaded piston (18) and spring-loaded
piston (15).
Note
In the following step, DO NOT use more than 30 psig (210 kPa) of air pressure when using
this method.
Note
It is extremely important that, when reassembling the actuator, that the assembly area be clean
and dust free. Hands of maintenance personnel must be clean and not oily and tools must also
be clean.
Note
Be certain valve cap (32) does not rest on abrasive surface and valve cap has completely air
dried before reassembly. Rest valve cap on a clean lint free cloth.
1. Install the three large Belleville washers (19) in cylinder valve base (16). Washers must be
positioned in an alternating bevel up, bevel down manner (to form a spring). Refer to Figures
6-2 and 6-3.
2. Apply a bead of Krytox 240 AC lubricant, or equivalent, in Bal-Seal grooves of spring loaded
piston (15).
3. Lubricate outside diameter of assembly tool (Part Number A00145). Be certain spring-
loaded Bal-Seal (13) is properly oriented with the associated spring facing up.
4. Using an "O" ring as a cushion, push spring loaded Bal-Seal (13) down on the assembly
tool until it snaps firmly into spring loaded piston (15) ring groove. Refer to Figure 6-4 on
the next page.
NOTICE
When installing Bal-Seals, handle them with extreme care. Do not remove Bal-Seal
springs for installation and do not nick or scratch Bal-Seals.
5. Apply a bead of Krytox 240 AC lubricant, or equivalent, in both Bal-Seal grooves of air-
loaded piston (18).
6. Using the pads of your fingers (or an "O" ring as a cushion), install the small spring loaded
Bal-Seal (20) in air loaded piston (18) groove with associated spring facing up. DO NOT
use a fingernail. Refer to Figure 6-5.
7. Push spring loaded Bal-Seal (20) to the bottom of groove.
8. Apply small bead of Krytox 240 AC lubricant, or equivalent, on the small Bal-Seal sealing
surface of lower spring loaded piston (15).
9. Place upper air loaded piston (18) over the small diameter of lower piston (25). Position
pistons using guide pin for proper orientation.
10.Screw the assembly stud and washer into the threaded hole in the lower spring loaded
piston (15) and evenly force the spring loaded Bal-Seal (20) over the bearing surface of
lower spring loaded piston (15). Leave the assembly stud and washer in place.
11.Moderately lubricate outsides of Bal-Seals with Krytox 240 AC lubricant, or equivalent. Also
lubricate each of the six fingers of spring. This is where fingers contact plunger valve body
(17).
12.Position valve upright with the three ports on the left. Place assembly guide tool (Part
Number T11000) on the valve, with the cutout on the lip of assembly tool over the upper
tube fitting. Refer to Figure 6-6.
13.Lift piston and Bal-Seal assembly and orient assembly with the upper piston index guide
pin towards the maintenance person.
14.Firmly, but evenly, press the piston and Bal-Seal assembly through the assembly guide
tool into the cylinder valve base (16). Refer to Figure 6-7.
15.Remove guide tool assembly stud and lock washer.
A B
Figure 4-69 Placing Assembly Guide Tool on Valve Base (16)
Figure 4-70 Inserting Piston Assembly (15 and 18) into Base (16)
1. Align plunger valve body (17) and insert piston index guide pin into one of the three bottom
plunger valve body holes.
2. Rotate plunger valve body (17) to align the plunger valve body screw holes with cylinder
valve base (16) threaded holes.
3. Install three Allen screws (35) each with two Belleville washers (36). Hand tighten screws
but DO NOT compress the Belleville washers (19) in cylinder valve base.
4. With the recessed tip facing up, install the six plungers (14) in the plunger valve body (17).
A clean plunger will fall under its own weight and bounce when dropped into the plunger
valve body.
5. Place a small drop of Krytox 143 AY or equivalent oil between each plunger.
6. Using a pair of tweezers, lift each plunger up and down to allow the oil to flow around a
plunger.
Note
Before reassembling the valve cap, clean it as described below.
1. Prepare a large syringe with a Tygon tubing adapter installed. Fill syringe with a
recommended cleaning solvent.
2. Using syringe, flush solvent through each port in the valve cap.
Note
When reassembling the valve cap, always install a new Teflon Seal Disc diaphragm (33)
and Nomex Cushion Disc (34) on plunger valve body (17). Do not install the previously
used Teflon Seal (33) and/or Nomex Cushion Disc (34). Before reinstalling seal and cushion
on plunger valve body, remove lint and any dust particles.
3. Place the actuator assembly upright on a clean lint free cloth surface. Refer to Figures 6-1
and 6-2.
4. Position the Nomex cushion disc diaphragm (34) between the three alignment pins on the
plunger valve body (17).
5. Using tweezers hold the Teflon seal disc diaphragm (33) by its edges. Before reinstalling
disc, remove lint, dust and oils by sliding disk between your index and middle fingers.
6. Install Teflon seal disc diaphragm (33) over the Nomex disc cushion diaphragm (34).
7. Align and lower valve cap (32) over the three guide pins of the valve plunger body (17).
Then install valve cap (32) onto the plunger valve body.
8. Install, but do not securely tighten the three Allen screws (35), each with two Belleville lock
washers (36), that secure the valve cap (32) to the valve plunger body (17).
Note
To assure proper tightness in the following two steps, it is recommended to use the torque
wrench (PN 1631005-002) and bit (PN 1631005-701) which are available from Siemens
and can be adjusted over the range of torque measurements listed below.
9. Referring to the following screw tightening rotation sequence, securely tighten the three
Allen screws (35), that connect the valve cap (32) to the valve plunger body (17). One at
a time, tighten each screw to first torque. Then continue with the next torque value until
the final value is reached.
a. Finger tighten
b. 20 inch-pounds (2.3 Nm)
c. 40 inch-pounds (4.5 Nm)
d. 60 inch-pounds (6.8 Nm)
10.Tighten the three Allen screws (16) that secure the plunger valve body (13) to the cylinder
base (14) to approximately 30 to 40 inch-pounds (3.4 to 4.5 Nm).
BE CERTAIN ALL ALLEN SCREWS ARE SECURELY TIGHTENED. DO NOT
OVERTIGHTEN.
Maintenance procedures for the Model 11 Valves are grouped into two types, Mini-
Maintenance procedures and Maxi-Maintenance procedures. Mini-Maintenance procedures
involve working on the valve while it is still installed in the analyzer. Maxi-Maintenance
procedures may be used when Mini-Maintenance does not correct a valve fault. This manual
covers the Maxi-Maintenance procedures in the following order.
● Mini-Maintenance procedures:
– Valve Cap Disassembly
– Cleaning Fittings and Tubing
– Valve Cap Assembly
● Maxi-Maintenance procedures
– Valve Body Disassembly
– Valve Body Cleaning
– Valve Body Assembly
To assure optimum valve operation, a clean contaminant free work environment is required
for this procedure. To repair the valve on site, the customer must have the necessary
maintenance tools and replacement parts. Recommended valve spare parts, including the
Model 11 Valve repair kit (PN K21040) and Model 11 LDV repair kit (PN 2015581-001), can
be obtained from Siemens. Recommended tools include an ultrasonic cleaner and a clean
workstation with lint-free cloth. In addition, special pliers that are available from Siemens (PN
V16031) are required to completely disassemble the valve. These pliers are part of the tool
kits mentioned above.
Additional procedures related to the Model 11 Valve can be found in the Model 11 Valve Repair
Manuals, which can also be found on the Maxum II Documentation CD.
It may be easier and less expensive to replace a valve or return it to Siemens for service rather
than perform Maxi-Maintenance.
Note
This procedure must only be executed with the consent and approval of all applicable local
safety personnel and/or the local authority having jurisdiction.
NOTICE
Do not allow polished face of valve cap to rest on any surface other than a lint free cloth.
Clean metal parts using a syringe or ultrasonic cleaner and an appropriate cleaning solution
as described in this procedure.
8. Valve Body
9. O-Ring
10. Finger Spring of Air
Loaded Piston
11. Air Loaded Piston
12. O-Ring
13. O-Ring
14. Spring Loaded Piston
15. Compensation Plate
16. Compression Spring
17. Compression Plate
18. Retaining Base
19. Retaining Ring Clip
20. Ball 5/32”
21. Set Screw
22. O-Rings (3 total)
23. Air Signal Manifold
24. Screw 3/8”
25. Screw 1/2”
Figure 4-72 Model 11 (or Model 11 LDV) Valve without Valve Cap
21
20
19
18
17
16
15
14
13
8. Valve Body
12
11 9. O-Ring
10. Spring
10
11. Air Loaded Piston
9 12. O-Ring
13. O-Ring
8 14. Spring Loaded Piston
15. Compensation Plate
16. Compression Spring
22 17. Compression Plate
To Valve 23
18. Retaining Base
Cap
19. Retaining Ring Clip
20. Ball 5/32”
21. Set Screw
24 22. O-Rings (3 total)
23. Air Signal Manifold
24. Screw 3/8”
25. Screw 1/2”
25
V16022 V16023
(Air Loaded) (Spring Loaded)
P49510
S52000
P49500
V16052
B00065
H10648
V16022
Apply
Loctite
Spring Piston
Pressure Points
3. Remove the three Allen head cap socket screws (1) and separate the cap (3) from the valve
body (8). When the valve cap is removed, the following components are exposed. Refer to
Figures 7-2 and 7-4.
- Teflon Sealing disc (4) [clear]
- Dacron Cushion disc (5) [white] and
- "O" ring (6)
4. Inspect the Teflon sealing disc (4), Dacron cushion disc (5) and silicon rubber "O" ring (6)
for dirt or breaks.
If damage is evident on the O-ring, discard damaged part and replace with new
component(s). Regardless of whether damage or contamination is evident on the old seal
and cushion, replace them with new components.
5. Visually inspect the rest of valve. If it is clean and in good condition, it may be possible to
install a new disc seal diaphragm (4) and cushion diaphragm (5) and re-assemble the valve.
6. Examine each of the six plungers (7) for evidence of damage or contamination. If damage
is evident, discard defective plunger(s) and replace with new ones. Refer to Figure 7-3.
7. To reassemble the valve cap (3), refer to the Valve Cap Assembly section later in this
chapter. If the valve actuating piston assembly is contaminated or malfunctioning, refer to
Valve Body disassembly.
Note
The valve cap and fittings will be cleaned before reassembly. This step will be executed
later in this chapter.
Note
If solvent becomes contaminated during performance of the following cleaning steps, it must
be replaced with a clean supply from a clean beaker.
1. (For Model 11 Valve) – Clean valve cap (3) while disassembled using a syringe and
appropriate solvent. Clean each port and attached tubing on the valve cap by flushing
solvent back and forth through each port while cap is immersed in a beaker of solvent.
2. (For the Model 11 LDV Valve) - Clean the valve cap (3) while disassembled and visually
verify that ports are clear. Use of an ultrasonic cleaner and an appropriate cleaning solution
is recommended.
3. Place the actuator assembly upright on a clean lint free cloth surface with the two valve
cap guide pins facing upwards.
4. Using a syringe with Krytox 143 AY lubricating oil, place a drop of oil on sidewall of each
valve body (8) plunger hole.
5. Reinstall the six plungers (7) into their valve body positions. Using tweezers, move each
plunger up and down to thoroughly lubricate them. Plungers must not protrude above valve
body (8) top surface. Refer to Figure 7-3 for plunger orientation.
6. Using clean lint free cloths wetted with acetone, remove excess lubricating oil from top of
valve body (8).
NOTICE
When installing "O" ring (6), Dacron cushion disc (5) and clear Teflon seal disc (4), do not
use any type of grease as a lubricant. There must be no foreign contaminants on discs.
7. Install silicon "O" ring (6), Dacron cushion disc (5) and clear Teflon seal disc (4). Do not
lubricate "O" ring (6).
Note
The clear Teflon seal disc (4) must be mounted ON TOP of the Dacron cushion disc (5).
Align discs over plungers (7).
8. Securely holding valve cap (3), blow out each port and/or tube with compressed air to
remove all acetone and foreign matter.
NOTICE
Do not use grease when installing O-ring.
9. It is recommended that appropriate torque wrenches be used for this step (available from
Siemens – PN’s 1631005-002 and 1631005-003). Install valve cap (3) using the three
10-32 Allen screws (1). Screws must be tightened evenly in sequence 1, 2, 3, 1 sequence.
Tightening steps are as follows. Refer to Figure 4-40.
- Run screws down until they contact valve cap.
- Tighten screws with Allen driver until they are finger tight.
- Tighten screws to approximately 15 inch-pounds
(1.69 Nm). This is a ¼ turn maximum.
- Tighten screws to approximately 20 inch-pounds
(2.26 Nm). This is another ¼ turn maximum.
- Tighten screws to approximately 35 inch-pounds (3.95 Nm)
- Torque bottom adjusting set screw to 6.5 inch-pounds (0.73 Nm).
10.Valve is now ready for reinstallation and placing into operational service.
NOTICE
When shaking plungers from valve body, do not allow them to fall on any abrasive surface.
It is recommended that a lint free cloth, free of contaminants, be placed under the hand
to protect plungers from damage.
2. Examine plungers for damage. Any plunger showing defects, such as nicks, must be
discarded and replaced with a new part.
3. Remove air signal manifold (23) by removing the two screws (24&25) that secure it to the
valve body (8). After manifold is detached, inspect the three o-rings (22) and replace if
necessary. If the o-rings are undamaged, then set them aside (on a clean surface) for
installation later.
4. Use the special set of pliers supplied with the repair kit to remove the retaining ring clip
(19). Inset the tips of the pliers into the holes in the clip and firmly squeeze. Extract the
clip from the base of the valve, holding the pliers firmly to prevent clip from flying off.
5. Remove retaining base (18), compression plate (17), compression spring (16) and
compensation plate (15) from bottom of valve body (8). Refer to Figure 7-4.
6. Use the special retaining clip pliers supplied with the repair kit to remove the spring‑loaded
piston (14) from valve body (8). Insert the tips of the pliers into the holes in the underside
of the piston and pull slowly.
7. Remove air-loaded piston (11) from valve body (8)
8. Using care to catch plungers (7), remove any stuck plunger using one of the tips from the
retaining ring pliers.
9. Examine plungers (7) for damage. Any plunger showing defects, such as nicks, must be
discarded and replaced with a new part.
10.Inspect interior of valve body (8), spring loaded piston (14) and air loaded piston (11) and
silicon rubber "O" rings (13, 12 and 9) for contamination, odor or mechanical wear.
Any part showing evidence of excessive wear or defects must be replaced with a new
component. Do not re-install any defective component.
NOTICE
Do not place polished valve body (8), or associated parts, against any surface in ultrasonic
cleaner or against any abrasive surface. Place parts on a lint free cloth, free of foreign
contaminants.
Do not wash O-rings in any type of cleaning solvent.
5. Place air loaded piston (11) over the small diameter of spring-loaded piston (14) with finger
springs (10) outside. Align piston with guide pin. Refer to Figure 7-5.
6. Apply a bead of KRYTOX 240 AC grease to the "O" ring air-loaded piston (11) groove.
Refer to Figure 7-7.
7. Install silicone "O" ring (9) and apply KRYTOX 240 AC grease to the "O" ring outer surface.
8. Apply a thin film of KRYTOX 240 AC grease to inside of valve body (8) where the pistons
(14 and 11) will be sliding.
9. Insert both pistons (14 and 11) into the bottom of cylinder. Use retaining ring pliers to install
the pistons with the guide pin in the hole of the valve body (8). Refer to Figure 7-5.
NOTICE
Exercise care not to damage the O-rings when sliding them past the lower retaining ring
groove.
10.Apply KRYTOX 240 AC grease to the compression plate (17) beveled cone. Insert the ball
(20) into the greased cone.
11.Insert both the compression plate (17) and ball (20) into retaining base (18). Refer to figure
7-6.
12.Apply KRYTOX 240 AC grease to base socket head set screw (21) then screw it into
retaining base (18). Leave about one thread of set screw showing.
13.Place compression spring (16) on compression plate (17).
14.Place compensation plate (15) over the compression spring (16).
15.Before final assembly of components, apply a thin film of KRYTOX 240 AC grease to the
outside of compensation plate (15) and inside of retaining base (18).
16.Place the compression spring (16), compression plate (17); socket head set screw (21),
retaining base (18) and compensation plate (15) into the valve body (8).
17.Use the retaining ring pliers supplied with the repair kit to reinstall the retaining ring (19).
NOTICE
Be certain the retaining ring (19) sets into its mounting groove.
18.Prepare to install the manifold (23) by cleaning the flat surface on the side of the valve body
(8) and then installing the three small O-rings (22) into the manifold (23).
19.Align and install manifold (23) onto valve body (26) with two 8-32 screws (24 and 25). The
shorter screw is installed in the top. Attach the manifold so that inlet holes on the manifold
align with inlet holes on the valve body. Refer to Figure 7-4.
When installing the manifold be careful not to damage the air tubes. If the tubes are bent
too close to the manifold, it is possible to break them.
Example Application
The following is an example of an actual application using the live tee. Actual flows and
pressures are indicated and chromatograms are provided to illustrate the set up process.
PA Pm (-) Pm (+)
Injector
Pre Column
Main Column
To FID
NV Cut NV Purge
Split and
Backflush
Vent
Cut Vent
to FID
Purge Vent
to TCD
4.3 Detectors
Note
Do NOT attempt to open the TCD with the power on.
Note
When removing materials from the analyzer, all items must be placed on a clean, non-abrasive
surface. Use a clean lint-free cloth.
4.3.2.3 Figures
The following figures are used during the maintenance procedure.
14 6
13 5
7
11 12
10 8
9
1. Label, Certification
2. Hammer Drive Screw (2 each)
3. Hex Head Screw and
Lock Washer (4 each) 4
4. Detector Block
5. Detector Connector Block
6. Hex Head Screw (4 each)
7. Lock Washer (4 each)
8. Detector Wiring
9. Button Head Hex Screw
10. Lock Washer
11. Flat Washer
12. Thermistor Board 1 3
(Filament Board for 2-Cell)
13. O-Ring 2
14. Flow Diverter (or Low
Volume Metal Insert)
Thermistor /
Filament Lead Groove
Screw Hole
Metal Insert /
Tube Holes in
Flow Diverter
Detector Block
1. Shut off flows and shut down power to the analyzer. Allow the detector to cool down.
2. Remove the 4 screws and lock washers (3) that secure the cover to the detector block (4)
and remove the cover.
3. Making note of the connection location for each wire, remove the wiring (8) that is connected
to the Thermistor/Filament Board (12) that is to be removed.
4. Remove the Thermistor/Filament Board (12) by removing the Button Head Hex Screw (9),
the Lockwasher (10), and the Flat Washer (11).
5. Discard board (12) and O-rings (13). Do not attempt to reuse old O-rings.
6. Remove the two metal inserts (14). These CAN be reused.
7. Before installing new board, examine the mounting surface and the holes for the Filaments/
Thermistors to verify there is no contamination or scratches on the machined surface.
If there is contamination on the surface, clean it using a lint free cloth and a cleaning solvent
such as acetone or hexane. If the surface is scratched it may be necessary to replace the
complete assembly.
Note
The elements on the board are exposed and are very delicate. Handle the board only by
its edges.
Hands and tools must be clean.
8. Install the metal inserts (14) in the detector block (4). These inserts should be installed with
the groove perpendicular to the tube holes in the block (so that air cannot flow in a straight
path between the holes). Refer to Figure 6-10.
9. Install the new O-rings (13) in hole in the Detector Block (4).
It is also possible to install the O-rings on the Thermistor / Filament board (12) instead of
in the hole. If installing the O-rings on the board, be careful not to damage the element.
10.Install the Board (12) into the Detector Block (4). When installing the board, exercise caution
not to damage the exposed elements.
11.Reinstall the Flat Washer (11), Lock Washer (10), and Button Head Hex Screw (9). Do not
over tighten the screw as this can damage the Board (12).
12.Reconnect wiring (8) to the board (12). Wiring MUST be connected to the same cells as
before. Verify all termination points.
Note: The color coding information for the wiring should be on the Detector Certification
Label (1). Also note that there are two wires of each color. For a specific cell it does not
matter which wire is connected to which lead as long as the color is correct.
13.Before installing cover back on the Detector Block (4), turn on carrier air to verify there are
no leaks between the Board (12) and the Block (4). Turn off carrier after this check is
complete.
14.Set the cover in place and reinstall the 4 screws and lockwashers (3) that secure the cover
to the detector block (4).
Mesh Description
This section describes the procedure to replace the mesh filter inside the FID in the Maxum
II. The mesh filter is a small round filter located inside the combustion chamber of the FID.
This filter is for the combustion air input. Because of the very small diameter of the air restrictor
though which combustion air passes, it is unlikely that the filter will become clogged.
Because it is difficult to remove this filter without damaging it, in the event that the filter does
become clogged or it should become necessary to remove the filter for some reason, then it
should be replaced and not reused.
It will be necessary to power down the analyzer for this procedure. When performing this
procedure, it should NOT be necessary to remove the FID from the Maxum II.
Note
This procedure must only be executed with the consent and approval of all applicable local
safety personnel and/or the local authority having jurisdiction.
21 22
20 19
3
18 17
15
14 2
Quartz Jet
16
Assembly
1
13
11 12
10
4
9 5
4
5 3. Detector Body (Bottom)
4. Filter
5. Retainer Clip - Small
6. Retainer Clip - Large
WARNING
Possible ignition source. Failure to follow proper safety procedures may result in injury or
death.
If the analyzer is equipped with a purged methanator and explosive gasses are present,
it is necessary to wait at least 8 minutes for the methanator to cool after powering down
the analyzer before opening the analyzer door.
CAUTION
Possible ignition source. Failure to follow proper safety procedures may result in injury or
death.
Do not open the FID with the flame burning or with the power on.
5. Unscrew Burner Nut (10) and remove the Quartz Jet and attached hardware (7, 8, 9, 10,
and 11). Set these items aside on a clean, lint free cloth.
6. Using a small flat-head screwdriver or similar tool, remove the Small and Large Retainer
Clips (5 and 6).
7. Turn on the air supply to the FID in order push the Mesh Filter (4) up so that it can be
removed.
If turning on the air supply does not dislodge the Mesh Filter (4), use a flat screwdriver to
carefully pry up the Filter (be careful not to scratch the surface of the FID body.
8. Turn off the FID combustion air.
9. Discard the old Mesh Filter (4) and install a new one in the FID.
10.Re-install the Small and Large Retainer Clips (5 and 6)
11.Re-insert the Quartz Jet and attached hardware (7, 8, 9, 10, and 11) into the FID Bottom
Body (3). Verify that the nozzle tip of the Quartz Jet (11) is still adjusted correctly (there
should be 10.5 mm from the nozzle tip to the Lower Body (3).
12.Tighten the Burner Nut (10) with fingers. Then retighten one quarter to one half rotation
using a wrench. The nozzle can break if it is tightened more.
13.Replace the graphite seal (12) before reassembling the FID body.
14.Reattach Upper Body (16) and Lower Body (3) and reinstall Cap Screws (19). Tighten Cap
screws firmly but do not over tighten (about 1/2 turn past finger tight).
15.Power the analyzer back on.
16.After the oven and FID has had time to heat up, check the flows and light the flame.
Maintenance work on the Maxum II analyzer should only be performed when the area is known
to be safe for the work to be done.
Note
This procedure must only be executed with the consent and approval of all applicable local
safety personnel and/or the local authority having jurisdiction.
WARNING
Possible ignition source. Failure to follow proper safety procedures may result in injury or
death.
If the analyzer is equipped with a purged methanator and explosive gasses are present,
it is necessary to wait at least 8 minutes for the methanator to cool after powering down
the analyzer before opening the analyzer door.
Description
This section describes the procedure to retrofit the FID igniter in the Maxum II. This involves
replacing the original FID igniter module with a new version FID igniter module. The procedure
also involves replacing of some of the related hardware, such as the purge tube and heater
tube. It will be necessary to power down the analyzer for this procedure.
Intended Users
This procedure is written to be understood by personnel who are trained to perform everyday
maintenance of the Maxum II analyzer. Users of this procedure must have strong working
knowledge of the safety systems of the Maxum II analyzer and have the knowledge to safely
power the analyzer down and back up. Users must also have a good working knowledge of
the Maxum II hardware and should be very familiar with the operation and day to day
maintenance of the analyzer.
However, this procedure involves retrofit of the Flame Ionization Detector which may impact
the safety protection of the analyzer. This procedure should only be executed with the approval
of applicable local safety personnel and/or the local authority having jurisdiction.
Note
This procedure must only be executed with the consent and approval of all applicable local
safety personnel and/or the local authority having jurisdiction.
Procedure - Parts
A parts kit (Siemens part number 2022073-001) is required for this procedure. This kit contains
the following items.
The list above is provided for reference only. The official parts list for the kit is included with
the kit when it is shipped. The Callouts above will be used throughout this procedure to help
the user identify the proper part to use for a specific step.
Also required is a tool kit including both standard and metric wrenches, Allen wrenches, and
nut drivers. A lubricant such as Krytox 240 AC or equivalent will be needed in order to lubricate
the new grommets. If the EC Cover Plate Gasket (Part Number 2021171-001) is damaged, a
replacement gasket will be required as well.
Note
All figures are located at the end of this procedure.
1. From GCP, backup the database of the Maxum analyzer that is to be modified (refer to the
Maxum Maintenance Manual for instructions).
2. From GCP, verify operation of analyzer. Verify that there are no alarms or that all alarms
are accounted for. (Refer to the Maxum Maintenance Manual for instructions).
3. Verify that all parts of the new FID igniter kit are on site prior to starting. Contents of the
kit are listed in the inventory list that is shipped with the kit.
4. Extinguish the flame to the FID either by shutting off the air supply to the detector (for
hydrogen carrier) or shutting off the hydrogen to the detector (if not using hydrogen carrier).
In order to prevent condensation in the detector, allow carrier to flow for several minutes
after flame is extinguished. Use a mirror to check for condensation at the FID vent to verify
the flame is not lit (no condensation means the flame is not lit).
WARNING
Possible ignition source. Failure to follow proper safety procedures may result in injury or
death.
If the analyzer is equipped with a purged methanator and explosive gasses are present,
it is necessary to wait at least 8 minutes for the methanator to cool after powering down
the analyzer before opening the analyzer door.
Note
A clean work surface should be used for disassembly of the old igniter and installation of the
new igniter. This is to prevent contamination of the detector gas inputs and electrical contacts.
1. Remove the four screws that secure the purge tube to the electrodes of the detector. Refer
to Figure 3-6.
2. Pull the purge tube about 1 inch away from the detector assembly and carefully remove
the wires from the electrodes.
3. The purge tube, EC cover plate, and igniter assembly will not be reused. Set these items
aside. However, the screws that were used to connect the tube to the detector will be reused.
4. Using an 11/16" wrench, remove the old RTD tube from the detector heater assembly. This
is the bent 3/8" tube that connects from the heater assembly near the base of the detector
to the smaller hole on the EC cover plate. Refer to Figure 3-6. Note that this tube will be
replaced with a different one to allow for installation of the larger purge tube.
5. Attach the new nut and ferrule (items 13, 14, and 15) to the new RTD heater tube (item
12). Refer to Figure 3-7.
6. Install the new 3/8" RTD tube (12) onto the detector heater assembly. To allow for easier
installation of the cover plate, do not completely tighten the nut at this time. Refer to Figure
3-7.
7. Install the Kalrez high-temperature O-ring (item 8) into the groove on the new purge tube
bushing. Refer to Figure 3-10.
8. Install the new purge tube bushing (item 5) onto the FID using the 4 screws removed from
the purge tube earlier in this procedure. The new pipe gasket (item 3) should be positioned
between the bushing and the FID body. Install the bushing such that the tab (used to attach
the igniter fastening strap) is on the bottom. Refer to Figures 3-9 and 3-10.
9. Using a 2.5mm Allen wrench, attach the fastening strap (item 10) to the new igniter board
(item 9). Use a socket head cap screw (item 6) from the kit for this connection. Refer to
Figure 3-9.
Note
Because the wires from the igniter to the electrodes are stiff, it is best to plug the wires in
before attaching the strap to the bushing.
10.Plug both igniter wires into the appropriate detector electrode positions. Refer to Figure
3-11. The wires from the igniter board to the DPM should not be connected yet.
11.Using a 2.5mm Allen wrench, attach the new igniter board to the bushing on the detector
assembly using the fastening strap. Use a socket head cap screw (item 6) and lock washer
(item 7) from the kit for this connection. Note that the igniter board is installed with the flat
side up and the round transformer down. Refer to Figure 3-9.
12.Plug the white signal wire (from the DPM) into the appropriate detector electrode position.
Refer to Figure 3-11. The wire should not be connected at the DPM end yet.
13.Place the white signal wire (from the DPM) across the top of the new igniter board as shown
in Figure 3-8.
14.Insert the unplugged ends of the wires into the new FID purge tube (item 2) and slide the
purge tube over the igniter board and wiring. Make sure that the white signal wire remains
positioned against the flat top side of the igniter board.
Note that it does not matter which end of the tube is inserted towards the detector since
both ends of the tube are identical.
15.Line up the hole on the new purge tube with the hole on the bushing and fasten the tube
to the bushing using a 2.0mm Allen wrench. Use the button head cap screw (item 11) from
the kit for this connection. Refer to Figure 3‑12.
16.If the new grommets (items 4 and 16) are not installed into the holes on the new EC cover
plate (item 1), then install them now. Refer to Figure 3-7.
17.Apply a coating of Krytox 240 AC or similar lubricant around the inside diameter of the
grommets to allow for easy sliding of the new purge tube.
18.Feed the detector wiring through the appropriate holes on the new EC cover plate and
install the cover plate onto the detector assembly. Refer to Figure 3-4.
19.Tighten the nut on the new RTD heater tube at this time. Refer to Figure 3‑7.
8. Place the FID flame arrestor insert and washer into the FID bottom body and tighten using
a 9/16" open-end wrench. Make sure the flat washer (item 17) fits into the recessed cavity
at the lower end of the FID bottom body to insure it does not leak. Refer to Figures 3-4 and
3-5.
9. Connect the FID flame arrestor insert tubing to the correct connection union in the air bath
oven using either a 1/4" or 5/16" open-end wrench depending on the fitting size.
10.Route the bias cable, the igniter cable, and the signal cable through the EC and connect
them to the FID DPM board locations from which they were unplugged earlier in this
procedure.
11.Route the FID heater RTD cable through the EC and plug it into the DPM location from
which it was unplugged earlier in this procedure.
12.Route the FID heater power cable through the EC and plug it into the PECM location from
which it was unplugged earlier in this procedure.
13.Turn on utility gases and check for leaks.
14.Turn on power to the analyzer and switch the valves checking all possible flow paths for
leaks. Refer to plumbing diagram provided in the custom documentation package for flow
paths.
15.Turn up oven air to the normal setting and allow the oven to come to temperature and
stabilize.
16.Set all gas flows after the detector is up to its temperature set point.
17.With the new igniter, it will be necessary to start Real Time Chromatograms on the HMI in
order to light the FID flame. On the HMI, choose the Maintenance Menu, and then select
option 5 (Detectors & Real Time Chroms). Then highlight the appropriate FID and then
press "View Chrom".
18.At this time you can ignite the FID using the HMI.
19.After 15 to 30 minutes the analyzer will be ready for operation. Verify that the FID operates
correctly and put analyzer back on line.
Procedure - Figures
FID EC Cover
Plate
Old Igniter
FID Bottom
Body
Flame Arrestor
Insert Tubing
Connection
Vent Tube
New Igniter
FID Bottom
Body
Flame Arrestor
Insert Tubing Connection
Insert
Washer
Narrow End of
FID Bottom Body
FID Flame
Arrestor Insert
Purge Tube
Utility Gas
Lines
RTD Heater
Tube
Grommets
EC Cover
Plate
Utility Gas
Lines
RTD Heater
Tube
Mounting
strap/ground strap
Groove for
Kalrez O-Ring
Specifications
FPD II Label
Components
The FPD comprises:
● Bottom part contains connections for combustion gas, combustion air, column and exhaust,
and a burner nozzle.
● Top part contains combustion chamber, glow plug and fiber optic interface.
Combustion Chamber
● The burner nozzle consists of two annular gaps. The combustion gas H2 flows out of the
outer annular gap and mixes with the combustion air from the inner gap. The carrier gas
flows from the nozzle into the dome-shaped flame.
● The exhaust is taken from the combustion chamber output via a flameproof joint.
● The glow plug is located above and to the side of the burner.
Optics
● The flame burns in a recessed area shielded from the fiber optic interface.
● The fiber optic cable connects to the photo multiplier tube (PMT) module in the EC.
● The optical interference filter is built into the PMT module
● All connections between the combustion chamber and the photomultiplier are absolutely
light-tight.
● The ignition cable of the FPD is routed through an EEx-e feed through to the EC.
Heater
he FPD is supplied with an external heater. Condensation would be formed in the FPD at
temperatures below 80°C and have a negative influence on the measuring properties. The
detector is insulated to prevent moisture from entering it.
The detector temperature is factory set depending upon the application. The temperature is
normally set equal to or higher than the oven temperature and at minimum 80°C.
Note
The FPD is a very sensitive detector. The gases and their supply lines must be extremely clean
and sulfur free to achieve a high signal/noise ratio.
Note
This procedure must only be executed with the consent and approval of all applicable local
safety personnel and/or the local authority having jurisdiction.
Note
The existing light pipe and PMT module are kept and used for the FPD II.
Note
Because this procedure is intended for expert users, many of the steps have limited detail.
4. If the analyzer has mechanical regulators, shut off the hydrogen and air supplies to the
detector.
CAUTION
Potential burn hazard. Handling hot components may result in personal injury.
Detector may still be hot during removal. Exercise care when handling detector parts.
5. Remove the cover and insulation from the old detector. Use caution at this point as the
detector may still be hot.
6. Disconnect the hydrogen and air lines to the detector and the detector vent line from the
back of the detector.
7. Disconnect the column from the detector in the Maxum II oven.
NOTICE
Sensitive components. Failure to observe proper procedures may damage the equipment.
The photomultiplier in the FPD is sensitive to light. Avoid prolonged exposure of the
multiplier to excessive light, even when powered down. Never subject the light entry
window to a bright light source.
8. Disconnect the light pipe from the side of the analyzer. Remove and discard the brown
Viton O-rings on the light pipe. The new FPD does not require O-rings in this location.
9. Remove the screws from the detector mounting plate and the cover plate on the back of
the mezzanine.
10.Remove the detector from the Maxum II along with its mounting bracket, heater and cover
plate. The heater wiring, glow plug supply wiring and the associated purge tubes need to
taken out as well. Note the wiring connections as you remove them from the DPM.
11.Before installing the new detector, the cover and insulation need to be removed. Replacing
the insulation and cover will be the last step in the installation.
12.Install the FPD II. As you install the detector feed the wiring through the mezzanine and up
to the DPM. Connect the screws on the mounting plate.
13.Attach the mezzanine cover plate.
14.Connect the heater, thermocouple, and glow plug wiring to the DPM.
15.Connect the column inlet, hydrogen and air supplies, detector vent and the light pipe.
16.Replace the insulation and cover on the detector. Restore power to the Maxum II.
17.After the Maxum II has had time to heat up, check the flows and light the flame.
4.3.6 Methanator
4.3.6.1 Methanator
The methanator is used with a Flame Ionization Detector (FID) when it is necessary to detect
carbon monoxide (CO) or carbon dioxide (CO2). In the methanator CO and CO2 are chemically
changed to methane using excess hydrogen and a catalytic reaction. The concentration of
methane, which can be detected using an FID, is proportional to the concentration of CO and
CO2. In this manner, it is possible to detect CO and CO2 using an FID. The methanator operates
at a very high temperature of approximately 400°C (752°F).
Two versions of the methanator exist. The original version is designed such that it is an
extension of the purged Electronics Enclosure (EC). It is connected to the CD via a pipe through
which purge air flows. This prevents explosive gases or vapor from entering the methanator
and contacting the hot surfaces.
The newer version of the methanator is an explosion proof version. This version is sealed
within an explosion proof enclosure. The interior of the explosion proof methanator is designed
somewhat differently than the original, but the theory of operation is identical.
Note
Important
Use in non-hazardous areas requires purging of the electronics area with air or nitrogen. PDD
is not certified for hazardous areas.
Oven options ● Single isothermal oven or divided oven with two independent isothermal zones
● Single oven or two independent airless ovens. The dual version has two separate oven
areas with separate doors which operate completely independently.
Detector modules Thermal conductivity, flame ionization, flame photometry, helium ionization, photo-ionization
and electron capture
Number of detector modules ● 1, 2 or 3 in any combination of detector module types for airbath ovens
● 1, or 2 in any combination of detector module types for airless ovens,up to 3 in special
configurations
Sample and column valves Diaphragm valves, diaphragm piston valves, sliding vane rotary valves, slider valves, or liquid
injection valve
Valveless option Live switching
Columns Packed, micropacked or capillary columns
Gas supply regulation Up to 8 electronic pressure regulator channels and up to 6 mechanical pressure regulators
Power supply ● Single-phase AC, 100 - 130V or 195 - 260V (selectable), 47 - 63Hz
● Single oven: max. 14A
● Dual oven: 2 circuits, max. 14A each
Instrument air ● At least 350kPa for units with valves Model 11 or Valco
● At least 825kPa for units with valves Model 50
● At least 175kPa for airbath ovens; 85l/min per oven
● No instrument air for fan-free ovens
Combustion gas ● Nitrogen or helium in compressed gas cylinder, purity 99.998%, or hydrogen with a purity
of 99.999%(depending on application).
● Typical consumption quantity: 5 - 100l/month per detector module
Combustion gas ● Hydrogen with a purity of 99.999%
● Typical consumption quantity: 2,000l/month per detector module
Combustion air ● Reference air (<1ppm THC, O2 concentration 20 - 21%). Supply through instrument air
with catalytic purification (optional).
● Typical consumption quantity: 26,000l/month
Corrosion protection ● Purging with dry air to protect the electronics
● Air bath oven with stainless steel lining
● Airless oven made of aluminum
● Steel lining painted on outside (epoxy powder coating)
A S
ABH1, 138 Sensor Near Electronics, 17
ABH2, 138 Sensor Near Electronics software module, 17
Applet, 13 SNE, 17
Applet Module, 13 SNE functions, 19
Application, 13 Solid State Relay Module, 138
C T
Columns, 20 TEMP CONTROL, 96
Thermistor, 21
D
DHCP, 26
E
EC, 20
Ethernet IP, 26
F
Filament, 21
Flame Ionization, 21
Flame Photometric, 21
Fuses, 139
H
Heater Termination Plug, 96
I
IP address, 26
M
Method, 13
P
Pulsed Discharge, 21