Technical Support Information No. 113 Revision 2.0 March 2005

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1 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 1 of 16 Neues PECM ersetzt alle PECM s in Maxum und Maxum Edition II - New PECM replaces all PECMs in Maxum and Maxum Edition II General Description Part Number Old Part Number New Features: Easy Access (no cover) Two on board temperature control circuits (Same as DPM Temperature Control) Medium wattage heater circuit. (5A Maximum at Line voltage) Improved, low-profile fuse holders Solenoid valve control, which can be used to replace all SVCM control boards. LED indicator for air pressure switch on Air Bath Heater circuit. UPS power connector for 24 volt power supply. Note: Some features listed above will require additional cables and other parts to function. For field replacement of the PECM use SAA Part Number: See Parts List in Appendix A, page 10. The Power Entry and Control Module (PECM) system contains the electronics that conditions electrical power entering the Maxum GC and distributes the power to various other components. The PECM provides electronic interface to the power relays for oven heating systems. Additionally, the PECM may provide controls for temperature control circuits and for the Solenoid Valve Control Module.

2 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 2 of 16 The Solenoid Valve Control Module (SVCM) is a single module which provides electrical solenoids which switch valve air on an off. The valve air is connected by tubes to chromatograph valves in the GC oven. The SVCM includes 8 electrical solenoids mounted on a gas manifold. The SVCM may also include an electrical circuit board which interfaces the solenoids to the Maxum electronics. Temperature controls in the Maxum are provided as needed by any particular application. Generally the chromatograph oven operates at an elevated temperature and requires temperature control. Additionally, the Flame Ionization and Flame Photometric Detectors require individual temperature control. Finally, some valves, the methanator and some sample conditioning equipment may require temperature control. Each device which is temperature controlled requires a set of electrical sensors to measure the temperature. These are connected as inputs to a dedicated temperature control circuit in Maxum electronics. Each device which is temperature controlled also requires a 50 to 1000 watt heater element. The heater element takes its electrical power from the PECM through a power relay. The relay is switched on an off by the same temperature control circuit to which the sensors were connected. Various safety circuits ensure safe control of these heating elements. Since the original release of the Maxum GC improvements and changes have been made to the PECM and SVCM. These are described below: UChanges to PECM The PECM has been changed in its design since its original release. The newest version of this part is also used as the spare part replacement for the previous version. The original PECM was a single electronic circuit board with a metal protective shield. It provided connection points for the electrical power coming into the Maxum GC and mounted low power electrical relays which could switch power to any electrical heater smaller than 200 watts. The newest version of the module, PECM-2, is a two part circuit board. One part connects the electrical power. The other part includes certain electronic circuits. Key features of the newer design are: Easy access (no cover) Two on-board temperature control circuits that can allow use of a lower cost Thermistor Detector Personality Module (TCD DPM): in some cases, the customer can now use less expensive instead of fullfeatured Additional medium-wattage heater circuit. May allow elimination of additional DPM when it is used for temperature control only, such as for heated valves and the methanator. Includes solenoid valve control which eliminates the need for individual SVCM controller boards. (When converting older design and eliminating original SVCM controller boards, additional long cables are required. Improved low-profile fuse holders LED indicators for air pressure switch on air-bath heater circuits Built-in provision for connection of Uninterruptible Power Supply (UPS) for 24vdc circuits The newest part is also used as the spare parts replacement for the earlier version. It provides all new features but at the same cost. In many cases, it can eliminate other spare parts used for the SVCM (see next paragraph) or for temperature control.

3 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 3 of 16 UChanges to SVCM The SVCM has been changed in its design since its original release to lower its cost and improve its reliability. The newest version of this part is also used as the spare part replacement for the original version. The type of solenoid has been changed to reduce leakage and improve reliability. In addition, if the PECM-2 is used, the separate electrical interface circuit board, originally part of the SVCM, is no longer needed. UTemperature Control and Heater Hardware The PECM-2 can be integrally involved in control of temperature zones in the Maxum GC. Aside from the changes described in the TSI #99 and changes to the PECM (described above), there have been improvements to reduce cost on the Solid State Relay Board (which provides temperature control power relays) and an alternative air bath heater assembly has been introduced. The original Maxum design provided for only one type of heater assembly for its air bath configurations (single isothermal; dual isothermal; or Programmed Temperature Control). This was a 1350 watt heater assembly. A single heater was used for the single isothermal configuration and two heaters are used in the other configurations. Now, a second air bath heater assembly has been introduced. It is a 650 watt heater and can be used in single isothermal configurations where the controlled oven temperature is 100 C or less. In all other air bath configurations, the original heater is still required. Additionally, a new medium power Solid State Relay Board (temperature control relay module) has been introduced. The original board included 4 large relays suitable for switching 2 of the 1300 watt air bath oven heater elements. However, many Maxum GCs do not require that much power. Therefore, a new SSRB has been added to the Maxum spare part offering which can lower spare parts costs for the user. The newer board provides smaller relays which are capable of controlling the new 650 watt air bath heater assembly (described above).

4 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 4 of 16 In addition, the medium power SSRB can be used to control the two 250 watt heaters used in the Maxum airless oven configurations. The newer board can also be used to control the low wattage heaters in the heated Flame Ionization and Flame Photometric detector housings or in heated sample injection valves. These changes and new parts create the following configuration options: One other change has been made on the Solid State Relay boards since the original Maxum design. The individual solid state relays have changed. The newer part provides an indicator LED which shows operational status. The newer part also provides a plastic shield which covers the connection screw terminals and helps prevent inadvertent contact. Note, however, the older relay is entirely enclosed in a sheet metal housing so human contact is not possible without disassembly of the module. Both the original and newer relays are available as a spare part and are interchangeable.

5 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 5 of 16 Installation Instructions 1. Turn off power to analyzer. 2. Label the cable connections of the PECM being replaced. 3. Unplug cables from all connectors. 4. Unplug the purge line from the purge switch. (SW1, tubing connection) 5. Use a 5mm nut driver to loosen two upper hex nuts. 6. Lift out the old PECM. 7. Install new PECM. 8. Make sure no wires are behind the new module. 9. Tighten 5mm nuts. 10. Start at the back of new controller and plug in the following. See diagram on next page for locations: a. Purge switch SW1 (tubing connection) b. Relay power plug TB9 2 c. IP PC connection d. Solenoid Control plugs * e. Low wattage heater controls * f. Temperature control plugs (RTD s) and jumpers.* g. AC inputs h. Heater pressure switch to J10* 11. If using temperature control circuits on the PECM, make sure the correct OT/TL boards are installed in their proper locations. This is important to maintain the correct analyzer T-ratings. 12. Make sure the correct fuses are in the correct positions. 13. Turn on power 14. Test analyzer for functionality. * Optional items NOTE: Cables and jumpers are supplied in the kit for additional temperature control. It is not required to use the temperature control features of this board if the unit was not using the PECM for temperature control before installing this kit. The Heater Termination Plug, should be installed in the TEMP RTD connector for each unused temperature control channel.

6 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 6 of 16 PECM SSR Board (back circuit board) UPS for 24V Power Supply H N G H N G AC Power Circuit 1 AC Power Circuit 2 H N G NOTES: Cable, Ground Strap, PECM AC Power Ground to chassis lug If UPS not used, then jumpers must be connected between Hot, Neutral and Ground terminals of AC Power Circuit 1 and UPS for 24V Power Supply TB7 Low Watt Heater 5 See Configure Options Next page TB8 Medium Watt Heater 6 Fuse Description on next page Ribbon Cable connected to front board

7 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 7 of 16 Configure Options for TB7 Configure Options for TB8 Fuses Used on PECM: ( ) Fuse Kit has 20 fuses of each amp rating. 115VAC F1 AC Power Circuit 1 16A ( ) F5 Heater Channel 6 6.3A ( ) F2 AC Power Circuit 2 16A ( ) F4 LWH A ( ) F3 Power Supply (24V out) 3.15A ( ) 230VAC 10A ( ) 6.3A ( ) 10A ( ) 10A ( ) 3.15A ( )

8 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 8 of 16 PECM Controller (front circuit board) I2C connections RTD connections Plug Heater Termination Overtemp/Temp. Limit circuits Heater Cable/SNE, Long Refer to OT/TL options document Document AI PECM Temp. Cont. Jumper from TEMP CTRL1 to OVEN HTR , Cable, Max II 24V Power PECM (TB2) to WDB (J1) Move 24V PS cable from WDB J1 To PECM TB1 Low watt heater connects Purge Disable JP2 Left Solenoid Ctrl Right-up Solenoid Ctrl Right Solenoid Ctrl

9 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 9 of 16 USpecial Notes: The PECM comes with jumpers installed from Temp Ctrl 1 to Oven Htr 1 and from Temp Ctrl 2 to Oven Htr 2. If desired, the jumpers can be removed and these heater channels and temp. controllers can be connected as needed, but it is best to use the PECM temperature control channels for oven heater control as it will simplify wiring and reduce cable clutter. Heater 6 (medium wattage heater - MWH) is limited to 5A maximum at 70 degrees Celsius. Note that heater 6 has a different connector to prevent accidental swapping with its neighbor and potential subsequent destruction of the PECM SSRs. Thus, if this heater channel was used on the old PECM, it will be necessary to move the wires from the old plug to the new one supplied with the board. The order of the wires in the connector is the same. Low wattage heater channels 1-5 are limited to 2A maximum at 70 degrees Celsius. Total PECM heater power is limited to 9A at line voltage. For example, if MWH is used at its limit of 5A, the remaining heater channels 1-5 must not exceed a combined consumption of 4A. Exceeding this limit can cause overheating and failure of components in the EC at high ambient temperatures. In a Maxum, there is a mechanical interference that prevents using the SVCM connections when there is a DPM in the leftmost slot. Maxum analyzer SVCMs do not require use of these connections because their SVCMs have their own printed circuit board. This interference does not occur in Maxum Edition II. UThe appropriate hardware ID s are now following: For temperature controllers: 11: (temp. cont. 1) 11: (temp. cont. 2) For the solenoid valves: 11: to 48 (right solenoid ctrl) 11: to 38 (left solenoid ctrl) 11: to 58 (right-up solenoid ctrl)

10 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 10 of 16 Appendix A PECM Kit Parts List

11 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 11 of 16 Appendix B PECM, SVCM and SSRB Part Number Tables Part No. Description (PECM and SVCM p/n Table) Statu s Individual Parker solenoid. Used on original design of SVCM. See also description of p/n For gasket, use p/n Comments Individual SMC solenoid Used on current (revised) design of SVCM. See also description of p/n For gasket, use p/n SVCM Solenoid Interconnect cable (50 mm) Cable to connect SMC solenoids directly to SVCM controller electronics board. Used on any SVCM module in any of three mounting locations; for cables intended to connect to PECM-2, see p/n or required per module (1 cable for 4 solenoids) SVCM Controller Board, Version 2 (Electronics only) Small controller electronics board used to interface Solenoid Valve Control Module (SVCM) This board is available as a normal spare part. However, it is no longer needed if the customer is using the new version of the Power Entry and Control Module (PECM-2; p/n ) In the original Maxum design, there is one of these parts required for EACH installed SVCM. However, the new PECM-2 eliminates the need for all three. Therefore, the customer may wish to purchase a new PECM-2 instead of purchasing this item as a spare part. This will save money in the future and provide best future compatibility. If the customer desires to eliminate existing SVCM controller boards and use the circuitry on the new PECM-2 instead, then a longer cable is needed to reach from the PECM-2 to each of the Solenoid Modules installed. The cables needed for this are provided as part of the PECM-2 replacement kit, p/n Customer may wish to use instead of this part.

12 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 12 of Oven Heater Sensor Connect Cable (short) Cable to connect OT / TL RTDs in the air bath or airless ovens to the heater control circuits on the Power Entry and Control Module, version 2 (PECM-2) Replaces the cable that previously connected to a Detector Personality Module when the PECM-2 circuits are used for temperature control Short cable is intended for heater wiring on the right side; for long cable, see p/n Oven Heater Sensor Connect Cable (long) Cable to connect OT / TL RTDs in the air bath or airless ovens to the heater control circuits on the Power Entry and Control Module, version 2 (PECM-2) Replaces the cable that previously connected to a Detector Personality Module when the PECM-2 circuits are used for temperature control Long cable is intended for heater wiring on the right side; for short cable, see p/n And High Power Heater Solid Sate Relay Module Complete relay module including sheet metal and mounting brackets. This item is used for new construction or significant reconstruction. It is not sold as a spare part. Replacement relays are available; see p/n The - version of this part is used on Maxum 1; the -002 version is used on Maxum II. Not sold as spare part. Use replacement relays for repair. See Power Entry and Control Module, original version (PECM) This original version PECM has been replaced by a new version with better features and more ruggedness. See Discontinued Default replacement Kit of 4 replacement solenoids for SVCM module (Parker) Kit contains for solenoids plus gaskets, seals, a fitting elbow and cables necessary to replace ½ of the solenoids that are on the SVCM, Customer may prefer to use as the replacement part. See notes. Note, the Parker solenoids may leak valve gas in some cases at higher operating temperatures. Therefore, rather than purchase this part, a customer may prefer to replace the entire solenoid module with the current (revised) design. Please see p/n and accompanying description.

13 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 13 of Replacement relay kit for High-Power Temperature Control Relay Module Provides 4 high power solid state relays to switch high power oven heaters Relays used on high-power Solid Sate Relay Module, p/n or Older style relay without indicators or shields. Recommended replacement kit is Individual relays also sold separately (p/n R60550). However recommended replacement relay is p/n Preferred replacement is Complete Solenoid Valve Control Module (without electronics) Complete module including: Manifold 8 solenoids (SMC type) 2 short cables that connect solenoids to SVCM Controller Board (p/n ) Assembled Gasket that mounts at the wall of the electronics enclosure between solenoid manifold and tubing manifold The module mounts 8 individual air-switching solenoids. The switched air is used to activate or de-activate sample and column valves in the chromatograph oven. This module has changed design since the original release of Maxum 1. The original module used Parker (brand) solenoids. These could sometimes leak air or valve gas at elevated temperatures. The current module uses SMC solenoids which have a better temperature operating performance. The SMC solenoids have a different foot-print than the original Parker; therefore, the metal manifold that the solenoids are mounted on also changed. The original manifold will mount only the Parker solenoids. (See spare parts kit p/n or individual solenoid p/n ) The current module manifold will mount only SMC solenoids. (See spare parts kit p/n or individual solenoid p/n ) The correct spare parts solenoids must be used with the matching manifold. However, if it is necessary to replace solenoids on the original design, a customer may prefer to replace the entire original solenoid module with this new design.

14 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 14 of Replacement relay kit for High-Power Temperature Control Relay Module Provides 4 high power solid state relays to switch high power oven heaters Relays used on high-power Solid Sate Relay Module, p/n or Relays include an indicator LED and plastic shield over all screw terminal connectors Individual relays also sold separately (p/n ) Medium Wattage Heater Solid State Relay Module, with cables Complete module, includes power relays to switch medium power oven heaters. Used on isothermal air bath ovens operating under 100 C and on all airless ovens. See also standard high power Temperature Control Relay Module, p/n xxx-xx PECM-2 with Temp. and SVCM Control; (Top controller board only) Bottom board, provided with the complete PECM-2 kit Contains power relays and connectors Normally provided also as a part of the complete replacement kit for all models of Maxum 1 and 2, p/n Also provided as a part of the electronics-only kit of PECM-2, PECM with Temp. and SVCM Control; (Bottom connect board only) Top board, provided with the complete PECM-2 kit Contains electronic circuitry and connectors Normally provided also as a part of the complete replacement kit for all models of Maxum 1 and 2, p/n Also provided as a part of the electronics-only kit of PECM-2, SVCM Solenoid Interconnect cable (1000 mm) Cable to connect SMC solenoids to Power Entry and Control Module, version 2 (PECM- 2). Used on either SVCM module in one of the two right-side mounting locations; for shorter version of this cable see p/n required per module (1 cable for 4 solenoids)

15 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 15 of SVCM Solenoid Interconnect cable (1000 mm) Cable to connect SMC solenoids to Power Entry and Control Module, version 2 (PECM- 2). Used on the SVCM module in the left-side mounting location; for longer version of this cable see p/n required per module (1 cable for 4 solenoids) PECM-2 Assembly with Temperature and Solenoid Valve Controls Both Circuit boards only, complete assembly, no cables. Normally provided also as a part of the complete replacement kit for all models of Maxum 1 and 2, p/n

16 Process Instrumentation and Analytics - A&D PI 2 - Karlsruhe Page 16 of Power Entry and Control Module, Version 2 (PECM- 2), complete replacement kit Universal replacement part for Maxum 1 and Maxum 2 Also provides new features that can lower the total cost of spare parts for either Maxum. Features include: Easy access (no cover) Two on-board temperature control circuits that can allow use of a lower cost Thermistor Detector Personality Module (TCD DPM): in some cases, the customer can now use less expensive instead of fullfeatured Additional medium-wattage heater circuit. May allow elimination of additional DPM when it is used for temperature control only, such as for heated valves and the methanator. Includes solenoid valve control which eliminates the need for individual SVCM controller boards. (When converting older design and eliminating original SVCM controller boards, additional long cables are required. Improved low-profile fuse holders LED indicators for air pressure switch on airbath heater circuits Built-in provision for connection of Uninterruptible Power Supply (UPS) for 24vdc circuits Kit includes: 1 ea PECM Assembly with Temperature and Solenoid Valve Controls 1 ea v Power Cable from PECM to Wiring Distribution Board (WDB) 2 ea Long cable from Heater to Sensor Near Electronics 2 ea Heater Termination Plug 2 ea Fuse, 10A, fast acting, ceramic, 5x20mm 2 ea Fuse, 16A, fast acting, ceramic, 5x20mm 1 ea Power Ground cable for PECM 1 ea On-board Temperature Control Jumper cable for PECM Kit of 4 replacement solenoids for SVCM module (SMC) Kit contains for solenoids plus gaskets, seals, fittings and cables necessary to replace ½ of the solenoids that are on the SVCM When using this part, the customer may wish to remove or disable any existing SVCM controller boards and supplemental temperature controller boards. Additional long cables to connect SVCMs may be needed.

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