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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. This pipe and the protective cover over the assembly effectively make the interior

assembly part of the pressurized EC. As described in AUTOHOTSPOT of this manual, this

higher pressure area prevents flammable vapors and gases from entering the methanator.

Figure 4-19

Purged Methanator

The purged methanator was replaced by the explosion-proof methanator described in the

following section.

Flame Ionization Detector
4.7 Methanator

Maxum Edition II Detectors

Service Manual, May 2018, A5E42019847001

Summary of Contents for Maxum II

Page 1: ...ors and related components used in Maxum II Gas Chromatographs The information in this manual supercedes the applicable topics in previous manuals May 2018 A5E42019847001 Detector Overview 1 Thermal Conductivity Detector 2 Flame Photometric Detector 3 Flame Ionization Detector 4 Valco Pulse Discharge Detector 5 ...

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: ... Indicator LEDs 28 3 7 Replacing a Base3DPM 29 3 8 FPD Specifications 30 4 Flame Ionization Detector 31 4 1 FID Maintenance Considerations 32 4 1 1 Intended Users 32 4 1 2 Safety and Certification Information 32 4 1 3 Available FID Repair Kits 32 4 1 4 Purge Coil and Filter 33 4 2 Replacing the FID Mesh Filter 33 4 2 1 Procedure to Replace Mesh Filter 35 4 3 Replacing the FID Quartz Jet 36 4 3 1 P...

Page 4: ...anator Specifications 53 4 7 5 Methanator Maintenance Considerations 54 4 8 Air Treater 55 4 8 1 Air Treater Maintenance Considerations 55 4 8 2 Air Treater Specifications 56 5 Valco Pulse Discharge Detector 57 5 1 PDD Specifications 57 Table of contents Maxum Edition II Detectors 4 Service Manual May 2018 A5E42019847001 ...

Page 5: ...one for each oven in an airless oven Three detectors are used in special configurations With the exception of the thermal conductivity detectors the detector modules are mounted in the detector compartment The detector compartment is located between the electronics enclosure EC and the oven The detector compartment houses the detector modules and provides a safe path for the electrical connections...

Page 6: ...Function TCM IS TCD DPM Base3DPM Thermistor x Filament x FID x FPD x VPD x Detector Overview 1 1 DPM Types Maxum Edition II Detectors 6 Service Manual May 2018 A5E42019847001 ...

Page 7: ... the carrier gas conducts either more or less heat from the heated element than the sample components The electronic circuits sense the change in heat flow and produce a proportional analog voltage signal Two types of TCD are used within the Maxum II Thermistor Model This TCD type uses thermistors It includes six independent measurement cells and two reference cells This detector connects to the I...

Page 8: ...tector in the Maxum Modular Oven model Both IS TCD3 DPM and IS TCD4 DPM are certified for use in the Maxum Modular Oven model The Maxum Airbath and Airless models that use an Intrinsically Safe detector are certified only when an IS TCD4 DPM is properly installed The IS TCD4 DPM part number A5E43267455001 is installed in current analyzers The IS TCD3 DPM cannot be used as a replacement for the IS ...

Page 9: ...A explosion protection safety standards lc en WW pnid 17741 for more information on the safe use of intrinsically safe circuitry in the Maxum II Connections The connections to the IS TCD DPM are shown below DPM Mounting Screw DPM Mounting Rail DPM Mounting Screw DPM Cage Reference Selector Switches I2 C Connector Intrinsic Safety Ground Connection Lugs Position ID Switch Inputs from Detector Figur...

Page 10: ...xplosion Protection Safety Standards Manual A5E02220442001 https support industry siemens com cs document 42017542 maxum edition ii 3A explosion protection safety standards lc en WW pnid 17741 for more information on the safe use of intrinsically safe circuitry in the Maxum II I2 C Bus Connection The white connector on the reverse side of the DPM connects to the I2 C Bus on the PECM Reference Sele...

Page 11: ...d or Filament Board for the Thermal Conductivity Detector TCD Possible configurations for the TCD include the 2 Cell Filament Detector and the 8 Cell Thermistor Detector The drawings in this section are for the 8 Cell Thermistor Detector However replacement of the Filament Board on the Filament Detector follows the same basic procedure It is possible to replace the Filament Thermistor Board with t...

Page 12: ...in the Exploded Diagram earlier in this section Refer back to the figure for locations 1 Shut off flows and shut down power to the analyzer Allow the detector to cool down 2 Remove the 4 screws and lock washers 3 that secure the cover to the detector block 4 and remove the cover 3 Making note of the connection location for each wire remove the wiring 8 that is connected to the Thermistor Filament ...

Page 13: ... the board be careful not to damage the element 10 Install the Board 12 into the Detector Block 4 When installing the board exercise caution not to damage the exposed elements 11 Reinstall the Flat Washer 11 Lock Washer 10 and Button Head Hex Screw 9 Do not over tighten the screw as this can damage the Board 12 12 Reconnect wiring 8 to the board 12 Wiring MUST be connected to the same cells as bef...

Page 14: ...tch those on the unit being removed Note For the reference selector switches the IS TCD4 DPM uses slide switches in place of the 2 position rotary switches on older units The function is the same Installing the Replacement IS TCD DPM 1 Install the new unit into the DPM cage Insert the bottom edge into the slot in the plastic DPM mounting rail on the DPM cage and secure with the two screws removed ...

Page 15: ...al Measuring Range at 60 C oven temperature 0 to 500 ppm 2 FS up to 0 to 100 0 5 FS Dynamic Range 105 Linear Range 104 Selectivity None Temperature Range Thermistor bead detector inside oven compartment 5 to 120 C Temperature Range Filament detector inside oven compartment 5 to 180 C Thermal Conductivity Detector 2 3 TCD Specifications Maxum Edition II Detectors Service Manual May 2018 A5E42019847...

Page 16: ...Thermal Conductivity Detector 2 3 TCD Specifications Maxum Edition II Detectors 16 Service Manual May 2018 A5E42019847001 ...

Page 17: ...ydrogen rich flame This generates light of specific wavelengths A filter passes light wavelengths which are characteristic for sulfur This is converted into an electrical signal using a photomultiplier device GURJHQ DLU IODPH 6DPSOH DQG FDUULHU JDV IORZ LJKW IURP VXOSKXU FRPSRXQGV 6PDOO PHDVXUDEOH YDULDWLRQV LQ OLJKW RXWSXW DW QP UHSUHVHQW YDULDWLRQV LQ VXOSKXU FRQFHQWUDWLRQ LOWHU LEHURSWLF OLJKW ...

Page 18: ...d from the fiber optic interface The fiber optic cable connects to the photo multiplier tube PMT module in the EC The optical interference filter is built into the PMT module All connections between the combustion chamber and the photomultiplier are absolutely light tight The ignition cable of the FPD is routed through an EEx e feed through to the EC Heater The FPD is supplied with an external hea...

Page 19: ...WW pnid 17741 This publication gives approximate requirements Specific requirements depend on the application Note The FPD is a very sensitive detector The gases and their supply lines must be extremely clean and sulfur free to achieve a high signal noise ratio Selection of Carrier Gas Nitrogen helium argon or hydrogen can be used as the carrier gas If hydrogen carrier is used the required flow of...

Page 20: ...ssure 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 To obtain the recommended flow settings for an analyzer refer to the custom documentation supplied with that analyzer Figure 3 3 FPD Exploded View Flame Photometric Detector Maxum Edition II Detectors 20 Service Manual May 2018 A5E420...

Page 21: ... familiar with the operation and day to day maintenance of the analyzer This procedure involves replacement of the Flame Photometric Detector which may impact the safety protection of the analyzer This procedure should only be executed with the approval of applicable local safety personnel and or the local authority having jurisdiction 3 3 Safety and Certification Information This retrofit may imp...

Page 22: ...dition ii 3A explosion protection safety standards lc en WW pnid 17741 3 4 Procedure Upgrade FPDI to FPDII Note The existing light pipe and PMT module are kept and used for the FPD II Note Because this procedure is intended for expert users many of the steps have limited detail 1 Put the analyzer in Hold 2 Turn off the flame to the FPD by stopping the flow of hydrogen to the detector Wait at least...

Page 23: ...with its mounting bracket heater and cover plate The heater wiring glow plug supply wiring and the associated purge tubes need to taken out as well Note the wiring connections as you remove them from the DPM 11 Before installing the new detector the cover and insulation need to be removed Replacing the insulation and cover will be the last step in the installation 12 Install the FPD II As you inst...

Page 24: ...niter Power Location ID Switch RTD Temp Control Input Flame Sense and Filament Detector Input Signal Cable from Detector Mezzanine Module Mounting Location Figure 3 5 Base3DPM With Mezzanine Module Part Number The Base3 DPM Part Number A5E02645925001 is shipped with current analyzers It can be used as a replacement part for earlier DPMs in Maxum I analyzers using an adapter part number A5E34938458...

Page 25: ...ctor Input via connector on right side as viewed inside analyzer EC Temperature control Temperature setpoint module connector Two RTD inputs Two heater control outputs System communication I2 C port with ID select switch Input Signal Paths The input signal functions are shown below Analog Flame Ionization or Flame Photometric Detector Network I2 C I2 C Analog GCP Color Touch Display SYSCON PECM Ba...

Page 26: ...n ID Switch shown previously in the photograph selects the DPM location that is incorporated in the address to be reported in the results The DPM I2 C port is connected directly to the system controller via the PECM or a wiring distribution board In this scenario the following values are applied Switch Value Location 1 Left 2 Center 3 Right NOTE If the DPM I2 C port is connected to an SNE the valu...

Page 27: ...utdown Compare Figure 3 9 Heater Control Path Using DPM A mounting location and connector are provided for two Temperature Setpoint Modules The modules are installed on the left side back of the DPM shown below This same position is used in the Temperature Control Module TCM RTD Temp Control Inputs I2 C Heater Control Outputs to PECM Location ID Switch Temp Setpoint Module Mounting Screw Access Te...

Page 28: ...tage output The AI signal will be treated like a normal detector signal with a 50 balance range Table 3 1 Mezzanine Part Number Descriptions Mezzanine Detector Sub Module Type Usage Normal Range Alternate Range 2020960 001 FID Low level FID 0 2nA none 2020960 003 Standard FID 1nA 20nA 2021328 002 Large Scale FID 100nA 1000nA 2021328 001 FPD FPD 100nA none 2021328 003 FPD 0 18 Hz Filter 100nA none ...

Page 29: ...sure 10 Disconnect the I2 C power cable and temperature control output cables from the rear edge of the board 11 Remove the unit from the analyzer and place on ESD safe work surface 12 Unscrew the two mounting screws at the top corners of the mezzanine module and unplug it from the Base3 DPM 13 Unscrew the mounting screw for the temperature setpoint module stack using the access hole in the metal ...

Page 30: ...t the RTD temperature input cables top rear of unit if present 10 Reconnect the fIlament detector cable if present 11 Reconnect the detector signal cable from the mezzanine module 12 Follow the steps in the General Analyzer Startup Procedure 3 8 FPD Specifications Table 3 2 Flame Photometric Detector FPD Parameter Value Target Components Sulfur Measurement Type Mass Smallest Measuring Range at 60 ...

Page 31: ...es For a high signal noise ratio ensure that the supply gases Hydrogen and Air and carrier gas have a purity of 99 999 and hydrocarbon content below 2 ppm For special detection sensitivity filter supply gases using a molecular sieve filter If plant air is used a catalytic Air Treater is strong ly recommended to reduce the pos sible hydrocarbon content of the air The FID is shown at right without c...

Page 32: ...sed 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 Note This procedure must only be executed with the consent and approval of all applicable local safety personnel and or the local authority having jurisdiction For more information see the Maxum II Explosio...

Page 33: ...at the filter will become clogged Because it is difficult to remove this filter without damaging it in the event that the filter does become clogged or it should become necessary to remove the filter for some reason then it should be replaced and not reused 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...

Page 34: ... 16 Detector Body Upper 6 Retainer Clip Large 17 Teflon Seal 7 Outer Ferrule 18 Collector 8 Graphite Ferrule 19 Socket Heat Cap Screw M5 x 60 9 Pressure Ferrule 20 Flame Arrestor Bushing 10 Burner Nut 21 Flat Washer 11 Quartz Jet with flame tip nozzle 22 Flame Arrestor Quartz Jet Assembly Figure 4 3 FID Assembly Flame Ionization Detector 4 2 Replacing the FID Mesh Filter Maxum Edition II Detectors...

Page 35: ...n the air supply to the FID in order push the Mesh Filter 4 up so that it can be removed If turning on the air supply does not dislodge the Mesh Filter 4 use a flat screwdriver to carefully pry up the Filter be careful not to scratch the surface of the FID body 8 Turn off the FID combustion air 9 Discard the old Mesh Filter 4 and install a new one in the FID 10 Re install the Small and Large Retai...

Page 36: ...er Nut 10 and remove the Quartz Jet and attached hardware 7 8 9 10 and 11 6 Detach the Quartz Jet 11 from the Ferrules 7 8 9 and the Burner Nut 10 Make note of the way they are assembled 7 If Quartz Jet 11 is dirty or clogged it may be possible to clean it using solvent in an ultrasonic cleaner However replacement is recommended If attempting to clean the quartz jet allow any excess solvent to eva...

Page 37: ...NG FID PURGE TUBE 1 1312420 331 SCREW M3X 4 SOCKET HEAD CAP SST 2 1312530 006 WASHER M3 HELICAL SPRING LOCK SST 1 A6X19905099 O RING SIZE 020 0 964 X O70 KALREZ 1 2021925 001 IGNITER FID ASSEMBLY MAXUM II 1 A5E41666948001 STRAP GROUND FID 1 A5E41666957001 115V ASSEMBLY HEATR FID FPD 1 A5E41666957002 230V A5E35374578001 COVER DETECTOR FID 1 A5E41381855001 PURGE FILTER 2 0 MICRON 10 32 THREAD 1 A5E4...

Page 38: ...ply to the detector for hydrogen carrier or shutting off the hydrogen to the detector if not using hydrogen carrier In order to prevent condensation in the detector allow carrier to flow for several minutes after flame is extinguished Use a mirror to check for condensation at the FID vent to verify the flame is not lit no condensation means the flame is not lit WARNING Possible ignition source Fai...

Page 39: ...rom PECM Filament Detector Flame Ionization Detector FID Detector Personality Module DPM Heater Control from DPM FID Heater Power from PECM Figure 4 4 Typical FID Connections 7 Disconnect the FID heater power cable from the PECM Note the connector location 8 Disconnect the FID heater RTD cable from the DPM connector board Note the connector location Flame Ionization Detector 4 4 Replacing the FID ...

Page 40: ...Igniter Tubing Connection FID Bottom Body Figure 4 5 FID Assy Bottom with Original Igniter 11 Remove the flame arrestor insert from the FID bottom body using a 9 16 open end wrench FID Flame Arrestor Insert Narrow End of FID Bottom Body Insert Washer Figure 4 6 FID Flame Arrestor Flame Ionization Detector 4 4 Replacing the FID Igniter Maxum Edition II Detectors 40 Service Manual May 2018 A5E420198...

Page 41: ...d Igniter assembly discard FID mounting plate Heater assembly screws 4 reuse Thermal gasket remains on FID Setscrew for FID bottom body FID bottom body FID body Heater purge tube discard Cable tie cut and discard Pipe gasket discard Cover setscrew A D B C Figure 4 8 FID FID Parts with Old Igniter 14 Remove the cover from the FID block by pulling up and out and then remove the insulation from the F...

Page 42: ...4 nuts from the FID EC cover plate using a 7mm nut driver 17 Using a 2 5mm Allen wrench remove the four M4 screws that secure the FID mounting plate to the mezzanine 18 Remove the FID assembly from the mezzanine by pulling up and then out when the FID bottom body clears the hole 4 4 3 Procedure Igniter Replacement Note A clean work surface should be used for disassembly of the old igniter and inst...

Page 43: ...rge filter A5E41381855001 and washer A5E41849023 Ground strap set screw goes here Hole for purge filter Figure 4 10 FID Installation Exploded Diagram 1 Remove the four screws that secure the purge tube to the electrodes of the detector 2 Pull the purge tube about 1 inch away from the detector assembly and carefully remove the wires from the electrodes 3 The purge tube with its bushing and gasket E...

Page 44: ...igniter fastening strap is on the bottom 9 Using a 2 5mm hex wrench attach the mounting strap to the new igniter board Use an M3 x 4 socket head cap screw 1312420 331 from the kit for this connection See New Igniter Attachment to Detector Note Because the wires from the igniter to the electrodes are stiff it is best to plug the wires in before attaching the strap to the bushing 10 Plug both ignite...

Page 45: ...to the new FID purge tube and slide the purge tube over the igniter board and wiring Make sure that the white signal wire remains positioned against the flat top side of the igniter board Place the end of the purge tube with the flat area around the hole towards the detector 7KLV HQG FRQQHFWV WR EXVKLQJ 7KLV HQG JRHV WKURXJK FRYHU SODWH 3XUJH ILOWHU VHFXUHV SXUJH WXEH WR EXVKLQJ ZDVKHU QRW VKRZQ 3...

Page 46: ... remove the paper backing to expose the adhesive Gasket installed on FID lower body To oven fitting Adhesive Figure 4 15 FID Thermal Gasket 3 Route the FID Module Assembly wiring into the EC and install the module into the analyzer Make sure that the FID bottom body fits into the hole at the bottom of the mezzanine section 4 Install the 4 M4 screws into the FID mounting plate and tighten using a 2...

Page 47: ...ocation from which it was unplugged earlier in this procedure 14 Route the FID heater ground braid through the EC and connect to the appropriate ground lug from which the old one was disconnected 15 Turn on utility gases and check for leaks 16 Turn on power to the analyzer and switch the valves checking all possible flow paths for leaks Refer to plumbing diagram provided in the custom documentatio...

Page 48: ... Combustible Components Temperature Range 105 to 260 C 4 6 Filament Detector The Filament Detector is a two cell device that provides a reference and a sample sense signal typically used in applications along with the FID Component Locations Figure 4 16 FID and Filament Detector in Typical Analyzer Flame Ionization Detector 4 6 Filament Detector Maxum Edition II Detectors 48 Service Manual May 201...

Page 49: ... LODPHQW HWHFWRU ORFN ORZ LYHUWHU QVHUWV 2 5LQJV LODPHQW RDUG 0 DUGZDUH LUH 6HDOHG LWWLQJ DEOH VVHPEO 0 DUGZDUH HOO LODPHQW RYHU 6HQVH KLWH OXH LUH 3DLU 5HIHUHQFH 5HG ODFN LUH 3DLU DV 7XELQJ DV 7XELQJ 3URSHU RULHQWDWLRQ RI ORZ LYHUWHU QVHUWV Figure 4 18 Filament Detector Exploded View Flame Ionization Detector 4 6 Filament Detector Maxum Edition II Detectors Service Manual May 2018 A5E42019847001 ...

Page 50: ...d with the groove perpendicular to the tube holes in the block so that air cannot flow in a straight path between the holes 11 Install the new O rings in hole in the Detector Block It is also possible to install the O rings on the filament board instead of in the hole If installing the O rings on the board be careful not to damage the element 12 Install the Board into the Detector Block When insta...

Page 51: ...temperature are converted into methane for detection by the FID 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 Features of Both Methanator Models As p...

Page 52: ...ator This pipe and the protective cover over the assembly effectively make the interior assembly part of the pressurized EC As described in AUTOHOTSPOT of this manual this higher pressure area prevents flammable vapors and gases from entering the methanator Figure 4 19 Purged Methanator The purged methanator was replaced by the explosion proof methanator described in the following section Flame Io...

Page 53: ...information see the Maxum II Explosion Protection Safety Standards Manual A5E02220442001 https support industry siemens com cs document 42017542 maxum edition ii 3A explosion protection safety standards lc en WW pnid 17741 4 7 4 Methanator Specifications Table 4 2 Methanator Parameter Value Non Ex Methanator Ex Methanator Classification n a Ex d IIB H2 Maximum Operation Temperature 400 C 400 C Hea...

Page 54: ...necessary to give the methanator time to cool down sufficiently If the door to the electronics cabinet is opened prematurely explosive gas or vapor can ignite by entering the electronics cabinet and then entering the methanator through the conduit tube Failure to follow proper safety procedures may result in equipment damage severe injury or death Explosion Proof Methanator The methanator should b...

Page 55: ...phere in the area of analyzer installation and will contain an ex plosion if combustible gases get inside the air treater The Air Treater is connected to electrical pow er by means of wiring installed in approved conduit Wiring connections are not supplied by the factory and must be made in the field Air Treater The instrument air flows into and out of the explosion proof enclosure through specifi...

Page 56: ...osure Input air quality Meet or exceed ISO8573 4 Class 3 requirements Maximum total hydrocarbon content less than 1 ppm and Dew point 20 C 4 F Input air flow 250 to 1500 ml min depending on requirements Input pressure 34 to 1034 kPa 5 to 150 psig depending on flow rate desired Warm up time Approximately 90 minutes Treated air purity Up to 95 of the trace hydrocarbons typically found in instrument ...

Page 57: ...um ii official product specifications lc en WW pnid 17741 This publication gives approximate requirements Specific requirements depend on the application Table 5 1 Pulse Discharge Detector Helium Ionization Mode Parameter Value Target Components All Measurement Type Mass Smallest Measuring Range at 60 C oven temperature 0 to 2 ppm 5 Typical Measuring Range at 60 C oven temperature 0 to 5 ppm 5 FS ...

Page 58: ...Type Mass Smallest Measuring Range at 60 C oven temperature 0 to 2 ppm 5 Typical Measuring Range at 60 C oven temperature 0 to 5 ppm 5 FS Dynamic Range 103 at fixed attenuation Linear Range 103 at fixed attenuation Selectivity Photon sensitive components example benzene to hexane 103 to 1 Temperature Range 70 110 C higher temperature ranges on request system configuration dependent Valco Pulse Dis...

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