Siemens Applied Automation, Inc.
Advance Maxum™ Gas Chromatograph
Revised October 2000
Installation Manual 2000582-001
Copyright Notice © 2000 by Siemens Applied Automation, Inc. 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, Inc. 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, Inc. Technical Communications 500 Highway 60 West Bartlesville, Oklahoma, 74003, U.S.A.
Trademarks Advance Maxum is a trademark of Siemens Applied Automation Inc.
Table of Contents
Chapter 1:
Chapter 2:
Technical Support Safety Practices & Precautions
iii v
Introduction
1
Overview Site Considerations Maxum Specifications Maxum Outline Drawing
1 2 3 6
Installation
7
Receiving a Non Crated Analyzer Receiving a Crated Analyzer Mounting the Analyzer CE Installation Requirements Installing Primary AC Power Utility Gas Supply Installation Sampling System Installation Analyzer Connections Preliminary Maxum Startup Procedures Maxum Startup Procedure Using the Workstation Software Requesting Start-Up Assistance
2000582-001
9 10 11 15 18 24 28 32 34 42 46
Table of Contents • i/ii
Technical Support Getting Help
At Siemens Applied Automation, Inc. we take pride in the on going support we provide our customers. When you purchase a product, you receive a detailed manual that should answer your questions; however, our technical support service provides a special “hot” line as an added source of information. If you require assistance call: Inside Oklahoma: (918) 662-7430 Outside Oklahoma: (800) 448-8224 Internationally: 001-918-662-7430
Before You Call
Before calling Siemens Applied Automation Customer Service for installation technical assistance, maintenance personnel should have the unit serial number and a detailed description of the problem for presentation to the customer service representative. Indicate the encountered installation problem and provide any other information that will aid the customer service representative in correcting the problem.
2000582-001
Technical Support • iii
Safety Practices and Precautions
Safety First
This product has been designed and tested in accordance with IEC Publication 1010-1, Safety Requirements for Electronic Measuring Apparatus, and has been supplied in a safe condition. This manual contains information and warnings, which have to be followed by the user to ensure safe operation and to retain the product in a safe condition.
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
2000582-001
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. Ensure that the power supply switch is to the correct input 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 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.
Safety Guidelines
DO NOT open the equipment to perform any adjustment, 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 "live parts or connections can be exposed".
vi • Safety Practices and Precautions
2000582-001
Chapter 1 Introduction Overview Description
This manual provides instructions for installation of the Advance Maxum™ Gas Chromatograph. After completing the instructions in this manual the Advance Maxum will be ready for startup. To ensure a safe and trouble free installation follow all instructions and associated advisories.
Other Installation Manuals
• • • • •
Advance Network Gateway Unit Advance DataNET Hub Unit Advance Network Access Unit Advance CAN Extension Unit Advance Maxum Automatic Purge Unit
Chapter Highlights
2000582-001
Topic
Page
Site Considerations
2
Maxum Specifications
3
Maxum Outline Drawing
6
Introduction • 1
Site Considerations Description
To protect the Advance Maxum™ Gas Chromatograph 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 120°F (49°C).
Location
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 room 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 inches high by 50 inches wide by 40 inches 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 Outline Drawing on page 6. Alternately, the analyzer can be installed on a portable stand. If Siemens Applied Automation, provides the portable stand (Part No. 2015548001), the space required for the analyzer will be the same height and width as stated above, but the depth must be increased to 48 inches (122 cm).
Figure 1-1. Typical Analyzer House To protect the Advance Maxum™ Gas Chromatograph from the elements it should be located in an analyzer house or a similar protected enclosure
2 • Introduction
2000582-001
Maxum Specifications Configuration Oven Detector Modules Number of Detector Modules Sample/Column Valves Columns Gas Supply Regulation
Single isothermal oven or split oven with 2 independent isothermal zones Thermal Conductivity, Flame Ionization 1, 2, or 3 in any combination of detector module types Diaphragm, diaphragm-plunger, and rotating or linear transport Packed, micro-packed, or capillary Up to 8 electronic pressure controls and up to 6 mechanical pressure controls
Performance Minimum Range (general)* Repeatability (general)*
Cycle Time Sensitivity* Linearity* Oven Temperature Range 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 ± 0.5% of full scale for full scale ranges from 2-100%; ± 1% of full scale for full scale ranges from 0.05-2%; ± 2% of full scale for full scale ranges from 50-500 ppm; ± 3% of full scale for full scale ranges from 5-50 ppm; ± 5% of full scale for full scale ranges from 0.5-5 ppm; (All values expressed at 2 times standard deviation.) 15 sec to 3 hr (application dependent) ± 0.5% of full scale ± 2% of full scale 40 to 440°F (5 to 225°C) ± 0.05°F (± 0.02°C) None 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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Introduction • 3
Maxum 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 IO: 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, common negative pole Floating double-throw contacts, maximum contact load rating 1 A at 30 Vdc -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 Sample Flow Sample Filtration Minimum Sample Pressure Maximum Sample Pressure Maximum Sample Temperature Material in Contact with Sample
50-200 cc/min (application dependent) 5 micron 2 psig (14 kPa), lower pressure optional 75 psig (517 kPa), standard; higher pressure optional 250°F (122°C) standard; higher temperature optional Stainless steel, Teflon, and polyimide; other material optional
Liquid Sample Requirements 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 micron 5 psig (34 kPa), standard 300 psig (2070 kPa) standard; higher pressure optional 250°F (120°C) standard; higher temperature optional Stainless steel and Teflon, other material optional
Installation Configuration Mounting
Dimensions
4 • Introduction
Single unit with multiple enclosures Wall mount only (analyzer typically mounted on 4 ft (1220 mm) center) Left side clearance: 18 in. (460 mm) from wall or other equipment 24 in. (610 mm) from wall with APU mounted Right side clearance: 18 in.(460 mm) in all cases Height: 35.5 in. (904 mm) Width: 26 in. (660 mm) Depth: 16.25 in.(411 mm)
2000582-001
Maxum Specifications, Continued
Weight Enclosure Rating EMI/RFI Rating
Hazardous Class
Ambient Temperature AC Power
Instrument Air
Carrier Gas
Flame Fuel
Flame Air
Corrosion Protection
170 lb. (77 kg) NEMA 3, IP54 (outdoor with weather protection) 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 1010-1 Standard Configurations: Certified by CSA NRTL/C 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 NRTL/C for use in Class I, Division 1, Groups B,C,D with air or nitrogen purge Certified by CENELEC as EEx pd[ib] IIB + H2 with air or nitrogen purge and purge control for Zone 1 or Zone 2 0 to 122°F (-18 to 50°C) 100-130 VAC or 195-260 VAC (switch selectable), 47-63 Hz., single phase Single oven: 14-amp max. Dual oven: 2 circuits, 14-amp max. each 60 psig (415 kPa) to 100 psig (689 kPa) minimum depending upon the analyzer’s application. 25 psig (175 kPa) minimum for oven; 3 scfm (85 Lpm) per oven 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 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) Dry air purge to protect electronics Stainless steel oven liner Painted steel exterior (epoxy powder coat)
Calibration Type Zero Span
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Manual or automatic Automatic baseline correction Standard sample cylinder
Introduction • 5
Maxum Outline Drawing LEFT SIDE VIEW 14 3/16 [360]
A
RIGHT SIDE VIEW
28 [710] 26 1/16 [660]
1 1/2 [38] 3/4 [20] 3 [76]
2 [51]
FRONT VIEW TYPICAL OF ALL MOUNTING BRACKETS
E B
Applied Automation
35 9/16 [903]
15 1/2 [393]
FAST PURGE
F G
OVEN AIR
VALVE AIR
CARRIER R1
CARRIER R2
34 [863]
CARRIER R3
C
C
D
SR1-6
SR3-6 FILTER
FILTER
SSO B
SSO A
H (ARVA & ARVB)
SAMPLE IN/OUT 1/8" TUBES
A
18 [460]
25 3/4 [654]
18 [460] or 22 (560) with APU mounted
TOP VIEW Minimum recommended clearance from adjacent obstructions to allow maintenance access is also shown. When multiple analyzers are mounted side-by-side, recommended spacing is 44” (1120 mm) centers for standard units and 48” (1220 mm) if APU’s are mounted.
NOTES A B C D E F G H
CONDUIT ENTRY PANEL FOR POWER AND SIGNAL CONDUIT INSTRUMENT AIR, 1/4" FEMALE NPT OVEN RESTRICTOR VALVE ADJUSTMENT PORTS OVEN VENTS, 1/8" (NO CONNECTION REQUIRED) CARRIER R1, 1/4" TUBE STUB (3" LONG) - HYDROGEN CARRIER R2, 1/4" TUBE STUB (3" LONG) - HYDROGEN CARRIER R3, 1/4" TUBE STUB (3" LONG) - HYDROGEN AIR SIGNALS (TWO), 1/8" TUBE STUB (3" LONG) - TO SAMPLING CABINET
Dimensions are shown as Inches [Millimeters]
6 • Introduction
2000582-001
Chapter 2 Installation
Introduction
This chapter is intended for installation personnel. After completing the procedures in this Chapter the Advance Maxum will be ready for startup. To ensure a safe and trouble free installation follow all instructions and associated advisories.
WARNING
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.
Custom Application Drawing Package
Included with your analyzer, but shipped separately 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: • • • • • • • • • • • •
2000582-001
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
Installation • 7
Installation, Continued
Installation Overview
Before beginning the installation process read through this Chapter to familiarize yourself with the installations requirements. This will aid you to ensure a safe and trouble free installation
Topic
CAUTION
8 • Installation
Page
Receiving a Non Crated Analyzer
9
Receiving a Crated Analyzer
10
Mounting the Analyzer
11
CE Installation Requirements
15
Installing Primary AC Power
18
Utility Gas Supply Installation
24
Sampling System Installation
28
Analyzer Connections
32
Preliminary Maxum Startup Procedure
34
Requesting Start-Up Assistance
46
Please handle the analyzer with care. It should be protected from rough treatment during receiving and installation.
2000582-001
Receiving a Non Crated Analyzer Instructions
A non-crated Maxum will be transported by an air-ride van to the installation site. The analyzer will be bolted to two temporary wooden supports, wrapped in protective padding, and strapped vertically to the side of the van.
WARNING
Depending on the configuration, a Maxum without a sampling system will weigh approximately 170 pounds (77 kg). With a sampling system, it could weigh more than 200 pounds (90 kg). You should have one or more persons help you remove it from the van wall. Step
2000582-001
Procedure
1.
While supporting the Maxum in the vertical position, loosen the straps holding it to the van wall, and gently lower it to the floor so it rests on the wooden supports.
2.
Remove the protective blanket and examine the Maxum for visible damage. If damage is observed, write "DAMAGED PARCEL" on all copies of the delivery ticket. Notify the carrier of the damage and file the necessary claims. Also notify your Siemens Applied Automation representative or authorized agent of damage to the equipment.
3.
Compare every item on the delivery ticket with the equipment received. If anything is missing, write "PARCEL(S) SHORT" and specify the items and the quantity missing on all copies of the delivery ticket. Also check the packing list. Make sure you receive all the merchandise shipped. Notify your Siemens Applied Automation representative or authorized agent if anything is missing.
Installation • 9
Receiving a Crated Analyzer Instructions
If the Maxum is shipped to the installation site in a reinforced crate, it will be clearly labeled for horizontal placement and handling. The Maxum will be bolted to the bottom of the crate through its temporary wooden supports, and will also be fastened with metal bands. The analyzer will be wrapped in a heavy plastic sheet. The cover will be nailed shut on the crate, and it will be bound securely with metal bands.
WARNING
Depending on the configuration ordered, a crated Maxum could weigh more than 200 pounds (90 kg). You should have one or more persons help you remove it from the van wall. Step
CAUTION
10 • Installation
Procedure
1.
Place the crate on the floor horizontally with the label "THIS SIDE UP" pointed up.
2.
Remove the metal bands from around the crate.
3.
Remove the crate cover.
4.
The Maxum will be bolted to two temporary wooden supports, which should remain on the analyzer until it reaches its final mounting location. Remove only the four lag bolts at the ends of the wooden supports. Do not remove the bolts holding the Maxum to the wooden supports. Leave them on the analyzer for use as hand holds skids, or lifting bars.
The Maxum must be lifted only by the wooden supports on the back. Never allow the analyzer to be supported on its side or front. 5.
Remove the Maxum from the shipping crate.
6.
Remove the plastic bag and drying agent from around the analyzer.
7.
Examine the Maxum for visible damage. If damage is observed, write "DAMAGED PARCEL" on all copies of the delivery ticket. Notify the carrier of the damage and file the necessary claims. Also notify your Siemens Applied Automation representative or authorized agent of the damage to the equipment.
8.
Compare every item on the delivery ticket against the equipment received. If anything is missing, write "PARCEL SHORT" and specify the item and quantity missing on all copies of the delivery ticket. Make sure you receive all the merchandise shipped. Notify your Siemens Applied Automation representative or authorized agent if anything is missing.
2000582-001
Mounting the Analyzer Instructions
The following procedures should be used to mount the Maxum to wall or bulkhead; see Figure 2-1. Advance Maxum Outline Drawing.
WARNING
Prior to wall mounting and without the sampling system, the Maxum will weigh approximately 170 pounds (77 kg). Two or more persons should be used to mount the Maxum to the wall. The number of personnel used should be in accordance with the user’s policy on lifting and installing.
CAUTION
The Maxum should be lifted only by the wooden supports on the back. Never allow the analyzer to be supported on its side or front. It can be moved in either the horizontal or vertical position. If a forklift or dolly is used, make sure the Maxum is strapped to it securely. Add padding wherever the painted surface could be rubbed or scraped. Do not leave it exposed to the weather.
Pre-installation Requirements
More Information
2000582-001
Before installing the Maxum to the wall, the following requirements should be followed: •
The house or shelter-mounting wall must be reinforced with studs into which the mounting screws can be inserted.
•
Insert braces between the studs to provide a stable-mounting surface.
•
DO NOT insert mounting bolts into a nonreinforced wall.
•
Before drilling mounting holes, determine the suitable height, from the floor, which allows for operator convenience. This provides easy access to front and internal components.
•
Locate the Maxum 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.
•
Application Drawing Package; Dimensional Diagram - Analyzer Sheet 4.1.
•
CE Installations Requirements page 15.
Installation • 11
Mounting the Analyzer, Continued
Wall Mounting Units
The following specifications must be adhered to when wall mounting the Maxum (Maxum typically mounted on 4’ (1220 mm) center). Left side clearance: Right side clearance:
18" (460 mm) from wall or other equipment 22" (560 mm) from wall with APU mounted 18” (460 mm) in all cases
Step
Refer to the following pattern, drill 12 mounting holes (16 if sample system is attached to Maxum) in the shelter. If using ¼x20 bolts use No. 7 (.201) drill bit or if using ¼x28 bolts No. 3 (.213) drill bit. Be certain mounting height is suitable for operator convenience. 28 in. [711 mm]
34 in. [863 mm]
15 ½ in. [393 mm]
1 ½ in. Typical [38 mm]
1.
Procedure
12 • Installation
2000582-001
Mounting the Analyzer, Continued
Step
Procedure
2.
With adequate personnel, lift and align Maxum mounting holes with those of the house or shelter wall pre drilled mounting holes.
3.
Insert the 12 or 16 bolts through Maxum 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 is securely mounted to the wall.
2000582-001
Installation • 13
Mounting the Analyzer, Continued
LEFT SIDE VIEW 14 3/16 [360]
A
RIGHT SIDE VIEW
28 [710] 26 1/16 [660]
1 1/2 [38] 3/4 [20] 3 [76]
2 [51]
FRONT VIEW TYPICAL OF ALL MOUNTING BRACKETS
E B
Applied Automation
35 9/16 [903]
15 1/2 [393]
FAST PURGE
F G
OVEN AIR
VALVE AIR
CARRIER R1
CARRIER R2
34 [863]
CARRIER R3
C
C
D
SR1-6
SR3-6 FILTER
FILTER
SSO B
SSO A
H (ARVA & ARVB)
SAMPLE IN/OUT 1/8" TUBES
A
18 [460]
25 3/4 [654]
18 [460] or 22 (560) with APU mounted
TOP VIEW Minimum recommended clearance from adjacent obstructions to allow maintenance access is also shown. When multiple analyzers are mounted side-by-side, recommended spacing is 44” (1120 mm) centers for standard units and 48” (1220 mm) if APU’s are mounted.
NOTES A B C D E F G H
CONDUIT ENTRY PANEL FOR POWER AND SIGNAL CONDUIT INSTRUMENT AIR, 1/4" FEMALE NPT OVEN RESTRICTOR VALVE ADJUSTMENT PORTS OVEN VENTS, 1/8" (NO CONNECTION REQUIRED) CARRIER R1, 1/4" TUBE STUB (3" LONG) - HYDROGEN CARRIER R2, 1/4" TUBE STUB (3" LONG) - HYDROGEN CARRIER R3, 1/4" TUBE STUB (3" LONG) - HYDROGEN AIR SIGNALS (TWO), 1/8" TUBE STUB (3" LONG) - TO SAMPLING CABINET
Dimensions are shown as Inches [Millimeters]
Figure 2-1. Advance Maxum Outline Drawing
14 • Installation
2000582-001
CE Installation Requirements Description
This section provides installation information for CE certification (Conformite European) sites. This applies for most installations in the European Community (EC). Typically, this does not apply to users outside the EC unless the equipment was purchased with the explicit requirements and expectations that it shall conform to EC Electromagnetic and Radio Frequency Interference (EMI/RFI) rejection specifications.
CE Installation Kit
Available from Siemens Applied Automation, Inc. CE Installation Kit P/N 2020264-001. This kit has all the parts for all the installations referenced in this section.
Instructions
The following information pertains to CE Installation for General Purpose, Zone 1 and Division 2 Equipment. For Zone 1 Installations all cabling is terminated in the Advance Maxum Purge Unit (APU) which is mounted to the Advance Maxum Electronic Enclosure.
Installation with Steel Conduit
The preferred method of installation of field wiring is to route the field wiring in steel conduit. If steel conduit is used, 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. Using 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-degree terminated at its entry to the Maxum GC enclosure (or bulkhead). 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 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 are met with standard/normal termination.
2000582-001
Installation • 15
CE Installation Requirements, Continued
Installation without Steel Conduit
If conduit is not used, the following installation practices must be used to ensure that the CE certification remains valid: 1. A shielded power cord or cable must be used for the input power wiring. The shield must be terminated at the Maxum GC (APU for Zone 1) in a 360-degree termination at the enclosure (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 each have split ferrite clamped on them and fixed immediately at the outside of the Maxum enclosure (APU for Zone 1); use an Siemens AAI part number 1263000-001 ferrite contained in CE Installation Kit or use a Fair-Rite part number 04431164181 split ferrite. This is required 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 ferrite clamp. 3. The Data Hiway cable shields must be terminated in a 360-degree termination at the enclosure (or bulkhead; use Siemens AAI P/N 2015729-001) contained CE Installation Kit or an equivalent part. 4. All Data Hiway cables must each have split ferrite clamped on them and fixed immediately at the outside of the Maxum enclosure (outside of APU for Zone 1); 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’s. This is required 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 ferrite clamp. 5. The I/O cable(s) must have all shield(s) terminated in a 360-degree termination at the Maxum enclosure (APU for Zone 1) or bulkhead use Siemens AAI P/N 2015729-001 contained CE Installation Kit or an equivalent part. 6. All Ethernet connections inside and outside the GC must use shielded Ethernet cable and coupled through the Maxum enclosure (APU for Zone 1) using a shielded RJ-45 coupler; use Siemens AAI part number 1183200-003 contained in CE Installation Kit. A mounting plate (Siemens AAI part number 2020261-001) is also available to accomplish this. If needed for Zone 1 installations Siemens AAI part number 2017984-001 and part number 2017985001 is available to maintain purge. All of the above parts are not required. If a PG gland is used to make the 360-degree termination of the Ethernet shield at the enclosure.
16 • Installation
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CE Installation Requirements, Continued
7. All DO lines with inductive loads must have transient suppression at the inductive load. 8. The user shall determine whether the Heavy Industrial Conducted Immunity requirements are pertinent to 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 are met with standard/normal termination.
2000582-001
Installation • 17
Installing Primary AC Power 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 Enclosure installed Power Supply.
Fuses
Fuses are located on the Power Entry Control Module located on the left sidewall of the Electronic Enclosure. 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.
WARNING
Installation personnel shall adhere to all AC power (Mains) specification requirements; see Application Drawing Package & Utility Diagram Sheet 2.1. Failure to do so, and operating the equipment in a manner not specified, can impair the safety protection provided by the equipment.
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 Application Drawing Package, Sheet 2.1, Block Diagram Utility Connections 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.
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-amp 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.
Caution
All AC power (Mains) wiring shall be in accordance with State and local codes.
18 • Installation
2000582-001
Installing Primary AC Power, Continued
Conduit
The AC primary power rigid and explosion proof conduit must be ½" (12.7 m). 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 Myers Hub be used to securely connect the conduit to the EC Enclosure. If an alternate hub type connector is used, it must meet the electrical codes for the area of installation.
Reference Information
Power Entry
•
Application Drawing Package, Sheet 2.1 and 6.1
•
CE Installation Requirements page 15.
The primary AC (Mains) power is routed to the Advance Maxum through the side or top access plates. The plates can be punched to accommodate pipe or cable gland connectors.
Cable Gland
Removable Access Plate
Figure 2-2. Top of Advance Maxum Showing AC Power Entry
2000582-001
Installation • 19
Installing Primary AC Power, Continued
Power Connections
The AC input power connection is made to a removable green connector (TB1) located on the upper left-hand side of the Power Entry Control Module (PECM). Refer to Figures 2-2 and 2-3. The bottom connector assembly is hardwired to the (PECM) circuit board and is nonremovable. TB2 is used if the analyzer has a second high wattage heater.
TB-2 Connections
This is an alternate connector used if the customer's installation requires a secondary primary AC power source for powering air bath heater #2 and low wattage heaters. The secondary AC power source must have its own explosion proof circuit breaker, ½ in. conduit with Myers Hub and 12-gauge wiring. To connect AC wiring to TB2, repeat the procedural steps for PECM connector TB1.
TB-2
TB-1
PECM
Figure 2-3. AC Power Entry to TB1 on Power Entry Control Module (PECM)
Installation Procedures
To install primary AC wiring, perform the following procedures: Step
20 • Installation
Procedure
1.
Shut off the primary AC Power Supply line to this location.
2.
Using a 4 mm Allen wrench, open the front door of the Electronic Enclosure.
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Installing Primary AC Power, Continued
Step 3.
4.
Procedure Install circuit breaker, conduit 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. Run the 12 gauge AC 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. There should be enough extra cable so that when terminations are made, there will be no sharp cable bends.
TB2 For 2nd Heater
TB1 AC (Mains) Power Connector C
AC Ground Lug H
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N
G
5.
Refer to Application Drawing Package, Block & Utility Sheet 2.1 for correct wiring of TB1 or TB2.
6.
Remove approximately 3 in. of outer insulation from input AC power cable.
7.
Remove approximately ½ in. of insulation from the hot, neutral and ground wires.
Installation • 21
Installing Primary AC Power, Continued
Step 8.
Procedure Loosen, but do not remove, the three TB1 fastening screws. TB connectors are labeled as to which are the Hot, Neutral and Ground.
For ease of connecting wires to TB1, the connector can be removed from its mounting assembly by pulling it straight up. 9.
Insert the neutral wire into TB1-H and securely tighten the fastening screw. Insert the neutral wire into TB1-N and securely tighten the fastening screw. Connect the green wire to the Enclosure AC ground connection. This connection is directly above and to the left of TB1. From the ground connection, connect a green wire to TB1-G. Securely tighten both the ground lugs fastening nut and TB1-G fastening screw.
10.
22 • Installation
If TB1 was removed for connecting wires, reinstall it into its mounting assembly.
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Installing Primary AC Power, Continued
Step
Procedure
11.
Verify that Advance Maxum Gas Chromatograph power supply switch is set to the correct VAC. It must be set to the primary AC power input voltage.
12.
Recheck all connections for tightness and shorts.
13.
Plug in power cable from PECM to Power Supply.
14.
Verify that the correct fuses are in place. Fuses are located on the PECM. 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
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DO NOT apply power to the unit until all circuits have been checked and that the proper fuses are in place.
Installation • 23
Utility Gas Supply Installation Description
This section provides the utility gas supply installation requirements for the analyzer. • • • •
Carrier Supply Gas Calibration Standard Detector Fuel Supply Compressed Air Supply
Refer to Application Drawing Package, Block Diagram Utility Connections, Sheet 2.1 for analyzer requirements. WARNING
Ensure that Personnel, Electrical and Local codes are considered when selecting the installation site for the calibration standard cylinders. Reference should be made to NFPA 55 Standard for the Storage, Use and Handling of Compressed and Liquefied Gasses in Portable Cylinders.
Carrier Supply Installation
The carrier gas (helium, hydrogen, nitrogen, or some other carrier) is specified in the Application Drawing Package on sheet 2.1, Block Diagram Utility Connections. Install two carrier gas cylinders in tandem near the analyzer mounting location. This allows you to exchange cylinders without disrupting the carrier supply. Rack mount the cylinders, or use a chain guard to secure them. Install carrier lines using new, clean, ¼ inch 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 ever occur.
Consumption
Typical carrier consumption is 180 standard cubic feet (SCF) [5098 dm3] per month.
Table 2-1. Regulators
Manufacturer's Name and Part Number
Siemens AAI Part #
Valve & Fitting Material
Helium or nitrogen of ultra high purity
ConCoa 2124301-580
X10014
Stainless Steel
Hydrogen of high purity
ConCoa 2124-310-350
X10035
Stainless Steel
Regulated Gas
24 • Installation
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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 sheet 2.1, Block Diagram Utility Connections contained in the Application Drawing Package.
Mounting
Always rack mount the calibration standard cylinder as close to the analyzer as practical. When installing calibration standard cylinders always use new, clean, 1/8-inch 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 Applied Automation or another supplier. If Siemens Applied Automation supplies the calibration standard, it will be noted in the " Notes" block on sheet 2.1, Block Diagram Utility Connections contained in the Application Drawing Package.
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Installation • 25
Utility Gas Supply Installation, Continued
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 sheet 2.1, Block Diagram Utility Connections contained in the Application Drawing Package. If heat tracing is used, it is essential that not even a single inch (2.5-cm) of 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.
Detector Flame Fuel Supply
Analyzers with FIDs or FPDs require flame fuel supplies that are 99.999% pure hydrogen with no more than 0.5-ppm total hydrocarbons. 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 in. stainless steel tubing between the hydrogen supply and the analyzer. The average flame fuel consumption is 70 SCF (1982 dm3) per month.
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.
FID Air Supply
If your analyzer uses a FID, air required for the FID flame typically comes from an air treater. Refer to Application Drawing Package for air and power connection to the air treater; Block Diagram Utility Connections, sheet 2.1.
26 • Installation
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Utility Gas Supply Installation, Continued
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.
WARNING
DO NOT USE a purge gas other than "air". This can fill up the area and 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, Sheet 2.1, Block Diagram Utility.
Analyzer Connections
Reference the Analyzer Connections Instructions on page 32.
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Installation • 27
Sampling System Installation Siemens Applied Automation Supplied Sample System
The sampling system provides a conditioned process sample to the analyzer. Refer to Application Drawing Package, Sampling System Sheets 5.1 and 5.2. Our 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:
Sample Probe Installation
•
A horizontal run
•
Containing a single sample phase (either all gas or all liquid)
•
Close to the analyzer
•
Reasonably protected from mechanical damage
•
Reasonably easy to access for installation and removal of the sample probe.
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 in. (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 2.1 and Sample Probe, Sheet 5.3. The sample probe should be long enough to be inserted to the process pipe's centerline, or at least 4 in. (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-in. (2.5 cm) of tubing between the packing gland and the shut-off valve when the probe is fully inserted. This decreases the changes of bending or breaking off the probe tube.
Additional Equipment
28 • Installation
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-in. (7.6-cm) long nipple upstream of the process gate valve. Refer to Application Drawing Package, Block Diagram Utility Connections, Sheet 2.1 and Sample Probe, Sheet 5.3.
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Sampling System Installation, Continued
Transport Tubing
Refer to Application Drawing Package, Block Diagram Utility Connections, Sheet 2.1.
Gas Samples
Transport tubing is typically ¼ in. (6.35 mm) OD for gas samples, and 3/8 in. (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 as low a pressure as possible, typically 5 to 15 psig (34 to 103kPa) or 5 psig (34 kPa) above the sample return pressure. The analyzer requires 5-psi (34 kPa) differential pressure. The pressure should be set at the probe site.
Liquid Samples
Liquids should have a minimum of 25-psi (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 3/8-in. (9.53 mm) OD more than 100-ft. (30.5 m) long may require more than 25-psi (172-kPa) differential.
Heat Tracing
Refer to Application Drawing Package, Block Diagram Utility Connections, Sheet 2.1. Some sampling systems require heat tracing of the transport tubing. If heat tracing is required, it will be noted on Sheet 2.1, Block Diagram Utility Connections. It is essential that not even a single inch (2.5-cm) of transport tubing be exposed to ambient conditions. The tubing must be continuously traced, insulated, and weather protected. Stream 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 stream tracing is used, it must be at the pressure recommended on the Block Diagram Utility Connections, Sheet 2.1. If electrical tracing is used, it must be safety treated for the hazard location. It must also be of the wattage recommended on sheet 2.1, Block Diagram Utility Connections.
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Installation • 29
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 Sheets 5.1 and Block Diagram Utility Connections Sheet 2.1. 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).
30 • Installation
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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 psi (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 psi (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 vents shall be vented outside of the shelter to protect maintenance personnel working on the unit from injury or death. This will enable toxic, flammable or oxygen depriving gasses if present to be vented outside the shelter.
Analyzer Connections
Reference the Analyzer Connections Instructions on page 32.
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Installation • 31
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 24 and the Sample System Installation requirements on page 28.
Input/Output Lines
If your system uses optional peripheral or control devices additional wiring is required. Siemens Applied Automation recommends the wire specifications shown on Sheet 2 of the "Application Drawings" "Cable Specifications". For CE Installation Requirements, see page 15.
WARNING
All vent lines and oven vents shall be vented outside of the shelter to protect maintenance personnel working on the unit from injury or death. This will enable toxic, flammable or oxygen depriving gasses if present to be vented outside the shelter.
Analyzer Connections
Refer to Application Drawing Package, Block Diagram Utility Connections, Sheet 2.1 for analyzer requirements. Step
WARNING
1.
Remove the plugs from the air supply lines. Purge the lines, then turn off the air supply. Connect the air lines to the 3/8-in. stainless tubing at the analyzer ports labeled "AIR IN" and "VALVE AIR," if this option is used.
2.
Remove the plug from the carrier line. Purge the line, then turn off the carrier supply. Connect the carrier line to the ¼ in. tubing at the analyzer port labeled "CARRIER IN."
3.
For an analyzer with a FID or an FPD that uses a carrier gas other than hydrogen, connect the hydrogen line (after purging and turning off the supply) to the ¼ in. tubing at the analyzer port labeled "HYDROGEN."
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. 4.
32 • Installation
Procedure
For an analyzer with an FID, connect a length of new, clean, ¼ in. stainless steel tubing to the analyzer port labeled "FLAME AIR OUT" and run it to the inlet port on a separately mounted air treater.
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Analyzer Connections, Continued
Step 5.
Procedure For an analyzer with an FID, connect a length of new, clean, ¼ in. stainless steel tubing to the analyzer port labeled "FLAME AIR IN" 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 in. diameter bolts. The air treater can be mounted on a wall or a portable stand in whichever direction is best for connecting the ¼ in. tubing to and from the analyzer.
2000582-001
6.
The analyzer oven vents typically are left unconnected. However, if needed, connect exhaust, drain, or return lines to the appropriate oven vent ports.
7.
Remove the plugs from the sample supply lines. If Siemens Applied Automation supply 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 Application Drawing Package, sheet 5.1, Sampling System Connections.
8.
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 sheet 5.1, Application Drawing Package, Sampling System Connections.
9.
Connect exhaust, drain, or return lines, as required to the appropriate sampling system vent refer to sheet 5.1, Application Drawing Package, Sampling System Connections.
Installation • 33
Preliminary Maxum Startup Procedures Important
Before proceeding with these procedures make sure the Maxum is installed correctly in accordance with the instructions contained in this Chapter.
Instructions
Perform all the procedures in this section consecutively starting with visual inspection of the Electronics Enclosure.
WARNING
When the Electronic Enclosure or Oven doors are open voltage dangerous to life exists. Comply with site’s regulations for working with “Hot” equipment.
Electronics Enclosure (EC)
The following procedure visually checks that the connectors and plugs in the Electronic Enclosure are properly connected.
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. Step
Procedure
1.
Turn off AC (Mains) power to Maxum.
2.
Open the electronic enclosure door and inspect all Power Entry Control Module (PECM) connections and all heater power connections to the solid state relay module.
Solid State Relay Module
Power Entry Control Module (PECM)
34 • Installation
2000582-001
Preliminary Maxum Startup Procedure, Continued
Electronics Enclosure, continued
Step
3.
Procedure
Inspect all SNE /DPM /EPC/SVCM connections. EPCM
SVCM
SNE/DPM
Oven Enclosure
The following procedure checks the oven operation.
WARNING
When the Electronic Enclosure or Oven doors are open voltage dangerous to life exists. Comply with site’s regulations for working with “Hot” equipment. Step
WARNING
2000582-001
Procedure
1.
Ensure AC (Mains) power to analyzer is off.
2.
Open the oven enclosure door and ensure that all of the packing material has been removed from the oven.
3.
Using the proper size wrenches make sure all-tubing connections are tight, especially the sample inlet and outlet connections and their associated components.
4.
Remove all caps from the carrier vent tubing on the right side of the oven enclosure. If the vent lines have been plumbed to tubing runs, ensure there isn’t any back pressure on any of the carrier vent lines including the FID vents.
Check all vent line and oven vents. All vent lines and oven vents shall be vented outside of the shelter to protect maintenance personnel working on the unit from injury or death. This will enable toxic, flammable or oxygen depriving gasses if present to be vented outside the shelter.
Installation • 35
Preliminary Maxum Startup Procedure, Continued
Maxum with Two Oven Heaters
The following procedure shall be performed on every newly installed Maxum Analyzer, which has two oven heaters.
WARNING
When the Electronic Enclosure or Oven doors are open hazardous voltages and exposed hot surfaces may cause death or serious injury. Comply with site’s regulations for working with “Hot” equipment. Step
1.
Procedure
Verify that the Maxum has two oven heaters installed. If two heaters are not installed in your analyzer do not perform this procedure and go the Checking Heater Power procedure.
LEFT SIDE HEATER
RIGHT SIDE HEATER
OVEN DIVIDER WALL
For illustration purposes only the key oven components are shown in the above illustration.
36 • Installation
2.
Disconnect all flammable and non-breathable gases attached to the unit. This includes carrier gases and any plant or calibration samples.
3.
Leave oven air connected and flowing. (If nitrogen or any non-breathable oven air is in use, discontinue this test, disconnect electrical power from the unit and contact Siemens Applied Automation, Inc. Customer Services.
4.
Disconnect AC (Mains) electrical power to the Maxum.
5.
Open the oven door and allow the unit to cool for 5 minutes. Verify by touching that both heater assemblies are cool. Use caution to avoid injury if surfaces are not cool!
2000582-001
Preliminary Maxum Startup Procedure, Continued
Maxum with Two Oven Heaters, continued
Step
Procedure
6.
Remove cover plate from connection box inside the oven on the left side heater assembly. This requires removal of 4 screws. Remove gaskets to allow viewing and access to the three heater wire connection points.
7.
Connect a Digital Multi-Meter (DMM) or Volt-Ohm Meter (VOM) to the heater wire connection points. Set the meter for measurement of ac voltage at 115 Vac or 230 Vac scale. For 115 Vac systems, measure between the center connector and either outer lead. For 230 Vac connections, measure between the two outer leads.
8.
Shut off oven air to the left side oven heater. This can be accomplished by using an external gate valve, if supplied, or by using the regulator controls supplied on the Maxum itself.
9.
Turn on the AC (mains) power to the Maxum. Use caution to avoid contact with high electrical voltages!
10.
Observe the voltage reading on the connected DMM or VOM for one minute. Zero volts are expected. If 115 Vac or 230 Vac are read, immediately turn off AC (Mains) electrical power and disconnect flammable carrier, sample and other gases. If the Maxum is not wired correctly immediately notify Siemens Applied Automation, Inc. Customer Services. We will make arrangements to send a qualified service person to your site to correct the problem. Siemens Applied Automation, Inc. Customer Services 500 West Highway 60 Bartlesville, OK 74003 U.S.A. Telephone: 1-918-662-7430 Telephone: 1-800-448-8224
11.
2000582-001
If O VAC is read on the DMM or VOM the heater circuits are properly wired. Turn off AC (Mains) power to the Maxum and continue with the Checking Heater Power procedure.
Installation • 37
Preliminary Maxum Startup Procedure, Continued
Checking Heater Power
Step
Procedure
1.
Unblock the utility air supply and set the oven air regulator to between 10 and 15 psig.
2.
Set the Valve air, if used, to the specified pressure as provided in the factory documentation.
3.
With the EC and Oven doors open turn on the analyzer AC (Mains) power to the analyzer. The system will begin to boot up. After boot-up the LED’s located on the DPM representing the oven heater control will alternately flash between yellow and green. The oven air should begin to feel warm. For units with two ovens both Heater 1 and Heater 2 LEDs will flash
Heater 1 LEDs Heater 2 LEDs
4.
Set the oven air regulator to zero and wait a minute for the oven to stabilize. The LED’s should no longer flash between yellow and green. The top LED should remain a solid green.
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.
38 • Installation
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Preliminary Maxum Startup Procedure, Continued
Leak Checking the Oven
Verifying Analyzer Carrier Flow
Step
Procedure
1.
Set the valve gas regulator to the setting recommended in the factory documentation.
2.
Unblock the carrier gas and set the bottle regulators to at least 25 psig above the factory recommended carrier pressures. This includes FID air fuel and air supplies.
3.
Check the EPC’s (Electronic Pressure Control modules). The programming for each EPC can be checked from the MMI. Press Menu\IO\Pressure Controllers to view the I/O Pres CTL screen. From the screen you can view the carrier set point and a pressure corresponding to the set point.
4.
If the EPC’s do not show a carrier pressure and there is no carrier flow on the carrier vents you will have to set the EPC’s manually. To do this from the MMI press the MODIFY softkey to set each EPC with the factory documentation pressure settings.
5.
Once all EPC’s are set you can leak check the plumbing in the Oven.
The following procedure checks the carrier flow pressure. Step
1.
Procedure
Close the oven door and set the oven pressure regulator between 12 and 15psig. The DPM oven control LED’s should begin to flash yellow to green. Wait until the oven reaches temperature setpoint. How to View the Setpoint Values The MMI Measurement screen displays the temperature setpoint for all ovens. The setpoint should match the factory documentation. If it does not, press Menu\IO\Temperature Controllers and modify the setpoint. When the oven is at setpoint the Green LED will flash off and on and the Yellow will remain off. IMPORTANT Any changes made to the factory setup of the EPC’s will have to be added to the EZChrom Method under EPC’s. When you make a pressure record it so you can add it into your EZChrom method.
2000582-001
Installation • 39
Preliminary Maxum Startup Procedure, Continued
Testing Hint for Step 2.
To check the flows according to the factory documentation you will have to set your EPC’s manually. See page 39, Steps 3 and 4 of the ‘Leak Checking the Oven’ procedure, and refer to the Application Drawing Package, sheet 8.1, Plumbing Diagram.
IMPORTANT
Remember an EPC can have more than one pressure setting for an EZChrom Method. Record any flow rate changes, and update the EZChrom Method when you are finished. Step
2.
Procedure
Connect a Magnahelic or Electronic flow-measuring device to the appropriate carrier vent lines. Follow the flow checks as outlined in the factory documentation. IMPORTANT If you have a FID turn off the FID air and any Makeup gas when verifying the FID (Vent) Carrier flow. Turn on the FID air and Makeup gasses to check the flow for the FID air and Makeup gases. The FID vent flow can only be checked properly with one gas flowing at a time.
3.
40 • Installation
After all flows have been properly verified and documented you are ready to apply the process and calibration gases.
2000582-001
Preliminary Maxum Startup Procedure, Continued
Applying Process and Calibration Gases
Sample handling is where the analysis process starts. If the sample system is not functioning properly, the analyzer can have problems processing the right data. Also a faulty sample system can cause the analyzer valves to have a shorter life span. Step
Procedure
1.
Review Chapter 1., Sampling System Installation.
2.
Ensure that the sample system panel/enclosure has been properly pressure tested at the site.
3.
Ensure that all Sample Shut Off (SSO) and or Atmospheric Reference Valves (ARV) are working properly.
4.
Ensure that all sample system vents and drains are properly orientated. WARNING All vent lines and oven vents shall be vented outside of the shelter to protect maintenance personnel working on the unit from injury or death. This will enable toxic, flammable or oxygen depriving gasses if present to be vented outside the shelter.
2000582-001
5.
Inspect carefully the sample system in accordance with the sample system documentation
6.
Circulate and purge all process gas through the sample system for a period of time before applying to the analyzer. If using a vapor sample make sure there is no liquid (droplets in the rotameters etc.) in the system. If using a liquid sample ensure there are no bubbles present in the sample.
Installation • 41
Maxum Startup Procedure Using the Workstation Software Before You Begin
Ensure that the analyzer has been properly installed and has past the Preliminary Maxum Startup Procedures, see page 34. Step
Procedure
1.
Connect utilities (see custom documentation and Installation Guide).
2.
Power up analyzer (before powering up verify connections. Look for proper LED’s).
Using System Manager
3.
Backup the analyzer database. You may have to wait until the icon appears in the system view window or you can add it manually if you know the analyzers IP address. (see Advance System Manger Users Guide, page 11 for Add Unit and page 12 for Backup/Restore. Recommended file name AX### Original.amd)
Using EZChrom
4.
Launch EZChrom Main Window from the System Manager.
5.
In the EZChrom Main Window you will need to create a new instrument (see Advance EZChrom Release Notes, Getting Started with EZ Chrom page 13.)
6.
You will need to Auto-Configure the Icon. (see page 16 in Advance EZChrom Release Note, Getting Started with EZChrom).
7.
Launch the instrument. (see Advance EZChrom Release Notes, Getting Started with EZChrom page 13.)
8.
Import the Method. Select File| Method | Import. Select the method you want to Import and select OK. Save the method on your hard drive. (Create a subdirectory for your analyzer and save the method. Recommended file name Method#.met)
9.
Check flows documenting the pressures for plant conditions using your custom documentation (if you are using Electronic Pressure Controllers see Maintenance Panel Operations page 85 on Maxum Online Library CDROM).
From the Maintenance Panel
42 • Installation
2000582-001
Maxum Startup Procedure Using the Workstation Software, Continued
Using EZChrom
2000582-001
Step
Procedure
10.
If the pressure is different you will need to adjust the settings for the method. (pressure is OK go to step 12). Open the instrument setup window and adjust the pressure settings in the EPC tabs. (see Getting Started with EZChrom Tutorial Acquisition Setup page 6-2).
11.
Save your method and export the method back to the analyzer. Overwrite the method you are working with in the analyzer. File | Method | Save and File | Method | Export
12.
Lineup the appropriate calibration cylinder. Run the analyzer. You can run the analyzer from the MMI or from EZChrom Control Application. (see Maintenance Panel Operations page 197 or Getting Started with EZChrom Control and Monitor Application page 46.)
13.
At the end of the cycle import the data (chromatogram). File | Data | Import. Select the appropriate stream and select import.
14.
Using the chromatograms in the custom documentation compare the acquired chromatograms to the ones in the custom documentation. If there are any differences they should be corrected. If the analyzer has a detector in the ITC position check that the cut times are correct. If not adjust them in Instrument Setup Valve tab. If you are using Electronic Pressure Control (EPC) and change the valve switch time you may need to change the time that the EPC switches pressure. (see Getting Started with EZChrom page 19 Instrument Setup or the EZChrom Tutorial Acquisition Setup page 6-2)
15.
Save your method and export the method back to the analyzer. Overwrite the method you are working with in the analyzer. File | Method | Save and File | Method | Export
16.
Run the analyzer again. You can run the analyzer from the MMI or from EZChrom Control Application. (see Maintenance Panel Operations page 197 or Getting Started with EZChrom Control and Monitor Application page 46.)
17.
At the end of the cycle import the data (chromatogram). File | Data | Import. Select the appropriate stream and select import.
Installation • 43
Maxum Startup Procedure Using the Workstation Software, Continued
Step
44 • Installation
Procedure
18.
Using the chromatograms in the custom documentation compare the acquired chromatograms to the ones in the custom documentation. If there are any differences they should be corrected. Repeat steps 15 – 18 until the ITC chromatograms look correct.
19.
Using the chromatograms in the custom documentation compare the acquired chromatograms to the main detector chromatograms in the custom documentation. Check the component peak retention times and gating. If there are any discrepancies they should be corrected. Adjust the peak retention times as necessary. (see EZChrom help on Method Development | Calibration | Peak Table.)
20.
Integrate the Chromatogram to verify the changes. Analysis | Analyze. You may want to place annotations on the chromatograms so you can visually see the changes you make. (To add annotations see EZChrom Basic Operations | Chromatogram Window | Chromatogram Annotations.)
21.
Save your method and export the method back to the analyzer. Overwrite the method you are working with in the analyzer. File | Method | Save and File | Method | Export
22.
Run the analyzer again. You can run the analyzer from the MMI or from EZChrom Control Application. (see Maintenance Panel Operations page 197 or Getting Started with EZChrom Control and Monitor Application page 46.)
23.
At the end of the cycle import the data (chromatogram). File | Data | Import. Select the appropriate stream and select import.
24.
Using the chromatograms in the custom documentation compare the acquired chromatograms to the ones in the custom documentation. If there are any differences they should be corrected. Repeat steps 19 – 24 until the Main chromatograms look correct.
2000582-001
Maxum Startup Procedure Using the Workstation Software, Continued
Step
Using the System Manager
2000582-001
Procedure
25.
At this point you are ready to calibrate the analyzer. Save the last acquired chromatogram to be calibrated. Analysis | Single Level Calibration. (See EZChrom Tutorial | Calibration Using a Stored Data File page 6-10.)
26.
You may want to verify calibration. (See EZChrom Tutorial | Reviewing Calibration Curves page 6-17.)
27.
Save your method and export the method back to the analyzer. Overwrite the method you are working with in the analyzer. File | Method | Save and File | Method | Export
28.
Run the analyzer again. You can run the analyzer from the MMI or from EZChrom Control Application. (see Maintenance Panel Operations page 197 or Getting Started with EZChrom Control and Monitor Application page 46.)
29.
At the end of the cycle import the data (chromatogram). File | Data | Import. Select the appropriate stream and select import and verify that the analyzer is reading correctly.
30.
Backup the analyzer database. You may have to wait until the icon appears in the system view window or you can add it manually if you know the analyzers IP address. (see Advance System Manager Users Guide page 42 for Add Unit and page 43 for Backup/Restore. Recommended file name AX###.amd)
31.
Put the analyzer in RUN.
• 45
Requesting Start-Up Assistance Instructions
When the analyzer is mounted and all of the connections are made, notify your Siemens Applied Automation, Inc. representative or authorized agent. A specialist can be sent to assist you in starting up the equipment and preparing it for use. Siemens Applied Automation Inc. Customer Service Department 500 Highway 60 West Bartlesville, Oklahoma 74003 Inside Oklahoma: (918) 662-7430 Outside Oklahoma: (800) 448-8224 Internationally: 001-918-662-7430
46 •
2000582-001
Siemens Applied Automation, Inc. 500 Highway 60 West, Bartlesville, OK 74003 Phone 918-662-7000, Fax 918-662-7052
