Transcript
Automation & Drives
Technical Support Information No. 85 Revision 2.0
A&D Sensors and Communications Process Analytics - Karlsruhe Germany
November 2006
Page 1 of 6
Information zu / to
Maxum AC Heizungsregelstrecke Zusammenfassung Im folgenden werden die unterschiedlichen Heizungen des Maxum vorgestellt und eine systematische Fehlersuche an der Maxum Heizungsregelstrecke wird beschrieben.
Maxum Heater AC Circuit MAXUM is available with - air bath ovens, in a single isothermal, dual split-oven isothermal and dual oven in a isothermal/programmable temperature version. - airless ovens, in a dual isothermal version.
Whereas TCDs are mounted inside the ovens, on top of each oven independently heated detectors such as FID, FPD or specific detectors such as PDHID are mounted on top of the oven. That provides additionally oven and application flexibility as well as simplifies maintenance.
© SIEMENS AG Karlsruhe - A&D SC PA AS 2 - Niko Benas +49 721 595 7216 -
[email protected] Als Betriebsgeheimnis anvertraut. Alle Rechte vorbehalten. Der Inhalt dieser TSI wurde auf Übereinstimmung mit der beschriebenen Hard- und Software geprüft, dennoch können Abweichungen nicht ausgeschlossen werden. Technische Änderungen vorbehalten. Proprietary data. All rights reserved. While we have verified the contents of this TSI in agreement with hardware and software described, variations remain possible. Thus we cannot guarantee full agreement. Technical data are subject to change.
Automation & Drives
Technical Support Information No. 85 Revision 2.0
A&D Sensors and Communications Process Analytics - Karlsruhe Germany
November 2006
Page 2 of 6
The single air bath oven has a size of about 580mm x 370mm x 280mm / 23" x x14.5" x 11" (wxhxd). The dual air bath ovens have each the size of about 270mm x 370mm x 280mm / 9" x 14.5" x 11" (wxhxd). The dual airless ovens have each the size of about 225mm x 340mm x 250mm (8.8"x13.5"x10") and has been added to MAXUM in 2003. Initially, when integrating the features of the European Siemens Process GC PGC302 into MAXUM, the significant preference of airless ovens of European users was the motivation. However, in the mean time the airless oven configuration is gaining fast followers in North America as well. Both ovens have about the same oven stability. There are a number of differentiators between air bath and airless ovens: 1: COST OF AIR Cost of instrument air can represent a significant operational cost factors. Typical cost of air over the life time (15 years) of an analyzer is shown in the following graph. The cost of air includes oven air as well as electronic purge air for airless oven MAXUM, air bath oven MAXUM and air bath oven of another Process GC manufacturer.
© SIEMENS AG Karlsruhe - A&D SC PA AS 2 - Niko Benas +49 721 595 7216 -
[email protected] Als Betriebsgeheimnis anvertraut. Alle Rechte vorbehalten. Der Inhalt dieser TSI wurde auf Übereinstimmung mit der beschriebenen Hard- und Software geprüft, dennoch können Abweichungen nicht ausgeschlossen werden. Technische Änderungen vorbehalten. Proprietary data. All rights reserved. While we have verified the contents of this TSI in agreement with hardware and software described, variations remain possible. Thus we cannot guarantee full agreement. Technical data are subject to change.
Automation & Drives
Technical Support Information No. 85 Revision 2.0
A&D Sensors and Communications Process Analytics - Karlsruhe Germany
November 2006
Page 3 of 6
2. MAXIMUM OVEN TEMPERATURE Air bath oven temperature range is 5 C to 225 C and 5 to 260 C for the airless oven. The temperature programmable oven temperature limit is 320 C. The temperature difference between split ovens is more than 100 C. For example 60 C in one and 160 C in the other. However, that difference becomes smaller if one oven is running close to ambient at 45 C without active cooling. A electrically heated coil is used to heat up the air used for the air bath oven. Because the surface temperature limitations (T-Rating) for an electrical hazardous area and because the poor thermal properties of air, the maximum oven temperature possible for a given T-Rating is low. For example, the maximum oven temperature than can be reached for a T3 area (200 C) is 140 C, T2 area (300 C) is about 200C On the other hand, an airless oven is heated by heating cartridges located inside the cast alloy oven casing. With much better conductivity, the maximum oven temperature for a T3 area (200 C) is about 175 C. T2 area (300 C) is about 260 C. 3. HEAT-UP RATE Although one might think that an air bath oven is faster heating up, this is not true in general and is strongly dependent on the T-rating. For example To 60 C 15 minutes for air bath and 30 minutes for airless (T3) - ambient to 70 C takes 70 minutes for air bath and 35 minutes for airless (T4 area) - ambient to 70 C takes 10 min for air bath and 35 minutes for airless (T3 area) - ambient to 80 C takes 20 minutes for air bath and 40 minutes for airless (T3 area) - ambient to 90 C takes 45 min for air bath 50 min for airless (T3) - ambient to 120 C not possible with and air bath for T3 rating - ambient to 120 C takes 40 minutes for air bath and 65 minutes for airless (T2-A area) - ambient to 160 C takes 90 min for air bath and 90 min for airless (T2A) The temperature programmable oven is located inside one of the split isothermal oven compartments. The temperature programmable oven compartment is independently heated with an air bath heater. Heat-up and cool down rate depends on the temperature of the isothermal oven. The heat up rate is 60-80 C/min at the lower temperature range. The average heat-up rate up to 220 C is exceeding 20 C/min, up to 320 C it is exceeding 15 C/min. Possible heat-up rates are T-rating dependent. The cool down speed is often accelerated by using a switching a Vortex cooler into the supply air line. The design of the temperature programmable enclosure provides heat along the column outlet to the detector base in order to prevent cold spots. © SIEMENS AG Karlsruhe - A&D SC PA AS 2 - Niko Benas +49 721 595 7216 -
[email protected] Als Betriebsgeheimnis anvertraut. Alle Rechte vorbehalten. Der Inhalt dieser TSI wurde auf Übereinstimmung mit der beschriebenen Hard- und Software geprüft, dennoch können Abweichungen nicht ausgeschlossen werden. Technische Änderungen vorbehalten. Proprietary data. All rights reserved. While we have verified the contents of this TSI in agreement with hardware and software described, variations remain possible. Thus we cannot guarantee full agreement. Technical data are subject to change.
Automation & Drives
Technical Support Information No. 85 Revision 2.0
A&D Sensors and Communications Process Analytics - Karlsruhe Germany
November 2006
Page 4 of 6
4. OVEN CONFIGURATION Airless ovens can accommodate 3 externally mounted (top of the oven), independently heated detectors such as FID, FPD or specific detectors. In addition 3 dual (total of 6) TCDs can be mounted inside the large air bath oven. A split air bath oven as the dual airless oven can accommodate 2 independently heated detectors on top of the oven and additionally in each oven a dual (total of 4) TCDs. In addition to each externally mounted FID, a Methanizer can be mounted next to it. The large air bath oven can accommodate 6 column train and still be accessible for maintenance. 8 column trains can be accommodated in total but generates a full oven. A dual air bath or dual airless oven accommodates 2 column trains with up to 3 valves comfortably. The single or dual air bath oven has a single large door whereas the dual airless oven has individual oven doors. Individual oven doors permit the maintenance on one oven with the second oven on-line analyzing.
5. POWER REQUIRMENTS The majority of the power is typically consumed by the analyzer oven. Power requirements as specified: Single Oven air bath: max. 1840 VA Dual air bath (2 x isothermal): 2x1400 VA (one for each oven) Dual air bath (temperature programmable / isothermal): 2x1400 VA Dual Airless: (2 x isothermal) is max about 1840 VA.
6. COMMENT In an enclosed shelter or laboratory airless analyzer oven are substantially quieter compared to air bath ovens. The air bath oven air should be vented outside the shelters in order to reduce air conditioning load on the shelter. The MAXUM electronics consumes about 400 VA which is dissipated into the shelter. However, whereas an airless oven typically consumes about 300-400 VA and will dissipate into the shelter. The air bath oven consumes at least twice as much. The majority of the hot air can be vented to the outside of the shelter. As a side note, the Thermistor TCD can be converted to a Filament TCD. Same detector block, although the DPM has to be changed.
© SIEMENS AG Karlsruhe - A&D SC PA AS 2 - Niko Benas +49 721 595 7216 -
[email protected] Als Betriebsgeheimnis anvertraut. Alle Rechte vorbehalten. Der Inhalt dieser TSI wurde auf Übereinstimmung mit der beschriebenen Hard- und Software geprüft, dennoch können Abweichungen nicht ausgeschlossen werden. Technische Änderungen vorbehalten. Proprietary data. All rights reserved. While we have verified the contents of this TSI in agreement with hardware and software described, variations remain possible. Thus we cannot guarantee full agreement. Technical data are subject to change.
Automation & Drives
Technical Support Information No. 85 Revision 2.0
A&D Sensors and Communications Process Analytics - Karlsruhe Germany
November 2006
Page 5 of 6
7. HEATER AC CIRCUIT CHECK Check the heater elements with an ohm meter to verify they are not shorted, shorted to ground or open. 1. Turn off the power to the analyzer, following normal shutdown procedures 2. Unplug the heater from the heater power cable at the blue connector. 3. Connect one lead of the ohm meter to the center pin (2) of the blue connector on the heater wires. Then connect the other lead to one of the outside pins (1 or 3). The ohm meter should read approximately 18 ohms +/- 2. 4. With one lead of the ohm meter connected to the center pin (2), connect the other lead to the other outside pin (1 or 3). The ohm meter should read approximately 18 ohms +/- 2. 5. Replace the heater if ether element does not measure 18 ohms +/- 2. An open resistance reading is the typical failure. Both elements must be functional for the heater circuit to work properly. In a 115VAC configuration one element can be open and the heater will heat the analyzer with just one element functioning. With just one element working the heater may not be able to reach the operating temperature or it could take longer to reach temperature. Several factors can cause a heater element to open. These include: particulates or moisture in the air, lack of sufficient air volume to the analyzer and excessive vibration. Heater elements can also be damaged if dropped or exposed to excessive physical shock (such as hitting the heater with a hammer). 6. Check each pin to chassis ground to verify none of the wires or heater elements are shorted to the case ground. Correct the problem or replace the heater if a short is detected. 115 VAC or 230 VAC Verify the system is configured for the correct voltage level. The analyzer can be configured to operate at 115 VAC or 230 VAC. This includes using the correct adapter and installing the correct fuses in the Power Entry Control Module. There are two adapters: The 115 Cable Adapter is SAA part number 2017595-001. The 230 Cable Adapter is SAA part number 2017595-002. In the Maxum I the adapter connector is located in the floor of the electronics enclosure between the left and center SNE locations. In the Maxum II the adapter connector is located on the left side of the electronics enclosure behind the detector mezzanine area. Remove the left side access panel to check or replace this adapter. 115 Adapter Cable The heater should be configured with the two elements in parallel when connected to 115 VAC service. The center tap of the heater is connected to AC Neutral. The center tap is pin 2 of the blue heater connector. The end of each element of the heater is connected to AC Hot, through the solid state relays. These are pins 1 and 3 of the blue heater connector.
© SIEMENS AG Karlsruhe - A&D SC PA AS 2 - Niko Benas +49 721 595 7216 -
[email protected] Als Betriebsgeheimnis anvertraut. Alle Rechte vorbehalten. Der Inhalt dieser TSI wurde auf Übereinstimmung mit der beschriebenen Hard- und Software geprüft, dennoch können Abweichungen nicht ausgeschlossen werden. Technische Änderungen vorbehalten. Proprietary data. All rights reserved. While we have verified the contents of this TSI in agreement with hardware and software described, variations remain possible. Thus we cannot guarantee full agreement. Technical data are subject to change.
Automation & Drives
Technical Support Information No. 85 Revision 2.0
A&D Sensors and Communications Process Analytics - Karlsruhe Germany
November 2006
Page 6 of 6
230 Adapter Cable The heater should be configured with the two elements in series when connected to 230 VAC service. The center tap is left open. One of the elements is connected to AC Neutral and the other is connected to AC Hot through the solid state relays. These are respectively pins 3 and 1 of the blue heater connector. Power Entry Control Module Fuses The heater element can operate from either 115 VAC or 230 VAC power sources with a total power output capacity of 1400 to 1500 watts. If the primary AC voltage is changed from 115 VAC to 230 VAC, the Power Entry Control Module (PECM) AB1 and AB2 fuses must be changed. For 115 VAC power the fuses are rated at 16 amps. For 230 VAC, the in-line fuses must be changed to 10-amp rating. DO NOT use a 16-amp rated fuse for 230 VAC primary AC power. Also note that the Power Supply Module 115/230 VAC switch must be set to the correct setting.
© SIEMENS AG Karlsruhe - A&D SC PA AS 2 - Niko Benas +49 721 595 7216 -
[email protected] Als Betriebsgeheimnis anvertraut. Alle Rechte vorbehalten. Der Inhalt dieser TSI wurde auf Übereinstimmung mit der beschriebenen Hard- und Software geprüft, dennoch können Abweichungen nicht ausgeschlossen werden. Technische Änderungen vorbehalten. Proprietary data. All rights reserved. While we have verified the contents of this TSI in agreement with hardware and software described, variations remain possible. Thus we cannot guarantee full agreement. Technical data are subject to change.
6. Check each pin to chassis ground to verify none of the wires or heater elements are shorted to the case ground. Correct the problem or replace the heater if a short is detected.
Several factors can cause a heater element to open. These include; particulates or moisture in the air, lack of sufficient air volume to the analyzer and excessive vibration. Heater elements can also be damaged if dropped or exposed to excessive physical shock (such as hitting the heater with a hammer).
An open resistance reading is the typical failure. Both elements must be functional for the heater circuit to work properly. In a 115VAC configuration one element can be open and the heater will heat the analyzer with just one element functioning. With just one element working the heater may not be able to reach the operating temperature or it could take longer to reach temperature.
1. Turn off the power to the analyzer, following normal shutdown procedures 2. Unplug the heater from the heater power cable at the blue connector. 3. Connect one lead of the ohm meter to the center pin (2) of the blue connector on the heater wires. Then connect the other lead to one of the outside pins (1 or 3). The ohm meter should read approximately 18 ohms +/- 2. 4. With one lead of the ohm meter connected to the center pin (2), connect the other lead to the other outside pin (1 or 3). The ohm meter should read approximately 18 ohms +/- 2. 5. Replace the heater if ether element does not measure 18 ohms +/- 2.
Check the heater elements with an ohm meter to verify they are not shorted, shorted to ground or open.
Heater AC Circuit Check
Calculate resistance based on voltage and wattage. (230 X 230) / 1400 = 37 ~~ 37 /2 = 18 ohms (115 X 115 ) / 1140 = 9 ~~ 9 * 2 = 18 ohms
230 Adapter Cable. The heater should be configured with the two elements in series when connected to 230 VAC service. The center tap is left open. One of the elements is connected to AC Neutral and the other is connected to AC Hot through the solid state relays. These are respectively pins 3 and 1 of the blue heater connector.
115 Adapter Cable. The heater should be configured with the two elements in parallel when connected to 115 VAC service. The center tap of the heater is connected to AC Neutral. The center tap is pin 2 of the blue heater connector. The end of each element of the heater is connected to AC Hot, through the solid state relays. These are pins 1 and 3 of the blue heater connector.
115 VAC or 230 VAC. Verify the system is configured for the correct voltage level. The analyzer can be configured to operate at 115 VAC or 230 VAC. This includes using the correct adapter and installing the correct fuses in the Power Entry Control Module. There are two adapters. The 115 Cable Adapter is SAA part number 2017595-001. The 230 Cable Adapter is SAA part number 2017595-002. In the Maxum I the adapter connector is located in the floor of the electronics enclosure between the left and center SNE locations. In the Maxum II the adapter connector is located on the left side of the electronics enclosure behind the detector mezzanine area. Remove the left side access panel to check or replace this adapter.
Power Entry Control Module Fuses. The heater element can operate from either 115 VAC or 230 VAC power sources with a total power output capacity of 1400 to 1500 watts. If the primary AC voltage is changed from 115 VAC to 230 VAC, the Power Entry Control Module (PECM) AB1 and AB2 fuses must be changed. For 115 VAC power the fuses are rated at 16 amps. For 230 VAC, the in-line fuses must be changed to 10-amp rating. DO NOT use a 16-amp rated fuse for 230 VAC primary AC power. Also note that the Power Supply Module 115/230 VAC switch must be set to the correct setting.
P E C M
Heater Wiring Schematic 230 VAC
2017595-002 CABLE, ADAPTOR, 230
JUMPERS 1-8, 2-6
230 Adapter Jumpers
Heater Elements measure approximately 18 ohms each Plug 3 or Plug4: P1 to P2 = 18 Ω +/- 2 P2 to P3 = 18 Ω +/- 2 P1 to P3 = 36 Ω +/- 2
LEFT HEATER
RIGHT HEATER
P E C M
Heater Wiring Schematic 115 VAC
2017595-001 CABLE, ADAPTOR, 115
JUMPERS 1-7, 2-5, 3-6, 4-8
115 Adapter Jumpers
Heater Elements measure approximately 18 ohms each Plug 3 or Plug4: P1 to P2 = 18 Ω +/- 2 P2 to P3 = 18 Ω +/- 2 P1 to P3 = 36 Ω +/- 2
LEFT HEATER
RIGHT HEATER
MAXUM TL/OT T-RATING SETPOINT RESISTOR TABLES 2020293-AI Table I. AIR BATH HEATER/MAXUM II FID/FPD BLOCK HEATER SETPOINT (SP) RESISTORS (see note 1) T-RATING – TEMPERATURE T4 T3C T3B T3A T3 T2D T2C T2B T2A T2 T1
135oC 160oC 165oC 180oC 200oC 215oC 230oC 260oC 280oC 300oC 450oC
275oF 320oF 329oF 356oF 392oF 419oF 446oF 500oF 536oF 572oF 842oF
SP RESISTOR 14.3K 15.4K 15.6K 16.2K 16.9K 17.4K 17.8K 18.7K 19.6K 20.5K 26.1K
SAA PCBA P/N (1521002-337) (1521002-339) (1521002-457) (1521002-341) (1521002-342) (1521002-343) (1521002-344) (1521002-345) (1521002-347) (1521002-349) (1521002-350)
2021716-004 2021716-010 2021717-001 2021717-005 2021717-009 2021717-010 2021718-001 2021718-005 2021718-009 2021719-001 2021719-002
Table II. MAT VALVE SETPOINT (SP) RESISTORS T-RATING – TEMPERATURE T3 T2C T2A
200oC 230oC 280oC
392oF 446oF 536oF
SP RESISTOR
SAA PCBA P/N
16.2K (1521002-341) 17.8K (1521002-344) 19.6K (1521002-347)
2021717-005 2021718-001 2021718-009
Table III. MAXUM I FID I HEATER SETPOINT (SP) RESISTORS T-RATING – TEMPERATURE T4 T3B T3A T3 T2D T2C T2B
135oC 165oC 180oC 200oC 215oC 230oC 260oC
275oF 329oF 356oF 392oF 419oF 446oF 500oF
SP RESISTOR 13.3K 14.7K 15.6K 16.2K 16.5K 17.4K 17.8K
SAA PCBA P/N (1521002-335) (1521002-338) (1521002-457) (1521002-341) (1521002-451) (1521002-343) (1521002-344)
2021715-009 2021716-007 2021717-001 2021717-005 2021717-007 2021717-010 2021718-001
TABLE IV. MAXUM I METHANATOR HEATER SETPOINT (SP) RESISTORS (see note 2) T-RATING - TEMPERATURE T4
135oC
275oF
SP RESISTOR
SAA PCBA P/N
26.1K (1521002-350)
2021719-002
TABLE V. MAXUM II METHANATOR HEATER SETPOINT (SP) RESISTORS (see note 3) T-RATING - TEMPERATURE T3 T1
200oC 450oC
D11709 Rev AK
392oF 842oF
Kesselhuth
SP RESISTOR
SAA PCBA P/N
26.1K (1521002-350) 26.1K (1521002-350)
2021719-002 2021719-002
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TABLE VI. AIRLESS HEATER SETPOINT (SP) RESISTORS T-RATING - TEMPERATURE 135oC 160oC 165oC 180oC 200oC 215oC 230oC 260oC 280oC 300oC
T4 T3C T3B T3A T3 T2D T2C T2B T2A T2
SP RESISTOR
275oF 320oF 329oF 356oF 392oF 419oF 446oF 500oF 536oF 572oF
13.4K 14.3K 14.5K 15.1K 15.8K 16.4K 16.9K 18.0K 18.8K 19.5K
SAA PCBA P/N (1521002-572) (1521001-337) (1521002-574) (1521002-449) (1521002-340) (1521002-577) (1521002-342) (1521002-578) (1521003-580) (1521002-581)
2021715-010 2021716-004 2021716-005 2021716-008 2021717-003 2021717-006 2021717-009 2021718-002 2021718-006 2021718-008
TABLE VII. MAXUM II SPARGER (WATER HEATER) SETPOINT (SP) RESISTORS (see note 4) T-RATING - TEMPERATURE 200oC
T3
392oF
SP RESISTOR
SAA PCBA P/N
12.4k (1521002-332) 2021715-005
TABLE VIII. SLIV HEATER SETPOINTS (SP) RESISTORS T-RATING – TEMPERATURE 135oC 160oC 165oC 180oC 200oC 215oC 230oC 260oC 280oC 300oC 450oC
T4 T3C T3B T3A T3 T2D T2C T2B T2A T2 T1
275oF 320oF 329oF 356oF 392oF 419oF 446oF 500oF 536oF 572oF 842oF
SP RESISTOR 14.2K 15.1K 15.2K 15.8K 16.5K 16.9K 17.4K 18.8K 19.6K 20.0K 24.6K
SAA PCBA P/N (1521002-587) (1521002-449) (1521002-575) (1521002-340) (1521002-451) (1521002-342) (1521002-343) (1521002-580) (1521002-347) (1521002-348) (1521002-588)
2021719-003 2021716-008 2021716-009 2021717-003 2021717-007 2021717-009 2021717-010 2021718-006 2021718-009 2021718-010 2021719-004
NOTES: 1. 2. 3.
4.
TABLE I IS VALID FOR THE MAXUM EDITION II FID/FPD BLOCK HEATER ONLY FOR HEATERS THAT ARE 80 WATTS OR LESS. TABLE IV T4 RATING APPLIES TO MAXUM I METHANATOR ONLY. TABLE V T1 RATING APPLIES TO MAXUM II METHANATOR FOR DIVISION 2 NONPURGED AND DIVISION 1 Y-PURGED CONFIGURATIONS. T3 RATING APPLIES TO DIVISION 2 Z-PURGED, DIVISION 1 X-PURGED AND CENELEC ZONE 1. WHILE TABLE VII SHOWS THE T3 TEMPERATURE, THE ACTUAL MAXIMUM TEMPERATURE WITH THIS SET POINT RESISTOR IS 67OC (OR 153OF).
D11709 Rev AK
Kesselhuth
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Maxum II RTD Wiring and Heater Channel Selection For standard products, the oven temperature controls are on the PECM. The DPM temperature control channels are used for their respective detector heater. Any unused temperature control channels can be used for custom items, i.e. sample valves, sample conditioning systems, etc.
1. Single oven heater: Channel 2 on the PECM is the oven heater (ALH2, ABH2). 2. Dual oven heaters: Channel 1 on the PECM is the left oven heater (ALH1, ABH1) and Channel 2 on the PECM is the right oven heater (ALH2, ABH2). 3. Left DPM: 3.1. TCD: No temperature control channels. 3.2. FID/FPD: Channel 1 is detector heater (LWH1). Channel 2 is unused. Add Methanator: Channel 2 of the FID/FPD (LWH4).
4. Center DPM: 4.1. TCD: No temperature control channels. 4.2. FID/FPD: Channel 1 is detector heater (LWH2). Channel 2 is unused. Add Methanator: Channel 2 of the FID/FPD (LWH4 or LWH5). 4.3. Temp controller (split oven only): Channel 1 and 2 are unused
5. Right DPM: 5.1. TCD: No temperature control channels. 5.2. FID/FPD: Channel 1 is detector heater (LWH3). Channel 2 is unused. Add Methanator: Channel 2 of the FID/FPD (LWH4 or LWH5). 5.3. Temp controller: Channel 1 and 2 are unused. (LWH3 & LWH6)
6. Dummy TL/OT PCBA for any unused channel: For any unused temperature channel SAA P/N 2021715-005 12.4K TL/OT PCBA should be installed.
D11709 Rev AK
Kesselhuth
Page 3 of 3
