Siemens Maxum II PD PA AP Service Manual Download

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Groove for

sample-flow

unit

Groove for

O-ring

Label for

Dosing

Volume

Alignment Groove

for attaching to

Control Cylinder

using hex set

screws

Figure 4-7

Liquid Injection Valve Body

4.2.3

Troubleshooting

Faults, Causes, Remedies

Fault

Causes

Remedy

All peaks appear smaller

Sample flow unit (15) or injection

blocked. Buildup of material on in‐

jection stem.

Clean injection hole, stem (6), va‐

porizer (16) and sample flow unit

(15).
Replace gaskets (14) if necessary.

Peaks are becoming wide and shifted to longer

times. Baseline becomes negative before injec‐

tion of sample.

Vaporizer (16) is contaminated.

Baseline becomes positive before injection of

sample.

Gasket (14) between sample flow

and vaporizer is leaking.

Interruption in chromatogram: sample is not get‐

ting injected.

Leaky pneumatic actuator, grease

used up, O-rings (4) damaged, con‐

trol pressure too low.

Clean pneumatic actuator, replace

O-rings, and grease sliding surfa‐

ces and O-rings.

Peaks too small and too wide, especially those

with higher boiling points.

Heating plate is faulty. Vaporization

temperature too low.

Replace heating plate. Set higher

equalization temperature.

Injection quantity slowly rises until a double peak

results (with calibration medium). Poor peak

form, platform following peak. Increase in base‐

line. Visible discharge of sample.

Worn gaskets (14) and/or stem (6). Replace gaskets (14) or stem (6).

The section of the injection stem that is normally

in the sample flow stream (near the notch) is

rough. Material wear on this section of the stem

is visible using a magnifier. The effect is signifi‐

cantly less on the rest of the stem.

Corrosive sample

Possibly replace injection stem (6)

by version made of another material

more compatible with the sample

chemical, such as Hastelloy.

Thin scratches are visible (with a magnifying

glass) on the stem near the sample groove.

These scratches run along the stem for several

millimeters.

Sample is contaminated by particles

(most frequent case). The particles

get lodged in the gasket and scratch

the stem during injection.

Check filter from sample system

and replace if necessary. Replace

stem (6) and gasket (14).

Valves

4.2 Liquid Injection Valve

Maxum II Valves and Oven Components

Service Manual, 10/2018, A5E42019844001

Summary of Contents for Maxum II PD PA AP

Page 1: ...PD PA AP Maxum II Valves and Oven Components Service Manual 10 2018 A5E42019844001 Oven Types 1 Using Small Tubing Fittings 2 Temperature Control Module TCM 3 Valves 4 Heaters 5 Appendix A Contact Information A ...

Page 2: ...l are those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Siemens products 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 us...

Page 3: ...27 4 1 1 Solenoid Valve Control Module SVCM 27 4 1 2 Replacing a Solenoid Valve 30 4 2 Liquid Injection Valve 31 4 2 1 SLIV Maintenance Overview 37 4 2 2 Liquid Injection Valve Component Locations 38 4 2 3 Troubleshooting 39 4 2 4 Service Procedures 40 4 2 5 Siemens Liquid Injection Valve Specifications 44 4 3 Model 50 Valve 45 4 3 1 Basic Maintenance Model 50 Valve 46 4 3 2 Preventing Port to Por...

Page 4: ...e Valve Cap Re assembly 79 4 5 12 Model 20 High Temperature Valve Specifications 80 4 6 Model 11 Valve 81 4 6 1 Valve Operation 82 4 6 2 Model 11 Maintenance Overview 85 4 6 3 M11 Intended Users 85 4 6 4 M11 Safety and Certification Information 85 4 6 5 Diagnostic Procedures 86 4 6 6 M11 Procedure Maintenance Facility 87 4 6 7 M11 Procedure Figures 88 4 6 8 Mini Maintenance Procedures Valve Cap an...

Page 5: ...r 11 Figure 1 5 Programmed Temperature Airbath Oven Component Locations 12 Figure 1 6 Airless Oven 13 Figure 1 7 Location of Temperature Probes and Heaters in Airless Oven 14 Figure 1 8 Airless Oven Heater Control Loop 14 Figure 1 9 Airless Oven Heater Locations 17 Figure 1 10 Typical Modular Oven Configuration 18 Figure 1 11 Heater and RTD Tubes for the Modular Oven 19 Figure 2 1 Valco Fitting 21...

Page 6: ...lve Base 16 77 Figure 4 23 Inserting Piston Assembly 15 and 18 into Base 16 78 Figure 4 24 Model 11 Valve Types 81 Figure 4 25 Model 11 Valve LDV Version Exploded View 83 Figure 4 26 Model 11 Operational Diagrams 84 Figure 4 27 Model 11 or Model 11 LDV Valve without Valve Cap 88 Figure 4 28 Model 11 Valve Cap Exploded View 89 Figure 4 29 Model 11 Plunger Orientation 89 Figure 4 30 Valve Body Explo...

Page 7: ...of these opposing constraints it is possible that this example application requires an oven temperature so high that the analysis zone itself becomes a source of ignition This situation is not permitted It is the responsibility of the user to ensure that the analyzer is never installed in an area that is not rated appropriately for the oven temperatures required for the application The temperature...

Page 8: ... instrument air continuously flows over the heating element and into the oven This air flow distributes heat to the oven An air pressure sense switch mounted on the PCM determines whether air pressure exists in the tubing that supplies air to the heater If pressure exists then air is flowing and the switch is activated allowing the oven heater to be energized If the switch does not detect pressure...

Page 9: ...order to create a short delay between the start of air flow and the activation of the pressure switch This delay forces the oven heater to purge for a short time before the heater is powered up See the photo below Figure 1 2 Timing Coil for Pressure Switch Oven Types 1 1 Isothermal Air Bath Oven Heater System Single and Split Maxum II Valves and Oven Components Service Manual 10 2018 A5E4201984400...

Page 10: ...temperature falls below the limit point If a component the TL control path should fail the overtemperature shutdown OTS feature is activated The Overtemperature OT sensor with its separate control circuit and relay activates at a slightly higher temperature than the TL sensor If this happens the power to the oven heater is interrupted Because this sensor should not activate unless there is a mecha...

Page 11: ...DIH EDUULHU PRGXOH LV ORFDWHG LQ WKH HOHFWURQLFV FDELQHW EHKLQG WKH GHWHFWRU Figure 1 4 Programmed Temperature Airbath Oven with Deflector The chromatographic column is mounted in the center of the deflector assembly along with a temperature sensor The heated oven air from an airbath heater assembly flows into a hole in the center of the deflector The interior shape of the deflector allows the tem...

Page 12: ... shown below This circuit is thus intrinsically safe Temp Probe IntrinsicallySafe barrier Module located in the electronics compartment behind the FID detector QWULQVLFDOO 6DIH EDUH HOHPHQW WHPSHUDWXUH SUREH 2YHQ DLU LQSXW IURP KHDWHU HIOHFWRU DVVHPEO Figure 1 5 Programmed Temperature Airbath Oven Component Locations Oven Types 1 2 Programmed Temperature Air Bath Oven Heater System Maxum II Valves...

Page 13: ...d 257mm 101 8 deep Figure 1 6 Airless Oven The primary explosion safety system within the Isothermal Airless Oven is the heating and temperature control system As mentioned above the oven is heated using two heating elements inserted into explosion proof channels within the aluminum walls The temperature of each heating element is detected by a dual RTD sensor probe that is also inserted into the ...

Page 14: ...rtemperature shutdown PWM Pulse width modulation OT Setpoint Resistor Compare Analog Overtemp RTD Temp Control RTD Analog Oven setpoint in software Figure 1 8 Airless Oven Heater Control Loop Two relays are used to control the power to the heater One relay powers the heater to maintain the set point temperature of the heater oven temperature in the software The second relay is connected in series ...

Page 15: ...e resistors are the wrong value it could be possible for temperatures within the oven to become too hot for the stated T rating of the analyzer Note Always replace the set point resistor board with the same part number and resistance values Multiple heated devices in the same analyzer with the same T rating can have different set point resistor values based on the size of the heater and design of ...

Page 16: ...e connector pins 1 and 2 6 Remove the wires from the wire sleeve 7 Loosen the 7mm nuts on the mounting plate in mezzanine electronics area to allow the heater to move 8 Remove mounting plug with a 4mm hex key 9 Remove heater by sliding it out the front of the analyzer A M6 bolt may be screwed in the bottom end of the heater and used to wiggle the heater back and forth and pull it out 10 Replace in...

Page 17: ...fy the temperature controller and heaters are working properly Heaters Left Oven Heaters Right Oven Heater Retainer Caps Heater Retainer Caps Figure 1 9 Airless Oven Heater Locations Oven Types 1 6 Airless Heater Replacement Maxum II Valves and Oven Components Service Manual 10 2018 A5E42019844001 17 ...

Page 18: ...he mounted application module The heater elements in the application module manifold maintain the temperature inside the application module at the desired temperature for measurement A small modular oven has one analytical heater element and a large oven has two analytical heater elements on for each side of the manifold Although they are mounted within manifolds inside of the modular oven the hea...

Page 19: ...y inserted into the tubes as shown in the previous section Heater wiring should be inspected for any damage and proper connection to the PECM DC Application modules should be properly installed with their cover plates and the face plate of the modular oven should be installed and secured with the provided thumb screws Because of the relatively low operating temperature low power and stable tempera...

Page 20: ...Oven Types 1 8 Maintenance Considerations for Modular Ovens Maxum II Valves and Oven Components 20 Service Manual 10 2018 A5E42019844001 ...

Page 21: ...ts length Visible scratches along the tubing where the ferrule will seat are not acceptable but those behind the front edge of the ferrule will not interfere with the integrity of the fitting 1 Slide the nut and ferrule onto the tubing 2 Insert this assembly in the fitting detail valve body screwing the nut 2 or 3 turns by hand 3 Push the tubing all the way forward into the fitting pilot so that i...

Page 22: ...the tubing 2 Slide the PTFE seal over the tubing and towards the tip of the nut 3 Place the compression collar over the seal so that the tip of the seal protrudes through the compression collar The illustration below shows how the parts fit together along with a cutaway view of how the compression ring works to create a secure seal Figure 2 3 Siemens Fittings Assembly 4 Insert the fitting into the...

Page 23: ...he Base3 DPM section RTD Temp Control Inputs I2 C Heater Control Outputs to PECM Location ID Switch Temp Setpoint Module Mounting Screw Access Temp Setpoint Module Mounting Location Status LEDs Figure 3 1 Temperature Control Module Connections The Temperature Control Module Part Number A5E02645925002 can be used as a replacement part for the temperature control functions of earlier DPMs in Maxum I...

Page 24: ...e setpoint module stack from the left side of the board 11 Remove the two mounting screws near the upper corners and remove the old unit from the cage Configuring the New TC DPM Set the location ID switch on the replacement unit to match the unit being removed Installing the Replacement TC DPM 1 Install the new unit into the DPM cage Insert the bottom edge into the slot in the plastic DPM mounting...

Page 25: ...r Startup Procedure in the Maxum Edition II Analyzer General Maintenance Manual A5E42019842001 from the Siemens web site http support industry siemens com cs products dtp Manual pnid 17741 Temperature Control Module TCM 3 1 Replacing a TCM Maxum II Valves and Oven Components Service Manual 10 2018 A5E42019844001 25 ...

Page 26: ...Temperature Control Module TCM 3 1 Replacing a TCM Maxum II Valves and Oven Components 26 Service Manual 10 2018 A5E42019844001 ...

Page 27: ...ver circuit board For the newer version of the SVCM this valve drive circuitry has been moved to the PECM module PECM DC in the Modular Oven model The newer version is more reliable and robust The SVCM electronics whether onboard for the old version or on the PECM for the new version receives commands from the SYSCON module via the I2 C bus Pulse timing is controlled from the SVCM electronics Sole...

Page 28: ... 4 way solenoids SVCM 1 is mounted in the lower right portion of the back wall SVCM 2 is mounted in the lower left portion of the back wall SVCM 3 is mounted vertically in the upper right portion of the back wall The original SVCM is equipped with Parker solenoids The newer SVCM is equipped with SMC solenoids Manifold in out SST tubing connections incorporate one touch push type tubing connectors ...

Page 29: ...d on the bottom of each SMC new solenoid Table 4 1 Digital Output Solenoid Valve Groups Group Solenoid Valve Left Valve 1 Valve 2 Valve 3 Valve 4 Right Valve 1 Valve 2 Valve 3 Valve 4 Table 4 2 SVCM I O Assignments SYSCON Channel Number I O Name Group Channel DO1 LEFT_GROUP_VALVE_1 1 80h DO 2 LEFT_GROUP_VALVE_2 40h DO 3 LEFT_GROUP_VALVE_3 20h DO 4 LEFT_GROUP_VALVE_4 10h DO 5 RIGHT_GROUP_VALVE_1 08...

Page 30: ...air 70 F 21 C with 345 kPa 50 psig on the common port 4 1 2 Replacing a Solenoid Valve The solenoid valves are mounted on either the floor or back of the electronic enclosure depending on configuration Valves are replaced individually The Solenoid Valve Replacement Kit is available as part number 2020149 001 WARNING Voltage dangerous to life exists Failure to follow proper procedures may result in...

Page 31: ...l A5E42019842001 from the Siemens web site http support industry siemens com cs products dtp Manual pnid 17741 4 2 Liquid Injection Valve The Siemens Liquid Injection Valve SLIV is used to automatically inject a fixed quantity of liquid sample fol lowed by fast complete vaporization Small gas quantities can also be injec ted using the valve Common sample injection sizes include 0 6 microliters 1 2...

Page 32: ... unit and control cylinder are located outside the chromatograph oven The vaporizer is loca ted in the chromatograph oven A heater assemble con trols the temperature of the vaporizer The vaporizer temperature can be raised to vaporize high boiling point samples Samples that contain salts that would cake on a dia phragm valve during injection are washed off when the valve stem is moved back to the ...

Page 33: ...perature can be set independently of the oven temperature and is set based on the sample composition Heater Cartridge 100W 120V or 240V Probe Push in Style 188 OD X 1 Long Liquid Injection Valve Heater Block Module Oven Interior View of SLIV Installation Oven Exterior View of SLIV Installation Figure 4 3 SLIV Installation Details Valves 4 2 Liquid Injection Valve Maxum II Valves and Oven Component...

Page 34: ...attage relay pairs on the PECM is used to control the SLIV heater A cable from the DPM to the PECM is used to control the low wattage relay on the PECM This cable is not shown in this diagram Liquid Injection Valve Installation Heater and Probe Connections Two Valve Installation Shown Wiring from Heater Module Probe Connection to DPM Heater Connection to H3 or H4 PECM Probe Wiring Diagram Figure 4...

Page 35: ... Teflon gaskets An adjustable adapter and Belleville washers position the Teflon gaskets with a constant pressure to align the sample hole or groove with the sample connections and to compensate for temperature expansion and gasket wear SLIV Cutaway View Main Components Sample Flow Unit Valves 4 2 Liquid Injection Valve Maxum II Valves and Oven Components Service Manual 10 2018 A5E42019844001 35 ...

Page 36: ...es at high temperatures above 200 C as shown below Figure 4 5 Vaporization Temperature Note Ex units To comply with electrical hazardous area requirements ensure that The sensor of the temperature sensor is fully inserted into the heating plate The purge tube vent is not being obstructed Filter Requirements The tappet and gaskets will wear faster if the sample contains solid particles In these cas...

Page 37: ...e that contains non volatile or easily polymerized components salts proteins monomers etc can deposit residues in the vaporizer 16 in the injection hole on the sample flow unit 15 and on the injection stem 6 Therefore these parts should be cleaned regularly if the sample contains materials which are not vaporized See Exploded View Page 38 The sample flow unit 15 should be oriented vertically when ...

Page 38: ...e Component Locations 1 Control Cylinder 2 Hex Set Screws 3 Control Piston 4 Large O Rings 5 Guide Pin Only on Cross Hole 6 Injection Stem tappet 7 Valve Body 8 Small O Ring and Piston Guide Hole 9 Label Indicating Injection Volume 10 Belleville Washer Plate Springs approx 8 11 Adjustment Nut 12 Adjustment Counter Nut 13 Adjustment Assembly 14 Gaskets 2 15 Sample Flow Unit 16 Vaporizer 17 Flange 1...

Page 39: ...eating plate is faulty Vaporization temperature too low Replace heating plate Set higher equalization temperature Injection quantity slowly rises until a double peak results with calibration medium Poor peak form platform following peak Increase in base line Visible discharge of sample Worn gaskets 14 and or stem 6 Replace gaskets 14 or stem 6 The section of the injection stem that is normally in ...

Page 40: ...ccordance with appropriate regulations before the analyzer can be placed back in service Removing the Valve Perform the following procedure to remove the valve from the oven Removing the vaporizer 16 and flange 17 is optional when removing the valve CAUTION Potential burn hazard Handling hot components may result in personal injury To prevent injury from burns always switch off the oven and valve ...

Page 41: ...injection stem 6 5 Remove the sample flow unit and the lens shaped gasket if the gasket is not present it is stuck in the vaporizer to allow the Belleville washer plate springs 10 to drop out 6 Pull the control piston 3 with stem 6 out of the valve body 7 Do NOT use any tools such as a screwdriver as a wedge between the piston and the valve body This would damage the valve body and control piston ...

Page 42: ...de hole 8 should be 5 7 mm and be smooth Replace the part if there are traces of wear on the piston shaft The adjustment assembly 13 must slide smoothly down inside the valve body 7 Procedure 1 Before assembling the valve apply a thin coat of grease discussed in O Ring Replacement above to the following parts Internal wall of control cylinder 1 Shaft of Control Piston 3 Piston Guide hole small O r...

Page 43: ...r 8 If the the flange plate 17 and vaporizer 16 were not removed from the analyzer screw the partially reassembled valve onto the already installed flange plate Figure 4 8 Orientation of Sample Flow Unit Hole Belleville Washer Spring Adjustment It may be necessary to adjust the amount that the Belleville washer springs are being compressed These washers should compress about 2 mm when adjusted app...

Page 44: ...hen installing the valve adjust the valve body 7 so that sample will flow vertically through the valve This is necessary to prevent bubbles from forming in the valve 2 Position the control cylinder 1 and tighten the two hex set screws 2 on the side The screws must firmly grip the groove in the valve body 5 wall See the Liquid Injection Valve Body illustration 3 Connect the control lines 4 Activate...

Page 45: ... parts The valve can both inject vapor samples and switch columns simultaneously The Model 50 is capable of switching gasses up to 75 psig 515 kPa Actuation air for the Model 50 can be either carrier gas or other bottled inert gas Consumption of gas for actuation is negligible One primary distinction that separates the Model 50 from the Model 20 and Model 11 valves is the port switching When the v...

Page 46: ...lled Leaks in the actuation gas lines could result in a lower actuation gas pressure which could result in port to port leaks The symptoms can include small peaks repeatability problems contaminated columns and noise on the detector 4 3 3 Maintenance Considerations If customer maintenance personnel are not technically trained to repair the Model 50 valve on site it is recommended that the valve be...

Page 47: ...te bottom plate and Valco fitting nuts using a syringe filled with cleaning solvent such as hexane acetone or methanol CAUTION Potential burn hazard Handling hot components may result in personal injury Before servicing the Model 50 valve it is important that primary AC power to the Maxum II be turned off from the main circuit breaker and the oven be allowed to cool Only maintenance personnel with...

Page 48: ...r the oven to cool to a safe temperature 2 Turn off all gases going to the valve Start by turning off the sample gas by blocking it in at the sample system Flush any hazardous gases in the sample loop with an inert gas Block the carrier gas by closing the block valve supplying carrier to the analyzer Block in the valve gas by closing block valve suppling valve gas to the analyzer 3 Shut off the ai...

Page 49: ...ng a 2 5 mm Allen wrench remove the five socket head fastening cap screws 3 Separate Top Center and Bottom plates of the valve placing them on a lint free cloth Both diaphragms are visible 4 Remove the old diaphragms from the plates DO NOT attempt to reuse the old diaphragms 5 Clean the valve parts by wiping with a dust lint free cloth and a cleaning solvent or clean using an ultrasonic cleaner as...

Page 50: ... valve fixture Valve Cleaning To clean the three valve plates use an Ultrasonic cleaner with clean acetone If cleaning solvent becomes contaminated during performance of the following steps replace it with a clean supply of cleaning solvent Do not place polished valve plates against any surface in ultrasonic cleaner or against any abrasive surface Place parts on a lint free cloth free of foreign c...

Page 51: ...nd set the diaphragm in place 4 Carefully remove the placement disc without moving the diaphragm Inspect the diaphragm for proper alignment If the diaphragm is not in the center of the plate repeat the placement procedure using the placement disc 5 Place the middle plate on the valve taking care to use the correct holes Check the alignment mark on the side of the plate It should align with the mar...

Page 52: ...unds of torque It is recommended to use the torque wrench available from Siemens PN 1631005 003 which is calibrated at 7 2 inch pounds Remove the assembled valve from the valve fixture 15 Reinstall the valve in the oven Use the same torque wrench with a 2 5mm hex bit to 6 to 8 inch pounds of torque to tighten the mounting screws Connect all tubing following the fitting manufacture s recommendation...

Page 53: ...c signal to the valve and the size of the pneumatic tubing to the valve Sample Filtration 5 micron Maximum Actuation Pressure 690 kPa 100 psig Minimum Actuation Pressure 140 175 kPa 20 25 psig higher than maximum carrier gas or sample gas pressure Maximum Port Pressure Carrier or Sample 515 kPa 75 psig contact factory for higher pressure options Minimum Port Pressure Carrier or Sample 35 kPa 5 psi...

Page 54: ...edures are discussed in other manuals however it is recommended that the valve be returned to Siemens for service when more detailed maintenance is needed 4 4 1 1 Maintenance Considerations If customer maintenance personnel are not technically trained to repair the Model 20 valve on site it is recommended that the valve be returned to Siemens for service repair or direct replacement To repair the ...

Page 55: ...a lint free cloth Clean metal parts using only a syringe and a cleaning solvent such as hexane acetone or methanol CAUTION Potential burn hazard Handling hot components may result in personal injury Before servicing the Model 20 valve it is important that primary AC power to the Maxum II be turned off from the main circuit breaker and the oven be allowed to cool Only maintenance personnel with pro...

Page 56: ...nted in the analyzer Other tests require the analyzer to be shut down and valve ports disconnected These diagnostic tests indicate specific areas of the fault or trouble Valve Leakage Sample Pressures Lower Than Carrier Gas Pressure Leakage may be from a carrier gas port to a sample port within the valve regardless of whether valve is actuated or deactivated With sample inlet flow turned off sampl...

Page 57: ... on site it is recommended that the valve be returned to Siemens for service repair or direct replacement Within the following procedures the numbers in parenthesis are callouts They denote parts referenced in the lists contained in the figure in section 6 5 2 refer back to the figure for locations Valve Cap Disassembly Cleaning and Reassembly 1 Loosen the three Allen screws 16 holding the plunger...

Page 58: ...must not leave any residue on evaporation Clean valve cap while it is disassembled After cleaning of cap using syringe flush solvent through each port in the valve cap NOTICE When reassembling the valve cap always install a new Teflon Seal Disc diaphragm 4 and Dacron Cushion Disc 5 DO NOT install the previously used Seal and or Cushion Disc 4 Position the Dacron cushion disc diaphragm 5 between th...

Page 59: ...nance procedures involve working on the valve while it is still installed in the analyzer Maxi Maintenance procedures may be used when Mini Maintenance does not correct a valve fault However it is often cheaper and easier to replace the valve or return it to Siemens for service This manual covers the Maxi Maintenance procedures in the following order Valve Cap Disassembly Actuator Disassembly Clea...

Page 60: ... authority having jurisdiction 4 4 2 4 M20 Procedure Overview Throughout this procedure there are steps that instruct the user to inspect the valve to determine whether additional disassembly is necessary This is to prevent unnecessary effort and to prevent the possibility of damaging the valve through further disassembly 4 4 2 5 M20 Procedure Maintenance Facility When cleaning the valve and assoc...

Page 61: ... Disc Seal Diaphragm 5 Dacron Cushion Diaphragm 6 Plungers 6 total 7 Ferrule Top 8 Ferrule Bottom 9 Connector 10 Port Tubing 12 Air Loaded Upper Piston 13 Valve Plunger Body 14 Cylinder Base 15 Spring Loaded Lower Piston 16 Allen Screws 3 total 17 Belleville Washers 6 total 18 Inner small O Ring 19 Outer large O Rings 20 Large Belleville Washers 3 total Figure 4 15 Section View of Model 20 Valve V...

Page 62: ... be inspected for cleanliness including catalyst or polymer buildup on the valve cap Before re assembly faces of the plunger valve body 13 should be wiped clean using hexane acetone or methanol and a lint free cloth An ultrasonic cleaner filled with a recommended cleaning solvent or detergent is recommended for cleaning all components However after cleaning there must not be any remaining residue ...

Page 63: ...ng pressure is relieved approximately 1 8 or 3 2 mm Do not remove the three Allen mounting screws at this time 2 To remove valve cap 1 remove the three Allen screws 3 and six Belleville washers 2 holding the valve cap 1 to the valve plunger body 13 3 Remove the valve cap 1 from the plunger valve body 13 NOTICE To prevent damage to the valve cap 1 do not place polished surface of the valve cap agai...

Page 64: ...r valve body 13 6 With plunger valve body 13 in the horizontal position remove it from the cylinder base 14 Carefully remove all six plungers 6 Note Perform EITHER step 7 or step 8 to remove the actuator piston from the cylinder base 7 Place cylinder valve base 14 in upright position Insert a 6 32 hex threaded standoff screw into the center threaded hole and pull to remove air loaded piston 12 and...

Page 65: ...tion pistons using guide pin 12b for proper orientation 7 Apply Krytox 240C lubricant to each of the six finger spring 12c pressure points This is the point where the spring fingers contact the plunger body 13 8 Position the valve upright with its three ports on the left Install a 6 32 screw in the center threaded hole of air loaded piston assembly 12 and bottom spring loaded piston 15 9 Lift the ...

Page 66: ...mbly upright on a clean lint free cloth surface Refer to Figures 5 1 and 5 2 4 Position the Dacron cushion disc diaphragm 5 between the three alignment pins on the plunger valve body 13 5 Using tweezers hold the Teflon seal disc diaphragm 4 by its edges Before reinstalling disc remove lint dust and oils by sliding disk between your index and middle fingers 6 Install Teflon seal disc diaphragm 4 ov...

Page 67: ...perating temperature 122 C 250 F standard Maximum sample pressure 1380 kPa 200 psi gage instrument air standard 10350 kPa 1500 psi gage with 2 80 550 kPa 80psi gage air signals Higher operating pressure available on special request Minimum sample pressure 34 5 kPa 5 psig Maximum leak rate between ports Less than 1 μl per minute between ports Material in contact with sample 316 stainless steel and ...

Page 68: ...r must have the necessary maintenance tools and replacement parts Recommended valve spare parts can be obtained from Siemens Recommended tools will include an ultrasonic cleaner and a clean workstation with lint free cloth Mini Maintenance procedures can be found in the Maxum II Maintenance Manual This manual can be found on the Maxum II Documentation CD part number 2000597 001 Additional procedur...

Page 69: ...the possibility of damaging the valve through further disassembly 4 5 5 M20HT Procedure Maintenance Facility When cleaning the valve and associated components it is imperative that the maintenance be performed in a clean and contaminant free facility Components should be placed on a lint free cloth to prevent impurities from contaminating the valve and or components Hands should be clean and free ...

Page 70: ...Plungers 6 total 15 Spring Loaded Lower Piston 16 Cylinder Base 17 Valve Plunger Body 18 Air Loaded Upper Piston 19 Large Belleville Washers 3 total 20 Inner Small Bal Seal 21 Actuator Air Input 32 Valve Cap 33 Teflon Disc Seal Diaphragm 34 Nomex Cushion Diaphragm 35 Allen Screws 6 total 36 Belleville Washers 12 total Figure 4 17 Cutout View of Model 20 HTV Valves 4 5 Model 20 HT Valve Maxum II Va...

Page 71: ...arge Belleville Washers 3 total 20 Inner Small Bal Seal 21 Actuator Air Input 32 Valve Cap 33 Teflon Disc Seal Diaphragm 34 Nomex Cushion Diaphragm 35 Allen Screws 6 total 36 Belleville Washers 12 total Figure 4 18 Cross Section View of Model 20 HTV Valves 4 5 Model 20 HT Valve Maxum II Valves and Oven Components Service Manual 10 2018 A5E42019844001 71 ...

Page 72: ... 33 Teflon Disc Seal Diaphragm 17 Valve Plunger Body 34 Nomex Cushion Diaphragm 18 Air Loaded Upper Piston 35 Allen Screws 6 total 19 Large Belleville Washers 3 total 36 Belleville Washers 12 total CAP BODY BASE Figure 4 19 Exploded View of Model 20 HTV Valves 4 5 Model 20 HT Valve Maxum II Valves and Oven Components 72 Service Manual 10 2018 A5E42019844001 ...

Page 73: ...an air or shaking Components must be air dry before reassembling It is possible and often better to use an appropriate detergent such as Alconox for cleaning instead of solvent However after cleaning with a detergent it is necessary to rinse the part thoroughly with deionized water distilled water is also acceptable in order to remove detergent residue All water must then be removed by blowing wit...

Page 74: ...eck for oil film on plungers This can prevent plungers from dropping 3 Apply gentle pressure to the top of each of the six plungers If plungers drop without excessive pressure the valve is operating normally and does not require additional disassembly If plungers stick or are sluggish in their operation they must either be thoroughly cleaned with a recommended cleaning solution repaired or the ent...

Page 75: ...when reassembling the actuator that the assembly area be clean and dust free Hands of maintenance personnel must be clean and not oily and tools must also be clean Note Be certain valve cap 32 does not rest on abrasive surface and valve cap has completely air dried before reassembly Rest valve cap on a clean lint free cloth 1 Install the three large Belleville washers 19 in cylinder valve base 16 ...

Page 76: ...rface of lower spring loaded piston 15 9 Place upper air loaded piston 18 over the small diameter of lower piston 25 Position pistons using guide pin for proper orientation 10 Screw the assembly stud and washer into the threaded hole in the lower spring loaded piston 15 and evenly force the spring loaded Bal Seal 20 over the bearing surface of lower spring loaded piston 15 Leave the assembly stud ...

Page 77: ...upper piston index guide pin towards the maintenance person 14 Firmly but evenly press the piston and Bal Seal assembly through the assembly guide tool into the cylinder valve base 16 Refer to Figure 6 7 15 Remove guide tool assembly stud and lock washer Figure 4 21 Installing Bal Seal 20 in Piston Groove 18 A B Figure 4 22 Placing Assembly Guide Tool on Valve Base 16 Valves 4 5 Model 20 HT Valve ...

Page 78: ...t piston index guide pin into one of the three bottom plunger valve body holes 2 Rotate plunger valve body 17 to align the plunger valve body screw holes with cylinder valve base 16 threaded holes Valves 4 5 Model 20 HT Valve Maxum II Valves and Oven Components 78 Service Manual 10 2018 A5E42019844001 ...

Page 79: ...n Disc 34 Before reinstalling seal and cushion on plunger valve body remove lint and any dust particles 3 Place the actuator assembly upright on a clean lint free cloth surface Refer to Figures 6 1 and 6 2 4 Position the Nomex cushion disc diaphragm 34 between the three alignment pins on the plunger valve body 17 5 Using tweezers hold the Teflon seal disc diaphragm 33 by its edges Before reinstall...

Page 80: ...quest Sample filter 5 μm recommended not furnished with valve Maximum operating temperature 150 C 300 F at 3450 kPa 500 psig maximum standard 234 C 450 F at 690 kPa 100 psig maximum for special applications Maximum leak rate between ports Less than 1 μl per minute between ports Material in contact with sample 316 stainless steel Other materials are available on special request Connection size and ...

Page 81: ...he Model 11 valve have tubing connected as part of the cap For the Model 11 LDV the ports are threaded holes and tubing is not part of the cap Within this section steps for these two types of valve are the same except where noted Further maintenance procedures for these valves including port to port leak tests are available in the Model 11 Valve Repair Manual PN M06115 and the Model 11 LDV Valve R...

Page 82: ...ally constructed manifold elimi nates leakage of air used for valve actua tion This feature is especially beneficial when bottled helium or nitrogen is used in place of instrument air Model 11 Valve LDV Version The Model 11 valve is a 6 port two position air actuated valve The six ports are arranged in a circular configuration Between each two ports is a plunger that opens or closes the passage be...

Page 83: ...ample volumes are 2 5 and 10 microliters The Model 11 valve must be protected against dirt filings column packing material or anything else that might affect the Teflon to metal seal Filter elements should be 5 micrometer or finer Purging below the seal disc area may be necessary in a trap valve when permeation through the seal disc causes air peaks or in a sample valve when corrosive gases attack...

Page 84: ...Figure 4 26 Model 11 Operational Diagrams Valves 4 6 Model 11 Valve Maxum II Valves and Oven Components 84 Service Manual 10 2018 A5E42019844001 ...

Page 85: ...le the valve These pliers are part of the tool kits mentioned above Additional procedures related to the Model 11 Valve can be found in the Model 11 Valve Repair Manuals which can also be found on the Maxum II Documentation CD It may be easier and less expensive to replace a valve or return it to Siemens for service rather than perform Maxi Maintenance 4 6 3 M11 Intended Users This procedure is in...

Page 86: ... sample pressures for example below 5 psi 34 kPa it may be possible to see problems where the flow path may not open This is more likely if the sealing disc has been held against the cap for a long time such as a valve in storage Check for flow across alternate flow paths such as air on and air off It may be necessary to temporarily increase the sample pressure to get the flow started and then red...

Page 87: ...e problems after reinstallation All foreign contamination adhering to valve must be removed quickly using a dust lint free cloth and a cleaning solvent such as hexane After cleaning valve cap and tubing shake excess cleaning fluid from tubes and let valve cap air dry before reassembling NOTICE Do not allow polished face of valve cap to rest on any surface other than a lint free cloth Clean metal p...

Page 88: ...r Spring of Air Loaded Piston 11 Air Loaded Piston 12 O Ring 13 O Ring 14 Spring Loaded Piston 15 Compensation Plate 16 Compression Spring 17 Compression Plate 18 Retaining Base 19 Retaining Ring Clip 20 Ball 5 32 21 Set Screw 22 O Rings 3 total 23 Air Signal Manifold 24 Screw 3 8 25 Screw 1 2 Figure 4 27 Model 11 or Model 11 LDV Valve without Valve Cap Valves 4 6 Model 11 Valve Maxum II Valves an...

Page 89: ... Dacron Cushion Disc 6 O Ring 7 Plungers 6 total required Figure 4 28 Model 11 Valve Cap Exploded View This end toward valve cap This end toward pistons Figure 4 29 Model 11 Plunger Orientation Valves 4 6 Model 11 Valve Maxum II Valves and Oven Components Service Manual 10 2018 A5E42019844001 89 ...

Page 90: ...ession Plate 18 Retaining Base 19 Retaining Ring Clip 20 Ball 5 32 21 Set Screw 22 O Rings 3 total 23 Air Signal Manifold 24 Screw 3 8 25 Screw 1 2 To Valve Cap Figure 4 30 Valve Body Exploded View Align Pin with Index Hole V16022 Air Loaded V16023 Spring Loaded Figure 4 31 Valve Base Alignment Pin Valves 4 6 Model 11 Valve Maxum II Valves and Oven Components 90 Service Manual 10 2018 A5E420198440...

Page 91: ...nd Fittings 4 6 8 1 M11 Procedure Valve Cap Disassembly 1 Perform a Job Safety Assessment JSA Review the procedure and take action to manage any safety risk 2 Place the analyzer out of service and put the analyzer in HOLD 3 Turn off the valve gas carrier gas and sample gas by closing the block valves for each of these gasses Valves 4 6 Model 11 Valve Maxum II Valves and Oven Components Service Man...

Page 92: ...t 8 1 This procedure can be done with the valve in the analyzer oven to save down time and reduce potential problems from removing and replacing the valve 8 Disconnect the Model 11 valve from the column and air lines and remove the valve from the analyzer 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 8 Valve Body 9 O Ring 10 Spring 11 Air Loaded Piston 12 O Ring 13 O Ring 14 Spring Loaded Pi...

Page 93: ...ap Assembly Page 94 section later in this chapter If the valve actuating piston assembly is contaminated or malfunctioning refer to Valve Body disassembly 4 6 8 2 M11 Procedure Cleaning of Parts All valve fittings and tubing must be clean and valve diaphragms inspected for cleanliness catalyst or polymer buildup Before re assembly valve cap and plunger valve body faces should be wiped clean using ...

Page 94: ... Belleville Washer 6 total required 3 Valve Cap 4 Teflon Seal Disc 5 Dacron Cushion Disc 6 O Ring 7 Plungers 6 total required Figure 4 35 M11 2 Exploded View of Model 11 Valve Cap 1 For Model 11 Valve Clean valve cap 3 while disassembled using a syringe and appropriate solvent Clean each port and attached tubing on the valve cap by flushing solvent back and forth through each port while cap is imm...

Page 95: ...plungers 7 8 Securely holding valve cap 3 blow out each port and or tube with compressed air to remove all acetone and foreign matter NOTICE Do not use grease when installing O ring 9 It is recommended that appropriate torque wrenches be used for this step available from Siemens PN s 1631005 002 and 1631005 003 Install valve cap 3 using the three 10 32 Allen screws 1 Screws must be tightened evenl...

Page 96: ...repair kit to remove the retaining ring clip 19 Inset the tips of the pliers into the holes in the clip and firmly squeeze Extract the clip from the base of the valve holding the pliers firmly to prevent clip from flying off 5 Remove retaining base 18 compression plate 17 compression spring 16 and compensation plate 15 from bottom of valve body 8 Refer to Figure 7 4 6 Use the special retaining cli...

Page 97: ...ody parts on a lint free cloth in ultrasonic cleaner 5 Turn Ultrasonic cleaner ON and allow to run for 10 minutes 6 Remove parts and shake cleaning solution from tubes If detergent is used make sure that no residue remains by rinsing thoroughly with deionized water or distilled water Let parts air dry before reassembling 4 6 9 3 M11 Procedure Valve Body Re assembly 1 Before reassembling valve body...

Page 98: ...d with the repair kit to reinstall the retaining ring 19 NOTICE Be certain the retaining ring 19 sets into its mounting groove 18 Prepare to install the manifold 23 by cleaning the flat surface on the side of the valve body 8 and then installing the three small O rings 22 into the manifold 23 19 Align and install manifold 23 onto valve body 26 with two 8 32 screws 24 and 25 The shorter screw is in...

Page 99: ...ter 5 μm recommended not furnished with valve Cap screw 33 Torque Setting 3 95 0 11 Nm 35 1 inch pounds Base Screw 12 Torque Setting 0 73 0 11 Nm 6 5 1 inch pounds Maximum operating temperature 122 C 250 F standard 66 C 150 F 2000627 014 Maximum sample pressure Up to 2068 kPa 300 psig Up to 414 kPa 60 psig 2000627 014 Minimum sample pressure before it is neces sary to apply vacuum assistance to lo...

Page 100: ...can be either stopped diverted or allowed to pass unimpeded through the switch Example Application The following is an example of an actual application using the live tee Actual flows and pressures are indicated and chromatograms are provided to illustrate the set up process Injector Pre Column Main Column Pm PA Pm Split and Backflush Vent NV Purge NV Cut Cut Vent to FID Purge Vent to TCD To FID F...

Page 101: ...e application dependent See the custom documentation package for your analyzer and obtain the applicable specifications for your specific application at the Valco Instruments Co Inc web site https www vici com Maximum operating temperature valve body only 225 C 437 F Connection size and type 1 6 mm 1 16 O D tubing with Valco fittings Actuating air 276 345 kPa 50 psig instrument air standard Valves...

Page 102: ...Valves 4 8 Valco Rotary Valves Maxum II Valves and Oven Components 102 Service Manual 10 2018 A5E42019844001 ...

Page 103: ... air bath heater assembly MEDIUM POWER CONFIGRUATIONS Single isothermal air bath oven operat ing at 70 C or below control temperature Medium power heater control relay board and 650 watt air bath heater assembly Airless ovens either Single isothermal airless Dual isothermal airless Medium power heater control relay board and standard heat ers for airless ovens Heated sample injection valves heated...

Page 104: ...G DWW HDWHU 2YHQ 6HW 3RLQW 7HPSHUDWXUH 3UREH 6DIHW URXQG UDLG DV VKLSSHG RQ VSDUH SDUW HDWHU 3RZHU 3UREH RQQHFWRU Figure 5 1 1400 Watt Air Bath Heater Programmed Temperature Heater Assembly with Deflector 2021680 001 Medium Wattage Heater Assembly 2021284 002 Heaters 5 1 Air Bath Oven Heaters Maxum II Valves and Oven Components 104 Service Manual 10 2018 A5E42019844001 ...

Page 105: ...t Heater Oven Temperature Shutdown and Temperature Limit Probe Heated Air Outlet Heater White White White White Black Black Red Red Mounting Flange Ω 57 Ω 57 Ω 57 Ω Ω Figure 5 2 Air Bath Oven Heater Assembly Heaters 5 1 Air Bath Oven Heaters Maxum II Valves and Oven Components Service Manual 10 2018 A5E42019844001 105 ...

Page 106: ... which sticks out of the top of the oven in the purged area of the mezzanine A threaded retainer cap is inserted in the shaft after the heater to keep it in place Apply a small amount of Loctite silver Grade Anti Seize 76732 or equivalent to the heater retainer cap Heaters Left Oven Heaters Right Oven Heater Retainer Caps Heater Retainer Caps Figure 5 3 Airless Oven Heater Locations Heaters 5 2 Ai...

Page 107: ... SUREH HIW RYHQ KHDWHUV HIW RYHQ SUREH 7KUHH ZLUH FRQQHFWRU WR UHOD PRGXOH Figure 5 4 Airless Oven Heater Locations in Mezzanine Area Heaters 5 2 Airless Oven Heaters Maxum II Valves and Oven Components Service Manual 10 2018 A5E42019844001 107 ...

Page 108: ...Heaters 5 2 Airless Oven Heaters Maxum II Valves and Oven Components 108 Service Manual 10 2018 A5E42019844001 ...

Page 109: ...UM Edition II and MicroSAM Procedures and Updates use the browser search function Ctrl F to search for the part number or name of this product SIOS Siemens Industry Online Support The foundation for product information is the SIOS site at http support industry siemens com cs products Searching for Manuals The following address starts a search for Maxum II manuals http support industry siemens com ...

Page 110: ...ouston TX 77041 USA Tel 1 713 939 7400 Fax 1 713 939 9050 Email saasales industry siemens com Web site www usa siemens com pa Training Tel 1 800 448 8224 USA Email saatraining industry siemens com Spares Tel 1 800 448 8224 USA Email PAspareparts industry siemens com Support Requests www siemens com automation support request Tel 1 800 448 8224 USA Email GCsupport industry siemens com Singapore Onl...

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