Siemens Applied Automation

Advance Maxum Automatic Purge Unit

First Printing – November 1999

Installation Manual 2000586-001

Copyright Notice  1999 by Siemens Applied Automation Bartlesville, Oklahoma, 74003, U.S.A. All rights reserved. This publication is for information only. The contents are subject to change without notice and should not be construed as a commitment, representation, warranty, or guarantee of any method, product, or device by Siemens Applied Automation. Reproduction or translation of any part of this publication beyond that permitted by Sections 107 and 109 of the United States Copyright Act without the written consent of the copyright owner is unlawful. Inquiries regarding this manual should be addressed to: Siemens Applied Automation 500 W. Highway 60 Bartlesville, Oklahoma, 74003, U.S.A.

Table of Contents

Chapter 1

Chapter 2

Chapter 3

Chapter 4

Chapter 5

2000586-001

Preface Safety Practices & Precautions

iii v

Automatic Purge Unit

1

Introduction System Description System Components

1 2 3

Installation

7

Overview Pre Installation Notes AC Power Requirements Installing Primary AC Power Installing Purge Air Supply Troubleshooting

7 8 12 13 17 21

Maintenance

25

Overview Maintenance Procedures

25 26

Parts Catalog

29

Introduction Available Parts

29 30

APU Drawings

31

Overview

31

Table of Contents • i/ii

Preface

Audience & Purpose

This manual is intended to introduce users to the Advance Maxum Automatic Purge Unit (APU). The manual includes complete instructions for safe installation and use of the APU.

Chapter Highlights

This Chapter covers the following topics: Topic

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Page

Automatic Purge Unit

1

Installation

7

Maintenance

25

Parts Catalog

29

APU Drawings

31

Preface • iii/iv

Safety Practices and Precautions

Safety First

This product has been designed and tested in accordance with the European Standard EN61010-1/A2 Safety Requirements for electrical equipment for measurement, control and laboratory use, and has been supplied in a safe condition. This manual contains information and warnings that have to be followed by the user to ensure safe operation and to retain the product in a safe condition.

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 cautionary or other information is to be found.

Symbols Marked on Equipment

DANGER - High voltage Protective ground (earth) terminal ATTENTION - Refer to Manual

Grounding the Product

2000586-001

A grounding conductor should be connected to the grounding terminal before any other connections are made.

Safety Practices and Precautions • v

Safety Practices and Precautions, Continued

Correct Operating Voltage

Before switching on the power, check that the operating voltage listed on the equipment agrees with the available line voltage.

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 can not 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.

Safety Guidelines

DO NOT open the equipment to perform any adjustments, measurements, maintenance, parts replacement or repairs until all power supplies have been disconnected. Only a properly trained technician should work on any equipment with power still applied. When opening covers or removing parts, exercise extreme care since "live parts or connections can be exposed". Capacitors in the equipment can retain their charge even after the unit has been disconnected from all power supplies.

vi • Safety Practices and Precautions

2000586-001

Chapter 1 Automatic Purge Unit Introduction Description

The Advance Maxum Automatic Purge Unit (APU) is manufactured by Expo-Telektron Safety Systems Ltd. The APU is designed to be used as part of the Advance Maxum system to automatically control purge/ pressurization/dilution of the Electronic Controller (EC) in hazardous areas. The pneumatically operated APU purges the interior of the EC then pressurizes it with a continuous flow of clean contaminate free air. Purging occurs when the input high airflow rate is sufficient to remove any flammable gasses that may have entered the EC while it was in a nonpressurized state.

APU

Figure 1-1 APU Mounted to Advance Maxum Electronic Controller

Chapter Highlights

This Chapter covers the following topics: Topic

2000586-001

Page

System Description

2

System Components

3

Automatic Purge Unit • 1

System Description Operation

The APU purges the Maxum’s Electronic Controller (EC) with a volume of air at a high flow rate sufficient to remove any flammable gas that may have entered the non pressurized EC. Power is returned to the system only after the purging has been completed. After purging has been completed the high purge flow rate is shut off and the system changes to a continuous flow mode. At this time the flow of air is reduced to the point where it is sufficient to compensate for any leakage taking place from the pressurized EC or from the containment system. See System Components (page 3) for an operational description of the major circuits.

Front Panel Lamps

The Operator Control Panel includes two status lamps; Alarm/Pressurized Lamp (two state indicator Red and Green) Red - Pressure Alarm. When illuminated, internal Electronic Controller pressure is too low. Green - Pressurized. When illuminated, interior of Electronic Controller is pressurized. System Purging Lamp (two state indicator Black and Amber) Black - Purge flow is too low or the unit is not in purge mode. This occurs during normal operation of pressurized Electronic Controller after purge is complete. Amber – System is in purge cycle.

Manual Override Key

A front panel key operated manual override switch allows maintenance personnel to defeat the system and its interlocks. The override should only be used when both the interior and the exterior of the EC are known to be non hazardous.

Certification

The APU is certified to European Standards using types of protection p, d, e, and m. APU installation shall conform to local codes.

2 • Automatic Purge Unit

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System Components Description

This Section presents the user with descriptive information on components that makeup the Automatic Purge Unit (APU) and how they interact with the other purge components. Refer to Chapter 5. APU Drawings, for component locations and mounting. The APU is mounted to the analyzer and consists of two compartments. The main operating pneumatics and other control components are located in the right compartment. The “interface section” is located in the left compartment and contains the power entry and I/O signal relay modules. An APU (depending upon application) can have up to four I/O relay modules.

“Interface Section” Power Entry & Signal Modules

“Pneumatics Section” Regulators & Manifold Components

Logic Pressure Regulator

The Logic Pressure Regulator provides a stable logic operational APU pressure supply. Logic pressure level is factory set; however, it can be verified using a pressure gauge. Logic pressure should only be adjusted if the gauge indicates that regulated pressure is inaccurate. Refer to Application Drawing Package that came with your system.

Manifold

Most of the APU Manifold logic components are located on a pneumatic printed circuit board. The manifold provides internal passageways that interconnect APU components to non-manifold components. The Manifold includes the following major components:

Minimum Pressure Sensor

The Minimum Pressure Sensor continuously monitors the internal Electronic Controller (EC) pressure. When the EC internal pressure is above the minimum for safe operation, the Pressure Sensor provides a pressurized output signal. The operator can observe the output signal by the Control Panel red/green visual indicator. The Pressure Sensor is calibrated at the factory to operate on a decreasing pressure at or above the minimum specified pressure.

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Automatic Purge Unit • 3

System Components, Continued

Purge Flow Sensor

The Purge Flow Sensor monitors the purge flow through Purge Output/ Pressure Relief Valve. When purge flow is above minimum purge flow, as specified by correct purging, the Purge Flow Sensor generates a purging output signal. The operator can observe the output signal by the Control Panel black/amber visual indicator. The Purge Flow Sensor has been calibrated at the factory to operate on a decreasing flow rate at or above the minimum specified purge flow rate.

Purge Timer Valve

When the Electronic Controller purge pressure is correct and purge flow occurs, a signal is sent to the Purge Time Valve to start timing cycle. The signal is sent through a dedicated in-line mini-filter to a ruby flow restrictor. Bleeding air is collected by the calibrated reservoir where purge pressure gradually increases. Also connected to the reservoir is a Timer Valve pilot port. The valve provides a signal to the Purge Complete Valve after the preset purge time has elapsed and when the reservoir pressure equals the Timer Valve operating pressure. The purge time is factory set and should not be adjusted.

Purge Complete Valve

The Purge Complete Valve receives a Purge Timer Signal when the purge time has been completed and checks that a pressurized signal is present. When both conditions are satisfied, a purge complete output signal is generated that performs the following functions: Turns ON the Electronic Controller electrical supply. Turns OFF high purge flow and starts leakage compensation mode and Provides hold-on signal that maintains system in this mode with power switch ON. This occurs even when Purge Timer has reset and is ready for the next purge cycle to start.

Alarm Only Circuit

The Alarm Only Circuit cuts-off Electronic Controller electrical power if the internal pressure is too low.

"OR" Gate

The "OR" gate places the Purge Complete Valve in an active state. When either the time-out signal or purge complete signal is present it allows the pilot signal to be applied to the Purge Complete Valve.

4 • Automatic Purge Unit

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System Components, Continued

Power Switch

The Manifold mounted Power Switch contains the pneumatic actuating piston. The Power Switch cable is terminated in the APU Junction Box.

Alarm Pressure Switch

The Alarm Pressure Switch is controlled by the pressurized signal and provides the control signal for the front panel status indicators.

Purge Air Inlet Valve

The Purge Air Inlet Valve allows purge air to flow to the pressurized Electronic Controller (EC). It also allows sufficient purge air to flow into the EC during purging cycle. The air flow rate during the purging is determined by the pressure range of the air supply, the purging outlet flow rate and the expected leakage rate from the pressurized EC. When the purging cycle completes the purge airflow is stopped. The purge cycle then waits in the closed state until the next purge cycle.

Purge Outlet/ Pressure Relief Valve

The Purge Outlet/Pressure Relief Valve performs the following functions: The valve is calibrated to open when the pressure within the pressurized Electronic Controller exceeds its setpoint. During normal operation this will occur each time the EC is purged. The valve is sized so that when the air supply pressure rises to the specified maximum, the valve decreases the internal EC pressure. This pressure will not exceed the specified maximum working pressure. This valve incorporates a Spark Arrestor that prevents emission of arcs, sparks and incandescent particles. When the correct purging airflow is occurring, the Spark Arrestor backpressure is noted and the results are used to calibrate the Purge Flow Sensor. The Spark Arrestor must be kept clean and free of foreign contaminants to insure accurate APU calibration.

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Automatic Purge Unit • 5

Chapter 2 Installation Overview Description

This Chapter is intended for installation personnel. The Advance Maxum Automatic Purge Unit is factory installed to the Advance Maxum Gas Chromatograph Electronic Controller (EC). All interface-wiring connections between the EC and the APU have also been factory wired. This chapter provides information on installing the input AC power and the external air supply lines to the Automatic Purge Unit (APU).

Chapter Highlights

This Chapter covers the following topics: Topic

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Page

Overview

7

Pre Installation Notes

8

Field Wiring Requirements

10

AC Power Requirements

12

Installing Primary AC Power

13

Installing Purge Air Supply

17

I/O Signal Wiring

20

Troubleshooting

21

Installation • 7

Pre Installation Notes Description

Before proceeding with the installation carefully review the following information.

Application Drawing Package

The Application Drawing Package that accompanies the Advance Maxum Gas Chromatograph, contains schematics and assembly drawings on how the customers APU and Advance Maxum Gas Chromatograph are interfaced together.

Air System

The operation of the APU pneumatic system can be affected by the prescience of water or oil and dirt contamination in the air supply. It is important that the APU air supply system be equipped with a dust and water filter. Equipping the system with these components is the customer's responsibility.

Installation Site

It is important that the surrounding area of APU installation be clean and free of foreign contamination.

Reference Installation Manual

For installation information applicable to the Advance Maxum Gas Chromatograph, refer to associated manual 2000582-001.

AC Power (Mains) Input

Primary AC (mains) input to the Maxum is made directly to the APU interface unit. The isolation of the AC power from the Electronic Controller is controlled from the APU by a Purge Complete pneumatic signal to operate a power switch. There are no valves connected between the Power switch and the APU other than the Manual Override circuit. The AC is factory wired from the APU to the Maxum Power Entry Control Module (PECM) terminal bus TB1. Refer to the Application Drawing Package, Block & Utility Sheet 2.1 for a schematic of the wiring that applies for your system.

Multiple Installed EC’s

More than one Advance Maxum Electronic Controller can be protected by a single APU. If the EC’s are connected and purged in series (daisy chained) the relief valve should be fitted on the last EC with the purge inlet to the first Controller. The bore and length of the conduit used to interconnect the EC’s is critical and will determine the maximum pressure experienced by the first EC in the series. If EC’s are to be connected in parallel each EC must have its own outlet relief valve, purge flow sensor and pressure sensor.

8 • Installation

2000586-001

Pre Installation Notes, Continued

External Alarm Devices

The APU uses a minimum pressure sensor that is set to a minimum setpoint pressure of 0.5mb. When APU pressure is above the setpoint pressure, a positive pressurized signal is generated. The pressurized signal can be displayed on a system-installed indicator. It can also be used with an external alarm or used to operate an integral EX alarm switch. When the EC internal pressure falls below the sensor pressure setpoint, the pressurized signal is removed. Absence of the sensor setpoint signal indicates a low-pressure alarm condition. When an alarm occurs, the operator must follow procedures in the codes for the area of installation. Codes include the following Zone 1 and Zone 2 installation recommendations.

Spark Arrestor

The interior and exterior of Spark Arrestor must be kept clean and free of foreign contaminants to insure accurate APU calibration.

CAUTION

The spark arrestor must not be painted or blocked for any reason. There must be an air gap of at least ½-inch (12mm) between spark arrestor outlet and any obstruction that would impede purging airflow.

2000586-001

Installation • 9

Field Wiring Requirements Description

This section provides installation personnel with field wiring instructions for the Advance Maxum Automatic Purge Unit (APU). These instructions comply with CE (Conformite Europeene) ceritification requirements.

Important

Read this section before performing any power or I/O wiring task.

Instructions

All power and I/O wiring is terminated in the Advance Maxum Purge Unit (APU) which is mounted to the Advance Maxum Electronic Controller. Special parts referenced in this section are contained in the Siemens Applied Automation CE Installation Kit, P/N 2020264-001.

Installation with steel conduit

The preferred wiring method is to route the field wiring in steel conduit. If steel conduit is used the power wires and the Ethernet wires can be unshielded. The power wiring, signal wiring, Ethernet and Data Hiway cables must be routed in separate conduit. If you use flexible conduit and/or armored cable is equivalent to using “steel conduit”. Flexible conduit or armored cable must have its flexible conduit and/or armoring conductivity 360 degrees terminated at its entry to the APU case. All DO lines with inductive loads must have transient suppression at the inductive load. The user shall determine whether the Heavy Industrial Conducted Immunity requirements are pertinent to their site location and application. If required, all AO lines must be terminated in a load that is CE/EMC certified to meet those requirements. All other CE requirements can be met using acceptable electrical termination practices.

10 • Installation

2000586-001

Field Wiring Requirements, Continued

Installation without steel conduit

If conduit is not used, the following installation practices must used to ensure that the CE certification remains valid: 1. A shielded power cord or cable must be used to supply the input. The shield must be terminated in a 360-degree termination at the APU case (bulkhead); use Siemens AAI P/N 2015729-001 contained in the CE Installation Kit or an equivalent part. 2. The power cord or cable must have split ferrite clamped on it and fixed to the outside of the APU; use an Siemens AAI part number 1263000-001 ferrite contained in CE Installation Kit or use a Fair-Rite part number 04431164181split ferrite. A split ferrite is only used to meet the Conducted Immunity requirement for CE/EMC Heavy Industrial. All other CE/EMC Heavy Industrial requirements are met without the use of a split ferrite. 3. The Data Hiway cables shields must be terminated in a 360-degree termination at the APU case (bulkhead); use Siemens AAI P/N 2015729-001 contained CE Installation Kit or an equivalent part. 4. All Data Hiway cables must have split ferrite clamped to them and then fixed to the outside of the APU; use Siemens AAI part number 1173000-013 ferrite contained in CE Installation Kit or use Steward part number 28B22024 or Fair-Rite part number 4431164181 split ferrite. The split ferrite clamp is only used to meet the Conducted Immunity requirement for CE/EMC Heavy Industrial. All other CE/EMC Heavy Industrial requirements are met without the use of a split ferrite. 5. The I/O cable(s) must have all shield(s) terminated in 360-degree termination at the APU case (bulkhead); Siemens use AAI P/N 2015729-001 contained in CE Installation Kit or an equivalent part. 6. All Ethernet connections (inside and outside) must use shielded Ethernet cable. The cable must be coupled through the APU using a shielded RJ-45 coupler; use Siemens AAI part number 1183200-003 contained in CE Installation Kit. The installation kit is not required if a PG gland is used to make a 360-degree termination.

Important

The installer must determine whether the Heavy Industrial Conducted Immunity requirement is pertinent to theirr site and application. If the requirments are pertinent to the site then comply with steps 7 and 8 below. 7. All DO lines with inductive loads must have transient suppression at the inductive load. 8. All AO lines must be terminated in a load that is CE/EMC ceritified to meet the Heavy Industrial Conducted Immunity requirements.

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Installation • 11

AC Power Requirements Description

It is the customer's responsibility to provide and install primary AC power wiring, circuit breaker and conduit to the Advance Maxum.

Important

Installation of primary AC power wiring must meet all electrical codes and certification requirements for the area of installation. Read the Field Wiring Requirements section before performing any power or I/O wiring task.

Primary AC Power

The Advance Maxum Gas Chromatograph operates from 100-130 VAC or 195-260 VAC 47-63Hz, single phase. Input power is switch selectable from the Electronic Controller installed Power Supply.

Fuses

Fuses are located on the Power Entry Control Module located on the left side wall of the Electronic Controller. Fuse requirements are: 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 Amperes 115 VAC or 230 VAC F4-LWH: 10 Amperes 115 VAC or 230 VAC.

Power Consumption

Maximum power consumption for the analyzer is 1700 watts during warm-up, 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 the "General Notes" on sheet 2.1 Block & Utility Diagram of the Application Drawing Package for your 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. Each component is described in the following sections.

Primary AC Wire Size

Customer AC power wiring must be three wire 12 gauge with a hot, neutral ground.

Circuit Breaker

The explosion proof circuit breaker should be a single-pole type rated for 20 Ampere service and be equipped with a shut-off handle. The circuit breaker must be installed in close proximity to the analyzer so it is easily accessible to the operator for turning power off to perform maintenance functions or for safety purposes.

12 • Installation

2000586-001

Installing Primary AC Power Instructions

The AC power input (Mains) can be either 115 VAC or 230 VAC. Refer to the Block and Utility Diagram contained in the Application Drawing package for your specific requirements. The primary AC (Mains) power is routed to the Advance Maxum through the APU side or top cover. The APU top cover is punched with two 1-inch holes to accommodate pipe or cable gland connectors.

Important

Installation of primary AC power wiring must meet all electrical codes and certification requirements for the area of installation. Read the Field Wiring Requirements section before performing any power or I/O wiring task.

Power Connections

The AC input power connection is made to the green INPUT connector located inside the APU Interface Unit; see Figure 2-1. The connector has two circuits L1 & L2 and L3 & L4. The bottom OUTPUT connector (which corresponds to the Input connections) is factory wired to the Electronic Controller Power Entry Control Module (PECM). The Application Drawing Package Block & Utility Diagram Sheet 2.1 shows which connections are used.

AC Input

AC Output

Figure 2-1. AC Power Entry to the APU Input Connector.

Warning

2000586-001

Installation personnel shall adhere to all power specification requirements; see AC Power Requirements, and to the Block & Utility, Diagram Sheet 2.1, in the Application Drawing package. Failure to do so, and operating the equipment in a manner not specified, can impair the safety protection provided by the equipment.

Installation • 13

Installing Primary AC Power, Continued

Installation Procedures

To install primary AC wiring, perform the following procedures: Step

Procedure

1.

Shut off the primary AC Power Supply line to this location.

2.

Loosen the four fasteners securing the APU interface cover to the unit and remove the cover.

3.

Install circuit breaker and primary AC wiring for the area of installation. Label the Breaker to make sure that the circuit is clearly identifiable. See Application Drawing Package Block & Utility Diagram Sheet 2.1 for Power Requirements.

4.

Run the 12 gauge AC wiring through a cable gland or conduit (per local codes) to the APU Interface interior. Allow enough extra cable to be run into the interior to be certain it reaches the INPUT Connector. There should be enough extra cable so that when terminations are made, there will be no sharp cable bends.

INPUT Connector

14 • Installation

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Installing Primary AC Power, Continued

Step

Procedure

5.

Remove approximately 3 in. of outer insulation from input AC power cable.

6.

Remove approximately ½ in. of insulation from the hot, neutral and ground wires.

7.

Refer to the Application Drawing Package, Block & Utility Sheet 2.1 for which of the INPUT connector circuits to wire to; L1(H) & L2(N) or L3(H) & L4(N).

8.

Loosen, but do not remove, the fastening screws on the INPUT connector to where the Hot and Neutral will be terminated; reference step 7 above.

9.

Insert the Neutral wire into INPUT connector N terminal and securely tighten the fastening screw; reference step 7 above. Insert the Hot wire into INPUT connector H terminal and securely tighten the fastening screw. Connect the ground wire to the ground terminal. Ground Terminal

2000586-001

Installation • 15

Installing Primary AC Power, Continued

Step

Procedure

10.

Using a 4 mm Allen wrench open the front door of the Electronic Controller.

11.

Refer to Application Drawing Package, Block & Utility Sheet 2.1 and ensure that the OUTPUT connector is wired correctly to the Power Entry Control Module.

12.

Verify that Advance Maxum Gas Chromatograph power supply switch is set to the correct VAC. It must be set to the primary AC (Mains) power input voltage.

13.

Recheck all connections for tightness and shorts.

14.

Plug in power cable from Power Entry Control Module to Power Supply.

15.

Verify that the correct fuses are in place. Fuses are located on the Power Entry Control Module. Fuse requirements are: 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 Amperes 115 VAC or 230 VAC F4-LWH: 10 Amperes 115 VAC or 230 VAC

Caution

16 • Installation

DO NOT apply power to the unit until all circuits have been checked and that the proper fuses are in place.

2000586-001

Installing Purge Air Supply Air Supply

Warning

The APU input air supply must be clean and not be contaminated with any flammable gas. A customer supplied shut-off valve must be installed on the air/inert gas supply source outlet connection. Using a purge gas other than “air” can fill up an area and cause death to personnel in the area. The external compressed air or inert gas supply source shall be installed in a non-hazardous location, and the suction designed to prevent leaks which can cause hazardous gases or vapors to be drawn into the compressor.

Air Pressure Specifications

The main air/inert gas supply pressure must meet the system specifications of 3 bar (45 lbs per sq. inch); refer to the Block and Utility Diagram contained in the Application Drawing package for your specific requirements.

Air Supply Filtration

A customer supplied 40-micron air filter shall be installed on the air supply source. The filter removes any solid particles and liquids, which could enter the system. If necessary, additional filtration can be provided upstream from the Analyzer input air supply source. The installation site will dictate the amount of air filtration needed.

Supply Line Regulator and Gauge

The APU is equipped with a regulator and gauge that allows input air supply pressure to be monitored and controlled. Air supply pressure to the APU circuits must be regulated to be within 2 bars and 2.2 bars (30 psi to 32 psi).

Warning

External Piping

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Inlet air/inert gas supply pressure must not exceed the 3 bars and 3.2 bars (45 psi to 48 psi) limits. The correct inlet supply pressure is important to system reliability and calibration.

Piping that connects the external air supply to APU must meet the codes, practices and specifications for the area of installation. If unsure of the specifications, refer to the agency responsible for determining the specifications. External tubing or piping must be 1/4" and meet MPTF standards.

Installation • 17

Installing Purge Air Supply, Continued

Instructions

The following procedure should be performed after completing the wiring and checkout of the AC Power to the system. If you account any problems refer to the troubleshooting section page 21. Step 1.

Procedure Connect the air supply to the purge air inlet. The purge air inlet input is located on the lower part of the unit below the Interface Unit.

Purge Air Inlet

18 • Installation

2.

Adjust the air supply pressure between 3 and 3.2 bars (45 psi and 48 psi).

3.

Open the Electronic Controller door.

4.

Ensure that primary AC power to system is on.

5.

Turn front panel key switch to maintenance mode.

2000586-001

Installing Purge Air Supply, Continued

Step 6.

Procedure Adjust the APU input regulator for a gauge reading between 2 bars and 2.2 bars (30 psi to 32 psi).

APU Air Input Adjustment & Gauge

7.

Observe that the front panel Alarm/Pressurized indicator is green and the System Purging indicator is amber. If the System Purging amber lamp is black, the purge airflow through the Pressure Relief valve is below minimum for which the purge flow sensor has been calibrated. Check the air inlet supply pressure is within the 3 bars and 3.2 bars (45 psi to 48 psi) limits while purging is occurring.

2000586-001

8.

Close the Electronic Controller door.

9.

Turn front panel key switch to Normal.

10.

Pressurizing and purging of the Electronic Controller is now automatic. To stop or start purging of system, turn the air supply on or off.

Installation • 19

I/O Signal Wiring Description

The APU is divided into two sections. The main operating pneumatics and other control components are located in the right compartment. The “interface section” is located in the left compartment. It contains the power entry and I/O signal relay modules. An APU (depending upon application) can have up to four I/O relays.

“Interface Section” Power Entry & Signal Modules

“Pneumatics Section” Regulators & Manifold Components

Instructions

The field installer makes all I/O signal wiring connections to the signal modules in the interface section. The signal modules outputs are factory wired to the I/O boards in the Electronic Controller of the chromatograph. The Application Drawing Package Block & Utility Diagram Sheet 2.1 defines the connections for your application. A schematic diagram of the signal modules can be seen in Chapter 4.0, Drawings.

Important

All I/O wiring must meet all electrical codes and certification requirements for the area of installation. Read the Field Wiring Requirements section before making any Analog or Digial I/O connections, Ethernet connctions or Data Hiway cable connections.

20 • Installation

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Troubleshooting Description

This section contains information on specific faults and how to correct them.

APU Drawings and Schematics

Drawings and schematics for the APU can be found in Chapter 4.0.

Testing Components

Many APU components are plug-in or Manifold mounted. To check if a component is defective, substitute the suspected defective component with a known good part. If the APU is under warranty, return the defective part for replacement to Siemens Applied Automation. A written fault report, APU serial number should accompany the defective part.

Before You Start

Before performing any checks be certain the pressure from both the primary air supply source and the regulated pressure are inputting the correct pressure. Refer to the Application Drawing Package provided with the system. Cause System Purges Correctly But Alarm Comes On at End of Purge Time and Purging Cycle is Repeated

Correction 1. Electronic Controller (EC) Enclosure Fault •

With a manometer or gauge, check to see if actual EC enclosure pressure is below the setting of Minimum Pressure Sensor.

•

Is there debris on Relief Valve Disk face? It could be on disk face by magnetism.

•

Is EC enclosure door closed and all conduit and cable connectors sealed?

•

Is there too much leakage in EC?

•

Is pressure sensing tube damaged or leaking?

2. System Fault

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•

If conditions in Cause 1 indicates the EC enclosure is OK, the fault is probably the Control Unit.

•

Check operation of Minimum Pressure Sensor by unscrewing 60mm diameter diaphragm housing. Using your finger, block the 12mm threaded hole in top of Sensor. The Sensor should operate and Operator Control Panel Alarm/Pressurized light should turn green. If this occurs, it is likely Minimum Pressure Sensor diaphragm needs to be re-calibrated or replaced.

Installation • 21

Troubleshooting, Continued

Fault Relief Valve Opens (continuously or intermittently

Purging Indicator Will Not Turn Amber During Purging

Correction 1. Dirty Pressure Relief Valve disk allowing valve air leakage. •

Remove Pressure Relief Valve cover and clean valve disk. If it is necessary to remove Pressure Relief Valve disk and spring draw a pencil line around valve. This allows accurate replacement before removal. Misalignment may cause opening pressure to be affected.

1. Insufficient purging airflow due to inadequate air supply pressure. •

Check air supply pressure at inlet to APU during purging. Excessive pressure drop in supply pipe is the usual cause. Pipe bore must be at least as large as APU inlet fitting.

2. Excessive Pressure Leakage in EC Enclosure •

When purging check EC enclosure seals for leakage. Correct leakage.

•

Perform a leakage test. Total leakage at Pressure Relief Valve opening pressure should not exceed 10% of Purge Flow Sensor setting.

•

Check for leakage around cables and conduit connections.

3. Tubing from Pressure Relief Valve Flow Sensing Point to Purge Flow Sensor (13) is not Air Tight •

Fitting nuts not tightened or tube damaged. Check and repair defective part.

4. Purge Flow Sensor is not Operating Correctly or is Out of Calibration •

Check operation of Purge Flow Sensor. Unscrew sensor 60mm diameter diaphragm housing and using your finger; block the 12mm threaded hole in the top of sensor. Valve should operate and the System Purging indicator should show amber. If this occurs, the Sensor diaphragm must be calibrated or replaced; see page 24 for calibration.

22 • Installation

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Troubleshooting, Continued

Cause System Fails to Switch Power On After Purge Time has Elapsed .

Correction 1. AC Power Fault •

Check that AC primary power is on

•

Check that the power isolator is closed

•

Check all fuses and circuit breakers

2. System fault or Timer Not Timed Out •

Is the Purging indicator showing amber for the entire purge cycle?

•

Verify that the logic pressure gauge is correctly set.

3. System fault or Timer Not Timed Out

.

•

Timer setting may be reduced for test purposes by pinching the reservoir connected tubing. Use only a tubing clamp or smooth jawed pliers. DO NOT PUNCTURE TUBING. New time will be approximately less than 1 minute.

•

Check operation of new purge time to be certain it functions correctly. Remove clamp and retest. If system does not time out, there is a reservoir air leak. Use soap water to detect the leak then perform corrective maintenance.

•

Recheck Purge Timer Valve at its full setting.

4. Faulty Power Switch •

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Check operation of Power Switch.

Installation • 23

Troubleshooting, Continued

Pressure Sensor Calibration

Perform the following steps to calibrate the Minimum Pressure Sensor or Purge Flow Sensor. 1. Disconnect pressure-sensing tubing from top of diaphragm. It is a push-in quick release fitting. Firmly push inward while maintaining pressure on the collar. 2. Unscrew the 60mm diameter diaphragm from top of Minimum Pressure Sensor. 3. Invert Sensor and observe the brass adjusting screw in center of Sensor. 4. Turn screw inwards (CW) to lower the setting. Screw may be tight due to locking sealant. If screw can not be moved, apply small amount of heat to brass screw. DO NOT OVERHEAT.

24 • Installation

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Chapter 3 Maintenance Overview Description

Procedures in this chapter are for use by maintenance personnel.

How to Use this Chapter

Perform all recommended procedures as presented in this Chapter. If through use, additional procedures are developed, they should be included with those in existence. Practical experience permits updating maintenance procedures and associated schedules over time. This results in many procedures being performed on a routine basis before potential problem(s) result in failure.

Safety First

When performing maintenance procedures in this chapter observe all warnings, cautions and notes to prevent physical injury to your self or unnecessary damage to the equipment

Chapter Highlights

This Chapter covers the following topics: Topic

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Page

Overview

25

Maintenance Procedures

26

Maintenance • 25

Maintenance Procedures Description

It is important that preventative maintenance schedule be established to examine the APU for internal and external cleanliness and damage. Even though the APU is tightly sealed against moisture and foreign contamination, it is recommended that the unit is examined and interior be inspected for moisture and/or contamination. If contamination is found, the APU should be shutdown and cleaned. If such contamination is not removed, it could render the APU inoperable.

WARNING

26 • Maintenance

Obtain a Hot Work Permit and observe all plant safety requirements before opening the equipment. Prior to removing any covers turnoff the primary AC (Mains) Power to the APU at the primary power circuit breaker

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Maintenance Procedures, Continued

6-Month Maintenance Procedures

It is recommended that the following procedures be performed every 6months: Step 1.

Procedure Check Pressure Relief Valve and Spark Arrestor. Remove any debris or foreign contamination from components. If necessary, replace defective component. Important The interior and exterior of Spark Arrestor must be kept clean and free of foreign contaminants to insure accurate APU calibration. CAUTION The Spark arrestor must not be painted or blocked for any reason. There must be an air gap of at least 1/2" (12mm) between spark arrestor outlet and any obstruction that would impede purging airflow.

2.

2-Year Maintenance Procedures

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Check condition of the air supply filter. If the element impedes airflow replace element.

It is recommended that the following procedures be performed every two years: Step

Procedure

1.

APU is suitable for the hazardous area of installation.

2.

No un-authorized modifications have been made to the APU.

3.

Air supply source is not contaminated.

4.

Interlocks and alarms function as designed.

5.

Certification identifications are legible and undamaged.

6,

Adequate supply of spare parts is maintained on site.

7.

Purge relay pressure activation is correct.

Maintenance • 27

Chapter 4 Parts Catalog Introduction Overview

This Chapter is intended for maintenance personnel. This Chapter provides a list of replaceable parts and assemblies for the Advance Maxum Automatic Purge Unit (APU).

How to Place an Order

Parts can be ordered from: Siemens Applied Automation. Customer Service Order Entry 500 W. Highway 60 Bartlesville, Oklahoma 74003 Inside Oklahoma: 918-662-7370 Outside Oklahoma: 800-448-8224 (toll free) Internationally: 001-918-662-7370 To ensure an immediate response to your request, you should provide the following:

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•

Purchase order number. If ordering by phone, a confirming P.O. should be sent.

•

Address where the parts are to be shipped.

•

Address where the invoice is to be sent.

•

Siemens Applied Automation part numbers as listed.

•

Quantity needed of each part.

•

Equipment Serial number or project number of the system (especially for warranty related orders).

•

Preferred method of shipment.

Parts Catalog • 29

Available Parts The available APU assemblies and parts, with their applicable part number are shown below.

Description

Part Description Timer Restrictor

1255001-032

Flow Sensor

1255001-033

Minimum Pressure Sensor

1255001-034

Timer Valve

1672009-007

Inline Filter

1282001-010

Non Return Valve

1672009-008

Indicator, Alarm/Pressurized

1422000-006

Indicator, Purge

1422000-007

Pneumatic OR Gate

1460700-002

Pneumatic YES Gate

1460700-003

Regulator, R06, 0-7 Bar

1461000-024

Limit Switch EExd w/Cable

1333011-004

Relay, Module EEx em, 4-Pole N/O (Power)

1517000-004

Relay, Module EEx em, 8-Pole N/O (Signal)

1517000-003

CE Installation Kit; Consists of:

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• • • • • • • • • •

30 • Parts Catalog

Ordering Number

EMI Grounded Cable Fitting Kit, ½-inch Conduit Filter, Ferrite, Split Core, Round Cable, 31 MTL Coupler, RJ-45 (8x8),Screen, Shld Coupler Plate, Gateway Filter, Ferrite , Split Core for Round Cable Cable, 10baseT, Cat5, shld, 2-Foot., Rj45, M-M Housing, Ethernet EMC Cover, Ethernet EMC Washer M3, Helical Spring Lock ,SST Screw M3X, Socket Head Cap , SST

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Chapter 5 APU Drawings Overview

Description

This Chapter presents engineering drawings for the Advance Maxum Automatic Purge Unit Drawings APU General Arrangement Interface Unit Component Layout Pneumatic Section Component Connections Manifold Assembly Component Locations Sub-Minpurge Circuit Diagram Interface Unit Circuit Diagram Manual Override Switch and Interface Connector Air Inlet Assembly

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APU Drawings • 31

Siemens Applied Automation 500 W. Highway 60, Bartlesville, OK 74003 Phone 918-662-7000, Fax 918-662-7052