Procedure to Upgrade from B&W Maintenance Panel to TIB Color Touchscreen Door in a Working Maxum or Maxum II Analyzer Equipped With a SYSCON2

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1 Procedure to Upgrade from B&W Maintenance Panel to TIB Color Touchscreen Door in a Working Maxum or Maxum II Analyzer Equipped With a SYSCON2 Difficulty Level: High Estimated time to execute: 3 Hours Revision History Issue Date Reason 000 5/21/2015 Initial release Copyright Siemens AG 2015 All rights reserved TIB Door Upgrade 1 IP-0028

2 Table of Contents 1.0 Description Prerequisites Software Upgrade Preparations Workstation Software Upgrade Steps Backup Information Replace the SIB2/CAC3 and the Door Assemblies Removing the Original Door and SYSCON Boards Installing the SYSCON2.1 and Color Touchscreen Door... 9 TIB Door Upgrade 2 IP-0028

3 1.0 Description The latest Color Touchscreen analyzer door is an integral assembly with the LCD, backlight, and Touch Interface Board (TIB). This is an intrinsically safe design when connected and grounded properly. The TIB door assembly is only compatible with the SYSCON2.1 with release 5.2 software. Therefore, earlier versions of these components must also be replaced. Figure 1. TIB Color Touchscreen Figure 2. TIB Door Assembly This document describes the procedure to upgrade the maintenance panel and SYSCON2 assembly on an existing Maxum or Maxum II analyzer to a TIB Color Touchscreen Display and a SYSCON2.1 with release 5.2 software. Note: This document is specific to Maxum II analyzers configured with a SYSCON2. For Maxum II analyzers configured with a SYSCON1/SYSCON+, see the appropriate procedure (IP-0027). TIB Door Upgrade 3 IP-0028

4 This procedure involves these major steps: 1. Backup the existing database 2. Replace the existing System Interface Board version 2 (SIB2) and CAC3 boards in the SYSCON cage assembly with a SIB3 and CAC3. 3. Replace the existing door assembly with the TIB door assembly 4. Verify operation This procedure involves replacement of the door and the circuit boards in the SYSCON cage. Two versions of the upgrade kit are available: For Maxum (Also called Advance Maxum or Maxum I):... A5E For Maxum II:... A5E Each door upgrade kit includes a door/display assembly and the two boards that make up the SYSCON2.1. The retrofit kit includes the following items. Description Quantity TIB Door assembly 1 System Interface Board (SIB3) with CAC3 mounting hardware 1 Control and Communication module version 3 (CAC3) 1 Workstation Software CD (current GCP 5.2 activation key required) 1 1 Note: The above lists are for reference only and is not intended to be all inclusive. For a complete list with part numbers, refer to the packing lists sent with the kits. Also required is a tool kit including both standard and metric wrenches, Hex wrenches, and nut drivers. A laptop computer with a COM port will be necessary for the upgrade as well. Warning: Full safety precautions must be followed throughout all sections of this procedure to prevent possible injury, equipment damage, or death. Verify that the area is clear of flammable gases and vapors and that appropriate authorization is obtained to do the work (hot work permits). 2.0 Prerequisites Caution: The SIB3 board, CAC3 board, and Ethernet Switch card can be damaged by electrostatic discharge (ESD). Take appropriate precautions when unpacking and handling these components to avoid ESD damage. Note: This procedure refers to other documents posted on the Siemens web site. Review this procedure and download any of these documents that may apply your installation before performing the work. 1 The latest patch, , must be downloaded from the Siemens support web site after installation. TIB Door Upgrade 4 IP-0028

5 This procedure must be performed by a user who has detailed knowledge of the Maxum analyzer. This includes detailed knowledge of the hardware, operation, and database setup of the device. In addition, the user should have sufficient computer skills to be able to install and operate the new software. If a customer does not have the knowledge required for this procedure, then it is recommended that Siemens Field Service personnel be contracted to assist. A tool kit including both standard and metric wrenches, Hex wrenches, and nut drivers is required to perform this procedure 3.0 Software Upgrade Preparations To prepare for the new hardware, software in the workstation and the SNECON must be up to date. The SYSCON 5.2 software to support the TIB door is preinstalled on the CAC3. A current GCP 5.2 activation key is required for the workstation. 3.1 Workstation Software Upgrade Steps This section covers upgrading of the Gas Chromatograph Portal (GCP) software to various workstations. This is required for proper communication with the version 5.2 Maxum II software. This section is not required if the software was installed previously. More information is available in the Gas Chromatograph Portal Help Manual, 05/2014, A5E at graph_portal_user_manual.pdf. 1. To upgrade the GCP software, insert the GCP installation CD. The installation program will launch automatically (if it does not run automatically, execute the setup.exe file on the CD). 2. Follow the directions given by the installation tool to upgrade to the new software. You may accept the defaults by clicking "Next" as needed in the installation windows. 3. Repeat the installation for all computers that you wish to upgrade. 3.2 Backup Information 1. Verify that hard copies of current chromatograms are available. This information will be used to verify the configuration and operation of the analyzer following the upgrade. Also verify that the IP addresses (IP address, IP mask, and router address) of the analyzer are recorded and available as they will be needed in order to configure the new SYSCON Place the analyzer in hold status and allow it to finish the current cycle. 3. Using GCP, save the analyzer's existing database to the hard drive of the Workstation. TIB Door Upgrade 5 IP-0028

6 a. From the Network Portal, select the line entry for the device and then click the Backup button at the top of the view. b. The "Save backup file as..." dialog box will appear. Type or select a name for the backup file in the File Name field. If the user does not identify a file extension, then the default extension of.amd will be used. c. Click the Save button in the dialog box to begin the backup. A progress dialog box will appear, showing the saving of the database to flash memory and then the saving of the file to the computer. When the backup is complete the progress box displays "Successful" and then closes. d. Click "OK" to close the progress box. Result: The.amd database file is saved to the hard drive of the PC. 4.0 Replace the SIB2/CAC3 and the Door Assemblies This section gives the steps to replace the SYSCON boards and HMI door with a SYSCON2.1 board set (SIB3 + CAC3) and color-touchscreen TIB door. NOTICE: Before undertaking this procedure make sure that the analyzer is powered down and disconnected from power-line (mains) voltage. 4.1 Removing the Original Door and SYSCON Boards 1. Unscrew the two nuts that secure the SYSCON2 tray, and pull the tray out to the dropped-down position as shown below. Figure 3. SYSCON Tray 2. If the analyzer is equipped with an HMI display, disconnect the HMI cable at the SYSCON end, from the back of the SYSCON2 board. Push the tabs at the sides of the black connector together as shown below to unlock the connector. TIB Door Upgrade 6 IP-0028

7 Clips Secured Clips Pressed to Remove 3. Disconnect the HMI cable from any clips that affix the cable to the EC. Leave the cable plugged into the HMI. 4. Disconnect the ESD ground wires on the door. If there are two green-with-yellowstripe wires on spade lugs near the top of the door, disconnect from the door. If there is a single flat green insulated braid, remove it entirely. 5. Remove the original door assembly by lifting it up off the EC hinge sockets. TIB Door Upgrade 7 IP-0028

8 6. One at a time, disconnect all other external cable connectors (both power and signal) that connect to the SYSCON board and cage. Label the cables with their connection points and functions as they are disconnected. See Figure 4. Figure 4. SYSCON2 (SIB2 with CAC3) Connections 7. Note: When disconnecting cables, disconnect the orange I/O connector blocks with the wires still attached. The blocks will connect into the new SIB3 board. It is very important that all I/O connectors are properly labeled to prevent them being reversed when connected into the SYSCON Make a note of which boards are located in which slots in the assembly tray. 9. Remove ESB 10. Remove I/O boards 11. Disconnect from the SIB2: a. I 2 C cables b. Purge cable c. Power cable d. Serial cables e. CAN bus cable if present TIB Door Upgrade 8 IP-0028

9 12. Remove 6 mounting screws from the locations shown in the illustration at right. Figure 5. SIB Mounting Screw Locations 13. Remove the SIB, rear edge first to pull the I/O connectors from the SYSCON cage opening. 4.2 Installing the SYSCON2.1 and Color Touchscreen Door CAUTION: To support backwards compatibility of peripheral boards, the board slots in the SYSCON2.1 are not keyed. In the following step DO NOT install any boards that are not approved for use by Siemens into the SYSCON2.1. Doing so may damage the board, the SYSCON2.1, or both. All boards received from Siemens for use with the SYSCON2 are approved for use with the SYSCON2.1. Boards not supplied by Siemens are not approved. Begin by installing the CAC3 on the SIB3. This is then defined as the SYSCON2.1. Note: Do not install the old CAC3 on the new SIB3. Use the new CAC3 board in the kit with the new SIB3. TIB Door Upgrade 9 IP-0028

10 Figure 6. Mounting the CAC3 on the SIB3 14. Carefully align the CAC3 connectors over the mating connectors of the SIB Press down to fully engage the connectors. 16. Install the 2mm screws with o-rings. Avoid overtightening. TIB Door Upgrade 10 IP-0028

11 17. Install the SYSCON2.1 in the SYSCON tray using the 6 screws removed earlier, shown in Figure Reinstall any extra boards that were installed in the SYSCON2 (I/O boards, ESB, or CAN boards) into the SYSCON2.1 assembly. Note: If any type of fiber optic converter board was present, it must be removed, and the ESBF (Ethernet Switch Board with Fiber - part number A5E ) must be used in place of the ESB. See Technical Support Information No. 194c at and-analytics/news-and-press/documents/si194c-maxum-ethernet-switch- Board-Fiber-ESBF.pdf for more information. 19. Insert the new SYSCON tray in the analyzer (leave the tray in the pulled-out dropped-down position). 20. Connect all cables to the new SYSCON. Use the labels that were applied earlier. See Figure 10 and Figure Place the Color Touchscreen Door assembly on the EC by inserting the hinge pins into the EC sockets. Make sure the pins are fully inserted into the sockets, and that the door can close and seal properly. Figure 7. TIB Door Installation 22. Connect the ESD ground wires (green with yellow stripe) onto the spade lugs on the door. TIB Door Upgrade 11 IP-0028

12 23. Connect the intrinsic-safety ground wires (green with ring lugs on the ends) onto the threaded studs on the left EC wall above the PECM. Figure 8. TIB Door IS-Ground Connections 24. Route the display cables from the door behind the SYSCON2.1 tray to the SIB3 connection points as shown in Figure 9. Figure 9. Display Cable Routing and Connection TIB Door Upgrade 12 IP-0028

13 Figure 10. SYSCON2.1 Board Connections TIB Door Upgrade 13 IP-0028

14 Purge signal (back) Power (front) Figure 11. SYSCON2.1 Cage Connections Notes on Serial Ports: The pinout for the serial ports, when configured for RS-485 operation, is different the SYSCON+ and SYSCON2.1. Also, the connection is now a male connector. There is adapter cable supplied with the upgrade kit used to adapt an existing RS-485 cable to the SYSCON2.1. If an RS-485 cable is equipped, adapter cable at this time. between RS-485 an that is install the In Release 5.2 software all serial ports may be configured as either RS-232 or RS-485. However, Serial 1 on the SYSCON2.1 is hard-coded to always operate as Modbus (Serial 2 may be used to operate as a printer connection). If there is an RS-485 Modbus connection on the SYSCON+, move the cable to Serial 1. Also, move any non-modbus cable in the RS-232 connector to Serial 2. Note that if this configuration exists, DBConverter automatically changes the program to match. Two additional serial ports are available on the SYSCON2.1. In release 5.2 these may be activated and used, although this activation is not described in this procedure. Notes on Other Connections: The external RJ-45 Ethernet connection is located on the Ethernet Switch board which is located in the far right slot of the cage. After setting the IP address and mode on the analyzer in the boot loader, the existing Ethernet cable can be connected into any location in the Ethernet Switch. If necessary, this cable can be connected after the tray is slid into the cage (step on the next page). As shown in Figure 9, the new display cable connects directly from the SYSCON2.1 board to J30 and J31. It does not connect to the front of the SYSCON tray as with the SYSCON+. TIB Door Upgrade 14 IP-0028

15 25. Slide the SYSCON tray into the cage and tighten the nuts. 26. Power up the analyzer. 27. From the color touchscreen in the door of the analyzer, set the IP addresses for the new SYSCON2.1. This will allow the GCP software to communicate with the device so that the updated database may be loaded. a. Push the reset button through the opening on the SYSCON cage. This provides access to the bootloader. b. Press the Home key when the message To enter the bootloader menu, press the Home key now appears. c. Press the 5 key to select the Configuration menu. d. Press the 4 key to select Choose Device Mode. e. Press the 2 key to select Standalone SysCon. f. The SYSCON reboots into standalone mode. g. Press the Home key to re-enter the boot loader h. Press the 5 key to select the Configuration menu again. i. Press the 2 key to select Primary Ethernet IP Configuration. j. The question Do you want to change this configuration? appears: Press the 9 key to select Yes. k. Press the 0 key to disable DHCP. l. Press the 9 key to change the IP address. m. Enter the desired IP address from information recorded previously. Press the Home key to return to the menu. n. Press the 9 key to change the subnet mask. o. Enter the correct subnet mask from information recorded previously. Press the Home key to return to the menu. p. Press the 9 key to change the Default Gateway address. q. Enter the Default Gateway address from information recorded previously. Press the Home key to return to the menu. r. Press the 0 key to select No to the question Change the DNS? s. Press any key to continue. t. Press the Back key to return to the bootloader menu. u. Press the 9 key to reset the device. The external Ethernet cable may now be reconnected. CAUTION: In the following step, verify that the CORRECT analyzer database is downloaded. Loading the wrong analyzer database will lead to loss of data. 28. Load New SYSCON2.1 with Converted Database: a. Open the GCP Analyzer List Window and click on the desired analyzer to select it. b. Click the Restore button, then enter the user name and password. c. Click the file name for the AMD file that was created by DBConverter earlier in this procedure. d. Click Open. e. A warning message will appear indicating that all of the current data on the analyzer will be destroyed and the analyzer will be rebooted. Verify that the CORRECT analyzer is chosen and click Yes to continue. f. The database will load and reset automatically. TIB Door Upgrade 15 IP-0028

16 g. Perform a startup of all hardware in accordance with all standard safety procedures. 29. After verifying that all hardware is up and running, start the analyzer and allow chromatographic measurements to stabilize. After stabilization, run test chromatograms on the analyzer. Verify that results are as expected by comparing with chromatograms obtained before the upgrade. 30. Calibrate the analyzer, if necessary. 31. Verify the operation of any I/O that is configured in the analyzer, including any remote I/O for the analyzer that is configured in other analyzers. Note that some modification of the I/O datatype may be necessary in order for the I/O to function the same as in the prior release. 32. Check the operation of the following (if equipped): a. GCP connection to the analyzer via Ethernet b. Maintenance Panel on the analyzer c. MaxBasic Programs (run each manually, if feasible) d. Any other communication links that may exist (e.g. Modbus, printer). 33. If the purge alarm wire is installed, verify that the purge alarm is working. Verify that a purge alarm is not present when properly purged and verify that a purge alarm is created when the door is opened. If purge bypass is used, verify that no purge alarm exists when the door is opened. 34. Perform any other system checks that may be needed. 35. The following steps must be taken to allow for the unlikely event of a fallback to the old hardware. a. A copy of the original AMD file must be saved. This file should be stored in a safe location to prevent it from being accidentally deleted. b. The original SYSCON+ board and cage should remain on site in a protected location to prevent damage. Any additional hardware or cables that were removed as part of the upgrade should remain with the original SYSCON+ board and cage. The original SYSCON+ and the other hardware must NOT be used as spares or replacements in any other analyzer. c. On a piece of paper, make notes indicating which boards were installed in which slots in the original SYSCON+ configuration. Store this information with the original SYSCON+ cage. d. All other kit hardware (including the SNECON debug cable and null modem cable) and removed hardware should remain with the old SYSCON board and cage. e. Save original chromatograms. This hardware and information should be saved for at least one month to ensure that no problems arise with the new device. If a problem arises, do not attempt to fall back without the advice and assistance of Siemens support. If a fallback becomes necessary, Siemens support will provide a fallback procedure. TIB Door Upgrade 16 IP-0028

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