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Siemens Maxum II Manual

Process gas chromatograph
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Maxum II
PD PA AP
Explosion Protection Safety
Standards
Manual
August 2017
A5E02220442001 Rev 8
General Information for the
User
Safety Systems - Purging
Safety Systems - Oven
Valves, Detectors, and
External Systems
Safe Operation
1
2
3
4
5

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Summary of Contents for Siemens Maxum II

  • Page 1 General Information for the User Safety Systems - Purging Safety Systems - Oven Maxum II Valves, Detectors, and External Systems PD PA AP Explosion Protection Safety Safe Operation Standards Manual August 2017 A5E02220442001 Rev 8...
  • 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 General Information for the User........................7 Contacts..........................10 Approved Use........................11 Qualified Personnel........................11 Applicable Standards and Regulations..................12 Safety Protection Principles....................13 Intrinsically Safe Devices.......................14 Safety Systems - Purging...........................17 Purging Overview........................17 Electronics Purging System (without Automatic Purge Unit)..........18 2.2.1 Overview..........................18 2.2.2 Instrument Air Inlet and Regulator..................20 2.2.3 Fast Purge Switch........................21 2.2.4...
  • Page 4 4.4.2 Methanator Maintenance Considerations................55 Safe Operation............................57 Maintenance Panel Functional Description................57 Maintenance Considerations for Maintenance Panel.............58 Color Touchscreen Display Functional Description...............58 Maintenance Considerations for Control Interface Module Display........59 Steps for Safe Startup of Maxum II..................60 5.5.1 Overview..........................60 5.5.2 Procedure..........................60 Glossary..............................63 Figures Figure 1-1 Reference of Hardware (MAA) to Applicable Sections of this Manual..........8...
  • Page 5 Figure 4-1 Siemens Liquid Injection Valve....................45 Figure 4-2 Siemens Liquid Injection Valve (Installed)...................46 Figure 4-3 Heater for Siemens Liquid Injection Valve..................46 Figure 4-4 Explosion Proof/Flameproof Thermal Conductivity Detector............49 Figure 4-5 Thermal Conductivity Detector Beads on Modular Oven Application Module (Intrinsically Safe TCD)...........................50...
  • Page 6 Table of contents Explosion Protection Safety Standards Manual, August 2017, A5E02220442001 Rev 8...

  • Page 7: General Information For The User

    These standards are to ensure that the Maxum II and related products can be safely installed and operated in hazardous areas. Each individual detail and component of these safety systems is important to help ensure that the chromatograph does not ignite flammable vapors and gases which may be present in the environment surrounding the analyzer.

  • Page 8: Figure 1-1 Reference Of Hardware (Maa) To Applicable Sections Of This Manual

    General Information for the User Exhaust Di user Electronics Automatic Purge Unit (APU) Sections 2.2, 2.3 Enclosure (Purged) or Pressure Relief Valve Sections 2.2, 2.3 (Inside Enclosure) Sections 2.2, 2.3 Proportinal Valve for APU (Section 2.3) or Signal Disconnect Purge Control Module Relay for APU (Section 2.2) Section 2.3...
  • Page 9 Trademarks All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 10: Contacts

    General Information for the User 1.1 Contacts Contacts Register at the Siemens Industry Online Support (SIOS) website: https://support.industry.siemens.com International Siemens AG Siemens Industry, Inc. I IA SC PA PM Process Analytics 5980 West Sam Houston Parkway North Oestliche Rheinbrueckenstrasse 50...

  • Page 11: Approved Use

    Low voltages which are connected must also be generated using safe isolation. If any part of the Maxum II is opened, certain parts of the device are accessible which may carry dangerous voltages. Therefore, only suitably qualified personnel may work on this device as indicated in the next section which is titled "Qualified Personnel".

  • Page 12: Applicable Standards And Regulations

    The ATEX certificate for the Modular Oven Configuration is Sira 12ATEX1260X and comes with the following conditions for safe use: ● The Maxum II Modular Oven Gas Chromatograph shall be fitted with cable glands or conduit entries having an IP54 minimum rating.

  • Page 13: Safety Protection Principles

    The protection principles used depend on such factors as the type of device, the certifying organization that is applicable for the site, and the type of environment. Table 1-2 details some of the protection principles used in the Maxum II along with the hardware that uses those protection principles.

  • Page 14: Intrinsically Safe Devices

    IS‑TCD and the connections to the CIM touch screen display. Intrinsic safety protection for circuits and devices within the Maxum II enclosure is designed to conform to IEC EN60079-11. This is the standard that is applicable to factory installed electrical components and also for circuits that are additionally protected by other methods, such as a purged Maxum enclosure.
  • Page 15 ● Maintenance for intrinsically safe devices, such as the IS-TCD, is limited to replacement. Repair or service on-site are not permitted. ● Intrinsically safe devices in the Maxum II that are equipped with a cover must have the cover attached during use. Leaving the cover off can violate requirements pertaining to mandatory separation from non-IS wiring.
  • Page 16 General Information for the User 1.6 Intrinsically Safe Devices Explosion Protection Safety Standards Manual, August 2017, A5E02220442001 Rev 8...

  • Page 17: Safety Systems - Purging

    The primary electronic devices of the Maxum II analyzer are housed inside the electronics enclosure (see Figures 1-1 and 1-2). All electronics in the Maxum II are designed to meet North American Division 2 and European Zone 2 safety requirements. This means that these electronics will not cause combustion of flammable vapors or gases under normal conditions.

  • Page 18: Electronics Purging System (Without Automatic Purge Unit)

    2.2.1 Overview The standard purging system of the Maxum II is controlled by the Power Entry Control Module (PECM) and the processor board (either SYSCON or CIM, depending on the Maxum II configuration). In the standard purging configuration, an alarm is generated whenever purging pressure is lost.

  • Page 19: Figure 2-2 Electronics Pressurization System (Type Py) For Airbath/Airless Oven Model (Old Pressure Relief Valve Configuration)

    Safety Systems - Purging 2.2 Electronics Purging System (without Automatic Purge Unit) Instrument Air System Controller Input - “Clean (SYSCON) Regulator and Dry” Electronics Purge Enclosure Purge Signal Warning Cable Light PECM to Purge SYSCON Power Entry Purge Control Control Module Pressure Sensor Module (PCM) (PECM)

  • Page 20: Instrument Air Inlet And Regulator

    Depending on the configuration of the Maxum II, the regulator may be labeled as either "Purge" or "Isothermal Oven Air" (refer to the section of this manual regarding Isothermal Ovens for more information). The purge air is connected to the purged electronics enclosure through two possible paths, the "normal"...

  • Page 21: Fast Purge Switch

    Safety Systems - Purging 2.2 Electronics Purging System (without Automatic Purge Unit) 2.2.3 Fast Purge Switch The fast purge control switch, which is shown in the following figure, is located inside the detector enclosure (middle door) or near the purge air regulator as shown in the figure below. This switch is operated by the user and is used to re-purge the electronics enclosure for a period of 8 minutes after the sealed enclosure has been opened and then re-sealed.

  • Page 22: Figure 2-5 Fast Purge Switch (Shown In The Off Position)

    Safety Systems - Purging 2.2 Electronics Purging System (without Automatic Purge Unit) Modular Oven Airbath/Airless Oven Modular Oven fast-purge switch label for Div 2 Modular Oven fast-purge switch label for Div 1 / Zone 1 Figure 2-5 Fast Purge Switch (Shown in the Off Position) Explosion Protection Safety Standards Manual, August 2017, A5E02220442001 Rev 8...

  • Page 23: Purge Control Module

    (either SYSCON or CIM, depending on configuration). The SYSCON or CIM then generates an alarm and flashes the purge alarm LED on the front door of the Maxum II analyzer electronics enclosure. The purge alarm LED flashes red when an alarm is present.

  • Page 24: Pressure Sensor And Atmospheric Pressure Reference

    Control Module (PECM). PECM may refer to either the PECM or PECM-DC, depending on the Maxum II configuration. Located on this module is a pressure sensor (Figure 2-7) that detects the pressure inside the enclosure and compares it to the pressure outside the enclosure.

  • Page 25: Fast Purge Pressure Relief Valve

    The pressure relief valve, which is shown in the following figure, is located either inside the detector enclosure (middle door or a Maxum II with Airbath/Airless oven) or inside the top left of the electronics enclosure for a Maxum II Modular Oven. The location of the pressure relief valve within the analyzer is shown in Figures 2-1 and 2-2.

  • Page 26: Electronics Purging System (With Automatic Purge Unit)

    Power and all other external wiring that enters the Maxum II is disconnected by the APU whenever purge is lost. This is referred to as purging with Type X pressurization (px). The APU is available in Maxum II Airbath/Airless Oven and the Maxum II Modular Oven configurations.

  • Page 27: Purge Air Inlet And Regulator

    Safety Systems - Purging 2.3 Electronics Purging System (with Automatic Purge Unit) 2.3.2 Purge Air Inlet and Regulator This is a pressure regulator with air input that is connected to an instrument air source. The regulator is necessary to ensure that the input pressure does not exceed a certain value. Excessive pressure could damage other components in the purging system.

  • Page 28: Proportional Valve

    8 minutes before power is connected to remove potentially hazardous levels of flammable gases and vapors from the analyzer before power up. The APU is mounted inside the electronics enclosure of the Maxum II as shown in the following figure. Explosion Protection Safety Standards...

  • Page 29: Maintenance Switch

    Safety Systems - Purging 2.3 Electronics Purging System (with Automatic Purge Unit) Figure 2-14 Automatic Purge Control Unit (APU) shown in Airless/Airbath model 2.3.5 Maintenance Switch This device allows a user to override the power cutoff function of the APU for maintenance purposes.

  • Page 30: Exhaust Diffuser

    Safety Systems - Purging 2.3 Electronics Purging System (with Automatic Purge Unit) Figure 2-15 Location and Close-Up of Maintenance Switch (MAA, Set for Normal Operation) The maintenance switch for the MMO configuration is on the top left of the regulator panel, to the right of the electronics enclosure.

  • Page 31: Signal Disconnect Relay

    Safety Systems - Purging 2.3 Electronics Purging System (with Automatic Purge Unit) Figure 2-17 Covered Purge Exhaust Diffuser 2.3.7 Signal Disconnect Relay The Signal Disconnect Relay is mounted externally to the analyzer. This relay disconnects all external wiring to the analyzer except for power to the APU. The Signal Disconnect Relay is controlled by the APU which deactivates the relay when purge pressure is lost.

  • Page 32: Maintenance Considerations For Purged Systems

    Signal Disconnect Relays Maintenance Considerations for Purged Systems The following practices must be observed in order to operate, maintain and prevent compromise of the Maxum II purging system. WARNING Avoid Equipment Contamination or Ignition of Explosive Gases Failure to correctly observe the following practices may result in a dangerous situation that could lead to severe personal injury or death and/or extensive property damage.
  • Page 33 A reference tube (see Figure 2-8) is used for this purpose. This tube must not be obstructed. Air does not flow through this tube. The tube is intended to sample the pressure immediately outside the Maxum II enclosure, and it should not be lengthened, shortened, or altered in any way.
  • Page 34 Safety Systems - Purging 2.4 Maintenance Considerations for Purged Systems ● The Maxum II Analyzer should be visually inspected at regular intervals to ensure the integrity of the purge system. The following inspections should be made: – Instrument air lines and fittings should be inspected for leaks and damage.

  • Page 35: Safety Systems - Oven

    This is accomplished by the oven heater system. A variety of oven configurations are available for the Maxum II. For isothermal (single set temperature) analyses air bath, airless, and modular ovens are available. Since the Maxum II...

  • Page 36: Isothermal Air Bath Oven Heater System (Single And Split)

    Isothermal Air Bath Oven Heater System (Single and Split) The isothermal air bath oven is the most common oven used in the Maxum II. It is available in single and split configurations to accommodate a wide range of chromatographic applications.

  • Page 37: Temperature Control

    Safety Systems - Oven 3.2 Isothermal Air Bath Oven Heater System (Single and Split) Figure 3-2 Timing Coil for Pressure Switch See also Safety Systems - Purging (Page 17) 3.2.2 Temperature Control As mentioned in section 3.1, the temperature of the oven is controlled via an RTD sensor. The temperature of the air itself is controlled via two independent sensors which work with the two set point resistors mentioned in section 3.1 to ensure that all temperatures remain below possible ignition limits.

  • Page 38: Programmed Temperature Air Bath Oven Heater System (Split)

    Within the Maxum II, temperature control and air purging of the air bath heater is the same for the programmed temperature oven as for the isothermal air bath oven.

  • Page 39: Isothermal Airless Oven Heater System (Split)

    3.4 Isothermal Airless Oven Heater System (Split) Isothermal Airless Oven Heater System (Split) The Maxum II airless oven is used to provide a very stable isothermal oven temperature without the need to supply oven air to the analyzer. This allows for excellent chromatographic results while reducing utility costs.
  • Page 40 Safety Systems - Oven 3.4 Isothermal Airless Oven Heater System (Split) Insert Location for RTD Probe (Same as on Opposite Side) Channel for Heating Element Figure 3-5 Location of Temperature Probes and Heaters on Airless Oven The heating elements are enclosed in hollow tubes running diagonally down the side of the aluminum casing.

  • Page 41: Maintenance Considerations For Air Bath And Airless Ovens

    (including programmed temperature oven) and airless ovens of Maxum II. Modular ovens are described in the next section. ● It must be ensured that the analyzer T-rating is suitable for the area in which the analyzer is to be installed.

  • Page 42: Modular Oven Heater System

    3.6 Modular Oven Heater System Modular Oven Heater System The Maxum II Modular Oven is used to provide a stable isothermal oven temperature for certain lower temperature applications. This allows for excellent chromatographic results at a greatly reduced product cost and simplified and low cost operation and maintenance for the applicable range of applications.

  • Page 43: Maintenance Considerations Modular Ovens

    Maintenance Considerations Modular Ovens The following practices must be observed in order to operate, maintain and prevent compromise of the Maxum II Modular Oven heater system. ● The installaion of the heater elements and RTDs should be inspected to verify that they are fully inserted into the tubes as shown in the previous section.
  • Page 44 Safety Systems - Oven 3.7 Maintenance Considerations Modular Ovens Explosion Protection Safety Standards Manual, August 2017, A5E02220442001 Rev 8...

  • Page 45: Valves, Detectors, And External Systems

    4.1.1 SLIV Functional Description Some applications require the use of a heated Siemens Liquid Injection Valve (SLIV) which is shown in figure 4-1. This valve is generally mounted through a side wall of the analyzer oven (refer to figure 4-2). The narrow portion of the valve that extends into the oven is known as the vaporizer.

  • Page 46: Sliv Maintenance Considerations

    4.1.2 SLIV Maintenance Considerations The Siemens Liquid Injection Valve (SLIV) should be inspected to assure that it is free of physical damage. All tubing and conduit connections should be correctly installed and tightened as prescribed by local safety requirements. Whenever maintenance is performed on the valve, care must be taken not to damage the temperature sensors and the heater element which are inserted in the valve body.

  • Page 47: Detectors

    Detector Functional Descriptions In order to analyze the chemical compositions of different samples, four major types of detectors are used in the Maxum II Gas Chromatograph (refer to figures 4-4 through 4-6). The types of detectors are: ● Explosion Proof/Flameproof Thermal Conductivity Detector (TCD) ●...

  • Page 48: Detector Maintenance Considerations

    For most detectors within the Maxum II, protection is accomplished by enclosing the active elements in a flameproof/explosion proof housing. In these cases electrical, optical and gas connections must penetrate the housing of the detector.
  • Page 49 Valves, Detectors, and External Systems 4.2 Detectors The circuits for the IS-TCD require special considerations to ensure that the circuit remains intrinsically safe. For important information on the safe use of intrinsically safe circuits, refer to the sections of this manual labeled "Intrinsically Safe Devices". Figure 4-4 Explosion Proof/Flameproof Thermal Conductivity Detector Explosion Protection Safety Standards...
  • Page 50 Valves, Detectors, and External Systems 4.2 Detectors Figure 4-5 Thermal Conductivity Detector Beads on Modular Oven Application Module (Intrinsically Safe TCD) Explosion Protection Safety Standards Manual, August 2017, A5E02220442001 Rev 8...
  • Page 51 Valves, Detectors, and External Systems 4.2 Detectors Figure 4-6 Flame Ionization Detector (without Insulation and Cover) Figure 4-7 Flame Photometric Detector (without Insulation and Cover) Explosion Protection Safety Standards Manual, August 2017, A5E02220442001 Rev 8...

  • Page 52: Air Treater

    4.3.1 Air Treater Functional Description To provide clean air for the Flame Ionization Detector (FID), the Maxum II uses a catalytic device known as an Air Treater (figure 4-8) to remove hydrocarbons from ordinary plant instrument air. The Air Treater is an independent unit mounted near the Maxum II. It consists of an extremely hot combustion chamber and a catalyst.

  • Page 53: Air Treater Maintenance Considerations

    Two versions of the methanator exist for use in the Maxum. The original is protected by purging/ pressurization. The more recent version is protected in an explosion proof enclosure. Both versions are designed to install in the detector enclosure of the Maxum II Airbath/Airless Oven configuration (refer to figure 1-1).
  • Page 54 When the purged/pressurized version of the methanator is installed, 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 enclosure door must be kept closed for at least 30 minutes.

  • Page 55: Methanator Maintenance Considerations

    Valves, Detectors, and External Systems 4.4 Methanator Figure 4-10 Explosion Proof Methanator (Both Versions) As protection measure, the gas inlets and outlets that enter and leave the methanator are configured as flame arrestors (refer to figure 4-8 and 4-9). In addition, both versions of the methanator assembly are insulated to prevent the surface temperature of the methanator from exceeding 180°C (surface temperatures for the explosion proof/flameproof methanator are significantly lower than 180°C).
  • Page 56 Valves, Detectors, and External Systems 4.4 Methanator never be cut or shortened or bent or bypassed in any way. If there is any physical damage, the device should be shut down until it can be replaced. WARNING The purged/pressurized methanator must not be operated without purge/pressurization unless it has been verified that the area is free of explosive gases and vapors.

  • Page 57: Safe Operation

    PC-based System Manager software and also via a user access display panel that is mounted on the front door of the Maxum II electronics enclosure. Two types of display panel exist, both of which can be used to perform the same user functions. The newest version is the Color Touchscreen display, which is described in section 5-3.

  • Page 58: Maintenance Considerations For Maintenance Panel

    If an APU is not installed, the "Purge" LED flashes when purge pressure is lost. The "Power" LED is lit at all times when power is applied to the analyzer. Note that the "Fault" and "Warning" LEDs are related to the trouble reporting systems of the Maxum II but are not applicable to the safety systems.

  • Page 59: Maintenance Considerations For Control Interface Module Display

    Maxum II Use of the display for maintenance and operation functions is covered in the Reference Manual and the Maxum II Reference Manual, Modular Oven Configuration . Note In addition to the display installed on the analyzer, there is an emulator (called HMI emulator) available through the PC-based workstation software.

  • Page 60: Steps For Safe Startup Of Maxum Ii

    Overview The startup procedure described in this section explains the principle steps necessary to power the Maxum II in a manner that does not compromise the safety systems that have been described in this manual. This section does not explain the startup procedures required that relate to software functions or the analytical application of the analyzer.
  • Page 61 Safe Operation 5.5 Steps for Safe Startup of Maxum II Note The remainder of the startup process is dependent on whether an APU is installed. (If APU is not equipped) Turn on the fast purge switch (figure 2-4) and allow fast purge air to flow for at least 8 minutes.
  • Page 62 Safe Operation 5.5 Steps for Safe Startup of Maxum II Explosion Protection Safety Standards Manual, August 2017, A5E02220442001 Rev 8...

  • Page 63: Glossary

    115 VAC or 230VAC and converts to 24V DC for distribution within the analyzer. Air Bath Oven One of three primary types of oven available for the Maxum II. Heating of the oven is accomplished by passing air over a heating element and into the oven. Available as a single oven or it can be split into two independent oven compartments.
  • Page 64 Glossary Detector Compartment The middle section of a Maxum II Chromatograph that is equipped with either Airbath or Airless oven. It houses various detectors that may be equipped in the Maxum II Airbath/Airless Oven. It also houses the Methanator, if equipped.
  • Page 65 CSA term for this concept is non-incendive. Oven Compartment The bottom area of a Maxum II that houses the ovens. Depending on the configuration of the Maxum II, this may be a Modular Oven Compartment or an Airbath/Airless Oven Compartment.
  • Page 66 Temperature Programming The process of increasing oven temperature incrementally in order to reduce the time needed to separate a sample using a chromatograph. In the Maxum II, a variant of the air bath oven may be used to employ temperature programming.
  • Page 67 A purged system where an alarm is generated whenever purge pressure is lost. In addition, any equipment which would exceed the T-Rating of the location upon loss of air flow (such as the Maxum II air bath oven heater) must be de-energized when purge is lost. Zone 1 An atmosphere where a mixture of air and flammable substances in the form of gas, vapor, or mist is likely to occur in normal operation occasionally.
  • Page 68 Glossary Explosion Protection Safety Standards Manual, August 2017, A5E02220442001 Rev 8...

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