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GAS CHROMATOGRAPHY p processMAXUMTM edition IIProcess Gas Chromatograph Maintenance Manual Edition 10/2012(Modular Oven Configuration)

Maxum II Specifications Configuration Oven Single isothermal airbath oven or split airbath oven with 2 independent isothermal zones or split airbath

Model 50 Valve, Continued If customer maintenance personnel are not technically trained to repair the Model 50 Valve on site, it is recommended that

Model 50 Valve, Continued The valve is serviced by disassembling and then thoroughly cleaning the components to remove all particulates. Ultrasonic c

Model 50 Valve, Continued Step Procedure 5. Place the valve bottom plate on a lint free cloth. Using a 2.5 mm Allen wrench, remove the five compon

Model 50 Valve, Continued Step Procedure 5. Turn the nut ¼ turn (90 degrees) past the point where the ferrule first starts to grab the tubing. 6.

Model 50 Valve, Continued Step Procedure 6. Repeat steps 3 and 4 with the middle plate. 7. Place the top plate on the valve, verifying alignmen

Intrinsically Safe Thermal Conductivity Detector (ISTCD DPM) This section provides removal and installation procedure for the Intrinsically Safe Therm

ISTCD DPM, continued Step Procedure 5. Remove DPM, along with its mounting bracket, using an 8 mm socket wrench or nut driver. There are two nuts

Analytical Modules This section describes repair procedures for the Analytical Modules for the Modular Oven. The Maxum Modular Oven configuration is d

Analytical Modules, continued Figure 4-7: Manifold and Pneumatic Diagram of Large Modular Oven (rear view) A5E31405710001 4-29

Analytical Modules, continued Figure 4-8: Manifold and Pneumatic Diagram of Small Modular Oven (rear view) 4-30 A5E31405710001

Maxum II Specifications, Continued Performance Minimum Range (general)* Thermal Conductivity: 0-500 ppm Flame Ionization: 0-1 ppm FPD: 0-1 ppm (ap

Analytical Modules, continued It is not required to power down the analyzer to remove an analytical module. However, it is important to place the ana

Analytical Modules, continued Replacement of Thermistor Board Step Procedure 1. Making note of the connection location for each wire, remove the

Analytical Modules, continued Figure 4-9: Thermistor Bead Board (Exploded View) Figure 4-10: Proper Alignment of Metal Inserts Step Procedure

Analytical Modules, continued Step Procedure 9. Reinstall the Flat Washer, Lock Washer, and Button Head Hex Screw. Do not over tighten the scre

Analytical Modules, continued Replacement Thermistor Wiring Harness Step Procedure 1. Making note of the connection location for each wire, remov

Use of Analytical Module Hardware Test Box This section provides describes the Module Hardware Tester device and its use for troubleshooting Modular O

Use of Analytical Module Hardware Test Box, continued Figure 4-12: Module Hardware Tester As shown above, the Module Hardware Tester is equipped w

Use of Analytical Module Hardware Test Box, continued • Gas Pressure Gauge – Shows the internal pressure of the pneumatic system of the test box. •

Use of Analytical Module Hardware Test Box, continued The following procedure should be used to set up the device for use. Refer back to figure 4-12.

Use of Analytical Module Hardware Test Box, continued The following procedure should be used to test the electrical characteristics of the TCD beads.

Maxum II Specifications, Continued Communication Options Serial Output RS232, RS485 Airbath/Airless Oven: Port 1 – RS232/RS485 (Modbus) Port 2 – RS

Use of Analytical Module Hardware Test Box, continued The following procedure should be used to test for internal leaks within an analytical module.

4-42 A5E31405710001 Use of Analytical Module Hardware Test Box, continued Step Procedure 3. VALVE 1 pressurizes the control ports for the Model

Chapter 5 Parts Introduction This chapter provides maintenance personnel with information concerning parts and assemblies for the Maxum II. Overview

Introduction, Continued ADIO I2C Combined Analog/Digital Input Output Board AIO I2C Analog Input Output Board CAC3 Communication and Analytical Cont

Available Parts Part Number Description 1671004-103 Sample Shut-off Valve (replacement) 2015946-002 GASKET, SVCM, 1/16" NEOPRENE 2020164-001

5-4 A5E31405710001 Available Parts (continued) A5E31277202001 KIT, SPARE PARTS, MODULE HARDWARE A5E03607125001 SINGLE MODULE, PRESSURE TEST, HARDWA

10/2012 Edition A5E31405710001Siemens Industry Inc.7101 Hollister Road, Houston, TX 77040United StatesPhone +1 (713) 939-7400Fax +1 (713) 939-9050ww

Maxum II Specifications, Continued Input/Output Options Standard I/O Airbath/Airless Oven Configuration: 2 analog outputs; 4 digital outputs (1 ind

Maxum II Specifications, Continued Gas Sample Requirements Sample Flow 50-200 cc/min (application dependent) Sample Filtration 0.1 micron Minimum S

Maxum II Specifications, Continued Installation Configuration Single unit with multiple enclosures Dimensions Height39 3/4" (1010 mm) [ Mod

Installation (continued) Hazardous Class Airbath/Airless Oven Standard Configurations: Certified by CSA C/US for use in Class I, Division 1, Groups

Maxum II Specifications, Continued Installation (continued) DC Power (optional) Modular Oven Configuration Only: 24VDC +/-10%, 10A minimum, with 32

Maxum II Specifications, Continued Calibration Type Manual or automatic Zero Automatic baseline correction Span Standard sample cylinder Not

About The Maxum II Modular oven The Maxum II GC is completely enclosed in an air-purgable, metal cabinet with hinged doors. Mounted above the isotherm

Maxum edition II Process Gas Chromatograph (Modular Oven Configuration)

About The Maxum II, Continued The regulator tower contains space for six gauges and regulators. The base Maxum II Modular Oven includes an electronic

About The Maxum II, Continued The application modules for the Maxum II Modular Oven use the Siemens Model 50 valve. The Model 50 is a 10-port diaphra

About The Maxum II, Continued The Maxum II uses a PC based network workstation for programming and data processing. Analyzers can be programmed and m

About The Maxum II, Continued The following are new terms that are used in this manual. Terms Application refers to the supporting hardware and softw

About The Maxum II, Continued Parallel Chromatography can reduce the cycle time for complex applications and also increase chromatograph analysis fre

About The Maxum II, Continued The Maxum edition II gas chromatograph is primarily used in all branches of the fine chemicals, refining and hydrocarbo

Maxum II Operation Overview This section provides an overview of the operation of the Maxum II analyzer. Figure 1-4 is an operational block diagram s

Maxum II Operation Overview, Continued Refer to Figure 1-4 for the following narrative. Analyzer Operation The Power Entry Control Module-Direct Curr

Maxum II Operation Overview, Continued In most applications, there are multiple columns in use that are typically switched by column valves located i

Maxum II Operation Overview, Continued The Embedded Sensor Near Electronics (EMSNE) software takes the place of a physical SNE Controller board (SNEC

Functional Tasks This section provides an operational overview of the Real-Time functional tasks of the Maxum II. Overview • Startup Tasks Applying P

Functional Tasks, Continued A check is made to see if the analyzer is to run a diagnostic type cycle. This is for the purpose of validating the analy

Functional Tasks, Continued The Analysis Cycle Clock is another clock that provides the time base for all events associated with the actual chromatog

Analyzer Internal Communications The primary internal communication link within the Maxum II Modular Oven analyzer is the I2C bus. This bus is used to

Maxum II Hardware Identification The Maxum II modules located in the electronic enclosure section have their own physical address and communicate via

Advance Communication System The Advance Communication System (ACS) uses industry standard protocols and provides high-speed communication among all d

A5E31405710001 2-1 Chapter 2 Maxum II Modules Overview This chapter provides a functional description for each replaceable module installed within th

Control Interface Module (CIM) The Control Interface Module (CIM) is a multipurpose assembly capable of functioning as the control processor, motherb

Control Interface Module, Continued Below is a summary of the basic functions performed by the CIM assembly CIM Operation • Memory storage for the a

Control Interface Module, Continued The CAC3 utilizes a 32-Bit, 240 MHz microprocessor. The on-board memory for the CAC3 consists of 128 MB SDRAM, 64

ii • A5E31405710001 Copyright Notice © 2012 by Siemens All rights reserved. This publication is for information only. The contents are subject t

Control Interface Module, Continued LED indicators for the CAC3 are as shown in figure 2-3 and table 2-1 CAC3 LEDs Figure 2-3: LEDs on the CAC3 Boa

Control Interface Module, Continued Other than the external Ethernet connection on the CAC3, CIMBase board provides all of the connections for the CI

Control Interface Module, Continued • Reset Switch – This pushbutton switch initiates a hard reset of the CIM (same as initial power up). CIMBase Bo

Control Interface Module, Continued Note: RS-485 serial ports are designed to comply with the Profibus standard. The pin layout is below. DB-9 Pin

Control Interface Module, Continued The CIMBase is equipped with several LEDs that relate useful information regarding the operating status of differ

Control Interface Module, Continued CIMBase LEDs Table Name Color Description Power LEDs Power Green Is connected directly to 3.3V supply. Should

I2C Input/Output Boards The Maxum II Modular Oven supports three different types of I/O circuit boards that communicate via the I2C bus. The availabl

I2C Input/Output Boards, Continued Switch SW1 located at the top of the board near the front (connector end) controls the mode setting for the on-boa

I2C Input/Output Boards, Continued The I2C AIO board makes available 8 Analog Outputs (AOs), 8 Analog Inputs (AIs), and 2 Digital Inputs (DIs). Analo

I2C Input/Output Boards, Continued There are eight AI circuits available on the AIO board. Analog inputs may be either voltage or current based. The

A5E31405710001

I2C Input/Output Boards, Continued Circuits on the AIO board are wired as shown in the following table. The table is the view as seen when looking at

I2C Input/Output Boards, Continued The I2C DIO board makes available 8 Digital Outputs (DOs) and 6 Digital Inputs (DIs). Digital Input/Output Board

I2C Input/Output Boards, Continued Circuits on the DIO board are wired as shown in the following table. The table is the view as seen when looking at

I2C Input/Output Boards, Continued The I2C ADIO board makes available 4 Digital Outputs (DOs), 4 Digital Inputs (DIs), 4 Analog Outputs (AOs), and 4

I2C Input/Output Boards, Continued Circuits on the ADIO board are wired as shown in the following table. The table is the view as seen when looking a

Intrinsically Safe TCD Detector Personality Module (ISTCD DPM) Output signals from Thermal Conductivity Detector (TCD) in the Modular Oven are input t

ISTCD Detector Personality Module (ISTCD DPM), Continued The connections to the ISTCD DPM are shown in figure 2-13 below. The connections are describ

ISTCD Detector Personality Module (ISTCD DPM), Continued The Board ID switch shown in figure 2-13 indicates the board number for the I2C bus. A diagr

Power Entry and Control Module–Direct Current (PECM-DC) The Power Entry and Control Module – Direct Current (PECM-DC) board contains the electronics t

Power Entry and Control Module–Direct Current (PECM-DC), Continued The Maxum II Modular Oven is typically installed with an internal 24V power supply

Safety Practices and Precautions This product has been designed and tested in accordance with IEC Publication 1010-1, Safety Requirements for Electro

Power Entry and Control Module–Direct Current (PECM-DC), Continued The PECM design provides control for the oven heaters. All oven heaters for a modu

Solenoid Valves The Solenoid Valves provide pneumatic interface to control flow to the oven sampling and column valves as well as optional control fo

Solenoid Valves, Continued The SMC brand solenoid valves used in the Modular Oven are 4-port valves that can optionally be used in 3-port operation.

Solenoid Valves, Continued Operation Test Step Procedure 1. Using a fine pointed object, depress orange button on the solenoid. 2. When depres

Electronic Pressure Control (EPC) Module The Electronic Pressure Control (EPC) Module reduces oven set-up time by using precise pressure control witho

Electronic Pressure Control (EPC) Module, Continued The EPC is made up of a printed circuit board with two pressure transducers, two proportional val

Electronic Pressure Control (EPC) Module, Continued As shown in the figure below, the EPC has a set of four DIP switches. These are used to set the

Electronic Pressure Control (EPC) Module, Continued The following specifications are applicable to the Electronic Pressure Control Module (EPC): Spec

24 Volt Power Supply The 24V Power Supply for the Maxum II Modular Oven configuration is comprised of a 110/230 VAC power supply manufactured by Delt

Chapter 3 CIM Display Panel Operation Overview This chapter is intended for operating and maintenance personnel. Introduction All of the Maxum II’s o

Safety Practices and Precautions, Continued A grounding conductor should be connected to the grounding terminal before any other connections are made

3-2 A5E31405710001 Overview, Continued A PC-based graphical simulation of the physical CIM Display, known as the HMI emulator, is available using th

CIM Display Hardware The CIM display contains a back-lit color graphic display screen layered with a touch screen sensor. It is part of the Control In

Screen Characteristics The screen is in color and back-lit for easy reading, and it is divided into several functional areas: Description • Main Navi

Screen Characteristics, Continued The status bar shows various data about the analyzer, including the name, date and time, and run/hold status. It al

Using the CIM Display As mentioned previously, the menu tree of the CIM Display is organized into three functional levels. This structure is used to a

Using the CIM Display, Continued The original Maintenance Panel for Maxum was equipped with a numeric keypad for data entry. The touch screen functio

Using the CIM Display, Continued The online help function of the CIM Display represents a large leap forward in usability over the original HMI. It a

Using the CIM Display, Continued One useful feature of the online help function of the CIM display is the ability to get detailed descriptions of ala

Password Restrictions It is possible to configure the CIM Display for different levels of password access. By default, six different levels of passwor

Password Restrictions, Continued Passwords can be modified from the User’s Passwords screen on the Configure menu. To change a password you must be l

A5E31405710001 1-1 Chapter 1 Knowing Your System Introduction The Maxum edition II © system, hereafter referred to as Maxum II, represents a signific

A5E31405710001 4-1 Chapter 4 Maintenance Overview Procedures in this Chapter are for use by maintenance personnel. When performing maintenance proce

Overview, Continued If technical assistance is required during performance of maintenance functions, or if parts are being returned, the customer sho

Overview, Continued Note: The tasks described below are provided as a suggested guidleine for routine maintenance. Requirements for a particular a

General Maintenance It is important that a preventative maintenance schedule be established to examine the Maxum II for internal and external cleanlin

General Maintenance, Continued To gain access to the modules, the electronic enclosure door must be opened. It will be necessary to use a #4mm Alle

Control Interface Module (CIM) This section presents the procedures for removal and installation of Maxum II door mounted Control Interface Module (CI

Control Interface Module, Continued Step Procedure Note: The CAC3 is mounted on the CIM-Base board, which is located on the inside of the Maxum doo

Control Interface Module, Continued CIM-Base Removal and Installation Step Procedure 1. Before beginning replacement, if possible, save the curren

Control Interface Module, Continued Step Procedure Note: Cable Routing: When replacing the cables on the CIM-Base in the following step, take note o

Control Interface Module, Continued CIM Display/Touch Screen Removal and Installation Step Procedure Note: Although the CIM color display and the to

Introduction, Continued Included with each analyzer is a custom documentation-drawing package. This package provides drawings and information pertine

Control Interface Module, Continued When installing the CIM Display assembly, it is necessary to use a torque wrench ensure a proper seal while at th

Control Interface Module, Continued The battery should only be replaced with an approved spare. Contact Siemens for a replacement. IMPORTANT Battery

Power Entry Control Module – Direct Current (PECM-DC) This section references procedures for the Power Entry Control Module –Direct Current (PECM-DC),

Power Entry Control Module – Direct Current (PECM-DC), Continued The following procedure should be used for replacement of the PECM-DC in the Maxum

24V Power Supply This section presents the procedures for removal or installation of the 24V Power Supply. This power supply is mounted to the back w

Power Supply, Continued Step Procedure 1. Turn off power to the Maxum II at the main circuit breaker. 2. Open electronic enclosure door (using

Solenoid Valves This section presents the procedures for removal or installation of a Solenoid Valve. The valves are mounted on either the floor or ba

Solenoid Valves, Continued Step Procedure 4. As show below, use a small screwdriver to remove the two screws that fasten the solenoid to the manif

Model 50 Valve This section provides maintenance instructions for the Model 50 Valve. The Model 50 is a pneumatically operated diaphragm valve specifi

Model 50 Valve, Continued Figure 4-5: Exploded View of Model 50 Valve 4-20 A5E31405710001