Siemens Maxum II Service Manual

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Page 1 Maxum Edition II Detectors Valco Pulse Discharge Detector Service Manual Descriptions and maintenance procedures for detectors and related components used in Maxum II Gas Chromatographs. The information in this manual supercedes the applicable topics in previous manuals. May 2018 A5E42019847001...
Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
Page 3: Table Of Contents
Table of contents Detector Overview............................5 DPM Types..........................5 Thermal Conductivity Detector........................7 Intrinsically Safe Thermal Conductivity DPM................8 Replacing TCD Components....................11 2.2.1 Replace TCD Thermistor Beads/Filaments Introduction............11 2.2.2 Procedure to Replace Thermistor Beads................12 2.2.3 Replacing an IS-TCD DPM....................13 TCD Specifications.........................15 Flame Photometric Detector........................17 Upgrade Description......................21 Intended Users........................21 Safety and Certification Information..................21...
Page 4 Table of contents Methanator..........................51 4.7.1 Methanator Function......................51 4.7.2 Purged Methanator........................52 4.7.3 Explosion-Proof Methanator....................53 4.7.4 Methanator Specifications......................53 4.7.5 Methanator Maintenance Considerations................54 Air Treater..........................55 4.8.1 Air Treater Maintenance Considerations................55 4.8.2 Air Treater Specifications.......................56 Valco Pulse Discharge Detector.........................57 PDD Specifications........................57 Maxum Edition II Detectors Service Manual, May 2018, A5E42019847001...
Page 5: Detector Overview
Inc. It can be equipped to operate in either the Helium Ionization, Photo Ionization, or Electron Capture modes. All of the detector modules within the Maxum II can be used in conjunction with both air bath and airless ovens. Depending upon the application requirements, a Maxum II can include up to three detector modules in a single air bath oven, or up to 2 detector modules, one for each oven, in an airless oven.
Page 6 Detector Overview 1.1 DPM Types Function IS-TCD DPM Base3DPM Thermistor Filament Maxum Edition II Detectors Service Manual, May 2018, A5E42019847001...
Page 7: Thermal Conductivity Detector
The Thermal Conductivity Detector (TCD) is a concentration-responsive detector of moderate sensitivity. The detector cell, containing the sensing element, is a flameproof/explosion-proof unit located in the chromatograph oven. The TCD is the only Maxum II detector type that is not mounted in the detector compartment.
Page 8: Intrinsically Safe Thermal Conductivity Dpm
TC DPM in a Maxum or Maxum II Analyzer on the Siemens web site. Intrinsic Safety The intrinsic safety feature of this module was not used in early versions of the Maxum II Airless and Airbath Oven model. The following two paragraphs apply only if this feature is used.
Page 9 To preserve the intrinsically safe design protection of the IS TCD, certain measures are required. Failure to adhere to all requirements for use of the IS TCD in the Maxum II could violate the safety protections of the analyzer and cause equipment damage or serious injury.
Page 10 Intrinsic Safety Grounds: The intrinsically safe design of the IS TCD DPM requires two ground connections to the chassis terminated to two different terminals. The Maxum II is shipped with these grounds connected correctly. See the Maxum II Explosion Protection Safety Standards Manual (A5E02220442001) (https://support.industry.siemens.com/cs/document/42017542/...
Page 11: Replacing Tcd Components
It is possible to replace the Filament/Thermistor Board with the detector installed in the analyzer. TCD parts should be removed or replaced only by a trained Siemens maintenance engineer or by the user’s maintenance personnel trained by Siemens. Note Do NOT attempt to open the TCD with the power on.
Page 12: Procedure To Replace Thermistor Beads
Thermal Conductivity Detector 2.2 Replacing TCD Components Note When removing materials from the analyzer, all items must be placed on a clean, non-abrasive surface. Use a clean lint-free cloth. µ µ Figure 2-7 8-Cell TCD Block Exploded View 2.2.2 Procedure to Replace Thermistor Beads Within this procedure, the numbers in parenthesis denote parts referenced in the list contained in the Exploded Diagram earlier in this section.
Page 13: Replacing An Is-Tcd Dpm
Thermal Conductivity Detector 2.2 Replacing TCD Components 4. Remove the Thermistor/Filament Board (12) by removing the Button Head Hex Screw (9), the Lockwasher (10), and the Flat Washer (11). 5. Discard board (12) and O-rings (13). Do not attempt to reuse old O-rings. 6.
Page 14 Thermal Conductivity Detector 2.2 Replacing TCD Components Removing the IS TCD DPM See the illustration IS TCD DPM Connector Locations for connector locations. General Analyzer Shutdown Procedure in the 1. Back up and shut down the unit using the Maxum Edition II Analyzer General Maintenance Manual . 2.
Page 15: Tcd Specifications
Thermal Conductivity Detector 2.3 TCD Specifications TCD Specifications Table 2-1 Thermal Conductivity Detector (TCD) Parameter Value Target Components Measurement Type Concentration Smallest Measuring Range (at 60°C oven temperature) 0 to 20 ppm ±5% Typical Measuring Range (at 60°C oven temperature) 0 to 500 ppm ±2% FS up to 0 to 100% ±0.5% FS...
Page 16 Thermal Conductivity Detector 2.3 TCD Specifications Maxum Edition II Detectors Service Manual, May 2018, A5E42019847001...
Page 17: Flame Photometric Detector
Two versions of the FPD have been available for the Maxum II. In 2007, enhancements were made to the original FPD that im‐ proved the performance. The en‐...
Page 18 Flame Photometric Detector Figure 3-2 Flame Photometric Detector Major Components Combustion Chamber ● The burner nozzle consists of two annular gaps. The combustion gas H flows out of the outer annular gap and mixes with the combustion air from the inner gap. The carrier gas flows from the nozzle into the dome-shaped flame.
Page 19 The detector temperature is factory set depending upon the application. The temperature is normally set equal to or higher than the oven temperature and at minimum 80°C. Detector Gas Supply For information on detector gas-supply requirements. see the Maxum II Official Product Specifications (A5E03012338001) (https://support.industry.siemens.com/cs/document/ 42017542/maxum-edition-ii%3A-explosion-protection-safety-standards?lc=en- WW&pnid=17741).
Page 20 Flame Photometric Detector Increasing the Sensitivity The sensitivity of the FPD can be increased by reducing the flow of combustion air. Most of the time, the FPD cannot be ignited with a normal air/hydrogen ratio. If an electronic pressure controller (EPC) is used for the combustion gasses an event will be written at the factory, which will automatically adjust the flows during the ignition sequence.
Page 21: Upgrade Description
In 2007 a new version of the FPD was released for the Maxum II. The original version is now known as FPD I. The new version is called FPD II. The FPD II is a more sensitive and more consistent detector than the FPD I.
Page 22: Procedure - Upgrade Fpdi To Fpdii
● The external part of the bushing shall be protected by pressurized enclosure “p”; not included in the ATEX certificate. Original FPD Label FPD II Label Figure 3-4 FPD Certification Lables Maxum II Explosion Protection Safety Standards Manual For more information see the (A5E02220442001) (https://support.industry.siemens.com/cs/document/42017542/maxum- edition-ii%3A-explosion-protection-safety-standards?lc=en-WW&pnid=17741). Procedure - Upgrade FPDI to FPDII Note The existing light pipe and PMT module are kept and used for the FPD II.
Page 23: Base3 Detector Personality Module (Dpm)
15.Connect the column inlet, hydrogen and air supplies, detector vent and the light pipe. 16.Replace the insulation and cover on the detector. Restore power to the Maxum II. 17.After the Maxum II has had time to heat up, check the flows and light the flame. Base3 Detector Personality Module (DPM) Output signals from any of the detectors connect to each associated Detector Personality Module (DPM) input.
Page 24 Flame Photometric Detector 3.5 Base3 Detector Personality Module (DPM) The method is the part of the application that contains the parameters for controlling the hardware used by one cycle clock. It provides peak areas and component concentrations and includes all cycle clock timed events. There is one cycle clock per method. RTD Temp Control Input Access hole for mounting screw for Temp Setpoint modules...
Page 25 Flame Photometric Detector 3.5 Base3 Detector Personality Module (DPM) Overview of DPM Functions The Base 3 Detector Personality Module (DPM) combines these functions in a single module: Input from detector via mezzanine module Ignite signal / glow-plug output Range-select output 300-V bias output Flame-sense input (used in Maxum I analyzers only) Input from detector via mezzanine module...
Page 26 5 V Power (FPD) Output Figure 3-8 Maxum II Detector Control Functions Location ID Switch The Location ID Switch, shown previously in the photograph, selects the DPM location that is incorporated in the address, to be reported in the results.
Page 27 Flame Photometric Detector 3.5 Base3 Detector Personality Module (DPM) DPM-Based Temperature Control The Base3 DPM has two temperature-control channels. Two RTD inputs feed two comparator circuits to drive two heater-control outputs. The heater-control outputs connect to inputs on the PECM in most analyzers. The control path is shown below. Air Bath Oven Analog Temp Control,...
Page 28: Base3Dpm Status Indicator Leds
Flame Photometric Detector 3.6 Base3DPM Status Indicator LEDs Mezzanine Modules A mezzanine module conditions the signal from a non-conductivity detector. The mezzanine plugs into the Base3 DPM in order to tailor the DPM for a specific measurement. Three primary types of mezzanine are available to accommodate FID and FPD detectors, and various detectors that produce a scaled analog output (AI) mezzanine.
Page 29: Replacing A Base3Dpm
Flame Photometric Detector 3.7 Replacing a Base3DPM Replacing a Base3DPM Removing the Base3DPM Base3 DPM With Mezzanine Module and Temperature Setpoint Modules See the illustration Installed on Left Side of Base3DPM for connector and module locations. General Analyzer Shutdown Procedure . 1.
Page 30: Fpd Specifications
Flame Photometric Detector 3.8 FPD Specifications 3. Reinstall the screw to secure the temperature setpoint module stack through the access hole on the right side of the unit. 4. Plug the mezzanine module onto its connector on the right side of the unit, and reinstall the two screws ear the top edge.
Page 31: Flame Ionization Detector
Flame Ionization Detector The Flame Ionization Detector (FID) is a very sensitive detector that is used for measuring hydrocarbons. It responds to most carbon containing compounds. Using a methanator, the FID can also detect carbon mon‐ oxide (CO) and carbon dioxide ).
Page 32: Fid Maintenance Considerations
It is important that these safety systems not be compromised. All instructions and warnings in this procedure must be followed. Maintenance work on the Maxum II analyzer should only be performed when the area is known to be safe for the work to be done.
Page 33: Purge Coil And Filter
It will be necessary to power down the analyzer for this procedure. When performing this procedure, it should NOT be necessary to remove the FID from the Maxum II. The following figures are intended for use as a reference throughout the procedure. The numbers in the diagrams relating to individual components are referenced in parentheses in the procedure steps.
Page 34 Flame Ionization Detector 4.2 Replacing the FID Mesh Filter uartz Jet embly Flame Arrestor Insert Assembly 12. Graphite Seal Flat Washer 13. Hammer Drive Screws (for Label) Detector Body (Bottom) 14. Label Filter 15. Socket Heat Cap Screw Retainer Clip - Small 16.
Page 35: Procedure To Replace Mesh Filter
Flame Ionization Detector 4.2 Replacing the FID Mesh Filter 4.2.1 Procedure to Replace Mesh Filter 1. Shut off the detector Hydrogen and allow the detector to cool down. Carrier gas should remain on during cool down to prevent condensation. 2. Turn off all supply gasses. WARNING Possible ignition source.
Page 36: Replacing The Fid Quartz Jet
This item rarely needs replaced. It will be necessary to power down the analyzer for this procedure. When performing this procedure, it should NOT be necessary to remove the FID from the Maxum II. 4.3.1 Procedure to Replace Quartz Jet 1.
Page 37: Replacing The Fid Igniter
13.After the oven and FID has had time to heat up, check the flows and light the flame. Replacing the FID Igniter This section describes the procedure to retrofit the FID igniter in the Maxum II. This involves replacing the original FID igniter module with a new version FID igniter module. The procedure also involves replacing of some of the related hardware, such as the purge tube and heater assembly.
Page 38: Procedure - Removing The Detector
Flame Ionization Detector 4.4 Replacing the FID Igniter 4.4.2 Procedure - Removing the Detector Note All figures are located at the end of this procedure. 1. From GCP, create a database backup of the Maxum analyzer that is to be modified (See the Gas Chromatograph Portal User Manual for instructions).
Page 39 Flame Ionization Detector 4.4 Replacing the FID Igniter 6. Open the electronics enclosure door, mezzanine door, and oven door. Use a 4mm Allen wrench if necessary and be careful not to place tension on the ribbon cable connecting to the Maintenance Panel. Detector Personality Module...
Page 40 Flame Ionization Detector 4.4 Replacing the FID Igniter 9. Disconnect the FID bias, igniter, and signal cables from the DPM making note of the connector locations. 10.Disconnect tubing from the FID flame arrestor insert tube in the oven. Old Igniter FID Bottom Body Flame Arrestor...
Page 41 Flame Ionization Detector 4.4 Replacing the FID Igniter 12.Remove the ¼ " vent tube from the top of the FID block using a 9/16" open-ended wrench. Vent Tube Figure 4-7 FID Vent Tube Location on FID Assy 13.Using a 3.0mm Allen wrench, remove the FID cover set screw from the front of the FID Assembly.
Page 42: Procedure - Igniter Replacement
Flame Ionization Detector 4.4 Replacing the FID Igniter 15.Disconnect utility gas lines from the FID at the connecting union using a 5/16" open-end wrench. Temporarily label the gas line leads to make sure they can be reconnected correctly. Disconnect utility gas at unions on the ends of supply lines (up to 3) Disconnect...
Page 43 Flame Ionization Detector 4.4 Replacing the FID Igniter Detector Bushing Ground strap set screw goes here cover Hole for purge filter Install signal cable so end is aligned with igniter cable ends Insulation Igniter Mounting/ground strap Insulation FID purge tube grommet EC cover plate body (A5E35374578001)
Page 44 Flame Ionization Detector 4.4 Replacing the FID Igniter 6. Install the new FID heater assembly (A5E41666957001 for 115V, A5E41666957002 for 230V) on the FID mounting plate using the 4 screws removed from the old heater assembly. Figure 4-11 Heater Assembly Note Do not disassemble the heater block assembly.
Page 45 Flame Ionization Detector 4.4 Replacing the FID Igniter 12.Plug the white signal wire (from the DPM) into the appropriate detector electrode position. See Electrode Connections for New Igniter. The wire should not be connected at the DPM end yet. Note: The black wire appears blue due to a Teflon coating over the wire.
Page 46: Procedure - Reinstalling The Detector
Flame Ionization Detector 4.4 Replacing the FID Igniter 16.Insert the purge filter (A5E41381855001) through the washer (A5E41849023), and screw into the bushing to secure the purge tube. 17.If the new grommets are not installed in the holes on the new EC cover plate or on the purge tubes, then install them now.
Page 47: Fid Specifications
Flame Ionization Detector 4.5 FID Specifications 8. Install the FID cover set screw and tighten using a 3mm Allen wrench. Note The next step is important in order to maintain the explosion proof protection of the FID. The threads of the FID flame arrestor must be clean and lubricant or other substances must NOT be applied to the threads.
Page 48: Filament Detector
Flame Ionization Detector 4.6 Filament Detector Parameter Value Smallest Measuring Range (at 60°C oven temperature) 0 to 1 ppm ±3% Typical Measuring Range (at 60°C oven temperature) 0 to 100 ppm ±1% FS up to 0 to 100% ±0.5% FS Dynamic Range Linear Range Selectivity...
Page 49 Flame Ionization Detector 4.6 Filament Detector Figure 4-17 FID with Filament Detector, Typical Application Filament Detector Assembly Details Figure 4-18 Filament Detector Exploded View Maxum Edition II Detectors Service Manual, May 2018, A5E42019847001...
Page 50: Replacing The Filaments
Flame Ionization Detector 4.6 Filament Detector 4.6.1 Replacing the Filaments 1. Remove the two bolts in the bottom of the detector block. 2. Separate the detector body (bottom) and detector cap (top) to allow access to the filament board. 3. Note location of each wire and disconnect from board. Wires are paired; Sense is White and Blue, and Reference is Red and Black.
Page 51: Methanator
Two versions of the methanator exist for use in the Maxum edition II. The original is protected by purging/pressurization. The more recent version is protected in an explosion proof enclosure. Both versions are installed in the detector compartment of the Maxum II Airbath/ Airless Oven configuration.
Page 52: Purged Methanator
Flame Ionization Detector 4.7 Methanator 4.7.2 Purged Methanator Although the purged/pressurized methanator assembly is installed in the detector compartment, it is installed inside a protective cover that limits air passage. The interior of the assembly is connected to the EC using a pipe which contains the electrical wiring for the methanator.
Page 53: Explosion-Proof Methanator
Safety Protection Principles section of this manual. This design enclosure as described in the eliminates the need to maintain a pressurized methanator enclosure as well as reducing some of the necessary safety measures required for maintenance of the Maxum II when a methanator is installed. Figure 4-20...
Page 54: Methanator Maintenance Considerations
EC for routine maintenance. If the purge air supply of the Maxum II is interrupted during operation, it is imperative that the analyzer be powered down. Once powered down, the electronics-cabinet door must be kept closed for at least 30 minutes.
Page 55: Air Treater
Air Treater to remove hy‐ drocarbons from ordinary plant instrument air. The Air Treater is an independent unit moun‐ ted near the Maxum II. It consists of an ex‐ tremely hot combustion chamber and a cata‐ lyst. Instrument air flows through the combus‐...
Page 56: Air Treater Specifications
Flame Ionization Detector 4.8 Air Treater The instrument air connections must always be made through the attached flame arrestors. The Air Treater must be firmly mounted to the wall, the floor, or a rack on which the analyzer is mounted. Install the Air Treater so that it cannot be damaged during normal maintenance operations.
Page 57: Valco Pulse Discharge Detector
Since a radioactive source is not used, the complex directives for radiation protection need not be observed by the customer. PDD Specifications For information on detector gas-supply requirements. see the Maxum II Official Product Specifications (A5E03012338001) (https://support.industry.siemens.com/cs/document/ 109742522/maxum-ii-official-product-specifications?lc=en-WW&pnid=17741). This publication gives approximate requirements.
Page 58 Valco Pulse Discharge Detector 5.1 PDD Specifications Parameter Value Selectivity Components with electron affinity to carbon 10 to 1 Temperature Range 70 - 110°C (higher temperature ranges on request; system configuration dependent) Table 5-3 Pulse Discharge Detector, Photoionization Mode Parameter Value Target Components Photon sensitive components...

Siemens Maxum II Service Manual

1 Detector Overview

2 Thermal Conductivity Detector

3 Flame Photometric Detector

4 Flame Ionization Detector

5 Valco Pulse Discharge Detector

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