Siemens MicroSAM User manual

Process Gas Chromatography
Process Gas Chromatograph
MicroSAM
Operating Instructions · 03/2012

Process analytics
Process Gas Chromatograph
MicroSAM
Operating Instructions
7KQ3101
06/2012
C79000-G5376-C560-07
Purpose of this
documentation
1
General information
2
Description
3
Mounting
4
Commissioning and
operation
5
Service and maintenance
6
Spare parts/accessories
7
Examples
8
Technical data
9
Dimension drawings
10
Appendix
A

Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the relevant information is not taken into account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: C79000-G5376-C560
Ⓟ 07/2012 Technical data subject to change
Copyright © Siemens AG 2012.
All rights reserved

MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07 3
Table of contents
1 Purpose of this documentation .................................................................................................................. 7
2 General information ................................................................................................................................... 9
2.1 Intended use ..................................................................................................................................9
2.2 Safety information ..........................................................................................................................9
2.3 Transportation..............................................................................................................................11
2.4 Protection against explosion........................................................................................................12
2.4.1 General regulations......................................................................................................................12
2.4.2 Directives for operation................................................................................................................15
2.5 Qualified personnel ......................................................................................................................17
2.6 Limitation of liability for external accessories...............................................................................17
2.7 Final shutdown and disposal........................................................................................................17
3 Description............................................................................................................................................... 19
3.1 Applications..................................................................................................................................19
3.2 Product features...........................................................................................................................20
3.3 MicroSAM design.........................................................................................................................21
3.4 Rating plate design ......................................................................................................................22
3.5 Functional description of the electronics......................................................................................23
3.6 Functions......................................................................................................................................25
3.6.1 Gas flow charts ............................................................................................................................26
3.6.2 Analysis module...........................................................................................................................28
3.6.3 Example of time switching commands.........................................................................................32
3.6.4 Thermal release in the analysis module ......................................................................................33
3.6.5 Measuring sequence....................................................................................................................33
3.6.5.1 Preparation of measurement .......................................................................................................35
3.6.5.2 Purge sample loop .......................................................................................................................39
3.6.5.3 Injecting........................................................................................................................................41
3.6.5.4 Empty sample loop completely ....................................................................................................43
3.6.5.5 Purge sample loop with sample...................................................................................................44
3.6.5.6 Cut - start .....................................................................................................................................45
3.6.5.7 Cut - end ......................................................................................................................................46
3.6.5.8 Backflushing.................................................................................................................................47
3.6.6 Cut - check...................................................................................................................................49
3.6.7 Backflushing - check ....................................................................................................................50
3.6.8 Monitoring of the chromatograph functions .................................................................................51
3.6.9 Temperature control systems ......................................................................................................53

Table of contents
MicroSAM
4 Operating Instructions, 06/2012, C79000-G5376-C560-07
4 Mounting.................................................................................................................................................. 55
4.1 On-site requirements................................................................................................................... 55
4.2 Space requirement...................................................................................................................... 55
4.3 Fixing........................................................................................................................................... 56
4.4 Mounting and connecting............................................................................................................ 57
4.4.1 Requirements for mounting:........................................................................................................ 57
4.4.2 Gas lines ..................................................................................................................................... 58
4.4.3 Sample lines................................................................................................................................ 59
4.4.4 Exhaust gas lines ........................................................................................................................ 60
4.4.5 Equipotential bonding cable/grounding....................................................................................... 60
4.4.6 Lightning protection..................................................................................................................... 60
4.4.7 Installing the communications cable ........................................................................................... 61
4.4.8 Breathing device ......................................................................................................................... 62
4.4.9 Power switch and fuse ................................................................................................................ 63
4.4.10 Fitting the power cable................................................................................................................ 64
4.4.11 Connecting of digital outputs and digital inputs........................................................................... 65
4.4.12 Connecting the HMI device......................................................................................................... 66
4.4.13 Connecting the HMI device on site (only for servicing purposes)............................................... 66
5 Commissioning and operation ................................................................................................................. 71
5.1 Connection of gas lines............................................................................................................... 72
5.2 Activating the gas supply ............................................................................................................ 72
5.3 Switching on the chromatograph ................................................................................................ 73
5.4 Starting the PC and operating software...................................................................................... 74
5.5 Shutting down ............................................................................................................................. 75
6 Service and maintenance ........................................................................................................................ 77
6.1 Maintenance of analysis module.................................................................................................77
6.1.1 Removal of analysis module ....................................................................................................... 77
6.1.2 Installing the analysis module ..................................................................................................... 84
6.2 Replacing the carrier gas cylinders............................................................................................. 87
6.3 Installing and removing electronic components.......................................................................... 87
6.3.1 Removal of electronic modules................................................................................................... 88
6.3.2 Installation of electronic modules................................................................................................ 92
6.4 Conversion of MicroSAM basic device AS09.............................................................................. 94
6.4.1 Preparation for use of analysis modules of type A ..................................................................... 94
6.4.2 Restoring of data for AS09 type A ..............................................................................................96
6.4.3 Returning for use of analysis modules of type D ........................................................................ 98
7 Spare parts/accessories ........................................................................................................................ 101
7.1 Spare parts list .......................................................................................................................... 101
7.2 Accessories............................................................................................................................... 102

Table of contents
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07 5
8 Examples............................................................................................................................................... 103
9 Technical data ....................................................................................................................................... 105
10 Dimension drawings .............................................................................................................................. 111
A Appendix................................................................................................................................................ 113
A.1 Principle of live column switching ..............................................................................................113
A.1.1 Advantages of live switching......................................................................................................114
A.1.2 Live switching function...............................................................................................................115
A.2 ESD guidelines ..........................................................................................................................120
A.3 EC Declaration of Conformity ....................................................................................................122
A.4 A marking in accordance with KC (Korea).................................................................................122
A.5 Service and Support ..................................................................................................................123
A.6 List of abbreviations ...................................................................................................................124
Glossary ................................................................................................................................................ 127
Index...................................................................................................................................................... 133

Table of contents
MicroSAM
6 Operating Instructions, 06/2012, C79000-G5376-C560-07

MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07 7
Purpose of this documentation 1
These instructions contain all information that you will require to commission and use the
device.
It is aimed at persons who install the device mechanically, connect it electrically,
parameterize and commission it, as well as at service and maintenance engineers.
Note
Please read the operating instructions before you use this device. The operating
instructions contain all important information for the device.
Observation of the information:
– Guarantees correct device functioning
– Provides reliable results
– Saves you servicing costs
Information
The contents of these instructions are neither part of an earlier existing agreement,
statement or legal commitment nor do they change this. All obligations on the part of
Siemens AG are contained in the respective sales contract which also contains the complete
and solely applicable warranty conditions. Any statements contained herein do not create
new warranties or modify the existing warranty.
The content reflects the technical status at the time of printing. We reserve the right to make
technical changes in the course of further development.
History
The following table shows the most important changes in the documentation compared to
each previous edition:
Issue Comment Firmware
04
03/2012
Revision of contents and editing FW: 3.10
03
02/2010
Revision of contents and editing FW: 3.00
02
09/2008
Revision of contents and editing FW: 02.08.00
01
08/2006
First edition FW: 01.17.00

Purpose of this documentation
MicroSAM
8 Operating Instructions, 06/2012, C79000-G5376-C560-07

MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07 9
General information 2
2.1 Intended use
● This gas chromatograph is used to separate and quantitatively determine components in
a gaseous sample.
● The device may only be used for the purposes specified in these instructions.
● Modifications to the device which are not expressly referred to in these instructions
therefore result in an application which is not in accordance with the intended use. Such
modifications to the device are then the exclusive responsibility of the user.
2.2 Safety information
The gas chromatograph complies with the applicable safety standards. If the handling
instructions and safety information are observed, no dangers exist when using the device
which could endanger the health of personnel or result in damage to property.
You will find the safety information:
● In these operating instructions and in the manual
● On the gas chromatograph
● On the chromatograph components
WARNING
Only appropriately qualified persons are permitted to make interventions on this device.
These persons must be thoroughly familiar with all sources of danger and service
activities in accordance with these operating instructions.
For trouble-free and safe operation of this device, the following requirements must be
met:
Transportation in accordance with proper procedures
Proper storage
Proper installation and assembly
Careful operation and maintenance
To avoid injury to persons and damage to the device, please observe the information in
the manual.

General information
2.2 Safety information
MicroSAM
10 Operating Instructions, 06/2012, C79000-G5376-C560-07
WARNING
Dangerous gases
The gas chromatograph requires various gases for operation which have different
danger potentials.
The gas chromatograph may require gases for operation which produce an explosive
mixture with air.
Route all exhaust gases out of the gas chromatograph and away from the position of
use using a common line.
Always provide sufficient ventilation as soon as you allow the sample gas line to run
empty and the sample gas contains corrosive or toxic components.
CAUTION
Corrosion danger
The housing and the pipelines are resistant to solvents as well as weak alkalis and
acids.
Check the resistance of the housing and the pipelines when using in an environment
with strong alkalis or acids and/or at higher temperatures.
Avoided corrosion and damage of the connection lines resulting from permanent contact
with the following substances:
Nitric acid
Hydrochloric acid
Carbon bisulfide
Ethanol
Formic acid
Petroleum spirit
Hydraulic oil
Isopropanol

General information
2.3 Transportation
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07 11
CAUTION
Electrostatic sensitive devices
This device contains electrostatic sensitive devices. Electrostatic sensitive devices may
be destroyed by voltages that are undetectable to a human. Voltages of this kind occur
as soon as a component or an assembly is touched by a person who is not grounded
against static electricity. The damage to a module as a result of overvoltage cannot
usually be detected immediately. It may only become apparent after a long period of
operation.
Protective measures against discharge of static electricity:
Before you work with modules, first discharge any static charges from your body, for
example by touching a grounded object.
Devices and tools used must be free of static charge.
Always pull the mains connector and disconnect the battery before installing or
removing modules.
Hold modules only by their edges, and do not touch pins or printed conductors.
2.3 Transportation
The gas chromatograph is supplied in various designs, and can also include a metal bracket
as a protective unit for the connection pipes (see ⑦, Fig. 3.1). If the chromatograph is
supplied with this metal bracket, it must only be transported or shipped together with it.
Furthermore, we also recommend operation of the chromatograph with the metal bracket
fitted.
If the chromatograph is transported or shipped without this metal bracket, the warranty is
nullified.
Exception: The metal bracket is not required if the chromatograph is mounted in a protective
casing approved by Siemens. In this case, transportation or shipping of the chromatograph is
only permissible in this protective casing.

General information
2.4 Protection against explosion
MicroSAM
12 Operating Instructions, 06/2012, C79000-G5376-C560-07
2.4 Protection against explosion
2.4.1 General regulations
The installation and operation of electrical equipment in potentially explosive atmospheres
are regulated by the directive RL 99/92/EU (ATEX 137). This directive refers to the generally
recognized process engineering regulations.
WARNING
Cancellation of the explosion protection
The test certificate for your explosion-proof gas chromatograph only applies to the original
configuration as well as to connection and installation according to the switching and piping
plans of Siemens AG. Changing one or more components will void the explosion protection
for your device.
Conditions
The test certificate and any supplements contain all conditions and regulations specified for
installation and operation of the device.

General information
2.4 Protection against explosion
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07 13
WARNING
Explosion hazard
The device is designed to analyze flammable and non-flammable gaseous media.
Hydrogen or inert gases are used as auxiliary gases.
For the analysis of flammable gases or use of hydrogen as a carrier gas, oxygen may
only be present in concentrations ≤ 2% in the sample.
Oxygen at concentrations up to 21% and pressure up to 1.1 bar (110 kPa) is permissible
for operation only if an additional constructive explosion protection measure is
implemented, for example, installation of a flame arrester between the process
connection and gas chromatograph.
Oxygen at concentrations up to 21% and pressure > 1.1 bar (110 kPa) is not allowed
under normal operating conditions for explosive mixtures.
The pneumatic conditions for the sample and the auxiliary gas must be strictly observed:
– Sample gas ≤ 1.6 bar (160 kPa) absolute pressure
– Auxiliary gas ≤ 8 bar (800 kPa) absolute pressure
If flammable gases are connected at a pressure > 1.1 bar (110 kPa), the chromatograph
and the gas line must be purged with process gas prior to analysis.
Flammable gases which are explosive under the analysis conditions even with the
exclusion of oxygen (acetylene and ethylene oxide), may only be present in the
analyzed mixture in concentrations that are uncritical for safety-related engineering.
Acetylene and ethylene oxide can be present in a concentration up to 100%.
The permissible ambient temperature range is -30° to +55° C.
The temperature range for continuous operation is -20 °C to +50 °C.

General information
2.4 Protection against explosion
MicroSAM
14 Operating Instructions, 06/2012, C79000-G5376-C560-07
Table 2- 1 Case examples for explosion protection
Case
no.
Concen-
tration of
oxygen
in normal
operation
Transient
concen-
tration of
oxygen
(not normal
operation)
Permis
sible
carrier
gases
Sample
pressure
(absolute)
External
flame
arrester
Substances
that are
explosive
under
exclusion of
oxygen
Process
medium
zone x
MicroSAM
(7KQ3101)
SITRANS
CV
(7KQ3105)
1 0 ... 2 % 0 ... 2 % H2, He,
N2, Ar
1.0 ... 1.6 bar Not
required
Not allowed Not
explosive
x x
2 0 ... 2 % 0 ... 21 % H2, He,
N2, Ar
1.0 ... 1.6 bar Not
necessary
Zone 1 x
3 0 ... 21
%
0 ... 21 % H2, He,
N2, Ar
1.0 ... 1.1 bar Required
Not allowed;
with the
exception of
acetylene
and ethylene
oxide up to
100% Zone 0 x
4 0 ... 4 % 0 ... 4 % He, N2,
Ar
1.0 ... 7 bar Not
necessary
Not allowed Zone 1 x
x = applies to the product
Identification of explosion protection
The gas chromatograph has a flameproof enclosure. With the flameproof enclosure, the
housing resists an internal explosion pressure.
The housing of your gas chromatograph has a rating plate which identifies the explosion
protection.
This device is approved for a sample gas inlet pressure of 1.6 bar absolute (160 kPa) in
accordance with ATEX II 2 G Ex d IIC T4.

General information
2.4 Protection against explosion
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07 15
Release version base device and the associated explosion protection
Release
version
base
device
New features of the basic device Protection against explosion Explosion protection certificate
Supplements
ATEX II 2 G EEx d IIC T4 ATEX
DMT 03 ATEX E 069 X
Supplement 1 to 3
FM
Class I, Div 1, Groups A, B, C, D T4
Class I, Zone 1, Group IIC T4
FM
Certificate 3017424
Date Issued 2005/12/14
CSA
Class I, Div 1, Groups B, C, D T4
CSA
Certificate 1915614
Date Issued 2007/06/07
AS 08 Live dosing, range of supply
voltage extended:
24 V DC (18.5 V ... 30.2 V)
Enclosure Type 4X
ATEX II 2 G EEx d IIC T4 ATEX
DMT 03 ATEX E 069 X
Supplement 1 to 3
FM
Class I, Div 1, Groups A, B, C, D T4
Class I, Zone 1, Group IIC T4
FM
Certificate 3017424
Date Issued 2005/12/14
CSA
Class I, Div 1, Groups B, C, D T4
CSA
Certificate 1915614
Date Issued 2007/06/07
AS 09 eLive injection: Introduction of a
5th solenoid valve, modification
of the micro-diaphragm valve
Enclosure Type 4X
ATEX
II 2G Ex d IIC T4 Gb
DMT 03 ATEX E 069 X
ATEX
DMT 03 ATEX E 069 X
Supplement 1 to 4
FM Certificate canceled
CSA
CLASS I, DIVISION 1 GROUPS B, C,
D T4
CLASS I, ZONE 1 GROUPS IIC T4
CSA
Certificate 1915614
Date Issued 2009/11/13
AS 10 Modified 3rd temperature control
system (model with temperature
protection)
Modified 4th temperature control
system (model with temperature
protection)
ENCLOSURE TYPE 4X / IP65
2.4.2 Directives for operation
Switching on the chromatograph
Only switch on the power supply to the device if this has been closed correctly.

General information
2.4 Protection against explosion
MicroSAM
16 Operating Instructions, 06/2012, C79000-G5376-C560-07
Opening the housing with the power supply switched off
WARNING
Explosions
If you open the housing prematurely, explosions may occur due to hot components and
residual electrical charges in the gas chromatograph. A corresponding label informing you
of this is present on the device.
Before opening the housing in a hazardous area, disconnect the device from the power
supply.
It is essential that you wait for 60 minutes following switching off of the power supply.
WARNING
Fire permission certificate
Replacement of the backup battery is only permissible if you have a fire permission
certificate. This instruction applies regardless as to whether the gas chromatograph is
switched on or off.
Opening the housing with the power supply switched on
A diagnostics connector is located behind the status display panel. You must open the
housing in order to access it.
WARNING
Fire permission certificate
Opening the housing in the hazardous area with the power supply switched on is only
permissible if you have a fire permission certificate.
Maintenance and repair of components
WARNING
Observe the directive
Observe the regulations of directive RL 99/92/EU (ATEX 137) when carrying out
maintenance and repairs on parts associated with the explosion protection.

General information
2.5 Qualified personnel
MicroSAM
Operating Instructions, 06/2012, C79000-G5376-C560-07 17
2.5 Qualified personnel
CAUTION
Qualified personnel
Only qualified personnel are authorized to install and use the process gas
chromatograph.
Insufficient knowledge of the operating instructions, or the complete absence thereof,
result in the deletion of all liability claims with regard to Siemens AG.
We therefore recommend owners to have the instruction of personnel confirmed in
writing.
Qualified personnel are people who are familiar with the installation, mounting,
commissioning, and operation of the product. These people have the following qualifications:
● They are authorized, trained or instructed in operating and maintaining devices and
systems according to the safety regulations for electrical circuits, high pressures and
aggressive as well as hazardous media.
● For explosion-proof devices: they are authorized, trained, or instructed in carrying out
work on electrical circuits for hazardous systems.
● They are trained or instructed in maintenance and use of appropriate safety equipment
according to the safety regulations.
2.6 Limitation of liability for external accessories
If you wish to use or connect accessories in the chromatograph which are not specifically
recommended by Siemens AG, please first obtain confirmation from Siemens AG that the
operational safety of the chromatograph is not influenced by the external accessory. Without
this confirmation, Siemens AG excludes all liability for the operational safety.
2.7 Final shutdown and disposal
It is essential to observe the environmental protection guidelines at the location of the
operating company for the final shutdown and disposal of the process gas chromatograph!

General information
2.7 Final shutdown and disposal
MicroSAM
18 Operating Instructions, 06/2012, C79000-G5376-C560-07