Siemens Applied Automation

Advance Maxum
Automatic Purge Unit

First Printing – November 1999 Installation Manual

2000586-001
 Copyright Notice
 1999 by Siemens Applied Automation
Bartlesville, Oklahoma, 74003, U.S.A.

All rights reserved.

This publication is for information only. The contents are subject to change without notice and should not
be construed as a commitment, representation, warranty, or guarantee of any method, product, or device
by Siemens Applied Automation.

Reproduction or translation of any part of this publication beyond that permitted by Sections 107 and 109
of the United States Copyright Act without the written consent of the copyright owner is unlawful.

Inquiries regarding this manual should be addressed to:

Siemens Applied Automation
500 W. Highway 60
Bartlesville, Oklahoma, 74003, U.S.A.
 Table of Contents

Preface iii
Safety Practices & Precautions v

Chapter 1 Automatic Purge Unit 1

Introduction 1
System Description 2
System Components 3

Chapter 2 Installation 7
Overview 7
Pre Installation Notes 8
AC Power Requirements 12
Installing Primary AC Power 13
Installing Purge Air Supply 17
Troubleshooting 21

Chapter 3 Maintenance 25
Overview 25
Maintenance Procedures 26

Chapter 4 Parts Catalog 29

Introduction 29
Available Parts 30

Chapter 5 APU Drawings 31

Overview 31

2000586-001 Table of Contents • i/ii

 Preface

Audience & Purpose This manual is intended to introduce users to the Advance Maxum
Automatic Purge Unit (APU). The manual includes complete instructions
for safe installation and use of the APU.

Chapter Highlights This Chapter covers the following topics:

Topic Page
Automatic Purge Unit 1
Installation 7
Maintenance 25
Parts Catalog 29
APU Drawings 31

2000586-001 Preface • iii/iv

 Safety Practices and Precautions

Safety First This product has been designed and tested in accordance with the Euro-
pean Standard EN61010-1/A2 Safety Requirements for electrical equip-
ment for measurement, control and laboratory use, and has been sup-
plied in a safe condition. This manual contains information and warnings
that have to be followed by the user to ensure safe operation and to re-
tain the product in a safe condition.

Terms in This Manual WARNING statements identify conditions or practices that could result in
personal injury or loss of life.

CAUTION statements identify conditions or practices that could result in

damage to the equipment or other property.

Terms as Marked on DANGER indicates a personal injury hazard immediately accessible as

one reads the markings.
Equipment
CAUTION indicates a personal injury hazard not immediately accessible
as one reads the markings, or a hazard to property, including the equip-
ment itself.

Symbols in This This symbol indicates where applicable cautionary or other

Manual information is to be found.

Symbols Marked on DANGER - High voltage

Equipment
Protective ground (earth) terminal

ATTENTION - Refer to Manual

Grounding the A grounding conductor should be connected to the grounding terminal

before any other connections are made.
Product

2000586-001 Safety Practices and Precautions • v

Safety Practices and Precautions, Continued

Correct Operating Before switching on the power, check that the operating voltage listed on
the equipment agrees with the available line voltage.
Voltage

Danger Arising From Any interruption of the grounding conductor inside or outside the equip-
Loss of Ground ment or loose connection of the grounding conductor can result in a dan-
gerous unit. Intentional interruption of the grounding conductor is not
permitted.

Safe Equipment If it is determined that the equipment can not be operated safely, it
should be taken out of operation and secured against unintentional us-
age.

Use the Proper Fuse To avoid fire hazard, use only a fuse of the correct type, voltage rating
and current rating as specified in the parts list for your product. Use of
repaired fuses or short circuiting of the fuse switch is not permitted.

Safety Guidelines DO NOT open the equipment to perform any adjustments, measure-
ments, maintenance, parts replacement or repairs until all power sup-
plies have been disconnected.

Only a properly trained technician should work on any equipment with

power still applied.

When opening covers or removing parts, exercise extreme care since

"live parts or connections can be exposed".

Capacitors in the equipment can retain their charge even after the unit
has been disconnected from all power supplies.

vi • Safety Practices and Precautions 2000586-001

 Chapter 1
Automatic Purge Unit
Introduction

Description The Advance Maxum Automatic Purge Unit (APU) is manufactured by

Expo-Telektron Safety Systems Ltd. The APU is designed to be used as
part of the Advance Maxum system to automatically control purge/
pressurization/dilution of the Electronic Controller (EC) in hazardous ar-
eas. The pneumatically operated APU purges the interior of the EC then
pressurizes it with a continuous flow of clean contaminate free air. Purg-
ing occurs when the input high airflow rate is sufficient to remove any
flammable gasses that may have entered the EC while it was in a non-
pressurized state.

APU

Figure 1-1 APU Mounted to Advance Maxum Electronic Controller

Chapter Highlights This Chapter covers the following topics:

Topic Page
System Description 2
System Components 3

2000586-001 Automatic Purge Unit • 1

System Description

Operation The APU purges the Maxum’s Electronic Controller (EC) with a volume
of air at a high flow rate sufficient to remove any flammable gas that may
have entered the non pressurized EC. Power is returned to the system
only after the purging has been completed.

After purging has been completed the high purge flow rate is shut off and
the system changes to a continuous flow mode. At this time the flow of
air is reduced to the point where it is sufficient to compensate for any
leakage taking place from the pressurized EC or from the containment
system.

See System Components (page 3) for an operational description of the

major circuits.

Front Panel Lamps The Operator Control Panel includes two status lamps;

Alarm/Pressurized Lamp (two state indicator Red and Green)

Red - Pressure Alarm. When illuminated, internal Electronic Controller

pressure is too low.

Green - Pressurized. When illuminated, interior of Electronic Controller is

pressurized.

System Purging Lamp (two state indicator Black and Amber)

Black - Purge flow is too low or the unit is not in purge mode. This occurs
during normal operation of pressurized Electronic Controller after purge
is complete.

Amber – System is in purge cycle.

Manual Override Key A front panel key operated manual override switch allows maintenance
personnel to defeat the system and its interlocks. The override should
only be used when both the interior and the exterior of the EC are known
to be non hazardous.

Certification The APU is certified to European Standards using types of protection p,

d, e, and m. APU installation shall conform to local codes.

2 • Automatic Purge Unit 2000586-001

System Components

Description This Section presents the user with descriptive information on compo-
nents that makeup the Automatic Purge Unit (APU) and how they inter-
act with the other purge components. Refer to Chapter 5. APU Drawings,
for component locations and mounting.

The APU is mounted to the analyzer and consists of two compartments.

The main operating pneumatics and other control components are lo-
cated in the right compartment. The “interface section” is located in the
left compartment and contains the power entry and I/O signal relay mod-
ules. An APU (depending upon application) can have up to four I/O relay
modules.

“Interface Section”
Power Entry & “Pneumatics Section”
Signal Modules Regulators & Manifold
Components

Logic Pressure The Logic Pressure Regulator provides a stable logic operational APU
pressure supply. Logic pressure level is factory set; however, it can be
Regulator
verified using a pressure gauge. Logic pressure should only be adjusted
if the gauge indicates that regulated pressure is inaccurate. Refer to Ap-
plication Drawing Package that came with your system.

Manifold Most of the APU Manifold logic components are located on a pneumatic
printed circuit board. The manifold provides internal passageways that
interconnect APU components to non-manifold components. The Mani-
fold includes the following major components:

Minimum Pressure The Minimum Pressure Sensor continuously monitors the internal Elec-
Sensor tronic Controller (EC) pressure. When the EC internal pressure is above
the minimum for safe operation, the Pressure Sensor provides a pres-
surized output signal. The operator can observe the output signal by the
Control Panel red/green visual indicator.

The Pressure Sensor is calibrated at the factory to operate on a de-

creasing pressure at or above the minimum specified pressure.

2000586-001 Automatic Purge Unit • 3

System Components, Continued

Purge Flow Sensor The Purge Flow Sensor monitors the purge flow through Purge Output/
Pressure Relief Valve. When purge flow is above minimum purge flow,
as specified by correct purging, the Purge Flow Sensor generates a
purging output signal. The operator can observe the output signal by the
Control Panel black/amber visual indicator.

The Purge Flow Sensor has been calibrated at the factory to operate on
a decreasing flow rate at or above the minimum specified purge flow
rate.

Purge Timer Valve When the Electronic Controller purge pressure is correct and purge flow
occurs, a signal is sent to the Purge Time Valve to start timing cycle. The
signal is sent through a dedicated in-line mini-filter to a ruby flow restric-
tor. Bleeding air is collected by the calibrated reservoir where purge
pressure gradually increases.

Also connected to the reservoir is a Timer Valve pilot port. The valve
provides a signal to the Purge Complete Valve after the preset purge
time has elapsed and when the reservoir pressure equals the Timer
Valve operating pressure. The purge time is factory set and should not
be adjusted.

Purge Complete Valve The Purge Complete Valve receives a Purge Timer Signal when the
purge time has been completed and checks that a pressurized signal is
present. When both conditions are satisfied, a purge complete output
signal is generated that performs the following functions:

Turns ON the Electronic Controller electrical supply.

Turns OFF high purge flow and starts leakage compensation mode and

Provides hold-on signal that maintains system in this mode with power
switch ON. This occurs even when Purge Timer has reset and is ready
for the next purge cycle to start.

Alarm Only Circuit The Alarm Only Circuit cuts-off Electronic Controller electrical power if
the internal pressure is too low.

"OR" Gate The "OR" gate places the Purge Complete Valve in an active state.
When either the time-out signal or purge complete signal is present it
allows the pilot signal to be applied to the Purge Complete Valve.

4 • Automatic Purge Unit 2000586-001

System Components, Continued

Power Switch The Manifold mounted Power Switch contains the pneumatic actuating
piston. The Power Switch cable is terminated in the APU Junction Box.

Alarm Pressure Switch The Alarm Pressure Switch is controlled by the pressurized signal and
provides the control signal for the front panel status indicators.

Purge Air Inlet Valve The Purge Air Inlet Valve allows purge air to flow to the pressurized
Electronic Controller (EC). It also allows sufficient purge air to flow into
the EC during purging cycle. The air flow rate during the purging is de-
termined by the pressure range of the air supply, the purging outlet flow
rate and the expected leakage rate from the pressurized EC.

When the purging cycle completes the purge airflow is stopped. The
purge cycle then waits in the closed state until the next purge cycle.

Purge Outlet/ The Purge Outlet/Pressure Relief Valve performs the following functions:
Pressure Relief Valve
The valve is calibrated to open when the pressure within the pressurized
Electronic Controller exceeds its setpoint. During normal operation this
will occur each time the EC is purged.

The valve is sized so that when the air supply pressure rises to the
specified maximum, the valve decreases the internal EC pressure. This
pressure will not exceed the specified maximum working pressure.

This valve incorporates a Spark Arrestor that prevents emission of arcs,

sparks and incandescent particles.

When the correct purging airflow is occurring, the Spark Arrestor back-
pressure is noted and the results are used to calibrate the Purge Flow
Sensor. The Spark Arrestor must be kept clean and free of foreign con-
taminants to insure accurate APU calibration.

2000586-001 Automatic Purge Unit • 5

 Chapter 2
Installation
Overview

Description This Chapter is intended for installation personnel.

The Advance Maxum Automatic Purge Unit is factory installed to the Ad-
vance Maxum Gas Chromatograph Electronic Controller (EC). All inter-
face-wiring connections between the EC and the APU have also been
factory wired. This chapter provides information on installing the input AC
power and the external air supply lines to the Automatic Purge Unit
(APU).

Chapter Highlights This Chapter covers the following topics:

Topic Page
Overview 7

Pre Installation Notes 8

Field Wiring Requirements 10

AC Power Requirements 12

Installing Primary AC Power 13

Installing Purge Air Supply 17

I/O Signal Wiring 20

Troubleshooting 21

2000586-001 Installation • 7
Pre Installation Notes

Description Before proceeding with the installation carefully review the following in-
formation.

The Application Drawing Package that accompanies the Advance

Application Drawing Maxum Gas Chromatograph, contains schematics and assembly draw-
Package ings on how the customers APU and Advance Maxum Gas Chromato-
graph are interfaced together.

Air System The operation of the APU pneumatic system can be affected by the pre-
science of water or oil and dirt contamination in the air supply. It is im-
portant that the APU air supply system be equipped with a dust and wa-
ter filter. Equipping the system with these components is the customer's
responsibility.

Installation Site It is important that the surrounding area of APU installation be clean and
free of foreign contamination.

Reference Installation For installation information applicable to the Advance Maxum Gas
Chromatograph, refer to associated manual 2000582-001.
Manual

AC Power (Mains) Primary AC (mains) input to the Maxum is made directly to the APU in-
terface unit. The isolation of the AC power from the Electronic Controller
Input
is controlled from the APU by a Purge Complete pneumatic signal to op-
erate a power switch. There are no valves connected between the Power
switch and the APU other than the Manual Override circuit. The AC is
factory wired from the APU to the Maxum Power Entry Control Module
(PECM) terminal bus TB1. Refer to the Application Drawing Package,
Block & Utility Sheet 2.1 for a schematic of the wiring that applies for
your system.

Multiple Installed More than one Advance Maxum Electronic Controller can be protected
by a single APU. If the EC’s are connected and purged in series (daisy
EC’s
chained) the relief valve should be fitted on the last EC with the purge
inlet to the first Controller. The bore and length of the conduit used to
interconnect the EC’s is critical and will determine the maximum pres-
sure experienced by the first EC in the series.

If EC’s are to be connected in parallel each EC must have its own outlet
relief valve, purge flow sensor and pressure sensor.

8 • Installation 2000586-001
Pre Installation Notes, Continued

External Alarm The APU uses a minimum pressure sensor that is set to a minimum set-
point pressure of 0.5mb. When APU pressure is above the setpoint pres-
Devices
sure, a positive pressurized signal is generated. The pressurized signal
can be displayed on a system-installed indicator. It can also be used with
an external alarm or used to operate an integral EX alarm switch.

When the EC internal pressure falls below the sensor pressure setpoint,
the pressurized signal is removed. Absence of the sensor setpoint signal
indicates a low-pressure alarm condition. When an alarm occurs, the
operator must follow procedures in the codes for the area of installation.
Codes include the following Zone 1 and Zone 2 installation recommen-
dations.

Spark Arrestor The interior and exterior of Spark Arrestor must be kept clean and free of
foreign contaminants to insure accurate APU calibration.

CAUTION The spark arrestor must not be painted or blocked for any reason.
There must be an air gap of at least ½-inch (12mm) between spark
arrestor outlet and any obstruction that would impede purging air-
flow.

2000586-001 Installation • 9
Field Wiring Requirements

Description This section provides installation personnel with field wiring instructions
for the Advance Maxum Automatic Purge Unit (APU). These instructions
comply with CE (Conformite Europeene) ceritification requirements.

Important Read this section before performing any power or I/O wiring task.

Instructions All power and I/O wiring is terminated in the Advance Maxum Purge Unit
(APU) which is mounted to the Advance Maxum Electronic Controller.
Special parts referenced in this section are contained in the Siemens
Applied Automation CE Installation Kit, P/N 2020264-001.

Installation with steel The preferred wiring method is to route the field wiring in steel conduit. If
conduit steel conduit is used the power wires and the Ethernet wires can be un-
shielded. The power wiring, signal wiring, Ethernet and Data Hiway ca-
bles must be routed in separate conduit.

If you use flexible conduit and/or armored cable is equivalent to using

“steel conduit”. Flexible conduit or armored cable must have its flexible
conduit and/or armoring conductivity 360 degrees terminated at its entry
to the APU case.

All DO lines with inductive loads must have transient suppression at the
inductive load.

The user shall determine whether the Heavy Industrial Conducted Im-
munity requirements are pertinent to their site location and application. If
required, all AO lines must be terminated in a load that is CE/EMC certi-
fied to meet those requirements. All other CE requirements can be met
using acceptable electrical termination practices.

10 • Installation 2000586-001
Field Wiring Requirements, Continued

Installation without steel If conduit is not used, the following installation practices must used to
conduit ensure that the CE certification remains valid:

1. A shielded power cord or cable must be used to supply the input.

The shield must be terminated in a 360-degree termination at the
APU case (bulkhead); use Siemens AAI P/N 2015729-001 contained
in the CE Installation Kit or an equivalent part.

2. The power cord or cable must have split ferrite clamped on it and
fixed to the outside of the APU; use an Siemens AAI part number
1263000-001 ferrite contained in CE Installation Kit or use a Fair-Rite
part number 04431164181split ferrite. A split ferrite is only used to
meet the Conducted Immunity requirement for CE/EMC Heavy In-
dustrial. All other CE/EMC Heavy Industrial requirements are met
without the use of a split ferrite.

3. The Data Hiway cables shields must be terminated in a 360-degree

termination at the APU case (bulkhead); use Siemens AAI P/N
2015729-001 contained CE Installation Kit or an equivalent part.

4. All Data Hiway cables must have split ferrite clamped to them and
then fixed to the outside of the APU; use Siemens AAI part number
1173000-013 ferrite contained in CE Installation Kit or use Steward
part number 28B22024 or Fair-Rite part number 4431164181 split
ferrite. The split ferrite clamp is only used to meet the Conducted
Immunity requirement for CE/EMC Heavy Industrial. All other
CE/EMC Heavy Industrial requirements are met without the use of a
split ferrite.

5. The I/O cable(s) must have all shield(s) terminated in 360-degree

termination at the APU case (bulkhead); Siemens use AAI P/N
2015729-001 contained in CE Installation Kit or an equivalent part.

6. All Ethernet connections (inside and outside) must use shielded

Ethernet cable. The cable must be coupled through the APU using a
shielded RJ-45 coupler; use Siemens AAI part number 1183200-003
contained in CE Installation Kit. The installation kit is not required if a
PG gland is used to make a 360-degree termination.

Important The installer must determine whether the Heavy Industrial Conducted
Immunity requirement is pertinent to theirr site and application. If the re-
quirments are pertinent to the site then comply with steps 7 and 8 below.

7. All DO lines with inductive loads must have transient suppression at

the inductive load.

8. All AO lines must be terminated in a load that is CE/EMC ceritified to

meet the Heavy Industrial Conducted Immunity requirements.

2000586-001 Installation • 11
AC Power Requirements

Description It is the customer's responsibility to provide and install primary AC power

wiring, circuit breaker and conduit to the Advance Maxum.

Important Installation of primary AC power wiring must meet all electrical codes
and certification requirements for the area of installation. Read the Field
Wiring Requirements section before performing any power or I/O wiring
task.

Primary AC Power The Advance Maxum Gas Chromatograph operates from 100-130 VAC
or 195-260 VAC 47-63Hz, single phase. Input power is switch selectable
from the Electronic Controller installed Power Supply.

Fuses are located on the Power Entry Control Module located on the left
Fuses side wall of the Electronic Controller. Fuse requirements are:

F1-ABH2: 16 Amperes, 115 VAC or 10 Amperes, 230 VAC

F2-ABH1: 16 Amperes, 115 VAC or 10 Amperes, 230 VAC
F3-FLT AC: 3 Amperes 115 VAC or 230 VAC
F4-LWH: 10 Amperes 115 VAC or 230 VAC.

Power Consumption Maximum power consumption for the analyzer is 1700 watts during
warm-up, and averages 500 to 700 watts during operation. In addition, a
sampling system with a heated cabinet can consume from 30 to 2000
watts, depending upon its particular arrangement. Refer to the "General
Notes" on sheet 2.1 Block & Utility Diagram of the Application Drawing
Package for your specific voltage and total power requirements (the
wattage for the sampling system, if required, will also be given).

Installation of The following customer provided components are required for installation
of primary AC power. Each component is described in the following sec-
Components
tions.

Primary AC Wire Size Customer AC power wiring must be three wire 12 gauge with a hot, neu-
tral ground.

Circuit Breaker The explosion proof circuit breaker should be a single-pole type rated for
20 Ampere service and be equipped with a shut-off handle. The circuit
breaker must be installed in close proximity to the analyzer so it is easily
accessible to the operator for turning power off to perform maintenance
functions or for safety purposes.

12 • Installation 2000586-001
Installing Primary AC Power

Instructions The AC power input (Mains) can be either 115 VAC or 230 VAC. Refer to
the Block and Utility Diagram contained in the Application Drawing pack-
age for your specific requirements. The primary AC (Mains) power is
routed to the Advance Maxum through the APU side or top cover. The
APU top cover is punched with two 1-inch holes to accommodate pipe or
cable gland connectors.

Important Installation of primary AC power wiring must meet all electrical codes
and certification requirements for the area of installation. Read the Field
Wiring Requirements section before performing any power or I/O wiring
task.

Power Connections The AC input power connection is made to the green INPUT connector
located inside the APU Interface Unit; see Figure 2-1. The connector has
two circuits L1 & L2 and L3 & L4. The bottom OUTPUT connector (which
corresponds to the Input connections) is factory wired to the Electronic
Controller Power Entry Control Module (PECM). The Application Drawing
Package Block & Utility Diagram Sheet 2.1 shows which connections are
used.

AC Input

AC Output

Figure 2-1. AC Power Entry to the APU Input Connector.

Warning Installation personnel shall adhere to all power specification re-

quirements; see AC Power Requirements, and to the Block & Utility,
Diagram Sheet 2.1, in the Application Drawing package. Failure to
do so, and operating the equipment in a manner not specified, can
impair the safety protection provided by the equipment.

2000586-001 Installation • 13
Installing Primary AC Power, Continued

Installation To install primary AC wiring, perform the following procedures:

Procedures
Step Procedure
1. Shut off the primary AC Power Supply line to this location.

2. Loosen the four fasteners securing the APU interface cover to

the unit and remove the cover.

3. Install circuit breaker and primary AC wiring for the area of

installation. Label the Breaker to make sure that the circuit is
clearly identifiable. See Application Drawing Package Block &
Utility Diagram Sheet 2.1 for Power Requirements.

4. Run the 12 gauge AC wiring through a cable gland or conduit

(per local codes) to the APU Interface interior. Allow enough
extra cable to be run into the interior to be certain it reaches
the INPUT Connector. There should be enough extra cable so
that when terminations are made, there will be no sharp cable
bends.

INPUT
Connector

14 • Installation 2000586-001
Installing Primary AC Power, Continued

Step Procedure

5. Remove approximately 3 in. of outer insulation from input AC

power cable.

6. Remove approximately ½ in. of insulation from the hot, neutral

and ground wires.

7. Refer to the Application Drawing Package, Block & Utility

Sheet 2.1 for which of the INPUT connector circuits to wire to;
L1(H) & L2(N) or L3(H) & L4(N).

8. Loosen, but do not remove, the fastening screws on the

INPUT connector to where the Hot and Neutral will be termi-
nated; reference step 7 above.

9. Insert the Neutral wire into INPUT connector N terminal and

securely tighten the fastening screw; reference step 7 above.

Insert the Hot wire into INPUT connector H terminal and se-
curely tighten the fastening screw.

Connect the ground wire to the ground terminal.

Ground Terminal

2000586-001 Installation • 15
Installing Primary AC Power, Continued

Step Procedure
10. Using a 4 mm Allen wrench open the front door of the Elec-
tronic Controller.

11. Refer to Application Drawing Package, Block & Utility Sheet

2.1 and ensure that the OUTPUT connector is wired correctly
to the Power Entry Control Module.

12. Verify that Advance Maxum Gas Chromatograph power sup-

ply switch is set to the correct VAC. It must be set to the pri-
mary AC (Mains) power input voltage.

13. Recheck all connections for tightness and shorts.

14. Plug in power cable from Power Entry Control Module to

Power Supply.

15. Verify that the correct fuses are in place. Fuses are located on
the Power Entry Control Module. Fuse requirements are:

F1-ABH2: 16 Amperes, 115 VAC or 10 Amperes, 230 VAC

F2-ABH1: 16 Amperes, 115 VAC or 10 Amperes, 230 VAC
F3-FLT AC: 3 Amperes 115 VAC or 230 VAC
F4-LWH: 10 Amperes 115 VAC or 230 VAC

Caution DO NOT apply power to the unit until all circuits have been checked
and that the proper fuses are in place.

16 • Installation 2000586-001
Installing Purge Air Supply

Air Supply The APU input air supply must be clean and not be contaminated with
any flammable gas. A customer supplied shut-off valve must be installed
on the air/inert gas supply source outlet connection.

Using a purge gas other than “air” can fill up an area and cause
Warning death to personnel in the area.

The external compressed air or inert gas supply source shall be

installed in a non-hazardous location, and the suction designed to
prevent leaks which can cause hazardous gases or vapors to be
drawn into the compressor.

Air Pressure The main air/inert gas supply pressure must meet the system specifica-
Specifications tions of 3 bar (45 lbs per sq. inch); refer to the Block and Utility Diagram
contained in the Application Drawing package for your specific require-
ments.

Air Supply Filtration A customer supplied 40-micron air filter shall be installed on the air sup-
ply source. The filter removes any solid particles and liquids, which could
enter the system. If necessary, additional filtration can be provided up-
stream from the Analyzer input air supply source. The installation site will
dictate the amount of air filtration needed.

Supply Line The APU is equipped with a regulator and gauge that allows input air
supply pressure to be monitored and controlled. Air supply pressure to
Regulator and Gauge
the APU circuits must be regulated to be within 2 bars and 2.2 bars (30
psi to 32 psi).

Inlet air/inert gas supply pressure must not exceed the 3 bars and
Warning 3.2 bars (45 psi to 48 psi) limits. The correct inlet supply pressure is
important to system reliability and calibration.

External Piping Piping that connects the external air supply to APU must meet the codes,
practices and specifications for the area of installation. If unsure of the
specifications, refer to the agency responsible for determining the speci-
fications. External tubing or piping must be 1/4" and meet MPTF stan-
dards.

2000586-001 Installation • 17
Installing Purge Air Supply, Continued

Instructions The following procedure should be performed after completing the wiring
and checkout of the AC Power to the system. If you account any prob-
lems refer to the troubleshooting section page 21.

Step Procedure
1. Connect the air supply to the purge air inlet. The purge air
inlet input is located on the lower part of the unit below the
Interface Unit.

Purge Air
Inlet

2. Adjust the air supply pressure between 3 and 3.2 bars (45 psi
and 48 psi).

3. Open the Electronic Controller door.

4. Ensure that primary AC power to system is on.

5. Turn front panel key switch to maintenance mode.

18 • Installation 2000586-001
Installing Purge Air Supply, Continued

Step Procedure
6. Adjust the APU input regulator for a gauge reading between 2
bars and 2.2 bars (30 psi to 32 psi).

APU Air
Input
Adjustment
& Gauge

7. Observe that the front panel Alarm/Pressurized indicator is

green and the System Purging indicator is amber.

If the System Purging amber lamp is black, the purge airflow

through the Pressure Relief valve is below minimum for which
the purge flow sensor has been calibrated. Check the air inlet
supply pressure is within the 3 bars and 3.2 bars (45 psi to 48
psi) limits while purging is occurring.

8. Close the Electronic Controller door.

9. Turn front panel key switch to Normal.

10. Pressurizing and purging of the Electronic Controller is now

automatic. To stop or start purging of system, turn the air
supply on or off.

2000586-001 Installation • 19
I/O Signal Wiring

Description The APU is divided into two sections. The main operating pneumatics
and other control components are located in the right compartment. The
“interface section” is located in the left compartment. It contains the
power entry and I/O signal relay modules. An APU (depending upon ap-
plication) can have up to four I/O relays.

“Interface Section” “Pneumatics Section”

Power Entry & Regulators &
Signal Modules Manifold
Components

Instructions The field installer makes all I/O signal wiring connections to the signal
modules in the interface section. The signal modules outputs are factory
wired to the I/O boards in the Electronic Controller of the chromatograph.
The Application Drawing Package Block & Utility Diagram Sheet 2.1 de-
fines the connections for your application. A schematic diagram of the
signal modules can be seen in Chapter 4.0, Drawings.

Important All I/O wiring must meet all electrical codes and certification require-
ments for the area of installation. Read the Field Wiring Requirements
section before making any Analog or Digial I/O connections, Ethernet
connctions or Data Hiway cable connections.

20 • Installation 2000586-001
Troubleshooting

Description This section contains information on specific faults and how to correct
them.

APU Drawings and Drawings and schematics for the APU can be found in Chapter 4.0.
Schematics

Testing Components Many APU components are plug-in or Manifold mounted. To check if a
component is defective, substitute the suspected defective component
with a known good part. If the APU is under warranty, return the defec-
tive part for replacement to Siemens Applied Automation. A written
fault report, APU serial number should accompany the defective part.

Before You Start Before performing any checks be certain the pressure from both the pri-
mary air supply source and the regulated pressure are inputting the cor-
rect pressure. Refer to the Application Drawing Package provided with
the system.

Cause Correction
System Purges 1. Electronic Controller (EC) Enclosure Fault
Correctly But Alarm
• With a manometer or gauge, check to see if actual EC
Comes On at End
enclosure pressure is below the setting of Minimum
of Purge Time and
Pressure Sensor.
Purging Cycle is
Repeated • Is there debris on Relief Valve Disk face? It could be on
disk face by magnetism.
• Is EC enclosure door closed and all conduit and cable
connectors sealed?
• Is there too much leakage in EC?
• Is pressure sensing tube damaged or leaking?

2. System Fault
• If conditions in Cause 1 indicates the EC enclosure is
OK, the fault is probably the Control Unit.
• Check operation of Minimum Pressure Sensor by un-
screwing 60mm diameter diaphragm housing. Using your
finger, block the 12mm threaded hole in top of Sensor.
The Sensor should operate and Operator Control Panel
Alarm/Pressurized light should turn green. If this occurs,
it is likely Minimum Pressure Sensor diaphragm needs to
be re-calibrated or replaced.

2000586-001 Installation • 21
Troubleshooting, Continued

Fault Correction
Relief Valve 1. Dirty Pressure Relief Valve disk allowing valve air
Opens (con- leakage.
tinuously or
• Remove Pressure Relief Valve cover and clean valve
intermittently
disk. If it is necessary to remove Pressure Relief Valve
disk and spring draw a pencil line around valve. This al-
lows accurate replacement before removal. Misalignment
may cause opening pressure to be affected.

Purging Indi- 1. Insufficient purging airflow due to inadequate air

cator Will Not supply pressure.
Turn Amber
• Check air supply pressure at inlet to APU during purging.
During Purg-
Excessive pressure drop in supply pipe is the usual
ing
cause. Pipe bore must be at least as large as APU inlet
fitting.
2. Excessive Pressure Leakage in EC Enclosure
• When purging check EC enclosure seals for leakage.
Correct leakage.
• Perform a leakage test. Total leakage at Pressure Relief
Valve opening pressure should not exceed 10% of Purge
Flow Sensor setting.
• Check for leakage around cables and conduit connec-
tions.
3. Tubing from Pressure Relief Valve Flow Sensing
Point to Purge Flow Sensor (13) is not Air Tight

• Fitting nuts not tightened or tube damaged. Check and

repair defective part.

4. Purge Flow Sensor is not Operating Correctly or is

Out of Calibration
• Check operation of Purge Flow Sensor. Unscrew sensor
60mm diameter diaphragm housing and using your fin-
ger; block the 12mm threaded hole in the top of sensor.
Valve should operate and the System Purging indicator
should show amber.
If this occurs, the Sensor diaphragm must be calibrated
or replaced; see page 24 for calibration.

22 • Installation 2000586-001
Troubleshooting, Continued

Cause Correction
System Fails to 1. AC Power Fault
Switch Power
• Check that AC primary power is on
On After Purge
Time has • Check that the power isolator is closed
Elapsed
• Check all fuses and circuit breakers
. 2. System fault or Timer Not Timed Out
• Is the Purging indicator showing amber for the entire
purge cycle?
• Verify that the logic pressure gauge is correctly set.

3. System fault or Timer Not Timed Out

• Timer setting may be reduced for test purposes by
pinching the reservoir connected tubing. Use only a tub-
ing clamp or smooth jawed pliers. DO NOT PUNCTURE
TUBING. New time will be approximately less than 1 mi-
nute.
• Check operation of new purge time to be certain it func-
tions correctly. Remove clamp and retest. If system does
not time out, there is a reservoir air leak. Use soap water
to detect the leak then perform corrective maintenance.
• Recheck Purge Timer Valve at its full setting.

. 4. Faulty Power Switch

• Check operation of Power Switch.

2000586-001 Installation • 23
Troubleshooting, Continued

Pressure Sensor Perform the following steps to calibrate the Minimum Pressure Sensor or
Purge Flow Sensor.
Calibration
1. Disconnect pressure-sensing tubing from top of diaphragm. It is a
push-in quick release fitting. Firmly push inward while maintaining
pressure on the collar.

2. Unscrew the 60mm diameter diaphragm from top of Minimum

Pressure Sensor.
3. Invert Sensor and observe the brass adjusting screw in center of
Sensor.
4. Turn screw inwards (CW) to lower the setting. Screw may be tight
due to locking sealant. If screw can not be moved, apply small
amount of heat to brass screw. DO NOT OVERHEAT.

24 • Installation 2000586-001
 Chapter 3
Maintenance
Overview

Description Procedures in this chapter are for use by maintenance personnel.

How to Use this Perform all recommended procedures as presented in this Chapter. If
through use, additional procedures are developed, they should be in-
Chapter
cluded with those in existence.

Practical experience permits updating maintenance procedures and as-

sociated schedules over time. This results in many procedures being
performed on a routine basis before potential problem(s) result in failure.

Safety First When performing maintenance procedures in this chapter observe all
warnings, cautions and notes to prevent physical injury to your self or
unnecessary damage to the equipment

Chapter Highlights This Chapter covers the following topics:

Topic Page
Overview 25

Maintenance Procedures 26

2000586-001 Maintenance • 25
Maintenance Procedures

Description It is important that preventative maintenance schedule be established to

examine the APU for internal and external cleanliness and damage.

Even though the APU is tightly sealed against moisture and foreign con-
tamination, it is recommended that the unit is examined and interior be
inspected for moisture and/or contamination. If contamination is found,
the APU should be shutdown and cleaned. If such contamination is not
removed, it could render the APU inoperable.

WARNING Obtain a Hot Work Permit and observe all plant safety requirements
before opening the equipment. Prior to removing any covers turn-
off the primary AC (Mains) Power to the APU at the primary power
circuit breaker

26 • Maintenance 2000586-001
Maintenance Procedures, Continued

6-Month Maintenance It is recommended that the following procedures be performed every 6-

months:

Procedures Step Procedure

1. Check Pressure Relief Valve and Spark Arrestor. Remove any
debris or foreign contamination from components. If necessary,
replace defective component.
Important
The interior and exterior of Spark Arrestor must be kept clean
and free of foreign contaminants to insure accurate APU cali-
bration.

CAUTION
The Spark arrestor must not be painted or blocked for any
reason. There must be an air gap of at least 1/2" (12mm)
between spark arrestor outlet and any obstruction that
would impede purging airflow.

2. Check condition of the air supply filter. If the element impedes

airflow replace element.

2-Year Maintenance It is recommended that the following procedures be performed every two
years:

Procedures Step Procedure

1. APU is suitable for the hazardous area of installation.

2. No un-authorized modifications have been made to the APU.

3. Air supply source is not contaminated.

4. Interlocks and alarms function as designed.

5. Certification identifications are legible and undamaged.

6, Adequate supply of spare parts is maintained on site.

7. Purge relay pressure activation is correct.

2000586-001 Maintenance • 27
 Chapter 4
Parts Catalog
Introduction

Overview This Chapter is intended for maintenance personnel.

This Chapter provides a list of replaceable parts and assemblies for the
Advance Maxum Automatic Purge Unit (APU).

How to Place an Parts can be ordered from:

Order
Siemens Applied Automation.
Customer Service Order Entry
500 W. Highway 60
Bartlesville, Oklahoma 74003
Inside Oklahoma: 918-662-7370
Outside Oklahoma: 800-448-8224 (toll free)
Internationally: 001-918-662-7370

To ensure an immediate response to your request, you should provide

the following:

• Purchase order number. If ordering by phone, a confirming P.O.

should be sent.

• Address where the parts are to be shipped.

• Address where the invoice is to be sent.

• Siemens Applied Automation part numbers as listed.

• Quantity needed of each part.

• Equipment Serial number or project number of the system (espe-

cially for warranty related orders).

• Preferred method of shipment.

2000586-001 Parts Catalog • 29

Available Parts

Description The available APU assemblies and parts, with their applicable part num-
ber are shown below.

Part Description Ordering Number

Timer Restrictor 1255001-032

Flow Sensor 1255001-033

Minimum Pressure Sensor 1255001-034

Timer Valve 1672009-007

Inline Filter 1282001-010

Non Return Valve 1672009-008

Indicator, Alarm/Pressurized 1422000-006

Indicator, Purge 1422000-007

Pneumatic OR Gate 1460700-002

Pneumatic YES Gate 1460700-003

Regulator, R06, 0-7 Bar 1461000-024

Limit Switch EExd w/Cable 1333011-004

Relay, Module EEx em, 4-Pole N/O (Power) 1517000-004

Relay, Module EEx em, 8-Pole N/O (Signal) 1517000-003

CE Installation Kit; Consists of: 2020264-001

• EMI Grounded Cable Fitting Kit, ½-inch Conduit

• Filter, Ferrite, Split Core, Round Cable, 31 MTL
• Coupler, RJ-45 (8x8),Screen, Shld
• Coupler Plate, Gateway
• Filter, Ferrite , Split Core for Round Cable
• Cable, 10baseT, Cat5, shld, 2-Foot., Rj45, M-M
• Housing, Ethernet EMC
• Cover, Ethernet EMC
• Washer M3, Helical Spring Lock ,SST
• Screw M3X, Socket Head Cap , SST

30 • Parts Catalog 2000586-001

 Chapter 5
APU Drawings
Overview

Description This Chapter presents engineering drawings for the Advance Maxum
Automatic Purge Unit

Drawings
APU General Arrangement

Interface Unit Component Layout

Pneumatic Section Component Connections

Manifold Assembly Component Locations

Sub-Minpurge Circuit Diagram

Interface Unit Circuit Diagram

Manual Override Switch and Interface Connector

Air Inlet Assembly

2000586-001 APU Drawings • 31

 Siemens Applied Automation
500 W. Highway 60, Bartlesville, OK 74003
Phone 918-662-7000, Fax 918-662-7052