Siemens GC..M.. Installation manual

Installation Manual Edition 8/2007
MAXUMTM edition II
Process Gas Chromatograph
pro
ces
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GAS CHROMATOGRAPHY
Maxum™ edition II
Process Gas Chromatograph
Table of Contents
Getting Help
Safety Practices & Precautions
Site Considerations
Maxum II Specifications
Maxum II Outline Drawing
Receiving a Crated Analyzer
Mounting the Analyzer
Cable Connection
Installing Primary AC Power
Utility Gas Supply Installation
Sampling System Installation
Analyzer Connections
Maxum II Initial Startup Procedures
Maxum II Shutdown, Restart, and Cleaning Procedures
Assigning IP & Sub Network Mask Addresses
Spare Parts
Siemens © 2001-2007 All rights reserved.
Maxum and Maxum edition II are trademarks of Siemens
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Getting Help
Contacts for Help
Siemens provides support for the Maxum System worldwide. Contact information is provided on all
Siemens products at the web sites noted below.
This page provides contact information for Maxum System technical support, training, spare parts, and
field service callout. Worldwide e-mail requests can be submitted 24 hours a day, 7 days a week. Service
contracts can be established for direct remote phone service for products or for regular field service visits
to the site.
When the analyzer is mounted and all of the connections are made, a specialist can be sent to assist you
in starting up the equipment and preparing it for use. To schedule, contact Customer Service.
To Contact Us:
Siemens AG
A&D PI 2 MIS Process Analytics
Oestliche Rheinbrueckenstr. 50
76187 Karlsruhe
Germany
Siemens Energy & Automation, Inc.
7101 Hollister Road
Houston, TX 77040
USA
Siemens Pte. Limited
A&D PI 2 Regional Headquarters
The Siemens Center
60 MacPherson Road
Singapore 348615
Tel:
Fax:
E-mail:
Tel:
Fax:
E-mail:
Tel:
Fax:
E-mail:
+49 721 595 4234
+49 721 595 6375
processanalytics@siemens.com
+1 713 939 7400
+1 713 939 9050
saasales.sea@siemens.com
+65 6490 8702
+65 6490 8703
splanalytics.sgp@siemens.com
www.siemens.com/processanalytics
www.usa.siemens.com/ia
www.siemens.com/processanalytics
Training
Tel:
+49 721 595 4035
E-mail: carmen.stumpf@siemens.com
Training
Tel:
+1 800 448 8224 (USA)
Tel.
+1 918 662 7030 (International)
E-mail: saatraining.sea@siemens.com
Siemens Industrial Automation
Shanghai
Spares
Tel:
+49 721 595 4288
E-mail: hans-peter.schaefer@siemens.com
Support
Tel:
E-mail:
+49 721 595 7216
niko.benas@siemens.com
Spares
Tel:
+1 800 448 8224 (USA)
Tel:
+1 918 662 7030 (International)
Fax:
+1 918 662 7482
E-mail: saaspareparts2z.sea@siemens.com
Support
Tel:
Tel:
E-mail:
+1 800 448 8224 (USA)
+1 918 662 7030 (International)
saasupport.sea@siemens.com
Siemens Process Analytics Ltd., Shanghai
PI and Analytics Technical Service Center
12 workshops, 175 XiMaoJing Road
Export Processing Zone, SongJiang
Shanghai, 201611
Peoples Republic of China
Tel:
Fax:
E-mail:
+86-21-5774 9977
+86-21-6774 7181
pipaservice@siemens.com
www.ad.siemens.com.cn
Before You Call
When contacting Siemens Customer Service for installation technical assistance, the user will need to
provide the unit serial number and a detailed description of the problem.
Indicate the installation problem encountered and provide any other information that will aid the customer
service representative in correcting the problem.
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Safety Practices and Precautions
Safety First
This product has been designed, tested, and supplied in a safe condition in accordance with IEC
Publication 61010-1, Safety Requirements for Electrical Equipment for Measurement, Control, and
Laboratory Use - Part 1: General Requirements. This manual contains information and warnings, which
have to be followed to ensure safe operation and to maintain the product in a safe condition. The user
must ensure that the Maxum II is installed in compliance with all applicable local and national codes for
safety compliance.
Terms in This Manual
WARNING statements identify conditions or practices that could result in personal injury or loss of life.
CAUTION statements identify conditions or practices that could result in damage to the equipment or
other property.
Terms as Marked on Equipment
DANGER indicates a personal injury hazard immediately accessible as one reads the markings.
CAUTION indicates a personal injury hazard not immediately accessible as one reads the markings, or a
hazard to property, including the equipment itself.
Symbols in This Manual
This symbol indicates where applicable warning, caution,
or other information is to be found.
This HOT symbol warns the user of a hot surface and
potential injury if touched.
Symbols Marked on Equipment
DANGER - High voltage
Protective ground (earth) terminal
ATTENTION - Refer to Manual
This HOT symbol warns the user of a hot surface and
potential injury if touched.
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Safety Practices and Precautions, Continued
Hazardous or Poisonous Gases
When hazardous gases (such as poisonous, flammable, or oxygen depleting) are potentially present in or
around the Maxum edition II Process Gas Chromatograph (hereafter referred to as Maxum II) area, all
national and international requirements must be fulfilled to protect personnel and the environment against
hazards that could arise. All process conditions (such as normal, backup, and upset) must be considered
in the determination for potential hazardous gas presence. To avoid leaks, scheduled preventive
maintenance and inspection for leaks should be performed by the customer. Leak sources should also be
minimized as is noted in the procedure by external venting of the oven exhaust and analyzer vents. This
reduces (does not eliminate) the sources for leaks, so personnel protection is a requirement whenever
hazardous/poisonous gases may be present. Disregarding this warning could result in serious injury or
death and damage to equipment.
Correct Operating Voltage
Before turning on the power initially, the responsible person should ensure the input voltage is correct for
the unit configuration.
Danger Arising from Loss of Ground
Any interruption of the grounding conductor inside or outside the equipment or loose connection of the
grounding conductor can result in a dangerous unit. Intentional interruption of the grounding conductor is
not permitted.
Safe Equipment
If it is determined that the equipment cannot be operated safely, it should be taken out of operation and
secured against unintentional usage.
Use the Proper Fuse
To avoid fire hazard, use only a fuse of the correct type, voltage rating, and current rating as
specified in the parts list for your product. Use of repaired fuses or short-circuiting of the fuse
switch is not permitted. Fuses should be replaced by trained service personnel only.
Safety Guidelines
DO NOT perform electrical parts replacement or repairs until all power supplies have been disconnected.
Only an adequately trained technician should service or repair the equipment.
When opening covers or removing parts, extreme care should be taken since hot surfaces and "live”
parts or connections can be exposed.
Caution should be taken when touching the outside surfaces of the analyzer when
installed in ambient conditions above 40°C.
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Site Considerations
Description
To protect the Maxum II from the elements, it should be located in an analyzer house or a similar
protected enclosure; see Figure 1-1. The air temperature around the analyzer should be maintained
between 0°F (-18°C) and 122°F (50°C). An installation drawing package will be sent out early in the
project to document the application specific information for each Maxum II needed for site preparation.
Final documentation will be shipped with the unit.
Figure1-1.Typical Analyzer House
To protect the Maxum II from the elements, it should be
located in an analyzer house or a similar protected enclosure
Location
The Maxum II is manufactured and tagged for a specific hazardous area classification. The unit must be
installed in an area that is suitable for this area classification.
WARNING The unit is tagged with a T-rating which quantifies the maximum surface
temperature that may occur in the instrument. The user must ensure that no combustible gas
concentrations will be present, whether on a continual or occasional basis, which has an
ignition temperature below the T-rating of the unit.
The analyzer house should be located as close as possible to where the sample is to be obtained to
minimize the sample transit time. It is preferable that this distance be less than 100 feet (30 m).
The analyzer house must be large enough to allow ample access for installing, operating, and
maintaining the analyzer. The concrete slab for the analyzer house should be large enough to
accommodate gas cylinders located on the outside. Make sure a cylinder rack or chain guard is provided
to secure the cylinders.
Space inside for the analyzer must be at least 90” high by 50” wide by 40” deep (229 cm high by 127 cm
wide by 102 cm deep.) The height may be somewhat less if there is no sampling system cabinet or panel
beneath the analyzer. Refer to Maxum II Outline Drawing on page 12.
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Site Considerations, Continued
When the Maxum II contains an air bath oven, it will vent in excess of 3 SCFM (85 liters per minute) of
heated air through the oven exhaust. See note below for the recommended approach.
WARNING All vent lines and oven exhaust should be vented outside the shelter. The vents
should be connected to a location where the pressure is atmospheric. Connection of oven or
analyzer vents to a variable pressure source such as a flare header should not be done, as
chromatographic performance will be severely affected. Backpressure on the oven vent could
cause the T-rating of the instrument to be exceeded, which might become an ignition source.
Refer to the comments on Hazardous gases on page 3.
Installation of the unit with a combustible gas coming into the EPC requires that a restriction be placed on
the flow into the Maxum II. This is required to limit the flow of the combustible gas into the unit. The
recommendation is to limit the flow prior to entry into the shelter.
WARNING The Maxum II will be tagged for flow restriction of combustible gases into the
Electronic Pressure Controller. The user/installer must ensure that this flow restriction is
implemented to permit safe operation of the unit.
Intended Use
The Maxum edition II gas chromatograph is used in all branches of the fine chemicals, refining and
hydrocarbon processing industries. It performs chemical composition analysis of gases and liquids that
are present in all phases of production. The Maxum II is built for installation in harsh environments either
directly or nearby in at-line process measurement laboratories. Its application flexibility allows it to
analyze samples of feedstock, partially processed streams, final products and process byproducts
including wastes and environmental hazards.
This product is intended to be used only in conjunction with other devices and components which have
been recommended and approved by Siemens. Appropriate safety standards were used in the
development, manufacture, testing, and documentation of the Maxum II. Under normal operation, this
product is safe for use providing that all safety and handling guidelines are observed with respect to
configuration, assembly, approved use, and maintenance. This device has been designed such that safe
isolation is guaranteed between high and low voltage circuits. Low voltages which are connected must
also be generated using safe isolation.
If any part of the Maxum II is opened, certain parts of the device are accessible which may carry
dangerous voltages. Therefore, only suitably qualified personnel may work on this device as indicated in
the next section which is titled “Qualified Personnel”.
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Site Considerations, Continued
Qualified Personnel
Only suitably qualified personnel may operate or perform maintenance on the Maxum II.
purposes of safety, qualified personnel are defined as follows:
For the
•
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 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.
7
Maxum II Specifications
The equipment is designed to be operated under normal environmental conditions unless noted
otherwise in the specifications that follow.
Configuration
Oven Options
Detector Modules
Number of Detector Modules
Sample/Column Valves
Valveless Option
Columns
Gas Supply Regulation
Solenoids
Air bath: Single isothermal oven or split oven with 2 independent isothermal
zones, or one isothermal and one PTGC
Airless: Single or dual independent ovens. Dual version has two distinct
oven compartments for complete operating independence for up to a
maximum temperature differential of 100°C.
Thermal Conductivity, Flame Ionization, Flame Photometric, or Pulsed
Discharge (in Helium Ionization, Photoionization, or Electron Capture Mode)
Air bath: 1, 2, or 3 in any combination of detector module types
Airless: 1 or 2 in any combination of detector module types
Diaphragm, diaphragm-plunger, heated liquid injection valve, and rotating or
linear transport,
‘Live’ Switching
Packed, micro-packed, or capillary
Up to 8 electronic pressure controls and up to 6 mechanical pressure
controls
Solenoids are 2 watts each, total SVCM wattage on continuous basis not to
exceed 17 watts
Performance
Minimum Range (general)*
Cycle Time
Sensitivity*
Linearity*
Oven Temperature Range
(Dependent on T – Rating)
Temperature Control
Ambient Temperature Effect
Vibration Effect
Mean Time To Repair
Mean Time Between Failures*
Thermal Conductivity: 0-500 ppm
Flame Ionization: 0-1 ppm
15 sec to 3 hr (application dependent)
± 0.5% of full scale
± 2% of full scale
Air bath: 40 to 440°F (5 to 225°C)
Airless: 40 to 500°F (5 to 260°C)
± 0.05°F (± 0.02°C)
Negligible with electronic pressure control
Varying effect with mechanical pressure control*
Negligible
1 hour
3 years excluding consumables
Communication Options
Serial Output
Ethernet
DataNET
Data Hiway
RS232, RS485
Standard 10BaseT Ethernet with RJ45 connectors
Proprietary high speed TCP/IP communication network (redundant pair
cable)
Proprietary serial communication network (redundant pair cable)
*confirm with application
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Maxum II Specifications, Continued
I/O Options
Standard I/O
Board Slots for Optional I/O
I/O Boards
Digital Inputs
Digital Outputs
Analog Inputs
Analog Outputs
Termination
2 analog outputs; 4 digital outputs (1 indicates system error, 3 are
user configurable); 4 digital inputs; 1 serial output
2
AO 8: 8 electrically isolated analog output channels
D I/O: 4 digital inputs and 4 digital outputs
A I/O: 2 digital inputs and 2 digital outputs,
2 analog inputs and 2 analog outputs
Optocoupler with internal 12-24 Vdc power supply, switchable
with floating contacts. Alternative: switchable with external 12-24
Vdc supply (floating relay contacts only), external power supply
negative terminal connected to common for specific DI being used
Floating double-throw contacts, maximum contact load rating
1 A at 30 Vdc. Diode shunt suppression should be used for
inductive loads. A DO should not drive more than a 0.5A
inductive load. Dry contact DOs (I/O boards and Syscon) can not
be used with line voltages. The PECM has SSRs which may be
controlling line voltage for the particular application
-20 to +20 mA into 50 ohms or -10 to +10 V Rin = 1 M ohm,
mutually isolated to 10 V
0/4 to 20 mA into 750 ohms max., common negative pole,
galvanically separated from ground, freely connectable to ground
Screw compression terminal strip for braided or solid cable with
maximum section of 16 AWG or 1.5 mm2
Gas Sample Requirements (application dependent)
Sample Flow
Sample Filtration
Minimum Sample Pressure
Maximum Sample Pressure
Maximum Sample Temperature
Material in Contact with Sample
50-200 cc/min (application dependent)
0.1 μm
5 psig (35 kPa), lower pressure optional
75 psig (515 kPa), standard; higher pressure optional
250°F (121°C) standard; higher temperature optional
Stainless steel, Teflon, and polyimide; other material optional
Liquid Sample Requirements (application dependent)
Sample Flow
Sample Filtration
Minimum Sample Pressure
Maximum Sample Pressure
Maximum Sample Temperature
Material in Contact with Sample
5-20 cc/min (application dependent)
5 μm
0.3 μm if SLIV used in application
5 psig (35 kPa), standard
300 psig (2070 kPa) standard; higher pressure optional
250°F (121°C) standard; higher temperature optional
Stainless steel and Teflon; other material optional
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Maxum II Specifications, Continued
Installation
Configuration
Single unit with multiple enclosures
CAUTION When mounting the analyzer on a wall, care should be taken to ensure that the wall
(vertical mounting surface) can withstand four times the minimum weight of the analyzer when
mounted with the appropriate hardware. In some cases, it is recommended that brackets, such
as Unistrut or angle iron be added to the mounting surface to help distribute the weight.
Mounting minimums
Dimensions
Weight
Enclosure Rating
EMI/RFI Rating
Hazardous Class
Ambient Temperature and
Humidity (for Normal Operation,
Storage, and Transport)
Altitude
Left side clearance:
Right side clearance:
Front side clearance:
Wall Mount Units
Center to center:
18” (460 mm) from wall or other equipment
18” (460 mm) in all cases
25 ¾” (654 mm) in all cases
44”
(1120 mm) in all cases
Height:
39 ¾“
(1010 mm)
Width:
26 1/16” (662 mm)
Depth:
16 3/16” (451 mm)
170 lb (77 kg)
NEMA 3, IP54 (outdoor with weather protection)
Pollution Degree 2
CE Compliance; certified to 89/336/ECC (EMC directive)
CE Compliance; certified to 73/23/EEC (Low Voltage directive)
Tested per EN 61010-1 / IEC 61010-1
Standard Configurations:
Certified by CSA C/US for use in Class I, Division 2, Groups B,C,D
Suitable for use in European Zone 2, Group IIB+H2 with local
approval
Suitable for use in general purpose and non-hazardous areas
Optional Configurations:
Certified by CSA C/US for use in Class I, Division 1, Groups B,C,D
with air or nitrogen purge
Certified CENELEC/ATEX as EEx pedmib IIB + H2 with air or
nitrogen purge and purge control for Zone 1 or Zone 2
Minimums - 0°F (-18°C) and 0% Humidity
Maximums Up to 104°F (40°C) at 50% relative humidity
Up to 86°F (30°C) at 80% relative humidity
Operational Maximums – The Maxum II may be operated at ambient
conditions of up to 122°F (50°C) and 95% relative humidity provided
the electronic doors are not opened and the electronics compartment
is purged with clean, dry instrument air. The instrument air must be
dry enough to prevent humidity condensation inside the electronics
enclosure.
Note: If the Maxum II is exposed to high condensing humidity with the
electronics open or without dry purge air applied, then it must be
allowed to re-stabilize at the above stated conditions for at least 8
hours before electrical power is applied.
Up to 2000m (6561 ft.) for analyzers using 230 VAC Supply
Up to 3000m (9842 ft.) for analyzers using 115 VAC Supply
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Maxum II Specifications, Continued
AC Power
Instrument Air
Carrier Gas
Flame Fuel
Flame Air
Corrosion Protection
100-130 VAC or 187-264 VAC (configuration dependent); 47-63 Hz.,
single phase
Transient Overvoltage – Category II (IEC 60364-4-443)
Single oven:
14 amperes maximum.
Dual oven:
2 circuits, 14 amperes maximum per oven
To meet European Standards, customer provided power cables
should be double insulated (unless both power and signal wiring are
rated for 300 volts, in which case basic insulation is sufficient)
50 psig (350 kPa) minimum for units using Model 11 or Valco valves
120 psig (825 kPa) minimum for units using Model 50 valves
Air bath: 25 psig (175 kPa) minimum; 3 scfm (85 liters per
minute)/oven
Airless: None for heating (may be used for electronics purge)
Cylinder nitrogen or helium at 99.998% purity, or hydrogen at
99.999% purity depending on application
Typical consumption – 180 scf/month/detector module
(5100 liters/month/detector module)
Hydrogen at 99.999% purity with no more than 0.5 ppm total
hydrocarbons
Typical consumption – 70 scf/month/detector module
(2000 liters/month/detector module)
Zero grade air (< 1ppm THC, O2 content 20-21%). Supplied from
instrument air with catalytic purifier (optional). Typical consumption –
900 scf/month (26,000 L/month)
Stainless steel oven liner
Painted steel exterior (epoxy powder coat)
Dry air purge to protect electronics. To maintain optimum
performance, the analyzer electronics must be kept clean and dry. If
the atmosphere in the installation environment contains condensing
liquids or corrosive gases, the electronics compartment should be
purged with clean, dry air
Calibration
Type
Zero
Span
Manual or automatic
Automatic baseline correction
Standard sample cylinder
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Maxum II Outline Drawing
Notes Unless otherwise specified, dimensions are shown as millimeters (Inches)
Recommended Minimum Clearances
2
3
Left Side - 460 (18”)
Right Side – 460 (18”)
Front Side – 654 (25 ¾”)
Center to Center – 1120 (44”)
For Air Bath Oven Only
Left Exhaust For Single Oven Applications (1” Nipple)
Left and Right Exhaust For Split Oven Applications (1” Nipple)
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Installation
Introduction
This section is intended for installation personnel. After completing these procedures, the Maxum II will
be ready for startup. To ensure a safe and trouble-free installation, follow all instructions and associated
advisories. The Maxum II has special instructions in the custom documentation and on tags placed on the
unit. These must be followed as well to ensure safe operation of the Maxum II.
CAUTION Ensure that all AC Power (Mains) specification requirements and advisories are met.
Failure to do so, and operating the equipment in a manner not specified, may impair the safety
protection provided by the equipment. Be sure to review the information provided on safety
practices and precautions (page v).
WARNING Specific additional instructions are provided with tags placed on the Maxum II and in
the custom application drawing package noted below. Installation should include all of the items
noted in both of these as well as the manuals. The tagging and custom application drawing
packages are unique to the particular Maxum II.
Custom Application Drawing Package
Included with your analyzer is a custom application drawing package that provides drawings and
information pertinent only to your analyzer. Because procedures in this manual reference the drawing
package, you should have this package readily available during installation.
Typical drawings included are:
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System Block and Utility Requirements
System Outline and Dimensional Drawings
Sampling System – Plumbing and Spare Parts List
Sampling System Dimensional Diagram
Sampling Probe
Electronic Controller – Internal Layout
Applicable Wiring Diagrams
Oven Plumbing Diagram – Sensor Near Electronics
Recommended Spare Parts - Analyzer
Manufacturing Test Charts
Stream Composition Data
Data Base
Considerations for Pulsed Discharge Detector Installation
Instructions
Special installation considerations may be required for installation, power, gas supply, wiring, etc. in
association with the Valco Pulsed Discharge Detector. If your Maxum II is equipped with this type of
detector, refer to the custom documentation provided with the Maxum II and the Instruction Manual for
the Pulsed Discharge Detector that is available from Valco Instruments Co. Inc.
13
Receiving a Crated Analyzer
Instructions
When the Maxum II is shipped to the installation site in a reinforced crate with vibration protection, it will
be clearly labeled for horizontal placement and handling.
ƒ
On receipt of goods, look for any visible damage and verify that all items noted to be shipped
were received. Record on the goods receipt any damage or missing items noting the item(s) and
quantity missing on all copies. If anything is damaged or missing, then also notify your Siemens
representative or authorized agent of the damage to the equipment.
CAUTION If the unit is to be stored, it should be protected from the weather (the crate does not
provide weather protection.) If left outside in the weather, severe damage to the unit may occur. If
the unit is to be shipped to another location, preserve the vibration isolation provided in the
original shipping crate, or address the vibration isolation in the shipment method.
WARNING A crated Maxum II will weigh a minimum of 200 pounds (90 kg), and can weigh
substantially more depending upon the configuration. It should be moved with a forklift until
uncrated.
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Place the crate on the floor horizontally with the orientation
label THIS SIDE UP pointed up.
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Remove the metal bands from around the crate.
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Unscrew the cover and remove the crate cover. Remove
the crate sides to facilitate removal of the unit. Remove the
2x4 supports and foam blocks from the top of the analyzer.
The analyzer will be covered in a plastic sheet.
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The Maxum II will be bolted to one wooden support, which
should remain on the analyzer until it reaches its final
mounting location. Do not remove the bolts holding the
Maxum II to the wooden supports. Remove the bolts holding the mounting brackets to the base of
the unit. Leave them on the analyzer for use as handholds, skids, or lifting bars.
CAUTION The Maxum II must be lifted only by the mounting brackets on the back. Never allow
the analyzer to be supported on its side or front. Lifting with of any of the equipment protruding
from the analyzer will damage the equipment.
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Remove the Maxum II from the shipping crate.
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Remove the plastic bag and drying agent from around the analyzer.
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Examine the Maxum II for visible damage. Notify the carrier of the damage and file the necessary
claims. Also notify your Siemens representative or authorized agent of the damage to the
equipment.
14
Mounting the Analyzer
Instructions
The following procedures should be used to mount the Maxum II to wall or bulkhead; see Figure 2-1.
Maxum II Outline Drawing on page 16.
WARNING Prior to wall mounting and without the sampling
system, the Maxum II will weigh a minimum of 170 pounds
(77 kg). To mount the Maxum II to the wall, use a mechanical
lift or the number of people specified in the user’s policy on
lifting and installing.
CAUTION The Maxum II should be lifted only by the mounting
brackets on the back or supported from the bottom (be sure to
protect any bottom connections). Never allow the analyzer to
be supported on its side or front. It can be moved in either the
horizontal or vertical position.
Pre-installation Requirements
Before installing the Maxum II to the wall, the following requirements
should be followed:
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Determine the suitable height from the floor to allow easy access to front and internal components.
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Locate the Maxum II in a position that allows easy access to primary AC power wiring, I/O, stainless
steel tubing connections, carrier gas and compressed air supplies, and connection of any peripheral
devices within the house or shelter.
The Maxum II does not have a power switch. Install a circuit breaker near the unit (or power switch
with a fuse) with a rating of at least 20A is required for 115V and 16A for 230V. Refer to the
Application Drawing Package for specific information on the utility requirements.
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CAUTION Installation regulations require the use of a ground fault interrupt (GFI) in the power
supply line.
More Information
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Application Drawing Package; Dimensional Diagram - Analyzer sheet.
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CE Installations Requirements page 17.
Wall Mounting Units
The following minimum specifications must be adhered to when wall mounting the Maxum II.
Left side clearance:
Right side clearance:
Front side clearance:
Center to center:
18" (460 mm) from wall or other equipment
18” (460 mm) in all cases
25 ¾” (654 mm) in all cases
44” (1120 mm) in all cases
15
Mounting the Analyzer, Continued
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Refer to Application Drawing Package, Dimension Diagram Analyzer sheet for drilling information.
The following diagram has typical information for mounting, and as shown in the example pattern
below, drill 12 mounting holes in the shelter (16 if sample system is attached to Maxum II.) If using
an M6 bolt, use a 5.10 mm (.201 inch) drill bit. If using ¼ x 20 bolts, use a No. 7 (.201) drill bit. If
using ¼ x 28 bolts, use a No. 3 (.213) drill bit. Be certain mounting height is convenient for the user.
Protective Earth Ground
Located on back of the
Maxum II (see page 16)
Dimensions
for Air Bath
Oven Models
Only
Figure 2-1: Maxum II Outline Drawing
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With a forklift or adequate personnel, lift and align Maxum II mounting holes with those of the house
or shelter wall pre-drilled mounting holes.
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Insert the 12 or 16 bolts through Maxum II mounting brackets and into mounting wall stud pre-drilled
holes. Before tightening mounting bolts, be certain unit is leveled both horizontally and vertically.
Securely tighten all bolts to be certain the Maxum II is securely mounted to the wall.
CAUTION Ensure ground wire / protective conductor from external protective earthing system is
connected to ground lug / protective conductor terminal before connection to mains power. Refer
to the drawing above for location of the PE lug.
16
Cable Connections
Protective Earth Ground
Install protective earth ground per applicable codes (see diagram on page 16). This is located on the
back of the Maxum II and is secured with a M5 x 10 socket head screw (uses M4 hex).
Cable Connection using Steel Conduit System
Using flexible conduit and/or armored cable is equivalent to using “steel conduit.”
„ The power wiring and the Ethernet wiring can be regular unshielded lines. The power wiring and signal
wiring (Ethernet and Data Hiway cables) must be routed in separate conduit.
„ All DO lines with inductive loads must have transient suppression at the inductive load.
„ Flexible conduit or armored cable must have its flexible conduit and/or armoring conductivity 360degree terminated at its entry to the Maxum II enclosure (or bulkhead.).
Cable Connection when conforming to CE / ATEX Requirements
Instructions
This section provides information on how to install Input/Output cabling to conform to maintain CE
conformance (Conformite European). This applies to most European Community (EC) installations.
Typically, this does not apply to users outside the EC unless the equipment was purchased with the
requirement that it shall conform to EC Electromagnetic and Radio Frequency Interference (EMI/RFI)
rejection specifications. The following information pertains to CE Installation for General Purpose, and
Zone 2 equipment. For Zone 1 Installations all I/O cabling is terminated in the APU relay box, externally
mounted to the Maxum II.
Cable Installation
All cables to the Maxum edition II must be shielded. The shield
must be 360-degree connected to ground only at one end,
normally at MAXUM's metal cable glands. The shield must end at
the cable gland. Mounting the cable to the cable gland:
„ Loosen nut (2) of a suitable cable gland and remove the sealing
ring (1)
„ Push cable into chromatograph as far as required
„ Remove isolation and screen from end of cable up to screwed
gland. Expose 2 cm (1") of screen
„ Connect screen around sealing ring (1) and tighten nut (2)
Signal Cable
„ With Zone 2 analyzers or non-Ex analyzers connect the signal
cables via the metal cable glands to the chromatograph.
„ With Zone 1 analyzers connect all signal cables, that can not
accidentally get voltage from outside (e.g. relay contacts), via the
metal cable glands to the chromatograph. With Zone 1 analyzers
connect all signal cables, that can accidentally get voltage from
outside (e.g. Ready, RS485, Ethernet)), to the cut off relay.
Power Cable
„ Refer to the Application Drawing Package for specific
requirements and routing for the power cable.
„ A shielded power cord or cable must be used for the input
power wiring.
„ With Zone 1 & 2 analyzers connect the power cable at the APU
terminal block at the back-top of the assembly shown.
Note:
All DO lines with inductive loads must have transient suppression
at the inductive load.
17
Installing Primary AC Power
Primary AC Power
For Installation of AC Power for CE / ATEX units, refer to the Application Drawing Package, and page 17
concerning the special requirements for these systems which will be different from the information
contained below. This section is documenting the requirements only for non-CE/ATEX units. The Maxum
II operates from 100-130 VAC or 187-264 VAC 47-63Hz, single phase.
WARNING Do not apply power to the unit until procedurally instructed to do so (this appears in a
later procedure in this manual.) Installation personnel shall adhere to all AC power (Mains)
specification requirements; see Application Drawing Package & Utility Diagram sheet. Failure to
do so, and operating the equipment in a manner not specified, can impair the safety protection
provided by the equipment.
Fuses
Fuses are located on the Power Entry Control Module located on the left sidewall of the Electronic
Enclosure. Fuse requirements are (see page 22 for part numbers and locations):
F1-ABH2: 16 Amperes, 115 VAC or 10 Amperes, 230 VAC
F2-ABH1: 16 Amperes, 115 VAC or 10 Amperes, 230 VAC
F3-FLT AC: 3.15 Amperes, 115 VAC or 230 VAC
F4-LWH: 10 Amperes,115 VAC or 230 VAC
F5-MWH: 6.3 Amperes,115 VAC or 230 VAC
WARNING No substitutes should be used for the fuses noted above. Most of these are sand
filled ceramic fuses with a very fast acting fuse to protect the heater relays. A fuse kit is available
which contains all of the listed fuses on page 42.
Power Consumption
Typical maximum power consumption for the analyzer is 1700 Watts (single oven heater) during warmup, and averages 500 to 700 Watts during operation. In addition, a sampling system with a heated
cabinet can consume from 30 to 2000 Watts, depending upon its particular arrangement. Refer to
Application Drawing Package, Block Diagram Utility Connections sheet for the analyzer’s specific voltage
and total power requirements (the wattage for the sampling system, if required, will also be given.)
Installation of Components
The following customer provided components are required for installation of primary AC power (if this is a
CE / ATEX installation, then the user should refer to the Application Drawing Package for specifics):
Primary AC Wire Size
Customer AC power wiring recommended is three wire 12 AWG for 115 VAC and 14 AWG for 230 VAC
with a hot, neutral, and ground.
18
Installing Primary AC Power, Continued
Circuit Breaker
The circuit breaker should have the correct ampere rating, number of poles, and rated for the area that it
will be installed. The circuit breaker must be installed in close proximity to the Maxum II so it is easily
accessible to the service technician for turning power off to perform maintenance functions or for safety
purposes. In addition, the circuit breaker must be labeled as the disconnecting device for the Maxum II.
CAUTION All AC power (Mains) wiring shall be in accordance with all applicable codes.
Conduit
The AC primary power rigid and explosion proof conduit must be ½” (1.26 cm) minimum diameter. The
conduit end, which terminates at the Enclosure, must be equipped with an explosion proof seal. The
conduit terminates at the Enclosure opening located on the top left side.
It is recommended that a conduit hub be used to securely connect the conduit to the EC Enclosure. The
conduit hub type used must meet the electrical codes for the area of installation.
Specific Application Information
ƒ
Application Drawing Package, Block Diagram Utility Connections sheet and Arrangement
Drawing Electronics Controller sheet.
ƒ
CE Conformance Requirements page 17.
Power Entry
The primary AC (Mains) power can be routed to the Maxum II through side or top access plates. The
plates can be punched to accommodate conduit or cable gland connectors.
Cable Gland
Removable
Access Plate
Figure 2-2: AC Power Entry Through Top Access Plate
Power Connections
The AC input power connection is made to a removable green connector (TB1) located on the upper lefthand side of the Power Entry Control Module (PECM). Refer to Figure 2-3. The bottom connector
assembly is hardwired to the (PECM) circuit board and is non-removable. TB2 is used if the analyzer has
a second high wattage heater. TB10 is the power source for the Maxum II electronics, exclusive of the
heaters.
19
Installing Primary AC Power, Continued
Installation Procedure
To install primary AC wiring, perform the following procedures:
ƒ
Shut off the primary AC power supply line to this location.
ƒ
Open the front door of the Electronic Enclosure (if locked, use a 4 mm Allen wrench to unlock it.)
ƒ
Install circuit breaker, conduit and primary AC wiring appropriate for the area safety classification.
The breaker should be located near to the Maxum II. Label the Breaker to make sure that the
circuit is clearly identifiable. See Application Drawing Package Block & Utility Diagram sheet for
power requirements.
ƒ
Run the 12 AWG (115 VAC) or 14 AWG (230 VAC) wiring through a cable gland or conduit (per
local codes) to the Electronic Enclosure interior. Allow enough extra cable to be run into the
Electronic Enclosure to be certain it reaches the Power Entry Control Module (PECM) Connector
TB1. Use enough cable so that there will be no sharp cable bends when the terminations are
made.
TB2 & TB10 Connections
The TB2 connector permits installation of a second AC power source for powering air bath heater #2 and
low wattage heaters. The TB10 connector permits installation of a separate UPS power source for the
Maxum II electronics exclusive of the heaters or alternately may be wired to the power source for TB-1.
Each secondary power source must have its own explosion proof circuit breaker, ½” (1.26 cm) conduit
with Myers Hub, and 12 AWG wiring for 115 VAC or 14 AWG for 230 VAC. To connect AC wiring to TB2
and TB10, repeat the procedural steps for PECM connector TB1 as specified in the Application Drawing
Package, Block Diagram Utility Connections, and Arrangement Drawing Electronics Controller sheet.
Figure 2-3. AC Power Entry to TB1 on Power Entry Control Module (PECM)
20
Installing Primary AC Power, Continued
ƒ
Install AC power wiring to the PECM connectors TB1, TB2, and TB10 as specified in the
Application Drawing Package, Block & Utility sheet. TB10 is used for AC input to power the
electronics enclosure. In the standard configuration TB10 is connected to TB1. Optionally, TB10
may be isolated from TB1 and connected to a separate UPS as specified in the drawing package.
TB1 - AC
Power Circuit
1
TB10 – AC
Power Input for
Electronics
(Optional UPS)
H N G
TB2 - AC
Power Circuit
2
H N G
HNG
Location of fuses. See description of correct fuses on following page.
21
Installing Primary AC Power, Continued
ƒ
F1
F5
F2
F4
F3
Verify that the correct fuses are in place. Fuses are located on the PECM. See diagram below for
correct placement.
AC Power Circuit 1
Heater Channel 6
AC Power Circuit 2
LWH 1-5 (low wattage
heaters)
Power Supply (24V out)
Fuses for
115VAC
Fuses for
230VAC
16A
10A
(1901693-001)
(1901694-001)
6.3A
6.3A
(1901695-001)
(1901695-001)
16A
10A
(1901693-001)
(1901694-001)
10A
10A
(1901694-001)
(1901694-001)
3.15A
3.15A
(1302004-033)
(1302004-033)
WARNING No substitutes should be used for the fuses noted above. Most of these are sandfilled ceramic fuses with a very fast acting fuse to protect the heater relays. A fuse kit is available
on page 42 which contains all of the listed fuses.
22
Utility Gas Supply Installation
Description
This section provides the utility gas supply installation requirements for the analyzer.
ƒ
ƒ
ƒ
ƒ
Carrier Supply Gas
Calibration Standard
Detector Fuel Supply
Compressed Air Supply
Refer to Application Drawing Package, Block Diagram Utility Connections sheet for analyzer
requirements.
WARNING Ensure that personnel, electrical, and local and national codes are considered for
storage, use, and handling of compressed and liquefied gasses in portable cylinders.
Carrier Supply Installation
The carrier gas is specified in the Application Drawing Package on the Block Diagram Utility Connections
sheet. See Technical Specifications on page 11 for requirements for the air supply.
Install two secured carrier gas cylinders in tandem near the analyzer mounting location. This allows
exchange of the cylinders without disrupting the carrier supply. Install carrier lines using new, clean, ¼”
(.635 cm) stainless steel tubing and fittings between the carrier gas cylinders and the analyzer. Do not
use cutting oil on the tubing. Install a check valve to prevent contamination if backpressure should occur.
Consumption
Typical carrier consumption is 180 standard cubic feet per month (5100 liters per month.)
Table 2-1 Regulator Assemblies
Manufacturer's
Name and Part
Number
Siemens
Part #
Helium or nitrogen of
ultra high purity
ConCoa
2124301-580
X10014
Stainless Steel
Hydrogen of ultra
high purity
ConCoa
2124-310-350
X10035
Stainless Steel
Regulated Gas
23
Valve & Fitting
Material
Utility Gas Supply Installation, Continued
Figure 2-4. Automatically Switched Carrier Gas Cylinders
Calibration Standard Supply Installation
The Calibration Standard Supply required is specified in the "Notes" block on the Block Diagram Utility
Connections sheet contained in the Application Drawing Package.
Mounting
Always mount the calibration standard cylinder as close to the analyzer as practical. When installing
calibration standard cylinders, always use new, clean, ¼” (.635 cm) stainless steel tubing and fittings for
the line between the cylinder and the analyzer. Before connecting the line to the cylinder, blow it out with
a clean, dry, inert gas and cap the open end of the tubing.
A certified calibration standard may be purchased from Siemens or another supplier. If Siemens supplies
the calibration standard, it will be noted in the "Notes" block on the Block Diagram Utility Connections
sheet contained in the Application Drawing Package.
Heat Tracing
Some vapor standards must be heated to prevent condensation. If heat tracing is required, it will be noted
in the "Notes" block on the Block Diagram Utility Connections sheet contained in the Application Drawing
Package.
When heat tracing is used, it is essential that none of the tubing be exposed to ambient conditions. Steam
tracing must be continuously sloped downward for draining any condensate, and it must have condensate
traps at any low points.
24
Utility Gas Supply Installation, Continued
Detector Flame Fuel Supply
The FPD will need supplemental hydrogen and the FID may also need supplemental hydrogen for the
flame depending upon the type of columns used. See Technical Specifications on page 11 for
requirements for the flame fuel supply.
If your analyzer uses a hydrogen carrier, it also serves as the flame fuel for a FID or an FPD. In this case,
the flame fuel regulator may or may not be supplied.
If your analyzer uses a carrier gas other than hydrogen, the flame fuel for a FID and an FPD must come
from a hydrogen cylinder. A flame fuel regulator will be supplied.
Install the hydrogen cylinder next to the carrier supply.
Install the flame fuel supply lines using new, clean ¼” (6.35 mm) stainless steel tubing between the
hydrogen supply and the analyzer.
The average flame fuel consumption per detector is 70 SCF (1982 dm3) per month.
WARNING Always shut off the flow of gas utilities when air is not present to reduce
consumption and the possibility of flammable gas in the oven and or sample system.
FID Air Supply
If your analyzer uses a FID, the air required for the FID flame usually comes from an air treater. Refer to
Application Drawing Package for air and power connection to the air treater; Block Diagram Utility
Connections sheet. See Technical Specifications on page 11 for requirements for the air supply.
Compressed Air Supply
Air of instrument quality (clean, dry, and oil-free) is required to ensure trouble-free operation. Applicable
codes require that the compressor intake be located in a non-hazardous area, and the suction be
designed to prevent leaks which might permit hazardous gases or vapors to be drawn into the
compressor. The air must contain no more than trace amounts of any flammable gas or vapor. See
Technical Specifications on page 11 for requirements for the air supply.
WARNING If a purge gas other than air is used, precautions must be taken to monitor and
prevent oxygen depletion from occurring in the area. This is also needed when a backup other
than air is used. Depletion of oxygen can cause death to personnel in the area.
Minimum Air Pressure
The minimum air pressure required for an analyzer will depend upon the analyzer’s application. For the
specific air pressure requirements for your analyzer refer to the Application Drawing Package, the Block
Diagram Utility sheet.
Analyzer Connections
Reference the Analyzer Connections Instructions on page 30.
25
Sampling System Installation
Siemens Supplied Sample System
The sampling system provides a conditioned process sample to the analyzer. This section is intended to
provide guidelines and is not intended to be a comprehensive installation procedure. Be sure to follow
local and national codes with regard to the installation of this equipment. If the sampling system was
provided by Siemens, then references will be given to link to the custom documentation package. Refer
to Application Drawing Package, Sampling System sheets for information concerning sampling system.
CAUTION Sample filtering is required to protect the sample valve from contaminants. Refer to
your custom documentation to check on the requirements for your system. In some cases these
are installed at the factory.
Siemens sample systems typically receive process samples from the transport system at 0 to 250°F (-18
to 122°C), and at 5 to 250 psig (34 to 1724 kPa) for gases, or 15 to 250 psig (103 to 1724 kPa) for liquids.
The process line selected for removal of the sample should have these characteristics:
ƒ
A horizontal run
ƒ
Containing a single sample phase (either all gas or all liquid)
ƒ
Close to the analyzer
ƒ
Reasonably protected from mechanical damage
ƒ
Reasonably easy to access for installation and removal of the sample probe.
Sample Probe Installation
To install a sample probe, use an existing full-port gate valve, or weld a half-coupling on the process line
and attach a 3” (7.6 cm) long schedule 160 nipple and gate valve, then hot-tap into the process line. The
probe can then be attached to the gate valve by a reducing bushing and a suitable packing gland. Refer
to Application Drawing Package, Block Diagram Utility Connections sheet and Sample Probe sheet.
The sample probe should be long enough to be inserted to the process pipe's centerline, or at least 4” (10
cm) past the process pipe's inside wall. The probe should be cut off at the valve end to leave a maximum
of 1” (2.5 cm) of tubing between the packing gland and the shut-off valve when the probe is fully inserted.
This decreases the chance of bending or breaking off the probe tube.
Additional Equipment
Additional equipment associated with the probe, such as a regulator and vaporizer, if required, is
attached with a U-bolt bracket connected around the 3” (7.6 cm) long nipple upstream of the process gate
valve. Refer to Application Drawing Package, Block Diagram Utility Connections sheet and Sample Probe
sheet.
26
Sampling System Installation, Continued
Transport Tubing
Refer to Application Drawing Package, Block Diagram Utility Connections sheet.
Gas Samples
Transport tubing is typically ¼“ (6.35 mm) OD for gas samples, and ⅜“ (9.53 mm) OD for liquids. Leave
enough extra tubing to make sure it will reach the connection points. The stainless steel tubing must be
very clean and dry. If in doubt, flush it with acetone and dry it with an inert gas. Cap the open tubing ends
to prevent contamination. Plan to transport gases at as low a pressure as possible, typically 5 to 15 psig
(35 to 103kPa) or 5 psig (35 kPa) above the sample return pressure. The analyzer requires 5 psig (34
kPa) of differential pressure. The pressure should be set at the probe site.
Liquid Samples
Liquids should have a minimum of 25 psig (172-kPa) differential between the sample take-off and return
points, allowing for a minimum liquid flow of ½ U.S. gal/min (1.9 L/min). Sample lines of ⅜“ (9.53 mm) OD
more than 100-ft. (30.5 m) long may require more than 25 psig (172-kPa) differential.
Heat Tracing
Refer to Application Drawing Package, Block Diagram Utility Connections sheet.
Some sampling systems require heat tracing of the transport tubing. If heat tracing is required, it will be
noted on the Block Diagram Utility Connections sheet. It is essential that none of transport tubing be
exposed to ambient conditions. The tubing must be continuously traced, insulated, and weather
protected. Steam tracing must be continuously sloped downward for draining any condensate, and it must
have condensate traps at low points and at least every 50 ft. (15.2 m). All joints and valves must also be
heat traced, insulated, and weather proofed. The tubing must be continuously traced through the analyzer
house wall and up to the edge of the sampling system cabinet. If steam tracing is used, it must be at the
pressure recommended on the Block Diagram Utility Connections sheet. If electrical tracing is used, it
must be safe for the hazardous area location. It must also be of the wattage recommended on the Block
Diagram Utility Connections sheet.
Sample Wetted Parts
Each Maxum II system is designed by Siemens with the customer’s specific application needs in mind.
This includes the design of all parts coming into contact with the sample. Each system is designed such
that all sample wetted parts (e.g. valves, fittings, tubing, etc.) are compatible with the sample materials.
This compatibility must be taken into account if any changes are to be made to the sample composition.
Refer to the Application Drawing Package for more information regarding the materials for which a
specific analyzer is designed.
27
Sampling System Installation, Continued
Figure 2-4. Typical Installed Sample Probe
Returning Samples to the Process Stream
Refer to the Application Drawing Package, Sampling System sheet and Block Diagram Utility
Connections sheet.
If the sample stream is a gas and is to be released to the atmosphere, install a vent line outside the
analyzer house to at least 8 ft. (2.4 m) above the ground. The exhaust end should be curved down, or a
vent cap added for weather protection. If the sample gas is to be returned to a pressurized line, a
minimum pollution valve is required in the sampling system. The return line should have only a very low
pressure (0 to 20 psig [0 to 138 kPa].) Install a check valve to prevent backflow.
When returning a gas sample that can condense, slope it downward to a liquid drain or return it to the
process stream using heat tracing to prevent any condensation. For details on installing heat tracing,
refer to the "Sampling System" description in this section.
28
Sampling System Installation, Continued
Liquid Samples
If the sample stream is a liquid, all of the liquid flows should be returned to the process. It is easiest to
return both the sample bypass and analyzer flows together; however, if the differential pressure available
at the analyzer house is less than 10 psig (69 kPa), a separate power pressure return is required for the
analyzer flow (typically 20 cm3/min.) If the liquid could reverse flow in the process line, install check
valves where applicable.
Make sure the return tubing is long enough to reach the connection points. Cap the open ends of the
tubing to prevent contamination.
Vents, Drains, or Means of Returning Samples to the Process Stream
If the sample gas is to be returned to a pressurized line, an atmospheric reference valve (ARV) is
required in the sampling system. The return line should have only a very low pressure (0 to 20 psig [0 to
138 kPa]). Install a check valve to prevent backflow.
When returning a gas sample that can condense, slope it downward to a liquid drain or return it to the
process stream using heat tracing to prevent any condensation. For details on installing heat tracing,
refer to the "Sampling System" description in this section.
If the sampled stream is a liquid, all of the liquid flows should be returned to the process. It is easiest to
return both the sample bypass and analyzer flows together; however, if the differential pressure available
at the analyzer house is less than 10 psig (69 kPa), a separate lower pressure return is required for the
analyzer flow (typically 20 cm3/min.) If the liquid could reverse flow in the process line, install check
valves where applicable.
Make sure the return tubing is long enough to reach the connection points. Cap the open ends of the
tubing to prevent contamination.
WARNING All vent lines and oven exhaust should be vented outside the shelter. The vents
should be connected to a location where the pressure is atmospheric. Connection of oven or
analyzer vents to a variable pressure source such as a flare header should not be done as
chromatographic performance will be severely affected. Backpressure on the oven vent could
cause the T-rating of the instrument to be exceeded, which might become an ignition source.
Refer to the comments on Hazardous gases on page 3.
29
Analyzer Connections
Before You Begin
Ensure that the Utility Gas Supply and Sample System are installed in accordance with the Utility Gas
Supply Requirements on page 23 and the Sample System Installation requirements on page 26.
Reference the Analyzer Connections below.
Input/Output Lines
If your system uses optional peripheral or control devices, additional wiring is required. Siemens
recommends the wire specifications shown in the Application Drawings Package, Cable Specifications
sheet. For CE Conformance Requirements, see page 17.
CAUTION External connections to inputs / outputs must be powered from a limited source of
supply.
WARNING All vent lines and oven exhaust should be vented outside the shelter. The vents
should be connected to a location where the pressure is atmospheric. Connection of oven or
analyzer vents to a variable pressure source such as a flare header should not be done as
chromatographic performance will be severely affected. Backpressure on the oven vent could
cause the T-rating of the instrument to be exceeded, which might become an ignition source.
Refer to the comments on Hazardous gases on page 3.
Analyzer Connections
Refer to Application Drawing Package, Block Diagram Utility Connections sheet for analyzer
requirements.
ƒ Remove the plugs from the air supply lines. Purge the lines, and then turn off the air supply.
Connect the air lines to the ⅜” (9.53 mm) stainless tubing at the analyzer ports labeled "AIR IN"
and "VALVE AIR," if this option is used.
ƒ Remove the plug from the carrier line. Purge the line, and then turn off the carrier supply.
Connect the carrier line to the ¼” (6.35 mm) tubing at the analyzer port labeled "CARRIER IN."
ƒ For an analyzer with a detector that uses a carrier gas other than hydrogen, connect the
hydrogen line (after purging and turning off the supply) to the ¼” (6.35 mm) tubing at the
analyzer port labeled "HYDROGEN."
WARNING To prevent dangerous conditions to life, always shut off the flow of gas utilities when
air is not present to reduce consumption and the possibility of flammable gas in the oven and or
sample system.
30
Analyzer Connections, Continued
ƒ
For an analyzer with an FID, connect a length of new, clean, ¼” (6.35 mm) stainless steel tubing
to the analyzer port labeled "FLAME AIR OUT," and run it to the inlet port on a separately
mounted air treater.
ƒ
For an analyzer with an FID, connect a length of new, clean, ¼” (6.35 mm) stainless steel tubing
to the instrument air supply, and run it to the outlet port on the separately mounted air treater.
Mount the air treater in a convenient location near the analyzer. The mounting bracket requires
four ¼” (6.35 mm) diameter bolts.
The air treater can be mounted on a wall in whichever direction is best for connecting the ¼”
(6.35 mm) tubing to and from the analyzer.
ƒ
The analyzer oven exhaust vent(s) should be routed outside the building or shelter. See warning
concerning vent lines on page 30.
ƒ
Remove the plugs from the sample supply lines. If Siemens is supplying the sampling system, the
sample conditioning portion will probably be mounted in a cabinet or on a panel beneath the
analyzer oven. Connect the sample supply lines to the port labeled by their stream numbers on
the side of the cabinet or on the panel; refer to the Application Drawing Package, Sampling
System Connections sheet.
ƒ
Remove the plug from the calibration standard supply line. Connect the line to the port labeled
"STANDARD" on the sampling system cabinet or panel; refer to Application Drawing Package,
Sampling System Connections sheet.
ƒ
Connect drain, or return lines, as required to the appropriate sampling system vent refer to
Application Drawing Package, Sampling System Connections sheet.
31
Maxum II Initial Startup Procedures
Important
Before proceeding with these procedures make sure the Maxum II is installed correctly in accordance
with these instructions and local and national codes. Refer to the custom documentation for particular
Maxum II details and/or procedures.
Instructions
Perform all the procedures in this section consecutively starting with inspection of the Electronics
Enclosure.
WARNING 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.
Inspection of the Electronics Enclosure
The following procedure visually checks that the connectors and plugs in
the Electronic Enclosure are properly connected.
WARNING/CAUTION The cable harness connectors and the
chassis plugs associated with the Heater power circuits are
marked with orange identifier tags. Before reconnecting any
connector or plug to a Heater power circuit, ensure that the
orange identifier tag on the connector or plug reads identical to
the orange identifier tag on its mating connector.
The ferrules connected on the gas supply side of the EPCM
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.
ƒ
Ensure that the AC (Mains) power is off to the Maxum II.
ƒ
Open the electronic enclosure door and inspect all connections to the Power Entry Control
Module (PECM.)
ƒ
Inspect all SNE/DPM/EPC/SVCM connections (see WARNING/CAUTION above.)
Preparation and Inspection of the Oven Enclosure
The following procedure checks the oven operation.
ƒ
Ensure that all caps from vents on the sides of the oven (outside) have been removed.
WARNING All vent lines and oven exhaust should be vented outside the shelter. The vents
should be connected to a location where the pressure is atmospheric. Connection of oven or
analyzer vents to a variable pressure source such as a flare header should not be done as
chromatographic performance will be severely affected. Backpressure on the oven vent could
cause the T-rating of the instrument to be exceeded, which might become an ignition source.
32
Refer to the comments on Hazardous gases on page 3.
Maxum II Initial Startup Procedures,
Continued
ƒ
Continuing with the main power still off, open the
oven door and carefully remove all material, if
present. If columns were removed for shipment,
these should be installed in the oven.
ƒ
Check for any crimped or broken tubing.
ƒ
Finger test fittings to make sure they are tight.
Establish Utility Gas Flows
ƒ
Unblock the instrument air supply. If oven air
regulators are set to their setpoints, adjust them to 0
psig to turn off the oven heaters.
ƒ
Set Valve gas, if used, to the pressure specified in the Maxum II factory documentation. If valve
gas is not air, first open the valves on the cylinder providing the gas. Note: the Maxum II has a
shutdown program based on valve gas pressure. A pressure switch is set at a decreasing
setpoint of 100 psig (700 kPa.) If supply line pressure drops below this setpoint, analyzer mode is
set to hold, and all EPCs and heaters are disabled. EPCs and heaters must then be manually
enabled through the MMI before restarting the analyzer.
ƒ
Unblock the carrier gas and set the cylinder regulators at least 25 psi (175 kPa) above the factory
carrier gas setpoints.
ƒ
If used, unblock the flame detector fuel and air supplies and set the cylinder regulators at least 25
psi (175 kPa) above the factory setpoints.
Establish Power to the Maxum II
ƒ
Turn on power to the Maxum II. Wait for the system to boot up.
ƒ
On the MMI, the system boots up to the Monitor menu. Select the Maintenance menu by pressing
Select menu > 2.
ƒ
In the Maintenance menu, press 8 > 6 to display the EPCs.
Leak Check the Column Oven Connections
ƒ
Confirm the EPCs are enabled and that the pressure indicated
matches the setpoint.
ƒ
Use a foaming liquid leak detector and leak test the fittings in the
oven. Do not use a foaming liquid detector on connections made with
fused silica capillary columns; instead, use isopropyl alcohol.
ƒ
Tighten any leaking fitting with the appropriate wrench until no leaks
are detected.
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Clean up any excess leak check fluid with absorbent paper towels.
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Check sample line(s) by blocking return or vent line and pressuring
with air or non-combustible and non-toxic gas to check for sample line
leaks in the oven.
33
Maxum II Initial Startup Procedures, Continued
Check Operation of Oven Heaters
For Air Bath heaters (including PTGC) perform the following procedure: Note that on PTGC units, it is
recommended to have carrier flow thru columns during this test.
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Turn heater circuit off by setting oven air regulator below 5 psig.
ƒ
Through the MMI, observe the oven temperature and set point temperature.
ƒ
Cool oven down, approximately 20 to 40 degrees below set point.
ƒ
Increase oven air regulator slowly until the oven pressure switch triggers the heater circuit
(between 6 and 9 psig), this is indicated when the top LED lights (green).
ƒ
Note: units with a vortex cooling device will have its regulator setting significantly above this.
Utilize the “Heater Air” gauge reading for this check.
ƒ
Observe when the heater circuit goes into temp limit. This is indicated when the third LED lights
(yellow).
ƒ
Press and hold the appropriate oven temp test button down (this may take a few minutes).
ƒ
Observe when the over temp shutdown light comes on. This is indicated when the fourth LED
lights (red).
ƒ
Release over temp test button and verify the over temp light stays on.
ƒ
Verify through the MMI that the oven temperature starts decreasing (this may take a few
minutes). Also, that an over temp fault alarm is generated.
ƒ
If dual oven applications, repeat steps above for second heater channel.
ƒ
Reset analyzer and turn up oven air regulator to the appropriate/normal setting(s) and verify that
the oven(s) will reach set point and maintain set point without any faults or failures.
For Airless Heaters (including detectors, methanators, SLIV’s etc.) perform the following procedure.
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Through MMI, observe the oven temperature and set point temperature.
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Momentarily disconnect/unplug and reconnect the RTD probe connector. Use safeguard
measures that static is not introduced when disconnecting and reconnecting this connector. The
use of antistatic wrist straps is recommended.
34
Maxum II Initial Startup Procedures, Continued
ƒ
Observe when the over temp shutdown light comes on. This is indicated when the fourth LED
lights (red).
ƒ
Verify through the MMI that the oven temperature (or heated device) starts decreasing (this may
take a few minutes). Also, that an over temp fault alarm is generated.
ƒ
If dual oven applications, repeat steps above for second heater channel.
ƒ
Reset analyzer and verify that the oven(s) will reach set point and maintain set point without any
faults or failures.
CAUTION Turning off the air will cause the air pressure switch on the right side of the
electronics enclosure to open and shut off the oven heating. If the oven continues to heat
without air, turn the power off immediately. Do not continue with the rest of the procedures until
the heater circuit checks out.
Check Flows and Pressures at Operating Temperature
ƒ
Close the oven door and set the oven pressure regulators between 12 to 15 psig (84 to 105 kPa.)
ƒ
To monitor the oven heater on the MMI,
from the EPC screen, press Back > 5 to bring up the heater screen.
From any other screen, press Home > 8 > 5.
ƒ
When the oven heater has stabilized at the setpoint, use an appropriate bubble
type or mass flow meter to measure the flows at the detector, column, and
reference vents at the sides of the oven. This will require adjustment of the EPC
pressures and column valve positions according to the notes provided with the
factory documentation.
To change the EPC setpoint at the MMI,
press Change Setpoint > enter the desired pressure > Accept Change.
To actuate a column valve, first find the appropriate valve abbreviation, e.g., CR1,
at the bottom of the EPC screen.
To access the complete list of valves (and other digital outputs), scroll right using
the “-.”
Once the correct valve is found in the list,
actuate it by pressing the number corresponding to it on the screen.
Press that number again to de-actuate it.
Note: Valves requiring two air signals from separate solenoid valves (Valco, SLIV, etc.) will be
listed twice, e.g. 3.CR2 ON 4. CR2 OFF. In this case, pressing 3 will pressurize the ON air signal
and actuate the valve. Pressing 3 a second time will depressurize the air signal; however, the
valve will still be actuated. Press 4 to de-actuate the valve, then 4 again to de-pressurize the air
signal.
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If the flows measured at the factory pressure setpoints agree with the factory flows within nominal
error expected for two different flowmeters, the flow check is complete. Proper flows will be
checked again by comparison of peak retention times after generating the first chromatograms.
ƒ
If the flows measured at factory setpoint pressures are significantly lower than factory flows, cool
the oven and leak check as a leak is indicated. If the flows measured are significantly higher than
factory flows at the same pressure setpoints, generate chromatograms and compare them to the
factory peak retention times before deciding to establish new pressure setpoints.
35
Maxum II Initial Startup Procedures, Continued
Prepare Flame Detectors If Present
ƒ
For FID and FPD detectors, disable carrier gas flows and check fuel and air flows. The flows
must be measured separately. Leak check or adjust pressure setpoints if necessary. Record any
changes in pressure setpoints for inclusion in the EZChrom method later.
ƒ
Ignite the detectors. The MMI in the EPC screen will include a Detector Manual Ignite entry in the
list of digital outputs (valves, etc.) at the bottom of the screen. The level of abbreviation may
make this difficult to find. The more recent FIDs require the detector to be enabled so the 300V
bias is on, or it will not light (this can be done with the Enable Det or by viewing RT Chrom.)
Push the number corresponding to the Detector Manual Ignite and the detector will undergo it’s
ignite routine.
Alternatively,
press Home > 5 (Detectors and Realtime Chromatograms),
highlight the desired detector
and press the Ignite button at the bottom of the screen.
Establish Sample Flow to the Maxum II
Sample handling is where the process analysis starts. If the sample system is not functioning properly, it
is possible to have a condition in which the analyzer correctly analyzes the sample delivered to it, but that
sample does not adequately represent the composition of the process fluid. Also, inadequate filtration by
the sample system can shorten the life of the analyzer valves.
ƒ
Review sample system installation and startup procedures.
ƒ
Ensure the sample system has been properly pressure tested at this site.
ƒ
Ensure that all SSO (Sample Shut Off) and ARV (Atmospheric Reference Valves) are working
properly.
ƒ
Ensure that all sample system vents and drains are properly oriented.
WARNING All vent lines and oven exhaust should be vented outside the shelter. The vents
should be connected to a location where the pressure is atmospheric. Connection of oven or
analyzer vents to a variable pressure source such as a flare header should not be done as
chromatographic performance will be severely affected. Backpressure on the oven vent could
cause the T-rating of the instrument to be exceeded, which might become an ignition source.
Refer to the comments on Hazardous gases on page 3.
ƒ
Inspect the sample system to ensure it is in accordance with the sample system documentation.
ƒ
Circulate and purge process sample through the sample system for a short period of time before
applying to the analyzer. Ensure there is no vapor visible in liquid streams or liquid visible in
vapor streams at the bypass rotameters.
ƒ
Open the valve to the analyzer slipstream and allow sample flow to the analyzer.
Establish Communications with System Manager and EZChrom
ƒ
Refer to the section on assigning IP and network Mask Addresses and input the desired address
into the Maxum II.
ƒ
Launch System Manager on the workstation.
36
Maxum II Initial Startup Procedures, Continued
ƒ
If analyzer with the IP address entered in the Maxum II does not appear in the analyzer list at the
bottom of the main screen in System Manager, add it manually via the menu,
System > Add Unit; a dialog box will appear,
enter the unit name, type and IP address,
then click Add and the unit will be added to the analyzer list.
ƒ
Launch EZChrom on the workstation.
ƒ
From the main window of EZChrom,
create a new instrument from the menu as follows:
File > New > Instrument. An icon representing an analyzer will appear in the main stream.
Right click on the icon and
select Configure > Instrument. In the dialog box,
press the Configure button on the upper right. In the next dialog box,
press the Set database button,
enter the analyzer IP address,
and press OK.
For simulated distillation or other special software,
press Analysis Options > check the appropriate box > OK.
Press Auto-Configuration > OK > OK.
If the analyzer icon is still named Analyzer, right click on it to rename it. The foregoing procedure
only has to be done once. Double click on the icon to launch the analyzer in EZChrom. For
details, see EZChrom release notes on the Maxum II disk.
ƒ
Import the EZChrom method:
File > Method > Import.
Highlight the desired method
and press the Import button.
Create a folder on the hard drive
and save a copy of the method there.
Run Chromatograms and Make Method Adjustments if Necessary
ƒ
If any changes were made to EPC setpoints in the preceding steps, update the setpoints in the
method and export the edited method back to the Maxum II.
To edit, use the menu:
File > Method > Instrument Setup,
then select the tab for the EPC.
To export:
File > Method > Export,
highlight the method
and press the Export button.
Save the updated method to the hard drive.
ƒ
With the sample flow running from the appropriate calibration sample, put the analyzer in run.
Control > Application,
then press the Run button on the dialog box.
Alternatively, from the MMI,
press Home > Run.
37
Maxum II Initial Startup Procedures, Continued
ƒ
At the end of the cycle, import the chromatogram:
File > Data > Import.
Compare the chromatogram to the factory chromatogram provided with the documentation. Pay
particular attention to the peak retention times, valve timing and separation. Adjust valve times
as necessary. If the retention times do not closely match factory documentation, first make sure
the column oven has been equilibrated at operating temperature for at least two hours. If not,
allow the oven time to equilibrate.
ƒ
If the oven has been equilibrated for two hours and the peak retention times are significantly
slower than shown in the factory data, cool down the oven and leak check. After finding and
eliminating the leak, repeat the previous two steps until there is reasonable agreement with the
factory retention times.
ƒ
If the peak retention times are significantly faster than the factory data, measure the flows and
adjust the EPC setpoints as necessary.
ƒ
Repeat the previous four steps until the chromatograms obtained are reasonably close to the
factory chromatograms.
Calibrate the Maxum II
ƒ
Save the last acquired chromatogram for calibration. Save the method.
Calibrate from the menu:
Analysis > Single Level Calibration,
check the Calibrate box at the top of the dialog box
and check the box for Clear All calibration.
Press the Start button to complete the calibration.
ƒ
Save the method, then export it to the Maxum II; do not change the method name when
exporting.
ƒ
Continue to run the analyzer. At the end of the cycle, import the chromatogram and verify that the
analyzer is properly calibrated.
ƒ
From the System Manager, through the menu, back up the Maxum II database:
System > Unit Backup/Restore,
select the Maxum II by it’s IP address in the dialog box,
type the desired name of the backup file to be created
or browse to select an existing file (press the arrow in the dialog box to browse), browse to
select the desired folder and subfolder,
and press the Backup The Analyzer button in the lower left of the dialog box.
Note: The Advanced button will allow selection or de-selection of the Save to Flash function
prior to the backup. It is recommended to always use the default Save to Flash option. For
details, see Workstation, Advance System Manager help file.
Run the Maxum II on Process Fluid
ƒ
From the MMI, select the desired process stream and leave the Maxum II in Run.
38
Maxum II Initial Startup Procedures, Continued
Check for Proper Reporting of Results
ƒ
In the main System Manager screen, double click in the analyzer icon at the bottom of the screen
to bring up the database tables. The analyzer name and IP address are located next to the
analyzer icon.
ƒ
Press the “+“ next to the appropriate application, i.e., App 1, App 2, etc., to expand the list of
tables.
ƒ
Double click on Tables to open an additional list of tables.
ƒ
Double click on Result to open the result table. Verify the proper peak concentrations are
reported to the result table.
39
Maxum II Shutdown, Restart, and Cleaning Procedures
Introduction
The Maxum II is designed to automatically recover to full operation after a power fail. This process will
take an amount of time depending upon the duration of power loss. It may be a few cycles to several
cycles, depending upon cycle length, oven temperature, and a number of other factors. If the user wants
to remove power for any reason, this can be done as simply as removing the power and then restoring it
when desired. To minimize the loss of utilities and restart time or for any maintenance in the Maxum II
oven, the following shutdown and restart procedure is recommended.
Shutdown Procedure
The following procedure is recommended for manual shutdown of the Maxum II, especially if the
shutdown period is for any significant length of time. Read the entire procedure and warning/caution
before proceeding.
WARNING Need to ensure that adequate timing (per the warning tags) is allowed before
opening any enclosure that contains heated items.
CAUTION Heated items may be too hot to touch for some internal surfaces.
ƒ
ƒ
ƒ
ƒ
ƒ
Place all applications in Hold - wait for them to complete the cycle.
Save the database to the Workstation and perform a Save to Flash to ensure recovery to the
same state.
Remove power from analyzer.
Shut off oven air immediately if not going to work on oven to maintain oven temperature longer. If
going to work on the oven, then delay for 10 minutes before turning off air (the delay for air flow
removal provides time for cooling of the oven if air bath - airless will take considerably longer).
Shut off the gas utility flows (start with sample flow - turn off valve gas last to minimize loss of
other utilities).
Restart Procedure
The following procedure is recommended to restart the Maxum II following the shutdown procedure noted
above. Note that the GC will attempt to restart automatically on power restore if it was in “RUN” when the
power was removed. Alarms will be generated for some number of cycles as the oven stabilizes and the
GC recovers back to normal operating conditions.
ƒ
ƒ
ƒ
ƒ
ƒ
Turn on valve gas.
Turn on other gas utilities including sample.
Turn on oven air.
Power up analyzer. Allow time for the oven to come up to temperature (timing varies with oven
temperature setting and oven type).
Clear alarms and place applications in Run.
Cleaning Procedure
The Maxum II has minimal requirements for cleaning. The user may take a damp cloth and wipe down
the outside of the unit when it has a buildup of dust or other air borne contaminants.
40
Assigning IP & Sub Network Mask Addresses
Overview
All Maxum II units connected to a network must have a unique 32-bit IP and a common sub network
mask (subnetmask) address. The subnetmask together with the IP address is used to define the logical
network number of the device. The user must assign the addresses before the unit is network
operational.
Definitions
IP Address. The IP address is a 32-bit address that defines each Maxum II’s network ID and host ID.
Typically the customer’s network administrator assigns the address. The address IP is entered in a dotted
decimal notation format; example: xxx.xxx.xxx.xxx.
Subnetmask. The subnetmask defines which portion of the IP address is the network address and which
portion is the host or device address. The subnetmask is a 32-bit value containing one bit for the network
and subnet ID and zero bits for the host ID. The subnetmask is ANDed with the IP address to determine
which portion of the IP address is the network address. For example, with the IP address 192.165.0.1 and
a subnetmask of 255.255.0.0, the network address is 192.165.X.X, and the host or device address is
X.X.0.1 (network.network.device.device.) This particular subnetmask is a Class B address and provides
16 bits for the local address. This means that with a Class B address mask there is room for 2^16 or
65535 unique host addresses. There are four standard subnet classes: Class A, B, C, and D.
How to Assign an IP & Sub Net Address
If the unit will be in a closed plant area and not connected to the Internet, you can use the factory set
addresses or you can select an address.
For an IP Address you can select an address within the entire range of 192.165.0.xxx (xxx equals 000 to
255.) For a subnet mask address you can select an address within the entire range of 255.255.0.xxx (xxx
equals 000 to 255.) Typically the same subnet mask is used on all Maxum II’s on a given network, e.g.:
255.255.000.000.
Ask your network administrator to assign the addresses within the specified range.
Setting Maxum II IP Address
The MMI can be used to view or modify the factory set addresses. From the main menu use the following
menu path:
Select Menu > Configuration Menu > 1 > IP Set Info
Go to line 1 and 2 and change LAN 1 IP address and LAN 1 IP mask address in accordance with the
input from your network administrator.
Note: The Maxum II must be reset for the new IP entries to take effect.
41
Spare Parts
Spare Parts List
Please refer to page 2 for information on where to order spare parts. Providing the unit serial number of
the instrument will expedite the ordering process.
Description
Part Number (Siemens global)
Part Number (Americas)
Maxum II Fuse Kit
GWK-AI2020151-001
2020151-001
The Recommended Spare Parts list contained in the custom Application Drawing Package contains a
comprehensive spare parts list for the Maxum II. Refer to this list for parts specific to the particular
Maxum II being installed.
42
8/2007 Edition 2000595-001
Siemens Energy & Automation, Inc.
7101 Hollister Road, Houston, TX 77040
United States
Phone +1 (713) 939-7400
Fax +1 (713) 939-9050
www.usa.siemens.com/ia