Procedure to Install an IO Expansion Cage Assembly in a Maxum II Modular Oven Analyzer Difficulty Level: Medium Estimated time to execute: 1 Hour Revision History Issue Date Reason 001 5/31/2016 Initial Issue Copyright Siemens AG 2016 All rights reserved
Table of Contents 1.0 Description... 2 1.1 IO Tray Servicing... 3 1.2 Custom Application Drawing Package... 4 2.0 General Analyzer Shutdown Procedure... 4 2.1 Back Up the Database... 4 2.2 Shutdown Steps... 4 3.0 Removing the Old IO Cage Assembly... 5 4.0 Install New IO Tray... 7 5.0 General Analyzer Startup Procedure... 11 1.0 Description This document describes the procedure to remove a single-piece horizontal IO cage (if present) and install a new vertical IO tray and backplane that can accommodate up to 2 I 2 C IO cards (DIO, AIO, ADIO), an Ethernet Switch with Fiber (ESBF), and an Advance Network Communications Board (ANCB). The Ethernet Switch Board (ESB) and CAN IO cards are not supported. The analyzer must be powered down for this procedure. 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). In this procedure, IO and I 2 C communication cables are unplugged, and the single-piece IO cage removed, if present. Any existing IO boards are simply moved to the new tray. The new IO tray and its two support brackets are installed on threaded studs in the electronics enclosure. Figure 1. Old IO Cage (Horizontal boards, no backplane) Figure 2. New IO Cage (Vertical boards, backplane) Maxum II Modular Oven IO Cage Upgrade Procedure IP-0032 2
A parts kit, Siemens part number A5E36582286001, is required for this procedure. This kit contains the following items. Item Quantity Part Number Description 1 1 A5E32106087001 Bracket, back, 24V IO expansion 2 1 A5E32106084001 Bracket, top, 24V IO expansion 3 4 1312601-004 Nut, M4 with lockwasher, zinc plated 4 1 A5E31626504001 Tray, 24V IO expansion 5 2 1312092-017 Screw, shoulder M5x3.18, socket head 6 2 1312601-005 Nut, M5 with lockwasher, zinc plated 7 1 A5E31368516001 PCBA, 24V IO expansion 8 6 1312530-009 Washer, M3, flat, 304SST 9 6 1312530-006 Washer, M3, helical spring lock, SST 10 6 1312107-814 Screw, M3x8, socket head cap, SST 11 4 1312420-331 Screw, M3x4, socket head cap, SST 12 1 2021837-003 Cable, 24V Power 13 5 C00150 Cable tie. Also required is a tool kit that includes metric wrenches, hex wrenches and nut drivers. 1.1 IO Tray Servicing Figure 3. Operating Position The Operating Position is the normal configuration of the analyzer. The two studs on the bottom rear of the tray slide into two slots on the bracket on the rear wall, and a single captive thumbscrew secures the front of the tray to the upper bracket. The IO tray with IO boards installed can quickly be moved from one position to the other without disconnecting the cables. Figure 4. Service Position Service Position allows the IO tray to be removed from the electronics enclosure and hung up with the IO cards exposed while keeping the IO and I 2 C wiring connected. Two studs on the bottom rear of the tray are inserted loosely into two holes on the front upper bracket. This facilitates testing and maintenance. NOTE: Service position can only be used if local regulations allow operating with the door open. Maxum II Modular Oven IO Cage Upgrade Procedure IP-0032 3
1.2 Custom Application Drawing Package The Custom Drawing Package delivered with the equipment shows what parts were installed by the factory. If no replacements have been made from installation, then the Custom Drawing Package will provide the user with the part numbers of the items in the unit. If changes have been made, this may still provide information on the type of parts that are currently installed. The analyzer has special instructions in the custom documentation. These must be followed to ensure safe operation of the unit. This section contains information for removal and installation of the specific components in your analyzer. See the specific section for each of these devices. Included with your analyzer is a custom application drawing package that provides drawings and information pertinent only to your analyzer. Because the drawing package has specific information concerning the specific Maxum II, you should have this package readily available during installation. Typical documents included in this package may include: System Block and Utility Requirements System Outline and Dimensional Drawings Sampling System Plumbing and Spare Parts List Sampling System Dimensional Diagram Sampling Probe Electronic Controller Internal Layout Applicable Wiring Diagrams Oven Plumbing Diagrams Recommended Spare Parts - Analyzer Manufacturing Test Charts Stream Composition Data Data Base Information Files 2.0 General Analyzer Shutdown Procedure 2.1 Back Up the Database If a current database has not been saved, backup the database using Gas Chromatograph Portal workstation software. Generally, a database reload is not needed for this procedure however it is a best practice to back up the Database when performing a planned shutdown. 2.2 Shutdown Steps 1. Put the analyzer in Hold and wait for the cycle to complete. This will provide the quickest restart of the application when power is restored. 2. After the cycle has completed and the analyzer is in Hold: a. Turn off supply gas and sample flows. b. Remove power from the unit. Warning: Voltage dangerous to life exists. Failure to follow appropriate safety procedures may result in severe injury or death. Before beginning to work inside the electronics enclosure, the power must be externally removed from the GC. Input power (110 220VAC or 24VDC) comes directly into the electronics enclosure, so power must be removed and secured/tagged to prevent inadvertent application while work is being performed Maxum II Modular Oven IO Cage Upgrade Procedure IP-0032 4
3.0 Removing the Old IO Cage Assembly If the horizontal IO cage is not installed skip to Install New IO Tray. See Figure 5 for locations of components described in the following steps. 1. Follow the General Analyzer Shutdown Procedure. 2. Open the electronic enclosure door. 3. Unplug the IO cables after marking the positions. 4. Unplug the I 2 C and other communication cables from the cards. 5. Note the locations of the cards. 6. Remove the card retaining screw to free each card. 7. Remove all cards from the cage. 8. Remove the 3 nuts to free the old cage. Figure 5. Interior Details Maxum II Modular Oven IO Cage Upgrade Procedure IP-0032 5
Figure 6. Mounting Screw Locations Maxum II Modular Oven IO Cage Upgrade Procedure IP-0032 6
4.0 Install New IO Tray 1. Install the rear bracket (part number A5E32106087001) on the two studs on the inside rear wall of the electronics enclosure using two M4 nuts from the kit. 2. Install the top bracket (part number A5E32106084) on the two studs on the inside top of the electronics enclosure using two M4 nuts from the kit. Figure 7. New IO Tray Brackets Maxum II Modular Oven IO Cage Upgrade Procedure IP-0032 7
3. Install the IO cards in new tray as shown below. c. Plug card edges into backplane connectors. d. Insert card bracket tab in IO cage slot. e. Install card retaining screws. Figure 8. IO Tray Maxum II Modular Oven IO Cage Upgrade Procedure IP-0032 8
4. Hang the IO tray in the service position. 5. Connect the 24V power cable from P2 of the PECM-DC to P9 or P10 on the IO Expansion Board. 6. Connect I 2 C cables to all IO cards as shown in below. (NOTE: The I 2 C IO cards are not powered by the backplane. They are powered by the 24V wiring in the I 2 C cable. (The ESBF and ANCB are, however, powered by the backplane via a 24V power cable to the PECM-DC. Communications to these cards are via cable only, not backplane signals.) Figure 9. Installing Cables 7. Connect IO cables to all IO cards. 8. Connect Ethernet and other communication cables if an ESBF or ANCB is used in the analyzer. Maxum II Modular Oven IO Cage Upgrade Procedure IP-0032 9
9. After connections are verified, install the IO tray in the normal operating position and secure with the captive thumbscrew. Figure 10. IO Tray in Operating Position NOTE: When inserting the IO-tray shoulder screws into the slots in the rear bracket, be sure that cables are not pinched between the metal parts. 10. Follow the General Analyzer Startup Procedure. Maxum II Modular Oven IO Cage Upgrade Procedure IP-0032 10
5.0 General Analyzer Startup Procedure Warning: Voltage dangerous to life exists. Severe injury or death can result if precautions are not observed. When the Electronic Enclosure door is open, voltage dangerous to life is exposed. If the unit must be operated with the electronics door open, a hot work permit may be required to ensure that there are no hazards for the personnel working in the area. Before proceeding with these instructions, make sure the unit is installed correctly in accordance with these instructions and local and national codes. See the custom documentation package for details and procedures for the individual unit. 1. Before applying power to the analyzer, inspect all connections. Verify that all connections are completely seated in the connectors. 2. If local regulations allow and permits are in place, the unit can be powered up so that the internal I 2 C LEDs are visible on the boards installed in the IO cage. If not, skip to step 3. When power is switched on, the yellow (warning) and red (fault) LEDs illuminate while the operating system boots up. After a few minutes, these LEDs go out and the green LEDs (normal) illuminate; bright green during communication, dim green to indicate normal operation. If normal operation is not observed after the touchscreen display indicates that the operating system has booted, power down the unit and check for cabling errors. The ESBF board has LEDs on each Ethernet port to indicate communication activity. With the IO tray in service position, ANCB operation can be verified by viewing the LEDs on the top edge. These are described in the Advance Network Communications Board User s Manual, document number 2000592. This is available at the Siemens Industry Online Support Website. 3. Close the electronics door and secure it per the applicable safety codes. 4. Apply power to the unit. No intervention should be necessary for the unit to begin to operate after a few minutes. 5. On the touchscreen display on the door, select Maintain, then 8.App I/O, Temperature & Pressure, then select the type of IO channel, and verify that the IO channels are functional. 6. Allow time for the unit to reach operating temperature. 7. Verify correct operation through the touchscreen display on the door. Maxum II Modular Oven IO Cage Upgrade Procedure IP-0032 11