Extrel MAX300-RTG User manual

MAX300-RTG Installation/Hardware
Manual
823518 Rev K, May 2019

MAX300-RTG Installation Manual
2
Notice
Material contained in this manual is proprietary information
and the property of Extrel CMS, LLC and is to be used only
for the purpose of understanding and operating this
product.
Specifications are subject to change without notice.
For Further Information or Assistance Contact:
Extrel CMS, LLC
575 Epsilon Drive, Suite 2
Pittsburgh, PA 15238
General Information: Telephone: [phone]
Fax: [phone]
Email: [email protected]
Technical Support: Telephone: [phone]
Email: [email protected]
Sales: Telephone: [phone]
Email: [email protected]
Web Page: http://www.extrel.com/
Copyright © 2017 Extrel CMS, LLC

MAX300-RTG Installation Manual
3
Introduction 5
INSTALLATION REQUIREMENTS.................................................................................................................................5
SHELTER REQUIREMENTS........................................................................................................................................5
AREA CLASSIFICATION OPTIONS..............................................................................................................................6
SPECIFICATIONS.......................................................................................................................................................6
.............................................................................................................................................................................8
Figure 1: Layout of the ATEX/IECx Zone 1/Class I Div 1 unit (230V or 115V), with cart option ...........8
Figure 2: Layout of the ATEX/IECEx Zone 2 /Class I Div 2 unit (230V or 115V), with cart option ...................9
Figure 3: Layout of the ATEX/IECEx Zone 1/Class I Div 1 unit (230V or 115V), without cart option.............10
Figure 4: Layout of the ATEX/IECEx Zone 2/Class I Div 2 unit (230V or 115V), without cart option.............11
................................................................................................................................................................................12
Figure 5: Layout of the ATEX/IECEx Zone 1/Class I Div 1 unit (230V or 115V) with water cooled heat
exchanger and cart option .................................................................................................................................12
................................................................................................................................................................................13
Figure 6: Layout of the ATEX/IECEx Zone 2/Class I Div 2 unit (230V or 115V), with water cooled heat
exchanger and cart option .................................................................................................................................13
Figure 7: Installation Clearances......................................................................................................................14
................................................................................................................................................................................14
SAFETY ...................................................................................................................................................................15
Model Definitions and Marking......................................................................................................................15
WARNINGS ..............................................................................................................................................................18
APPLICATION SUITABILITY......................................................................................................................................24
INSTALLATION.........................................................................................................................................................24
PRESSURIZATION GAS SUPPLY .................................................................................................................................24
SAMPLE GAS SUPPLY.............................................................................................................................................25
AC POWER REQUIREMENTS ....................................................................................................................................26
MAX300-RTG ELECTRICAL CONNECTION DIAGRAMS.........................................................................................27
Figure 8: Power connection diagram, Zone 1/Div 1 units, 230VAC ........................................................27
...........................................................................................................................................................................28
Figure 9: Power connection diagram, Zone 1/Div 1 units, 115VAC ........................................................28
Figure 10: Power connection diagram, Zone 2/Div 2 units, 230VAC ......................................................29
Figure 11: Power connection diagram, Zone 2/Div 2 units, 115VAC ......................................................29
...........................................................................................................................................................................30
Figure 12: Earth connection diagram ...........................................................................................................30
Earthing.............................................................................................................................................................30
Plumbing Connections....................................................................................................................................31
Rotary Valve Inlets..........................................................................................................................................31
Figure 13: Diagram of 16 port rotary valve inlet..........................................................................................33
Figure 14: Diagram of 31 port rotary valve inlet..........................................................................................34
...........................................................................................................................................................................34
Figure 15: Diagram of 46 port rotary valve inlet..........................................................................................35
Figure 16: 16 port rotary valve details..........................................................................................................36
Figure 17: FastValve (40/80/120/160 port valve option) –for use with non-explosive sample ...........37
Calibration Gases............................................................................................................................................37
Figure 18: Calibration Gas Connection........................................................................................................38
Figure 19: External communications disconnect box option.....................................................................41
Status Connections.........................................................................................................................................44
4-20mA Analog Inputs and Outputs .............................................................................................................46
4-20mA Analog Inputs: KL3012 and KL3022..............................................................................................47
4-20mA Output: KL4021 and KL4022 Modules..........................................................................................47
Digital I/O..........................................................................................................................................................48

MAX300-RTG Installation Manual
4
KL1408 –(8) digital input, 24VDC ................................................................................................................49
Relay Output....................................................................................................................................................49
KL2612 (2) Relays...........................................................................................................................................49
Distributed Control System (DCS)................................................................................................................50
INSTRUMENT START-UP..........................................................................................................................................51
General Start-up Procedure...........................................................................................................................51
MAX300-RTG HARDWARE MAINTENANCE ...........................................................................................................53
VENTING THE VACUUM SYSTEM.............................................................................................................................53
Figure 29: Pump Configuration on VacTrac.....................................................................................................55
Pump Maintenance.........................................................................................................................................56
Turbomolecular Vacuum Pump.....................................................................................................................56
Mechanical Vacuum Pump............................................................................................................................57
Inlet Valves.......................................................................................................................................................58
CHANGING THE INLET.............................................................................................................................................59
CHANGING THE IONIZER ASSEMBLY.......................................................................................................................64
QUADRUPOLE MASS FILTER....................................................................................................................................67
Quadrupole Collar Shield Disassembly .......................................................................................................69
QUADRUPOLE CLEANING........................................................................................................................................70
QUADRUPOLE REASSEMBLY AND VACUUM CHAMBER INSTALLATION...................................................................72
ELECTRON MULTIPLIER REMOVAL AND REPLACEMENT ........................................................................................74
REMAINING COMPONENTS IN THE ENCLOSURE........................................................................................................77
RESONATING THE QUADRUPOLE POWER SUPPLY (QC).......................................................................................77
DATA SYSTEM.........................................................................................................................................................79
AIR CONDITIONER...................................................................................................................................................79
VALVE BOX HEATER (OPTIONAL)...........................................................................................................................81
Figure 52: Valve Box Heater, T4, standard option............................................................................................82
Figure 53: Valve Box Heater, high temperature T4 and T3 options..................................................................83
CORROSIVE PUMP OPTION.......................................................................................................................................83
MAX300-RTG Preinstallation Checklist 85

MAX300-RTG: Installation Manual Hardware Installation
5
Introduction
The MAX300™-RTG process mass spectrometer is a versatile real-time process
analyzer capable of fully automatic operation. It can handle a wide range of
applications for quantitative analysis of gases and vapors, as well as monitor
multiple components in any one stream and analyze up to 128 streams (including
calibration gases).
This document is intended to inform the customer of the necessary preparations
for successful installation. As Extrel CMS does not generally inspect a site prior to
installation, it is extremely important to provide the necessary support for the
instrument to avoid significant delays. All utilities and environmental requirements
discussed in this document are the responsibility of the customer. Please note,
depending on which options were purchased, specific accommodations will be
required; refer to the purchase order for clarification.
Installation Requirements
In order for Extrel CMS to assist with the successful installation and operation of
the MAX300-RTG, the customer must:
Complete the Pre-installation Checklist found in Appendix A.
Fax or email to Extrel CMS any legal documents required for access to the
site.
Allocate time for any training programs required for site access.
Prepare a suitable site for the instrument.
Provide and install the required utilities.
Install vent and sample lines and the vacuum system exhaust.
Obtain and install required calibration gases.
Install the compressed air plumbing for the purge systems
Install wiring or fiber for instrument control.
Install wiring for external communications options.
Shelter Requirements
The MAX300-RTG may be located outdoors provided no direct exposure to any
weather conditions exist. A shelter with a 9 ft. (2.75 m) roof, with 7 ft. (2.1 m)
vertical clearance, and at least three sides is required. Although, a fully enclosed
and appropriately designed analyzer shelter is recommended. All environmental

MAX300-RTG: Installation Manual Hardware Installation
6
requirements must be maintained for proper operation of the analyzer. Electrical
power and signal wiring to the instrument must be consistent with instrument
conditions and meet all applicable local building codes. When considering an air
conditioner for the instrumentation housing it is important to keep in mind the heat
dissipation and ambient temperature ranges of the instrument (See Table 1). Any
air conditioner and filter installed in the shelter must be kept clean, unblocked and
allow for adequate air circulation.
Table 1: Temperature considerations for instrument housing.
Area Classification Options
The MAX300-RTG analyzer can be configured for use in these hazardous
locations:
IECEx/ATEX Category 2 (Zone 1), Gas group IIC or IIB+H2, Temperature
code T4 or T3
IECEx/ATEX Category 3 (Zone 2), Gas group IIC, Temperature code T4 or
T3
Class I Division 1, Group BCD, Temperature code T4 or T3
Class I Division 2, Group ABCD, Temperature code T4 or T3
It is imperative to ensure that the appropriate analyzer option is chosen for
installation in the hazardous location.
Please refer to the Safety section of this manual for more information.
Specifications
Power requirements:
115V 60 hz option: 115(+/- 10%) VAC, 60 Hz, single phase, two 20 amp
circuits required
Type
Range
Heat Dissipation
10,200 Btu/hour, A/C:6000 Btu/hour
3 Kilowatts, A/C: 1.8 Kilowatts
Ambient Temperature Range
-4oF (-20oC) to 122oF (50oC )
A/C cold start ≥ 54oF (12oC)

MAX300-RTG: Installation Manual Hardware Installation
7
115V 50/60 hz option: 115(+/- 10%) VAC, 50/60 Hz, single phase, two 20
amp circuits required
230V option: 230(+/- 10%) VAC, 50/60 Hz, single phase, one 20 amp circuit
required
Ambient temperature: -20°C to 50°C
Purge/pressurization gas requirements:
Purge/pressurization gas - Clean, dry instrument quality air or inert gas
Zone 1/Div 1 units: 620 –793 kPa (90 –115 psig), 300 LPM (10.6 SCFM)
purge, 80 LPM (2.8 SCFM) continuous
Zone 2/Div 2 units: 414 –793 kPa (60 –115 psig), 142 LPM (5 SCFM)
continuous
T rating: T4 (135°C) or optional T3 (200°C)
Maximum surface temperature: 130°C for T4 units, 190°C for T3 units
Tool required for opening enclosure doors: Screwdriver, flat blade, 9 mm (3/8”)
wide
Weight: 182 kg (400 lbs) approximately (option dependent)

MAX300-RTG: Installation Manual Hardware Installation
8
Figure 1: Layout of the ATEX/IECx Zone 1/Class I Div 1 unit (230V or 115V), with
cart option

MAX300-RTG: Installation Manual Hardware Installation
9
Figure 2: Layout of the ATEX/IECEx Zone 2 /Class I Div 2 unit (230V or 115V), with
cart option

MAX300-RTG: Installation Manual Hardware Installation
10
Figure 3: Layout of the ATEX/IECEx Zone 1/Class I Div 1 unit (230V or 115V), without
cart option