model 6553 series instruction manual gas analyser systems ... · zero zero hydrogen purity &...

Zero

Zero

Hydrogen Purity

& Purge Gas Monitor

Range

1

3

4600

ABB

95.0H2-AIR

4600

ABB

2

UIN O

N S E

Model 6553 SeriesGas Analyser Systems forIntrinsically Safe Hydrogen &Purge Gas Purity Measurement

Instruction Manual

Digital Displays 4689 500/503

ABB Automation

Note.Clarification of an instruction or additional information.

Information.Further reference for more detailed information ortechnical details.

Although Warning hazards are related to personal injury, and Caution hazards are associated with equipment or property damage,it must be understood that operation of damaged equipment could, under certain operational conditions, result in degradedprocess system performance leading to personal injury or death. Therefore, comply fully with all Warning and Caution notices.

Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manualfor any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval ofMarketing Communications Department, ABB Automation.

The Company

ABB Automation is an established world force in the design and manufacture ofinstrumentation for industrial process control, flow measurement, gas and liquid analysis andenvironmental applications.

As a part of ABB, a world leader in process automation technology, we offer customersapplication expertise, service and support worldwide.

We are committed to teamwork, high quality manufacturing, advanced technology andunrivalled service and support.

The quality, accuracy and performance of the Company’s products result from over 100 yearsexperience, combined with a continuous program of innovative design and development toincorporate the latest technology.

The NAMAS Calibration Laboratory (No. 0255) is just one of ten flow calibration plantsoperated by the Company, and is indicative of ABB Automation’s dedication to qualityand accuracy.

BS EN ISO 9001

St Neots, U.K. – Cert. No. Q5907Stonehouse, U.K. – Cert. No. FM 21106

Stonehouse, U.K.

EN 29001 (ISO 9001)

Lenno, Italy – Cert. No. 9/90A

Use of Instructions

Warning.An instruction that draws attention to the risk of injury ordeath.

Caution.An instruction that draws attention to the risk of damage tothe product, process or surroundings.

Health and SafetyTo ensure that our products are safe and without risk to health, the following points must be noted:

1. The relevant sections of these instructions must be read carefully before proceeding.

2. Warning labels on containers and packages must be observed.

3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance with theinformation given.

4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressureand/or temperature.

5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling proceduresmust be used.

6. When disposing of chemicals ensure that no two chemicals are mixed.

Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where applicable) may beobtained from the Company address on the back cover, together with servicing and spares information.

REGISTERE

D

0255

1

CONTENTS

1 INTRODUCTION................................................................ 2

2 DESCRIPTION................................................................... 32.1 Model 6553 Gas Monitor ........................................... 3

2.1.1 Dual Range Display .................................... 32.2 Katharometer Analyzer Panels .................................. 3

2.2.1 Panel 6540 2032 ......................................... 32.2.2 Panel 6548 000 (High Pressure Version) .... 4

2.3 Model 4234 Power Supply Unit ................................. 42.4 Remote Indicator/Controllers ..................................... 4

3 PREPARATION ................................................................. 53.1 Identification .............................................................. 5

3.1.1 Model 6553 Monitor Unit ............................. 53.1.2 Models 6540 203 and 6548 000

Katharometer Analyzer Panels .................. 53.1.3 Model 4234 Power Supply Unit ................... 63.1.4 Coding System ............................................ 73.1.5 Ordering Code – 6553 Hydrogen

Purity and Purge Gas. ............................... 73.1.6 Option Combinations (6553/[X]) .................. 7

4 MECHANICAL INSTALLATION ........................................ 84.1 Locating and Mounting System Items ....................... 8

4.1.1 Model 6553 Gas Monitor ............................. 84.1.2 Katharometer Analyzer Panels ................... 94.1.3 Model 4234 Power Supply Unit ................. 10

4.2 Sample Gas Interconnections ................................. 10

5 ELECTRICAL INSTALLATION........................................ 115.1 Electrical Interconnections ...................................... 11

5.1.1 Model 6553 Gas Monitor ........................... 115.1.2 Models 6540 203 and 6548 000

Katharometer Analyzer Panels ................ 125.1.3 Model 4234 Power Supply Unit ................. 15

5.2 Intrinsically Safe Requirements ............................... 155.2.1 Cable Requirements ................................. 155.2.2 Recommended Cables ............................. 165.2.3 Installing Remote Ancillary Items .............. 165.2.4 Full Intrinsically Safe Requirements .......... 16

6 SETTING UP.................................................................... 176.1 Katharometer Analyzer Panel – Filling the Drying

Chamber ............................................................. 176.2 Setting Sample Flow ............................................... 176.3 Electrical Checks ..................................................... 18

6.3.1 Model 4234 Power Supply Unit Output ..... 186.3.2 Zener Barrier Units .................................... 186.3.3 Checking System Earth ............................ 18

7 CONTROLS & DISPLAYS ............................................... 197.1 Displays ................................................................... 197.2 Switch Familiarization .............................................. 19

8 STARTUP ........................................................................ 208.1 Instrument Start-up .................................................. 208.2 Alarm Set-points ...................................................... 20

8.2.1 Type of Alarm Action ................................. 208.2.2 Hydrogen Alarm Set Point ......................... 20

8.3 Calibration ................................................................ 208.3.1 Purge Gas ................................................. 218.3.2 Hydrogen .................................................. 21

9 OPERATION .................................................................... 229.1 Normal ..................................................................... 22

9.1.1 Purging of Hydrogen Coolant Gas ............ 229.1.2 Filling with Hydrogen Coolant Gas ............ 22

9.2 Operating Page – Range 1 (Read Only) ................. 239.3 Operating Page – Range 2 (Read only) .................. 249.4 Operating Page – Range 3 (Read only) .................. 24

10 PROGRAMMING ........................................................... 2510.1 Range 1 ................................................................. 28

10.1.1 Access to Secure Parameters ................ 2810.1.2 Langauge Selection ................................ 2810.1.3 Set Up Outputs Page .............................. 2810.1.4 Electrical Calibration Page ...................... 30

10.2 Range 2 ................................................................. 3110.2.1 Access to Secure Parameters ................ 3110.2.2 Language Page ....................................... 3110.2.3 Set Up Outputs Page .............................. 3110.2.4 Electrical calibration page ....................... 33

10.3 Range 3 ................................................................. 3410.3.1 Access to Secure Parameters ................ 3410.3.2 Language Page ....................................... 3410.3.3 Set Up Outputs Page .............................. 3510.3.4 Electrical Calibration Page ...................... 36

11 MAINTENANCE ............................................................. 3811.1 General Maintenance ............................................ 38

11.1.1 Pressure .................................................. 3811.1.2 Flow ......................................................... 3811.1.3 Leaks ....................................................... 3811.1.4 Vibration .................................................. 3811.1.5 Contamination ......................................... 3811.1.6 Ambient Temperature .............................. 3811.1.7 Bridge Current ......................................... 38

11.2 Diagnostic Tests ..................................................... 3811.2.1 Checking Output of 4234 Power Supply

Unit .......................................................... 3811.2.2 Checking Integrity of Zener Barrier Units 3811.2.3 Checking the Katharometer Output ......... 38

11.3 Routine Maintenance ............................................. 3811.3.1 Hydrogen Katharometer Calibration ........ 3811.3.2 Purge Gas Katharometer Calibration ...... 3811.3.3 Changing Desiccant in Drying Chamber . 39

11.4 Repair Maintenance .............................................. 3911.4.1 Removing Liquid from Katharometer

Measurement Block ................................. 3911.4.2 Removal of a Display Unit Chassis .......... 40

12 SPARE PARTS LIST ..................................................... 4012.1 Consumables ........................................................ 4012.2 Routine Maintenance Parts ................................... 4012.3 Repair Maintenance Parts ..................................... 40

13 SPECIFICATION............................................................ 41

APPENDIX ........................................................................... 43A1.1 Model 4234 Power Supply Unit ............................. 43

A1.1.1 Functional Description ............................ 43A1.1.2 Fault Finding ........................................... 43A1.1.3 Parts List ................................................. 43

2

Warning. This operating manual applies only tothose systems which have been designed and constructed tothe standards specified in the schedules of the BASEEFAcertificates listed. The separate units to which thesecertificates apply are clearly identifiable by model numbersand the data on the identification and BASEEFA certificationlabels fixed to them. Other combinations of similarequipment built to any earlier specifications are not coveredby certificate number EX 77138. This is particularly importantwhere new replacement units are to be incorporated intoexisting installations covered by any earlier certificationstandards. If in any doubt about the installation of particularcombinations of certified equipment, please contact theCompany for advice before proceeding. It is essential thatunits are installed strictly in accordance with the appropriatestandards for electrical equipment for use in flammableatmospheres. Any deviation from the specified installationconditions, or any unauthorized repairs or adjustments caninvalidate the safety assurances given by the certification ofthe unit.

The ultimate responsibility for any particular installation lieswith the installing user/contractor.

This manual gives the installation, operating and maintenanceinformation for the Company's range of Model 6553Intrinsically Safe Gas Analyzer Systems, normally used withhydrogen cooled electrical power generators.

The complete 6553 analyzer system uses a combination ofthree different units. Each unit is independently certified byBASEEFA (EECS) for use as part of an intrinsically safesystem to the standards of SFA.3012:1972 for use inassociation with Group IIC (hydrogen) hazardousatmospheres. The different units of the system are

1) The Model 6553 Gas Monitor Unit which is available inseveral options. The inputs to these units are certified tocode Ex(ia)IIC under BASEEFA certificate Ex 77124/B/Swith the unit installed in the safe area only.

2) Models 6539-960 and 6548-001 Katharometer Units whichform part of an intrinsically safe Model 6540-203 or6548-000 Katharometer Analyzer Panel. The 6539-960unit is certified to code Ex (ia) IIC T5 under BASEEFAcertificate Ex 76179/B for installation in the hazardousarea.

Warning. The 10 bar unit, 6548 001, has beencertified EX (ia) T5 by BASEEFA. However, it must bepointed out that the standard to which it has been certifiedonly considers flammable gas mixtures at nominally 1 barpressure, as neither BASEEFA nor any other certifyinghouse have a standard covering such gas mixtures atelevated pressures. It is recommended that to fullyconform with the certification, gas sample mixtures atelevated pressures (i.e. above 1 bar) are reduced tonominally atmospheric pressure before presentation tothe katharometer, and that gases leaving thekatharometer system are vented to atmosphere.

The 6539 960 katharometer may or may not be fitted withignition arrestors in the sample connection lines,depending on user requirements.

3) The Model 4234 constant current Power Supply Unit,which provides a suitable supply for one katharometer unit.These units have their output certified to code Ex (ia) IICunder BASEEFA certificate Ex 76180/B/S for installation inthe safe area only.

The complete gas monitoring system, if installed inaccordance with the certificate schedules and therequirements given in this manual, is itself certified intrinsicallysafe to an overall code Ex (ia) IIC under the system certificatenumber Ex 77138.

If further information or assistance is required, the Company'sspecialist staff, service centres or worldwide organization maybe contacted through the most convenient address given onthe back cover of this manual. Specialist training courses canalso be arranged by our Training Centre.

1 INTRODUCTION

3

All the various system options consist of one or more of thefollowing units with the further option of fitting the monitor andpower supply units in a cubicle. Specific information relating toa cubicle option will be supplied separately.

2.1 Model 6553 Gas MonitorThe Gas Monitor is a unit suitable for panel mounting or in acontrol cubicle in the safe area. The various monitor optionsuse one or two digital displays with protected access for zeroadjustments and may also have a range selector switch – seeFig. 2.1.

2.1.1 Dual Range DisplayWhen a dual range display is fitted, the range selector switchmay be used to select parameters as follows:

Position (1) Percentage of hydrogen in air, by volume,shown on the upper display.

Position (2) Percentage of hydrogen in carbon dioxide, byvolume, shown on the lower display.

Position (3) Percentage of air in carbon dioxide, by volume,shown on the lower display.

The top display is single range, and is preprogrammed toindicate the hydrogen purity measurement of the coolant gasunder normal operation of the system. The display covers arange 85 to 100 % or 80 to 100% hydrogen purity in air with twoalarm set points. Two alarm outputs and a valueretransmission signal are also available.

With a second (bottom) display fitted, this may be dual rangemarked 0 to 100% hydrogen in carbon dioxide and 0 to 100% airin carbon dioxide for use in the hydrogen purging operation. Arange selector switch is fitted with the dual range display, and avalue retransmission signal and two alarms are available. Withthe dual range display there is a further option of providing remoteindication of the range selector switch position. There is a further

98.8H2–CO2

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Hydrogen Purity

& Purge Gas Monitor

RangeRange Selector Switch

DigitalDisplays

option of fitting a second single range bottom display similar to thetop display. An alarm output and a value retransmission signal areavailable from this display option.

Each display defaults to indicate NOT IN USE when not selected.

The Model 4689 displays are dedicated variants of theCompany’s Model 4600 Series Indicator/Controllers. With thisspecial variant (4689), the displays and alarm indicators on thefront panel remain the same but software control is specific to theKatharometer systems. All user programmable data can beprotected from unauthorized alteration by a programmable 5-digitsecurity number.

The zero adjustments on the front panel of the monitor allowremote zeroing of the katharometers in the hazardous area. Theadjustment access for a particular display is adjacent to thedisplay and at the same level.

The monitor unit has a protective case which can be removed foraccess to the interior without removing the whole monitor unitfrom the katharometer panel. Separate cable glands are providedfor cables to the hazardous area and to the safe area.

The monitor also contains encapsulated zener barrier units tolimit the electrical energy level that can be applied from theinstrument circuits into the hazardous area. These zener barrierunits are located below the display units, on a bus-bar whichMUST be earthed (grounded). A metal screening arrangementsegregates the connections made to equipment in thehazardous area. A main fuse is fitted inside the monitor case forthe electricity supply line.

Caution. A monitor supplied for nominal a.c.mains voltage of 110 V cannot be adapted for use on a230 V supply and vice versa.

2.2 Katharometer Analyzer Panels

2.2.1 Panel 6540 203 – Fig. 2.2This panel incorporates the 6539 960 Katharometer Unit.When the gas monitoring system is certified for hydrogenpurity and purge gas monitoring applications there are twokatharometer analyzer panels in the hazardous area. Singledisplay systems only require one katharometer panel. Eachpanel has a katharometer assembly which comprises athermally lagged katharometer type 6539 960, a meteringvalve, a flowmeter and a drying chamber. These items aremounted on a flat panel suitable for fixing to a vertical surfaceclose to the sample point. One of the katharometers iscalibrated for the hydrogen purity measurement, while anyother may be similar or dual ranged for hydrogen and air incarbon dioxide measurements.

The inlet and outlet gas unions to these katharometer unitsmay, in some instances, be fitted with ignition arrestors, butthese are not a necessary part of the certification. Thekatharometer analyzer panel has a model number of6540 203/J if the katharometer is fitted with ignition arrestorsand 6540 203/K if no arrestors are fitted.

2 DESCRIPTION 2 DESCRIPTION…

Fig. 2.1 Model 6553 Gas Monitor

4

2.2.2 Panel 6548 000 (High Pressure Version)A 6548 001 Katharometer Unit is fitted on this analyzer panel, forarrangements similar to those above, incorporating high pressurefixtures and fittings. Ignition arrestors are not available for this version.

Each sealed katharometer assembly incorporates a WheatstoneBridge made up of fine glass coated platinum filaments. One pair ofparallel arms is sealed in the reference gas (hydrogen or carbondioxide) and the other pair exposed to the sample gas.

When the intrinsically safe stabilized current from the power supplyunit (Model 4234) is passed through this bridge, the temperature ofthe platinum filaments rises to a point of thermal equilibrium. Underconditions which are arranged to give minimum radiation andconvection heat transfer, the equilibrium temperature depends on thethermal conductivity of the gas surrounding the filament. Thus anydifference between the thermal conductivity of reference and samplegases will cause an imbalance in the bridge; this imbalance (as amillivolt signal) is indicated by the monitor unit.

Zener diodes are connected across the input connections fromthe power supply unit to the katharometer in order to limit themaximum voltage which could be developed across thefilament bridge under external fault conditions. The current islimited to a safe value under fault conditions by the powersupply unit.

2.3 Model 4234 Power Supply Unit – Fig. 2.3To operate a katharometer unit in the hazardous area, oneModel 4234 Power Supply Unit is required for eachkatharometer. The Power Supply Unit supplies a stabilized350 mA d.c. signal, and must be mounted in the safe area.There are two separate versions available for either a nominal110 to 120 V a.c. or 200 to 220/230 V a.c. supply voltage. Thestabilized current output is current and voltage limited torestrict the energy supply into the hazardous area.

The model 4234 is housed in a metal case fitted with lugs forwall/panel mounting. Cable gland entries are provided atopposite ends of the case for supply voltage input andstabilized output cables to the hazardous area. The printedcircuit board assembly and diode heat sink are mounted on ametal chassis and separate labelled terminal blocks are usedfor making electrical interconnections.

The circuit is protected by a cartridge fuse.

This fuse must have a high breaking capacity (h.b.c.) rating of4000 A to comply with the terms of the certification.

2.4 Remote Indicator/ControllersThe 6553 monitor unit has provision for retransmission valuesand ancillary indicator/controllers may be connected to theseoutputs, providing that they are installed in the safe area andthe installation conforms to the requirements given inSection 5.1.

ElectricalInterconnections

Flow Gauge

Ignition Arrestors(optional)

Gas SampleOutlet

Coarse ZeroAdjustment

Drying Chamber

Katharometer Unit Case

MeteringValve

GasSample

Inlet

A.C. SupplyVoltage Input

350mA Stabilisedd.c. Output

…2 DESCRIPTION

Fig. 2.2 Location of Items – Model 6540 203 Katharometer Analyzer Panel

Fig. 2.3 Model 4234 Power Supply Unit

5

3.1 IdentificationIt is essential that installers and users clearly identify thevarious units of the monitoring system as follows:

3.1.1 Model 6553 Monitor Unit – Fig. 3.1The 6553 monitor is available in several options, these beingdefined by the code number as given in Section 3.1.4.

The identification and certification labels are fixed to theoutside of the monitor case as shown in Fig. 3.1. The preciseinterpretation of the identification code gives information onthe 6553 system as a whole, as shown in Section 3.1.5.

Note. Although the display units may be marked asABB Kent-Taylor 4600 on their front panels, they arespecial units for this monitor and a standard Model 4600cannot be used. The precise identity of the display unit isgiven on the identification label shown in Fig. 3.1.

3.1.2 Models 6540 203 and 6548 000 KatharometerAnalyzer Panels – Fig. 3.2The identification of a panel is given by the panel referencenumber label as shown. Identification and certification labelsof the individual katharometer units are fixed to thekatharometer case, also shown in Fig. 3.2. The differentkatharometer units for hydrogen or purge gas aredistinguished by reference to the ‘zero gas’ specified on theiridentification label.

98.8H2–CO2

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Hydrogen Purity &

Purge Gas Monitor

Range

ABB Instrumentation Limited

PURGE GAS MONITOR TYPE 6553

(ia) IIC/BAS No.Ex77124/B/S

SFA3012

Ex

ABB Instrumentation LtdSt. Neots England PE19 3EU

TYPE 4689/500SERIAL No. L/50753/1/3

RetainingScrew

ABB Instrumentation LtdOldends Lane, StonehouseGlos, England GL10 3TA

Code No. 6553–6131101101Serial No. GB41424Voltage. 110–120Hz. 50–60Watts. 30

6540 203K

Panel Reference No.

ABB Instrumentation Ltd

ia IIC T5/BAS No.Ex 76179/BSFA 3012

Katharometer Type 6539960 Issue J

Intrinsic Safety Label (UK)

(Katharometer Unit)

ABB InstrumentationStonehouse, England

Type No. 006539960KContract No. V60127Serial No. G841444Range 100–85%Output 0–10mVZero Gas 100% H2

Model No.

UniqueReference No.

Gas Type

(Hydrogen in Air Katharometer Unit)

Ex

3 PREPARATION 3 PREPARATION…

Fig. 3.1 Typical Identification Labels and Locations –Model 6553 Gas Monitor Unit with Digital Displays

Fig. 3.2 Typical Identification Labels and Locations –Model 6540 203 Katharometer Analyzer Panel

6

3.1.3 Model 4234 Power Supply Unit – Fig. 3.3The identification and certification labels are fixed to theoutside of the unit case as shown.

Ex

ABB Instrumentation Limited

POWER SUPPLY UNIT TYPE 004234000 Issue 5

(Ia)IIC/BAS.NoEx76180/B/S

SFA 30121972

MAX. L/R 20uH/Ω

IntrinsicSafety Label(UK)

ABB Instrumentation LtdOldens Lane StonehouseGloucs England GL10 3TA

Cat.No. 004234000Serial No.G 841200Voltage. 110-120Hz. 50-60Watts. 10

Model No.UniqueReference No.

…3 PREPARATION

Fig. 3.3 Typical Identification Labels and Locations –Model 4234 Power Supply Unit

7

3.1.4 Coding System

The equipment conforms with the requirements of SFA 3012 for class IIC gases to Code Ex (ia) IIC provided that the equipmentis installed in accordance with instructions provided. The display unit and power supply units must be installed in a safe(nonhazardous) area, and gas analysis panels may be mounted close to the sample point in the hazardous area.

/3556 X X X X X X X X X X

A B C D E F G H J K

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3.1.5 Ordering Code – 6553 Hydrogen Purity and Purge Gas.

F Additional Output Signal0 Not used

G Fitted with Labels1 English2 French3 German4 Polish

H Type of Cubicle1 Without Cubicle2 German CO2

3 German Argon4 Purge Cubicle (D1)5 Purity Cubicle (D2 or D3)

J Special Features0 None9 Fitted

K Mains Supply1 110 V, 50/60 Hz2 220 V, 50/60 Hz3 230 V, 50/60 Hz

3.1.6 Option Combinations (6553/[X])The digit decode is shown in Section 3.1.5.

A Features of Upper Indicator6 Two alarms + Retrans. 4 to 20 mA

B Scale of Upper Indicator1 100 to 85% H2 in Air2 100 to 80% H2 in Air3 0 to 100% Air in CO2, 0 to 100% H2 in CO2,

85 to 100% H2 in Air4 0 to 100% Air in CO2, 0 to 100% H2 in CO2,

80 to 100% H2 in Air5 85 to 100% H2 in Air6 80 to 100% H2 in Air7 0 to 100% Air in Ar, 0 to 100% H2 in Ar

85 to 100% H2 in Air8 0 to 100% Air in Ar, 0 to 100% H2 in Ar

80 to 100% H2 in Air9 Special

C Features of Lower Indicator0 Indicator Not Fitted3 Two Alarms + Retrans. 4 to 20 mA

D Scale of Lower Indicator0 Indicator Not Fitted1 0 to 100% Air in CO2, 0 to 100% H2 in CO22 100 to 85% H2 in Air3 100 to 80% H2 in Air4 0 to 100% Air in CO2, 0 to 100% H2 in CO2,

85 to 100% H2 in Air5 0 to 100% Air in CO2, 0 to 100% H2 in CO2,

80 to 100% H2 in Air6 85 to 100% H2 in Air7 80 to 100% H2 in Air9 Special (N2 Purge Gas)A 0 to 100% Air in Ar, 0 to 100% H2 in Ar,

85 to 100% H2 in AirB 0 to 100% Air in Ar, 0 to 100% H2 in Ar,

80 to 100% H2 in Air

E Range Selector Switch0 Not fitted2 Fitted, with facilities for Remote Indication of Switch

Position.3 Fitted with 2 range switches, upper and lower

indicator plus remote range indication.

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A 6 6 6 6 6 6B 6,5,2,1 8,7,4,3 6,5,2,1 6,5,2,1 9,8,7,4,3 6,5,2,1C 0 0 3 3 3 3D 0 0 1 7,6,3,2 B,A,9,5,4 B,A,5,4E 0 2 2 0 3 3F 0 0 0 0 0 0G 4ot1 4ot1 4ot1 4ot1 4ot1 4ot1H 5,1 4,1 4,1 5,1 4,3,2,1 4,1J 9,0 9,0 9,0 9,0 9,0 9,0K 3,2,1 3,2,1 3,2,1 3,2,1 3,2,1 3,2,1

…3 PREPARATION

8

4.1 Locating and Mounting System Items

4.1.1 Model 6553 Gas Monitor – Fig. 4.1The monitor must be located in the safe area of the application plant in a sheltered interior environment.

The monitor is intended to be panel mounted in a position to suit reading of the displays and with access to the rear to enablewiring interconnections to be made. The panel preparation requirements and installation dimensions are shown in Fig. 4.1. Themonitor is secured to the panel by two clamping brackets at opposite corners of the monitor chassis.

362

Katharometerintrinsicallysafe circuits

Power and signalconventional

circuits

Cableentries

Mounting panelthickness range 34

50-20

17294 23

Mou

ntin

g pa

nel

disp

lay

face

95

350

± 0.

5

25.5 3

View on display face ofmounting panel requirements

Area forclampingbrackets

9550

3

274

278 ± 0.5

%H2 IN CO2

95.0

290 30 272

Monitorcase

NOT IN USE

-----

4 MECHANICAL INSTALLATION

Fig. 4.1 Installation Dimensions and Interconnection Positions – Model 6553 Gas Monitor Unit with Digital Displays

9

4.1.2 Katharometer Analyzer Panels – Fig. 4.2

Caution. Ensure that the correct panel, specifying zero gas ‘Hydrogen’ or ‘CO2’, is located at the required position andensure that the panel is of the correct pressure rating.

The panel is located in the hazardous area (zone 0,1 or 2) of the application plant in a sheltered interior environment. Avoid alocation which subjects the katharometer unit to direct sunlight. When two katharometer panels are used they should bepositioned so as to be at the same ambient temperature.

The katharometer unit is fixed to the panel, which has fixing holes at each corner, and should be mounted on a suitable verticalsurface close to the sample tapping point. The installation dimensions for the panels are shown in Fig. 4.2 and 4.3.

43

14

114 38

2

14

610

572 ±0.3

Gland for Ø7 - 10.5 cable

11210

19

305

267

±0.3

Cou

plin

g fo

rØ

8 tu

be

Inle

t98

179

233

Outlet

Coupling forØ8 tube

4 fixingholes Ø10

19

50

Note. All dimensions nominalmillimetres unless indicated otherwise.

148

38

10

19

305

267

±0.3

Cou

plin

g fo

rØ

6 tu

be

Inle

t98

610

572 ±0.3

112

179

Outlet Coupling forØ6 tube

19

Gland for Ø7 – 10.5 cable

4 fixingholes Ø10


4 MECHANICAL INSTALLATION…

Fig. 4.2 Installation Dimension and Interconnection Positions – Model 6540 203 Katharometer Analyzer Panel

Fig. 4.3 Installation Dimension and Interconnection Positions – Model 6548 000 Katharometer Analyzer Panel

10

4.1.3 Model 4234 Power Supply Unit – Fig. 4.4The unit must be located in the safe area of the applicationplant in a sheltered interior environment.

The power supply unit has 4 fixing lugs and should be mountedon a suitable vertical surface. The installation dimensions areshown in Fig. 4.4.

4.2 Sample Gas Interconnections

Warning. A hazardous mixture of hydrogen in aircould develop in the event of leakage from the sample gassystem. Katharometer analyzer panels should be locatedin a ventilated area.

The sample pressure must not exceed the value given inSection 13.

The incoming sample gas temperature must not exceed thetemperature given in Section 13.

If there is a risk of significant particle contamination, a suitable1 µm filter unit should be incorporated in the system before thesample gas enters the analyzer system.

Compression couplings are supplied at the sample inlet andoutlet to the katharometer panel. These couplings are suitablefor connecting 8 mm (Model 6540 203) or 6 mm (6548 000)outside diameter metal tube. It is recommended that stainlesssteel tube is used.

The complete tubing system should be tested for leaks inaccordance with the requirements of the responsible authority.

283

50 160 ± 1

230

194

± 0.

5

148

26

Power in

2 G

land

sfo

r Ø

7 10

.5ca

ble

Regulated

power out

10.5

20

26

55

135

Gland positions foralternative orientation of unit


…4 MECHANICAL INSTALLATION

Fig. 4.4 Installation Dimension and Interconnection Positions – Model 4234 Power Supply Unit

11

5.1 Electrical Interconnections

Warning.• Equipment in this system operates on a.c. mains

supply voltage electricity. Suitable safety precautionsmust be taken to avoid the possibility of electric shock.

• Although certain instruments are fitted with internalfuse protection, a suitably rated external protectiondevice, e.g. a 3 A fuse or miniature circuit breaker(m.c.b.), must also be fitted by the installer.

• The proper electrical connections and wiring standardsmust be achieved to establish the intrinsic safety of thesystem, as certified.

• The a.c. input and intrinsically safe d.c. output wiringmust be routed separately from non-intrinsically safewiring.

Fig. 5.3 shows the interconnecting wiring requirements for thegas analyzer system, which must be strictly observed. Detailsof cable requirements, which must be strictly adhered to, arealso given – see Section 5.2.1.

After completing the wiring, check that the continuity earthing(grounding) and isolation of all circuits is to the required localelectrical standards for intrinsically safe circuits.

The separate units of the analyzer system must beinterconnected as follows:

5.1.1 Model 6553 Gas Monitor – Fig 5.1

Warning. No connections must be made to thehazardous area terminals (Terminal Block 2) other than asspecified in wiring diagram Fig. 5.3. The appropriate cablerequirements must be also satisfied.

Remove the outer case from the back of the unit to gain accessto the cable glands and terminal blocks.

The electrical connections are made through the appropriatecable gland at the bottom of the unit into the terminal blockimmediately above them. There are separate cable glands forwires to the Hazardous and safe areas – see Fig. 5.1.

The alarm and signal outputs on terminal block 1 (TB 1), betweenTB1 - 1 and TB1 - 16, may be connected as required. Theavailability of signal outputs will vary with the particular 6553system. Refer to Fig. 5.3 for details.

Make the wiring connections in accordance with the informationgiven in the wiring diagram Fig. 5.3 and Section 5.1.

1 16 17 32

Area forBarriers

SelectorSwitches

Zero adjustmentfor remotekatharometers

Clampbrackets

Type : 4689/503top display unit

Type : 4689/500bottom display unit

Zener barriers

Terminal block (TB2)for katharometerintrinsically safe circuits

Safety earthterminal (TS1)

3-way mainssupply terminalblocks

Fuses

Upper IndicatorTerminal Block (TB1)for power and signalconventional circuits

Lower Indicator TerminalBlock (TB1) for power andsignal conventional circuits

5 ELECTRICAL INSTALLATION 5 ELECTRICAL INSTALLATION…

Fig. 5.1 Location of Components Inside Case – Model 6553 Gas Monitor Unit with Digital Displays

12

Caution. The integrity of the fail-safe operation ofthe zener barrier units depends on a Safety Earthconnection which must not have a resistance greater than1R0 to the application plant earth (ground).

Make the Earth (Ground) and Safety Earth connection at thestud (TS1) – see Fig. 5.1.

On completion of wiring and checks, replace the outer caseand secure the clamping brackets to the mounting panel.

5.1.2 Models 6540 203 and 6548 000 KatharometerAnalyzer PanelsElectrical connections are made inside the katharometer unit(6539 960) on the analyzer panel as detailed in Fig. 5.2.

Make the electrical connections to the Gas Monitor inaccordance with the information given in wiring diagram Fig.5.3 and Section 5.2.

Remove the cover of the katharometer unit to gain access tothe terminal block (TB1) inside – see Fig. 5.2.

The electrical connections are made at the terminal block(TB1) via the cable gland, or any replacement gland to suit theintrinsically safe wiring requirements. Remove the 510Rdummy load resistor from across terminals 9 and 10, when theappropriate interconnections have been made.

Replace the cover of the katharometer unit on completion ofwiring up.

Coarse ZeroAdjustment

MeasuringUnit

TubingConnections

Terminal Block (TB1)

DummyLoad

Resistor

Mounting Pillars

10

910

9

…5 ELECTRICAL INSTALLATION

Fig. 5.2 Location of Components Inside Case – Model 6539 960 Katharometer Unit

13

6553

/6

Mon

itor

Uni

t

1718

1920

2122

2324

2526

2728

2930

3132

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2

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5 ELECTRICAL INSTALLATION…

Fig

. 5.3

Inte

rco

nn

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on

Wir

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Dia

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m –

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655

3 In

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and

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15

5.1.3 Model 4234 Power Supply Unit – Fig. 5.5

Warning. Do NOT connect mains supply to thepower supply unit with the output terminals open circuit.This causes premature component failure.

Caution. Ensure that the power supply unit iscorrect for the mains supply voltage available. A nominal110 V unit cannot be adapted for use with a nominal 240 Vsupply, or the other way round.

Remove the cover of the unit to gain access to the terminalblocks inside.

Locate the terminal block (TB3) adjacent to the transformerT1. To ensure the correct transformer tapping is used for theincoming mains supply, adjust the brown wire, if necessary, tothe appropriately marked TB3 terminal to either 110 or 120 V(200, 220 or 240 V, for alternative power supply unit).

Make electrical connections in accordance with theinformation given in the wiring diagram Fig. 5.3 andSection 5.2.1.

The electrical connections are made at terminal blocks TB1and TB2, through the appropriate cable gland, or anyreplacement gland to suit intrinsically safe wiringrequirements. Secure the incoming cable by the cable clipsadjacent to the terminal blocks – see Fig. 5.5.

Fit the cover on completion of wiring up.

5.2 Intrinsically Safe RequirementsThese requirements relate to the interconnecting wiring madeto and from Models 6540 203 or 6548 000 KatharometerAnalyzer Panels in the hazardous area, and those for remoteancillary items connected to the system.

5.2.1 Cable RequirementsThe interconnecting cables between the various units of thegas analysis system are subject to stringent limitationsbecause of the requirements of the intrinsic safetycertification. These are listed below and detailed in Fig. 5.4.

All cables entering the hazardous area must be kept separatefrom cables in the safe area. Cables entering the hazardousarea must not be run with other cables, and terminations musthave an earthed screen to separate them from connections forother circuits. The detailed requirements are as follows:

1) Connections between Models 6540 203 or 6548 000Katharometer Analyzer Panels and Model 4234 PowerSupply Unit.

All cables from the Katharometer into the hazardous areamust have an inductance/resistance ratio not exceeding18 µH/Ω, (for Group IIC gases). There is a furtherrequirement that the maximum resistance of thisinterconnecting cable is limited to 2 Ω. This may place alimitation on the length of the total cable run.

Spare Fuse

FS1

InputTerminals

(TB1)

Cable Clamp Voltage SelectionTerminals (TB3)

Cable Clamp

OutputTerminals

(TB2)

R103

C101 R101 D102 R104 RV101D101

R102

TR101

Z101

D103

C102 C103TR102

5 ELECTRICAL INSTALLATION…

Fig. 5.5 Location of Components Inside Case – Model 4234 Power Supply Unit

16

Single sheathed conductor cables should be twistedtogether to reduce their mutual inductance, and routedseparately from cabling for non-intrinsically safe circuits inthe safe area.

2) Connections between Models 6540 203 or 6548 000Katharometer Analyzer Panels and Model 6553 GasMonitor Unit.

Katharometer to display unit cables, carrying the outputsignals through zener barrier units inside the monitor unit,are subject to of a maximum inductance/resistance ratio of18 µH/Ω (for Group IIC gases). These wires are indicatedby a in Fig. 5.3.

No special requirements are necessary to limit the choiceof cable for the interconnection between the katharometerzero adjustment controls and the monitor unit.

5.2.2 Recommended CablesThe limitations imposed restrict the choice of wiring cable to afew types. ‘Pyrotenax’ meet the requirements of less than18 µH/Ω with their mineral insulated cable type CC 2L1.

The Company should be consulted with information on anyother cables proposed for use in the installation of this system.

Detailed cable specifications of the above mentioned type isavailable from:

B.I.C.C. Pyrotenax Limited or Draka CalfaxP.O. Box 20 Park RoadPRESCOTT CalveronMerseyside L34 5GB NOTTINGHAM NG14 6OOTel: 0151 430 4000 (Tech.) Tel: 0115 965 257

0151 430 4050 (Sales)

5.2.3 Installing Remote Ancillary ItemsAny indicator/controllers, or other electrical equipment,connected to TB1 of the Model 6553 Gas Monitor Unit must notbe supplied from, nor contain, a potential source greater than250 V d.c. or 250 V r.m.s. with respect to earth (ground).

5.2.4 Full Intrinsically Safe RequirementsFor systems to be modified or used with other gases the fullBASEEFA requirements must be complied with as follows:

1) The total capacitance and inductance or inductance toresistance ratio (L/R) of the cables connecting thekatharometer unit to the hazardous area terminals of themonitor unit (TB2) and power supply unit terminals (TB1)must not exceed the values given in Table 5.1.

2) Any terminal boxes used in the hazardous or safe areasmust conform to BASEEFA Standard SFA.3012,Clause 6.3.

3) The overall installation must conform to the BASEEFAinstallation conditions, Issue 6 (September 1976).See Fig. 5.4.

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Table 5.1 6553 – Intrinsically Safe Wiring Requirements

17

When the gas analyzer system has been correctly installed inaccordance with the requirements for intrinsic safety given inSection 5.2, carry out the following setting-up procedures:

6.1 Katharometer Analyzer Panel – Filling theDrying Chamber – Fig. 6.1

Caution. Extra care is required with the highpressure version to prevent displacement of the gauze atthe bottom of the drying chamber.

1) Remove the drying chamber on the katharometer analyzerpanel by unscrewing the large knurled nut at the base ofthe chamber. Pull the chamber down and out of the sealinggroove to remove it from the panel.

2) Open a container of fresh granular calcium chloride.Ensure the filter gauze is in place at the bottom of thechamber, and immediately fill the drying chamber.

Note. The capacity of the drying chamber is about140 ml. To fill the chamber, approximately 100 g of calciumchloride is required.

3) Replace the drying chamber in its sealing groove andreposition the chamber to enable it to be secured andsealed by hand tightening the knurled nut.

4) Carry out an approved leak testing procedure beforepassing sample gas through the system.

6.2 Setting Sample FlowWhen all tubing interconnections have been made andexternal parts of the sample system checked for leaks, thesuggested procedure is as follows:

1) Arrange to supply calibration quality carbon dioxide gasthrough the gas analyzer system at the normal workingpressure of the application plant and within the limits givenin Section 13.

2) Gradually open the metering valve on the katharometerpanel to pressurize the complete system to the maximumpressure given in Section 13.

Caution. Testing for leaks with carbon dioxidemay not be considered an adequate check of gas tightintegrity in respect of the more penetrating hydrogen gas.Consideration may be given to the use of a gas, such ashelium, which has penetrating properties nearer to that ofhydrogen.

3) Slowly open the metering valve to give a nominal flowrateof gas of 100 to 150 ml min–1. Do not exceed the maximumflowrate given in Section 13.

4) Set the flowrate and shut off the calibration gas external tothe analyzer system.

5) Repeat this procedure for each katharometer analyzerpanel, as required.

Flow Gauge

Gas SampleOutletDrying chamber Katharometer Unit

MeteringValve

GasSample

Inlet

Knurled Nut

6 SETTING UP 6 SETTING UP…

Fig. 6.1 Katharometer Analyzer Panel

18

6.3 Electrical ChecksCarry out the following electrical checks:

6.3.1 Model 4234 Power Supply Unit Output

Warning. This unit is part of the certifiedintrinsically safe system. Appropriate safety precautionsmust be taken to prevent any incendive electricaldischarges in the hazardous area when carrying out thistask.

Testing the output may only be carried out with the hazardousarea cable disconnected and a dummy load resistor fittedacross the output. Never operate the unit to supply an opencircuit.

1) Electrically isolate the power supply unit.

2) Remove the cover from the power supply unit.

3) Disconnect the output wires to the hazardous area atterminals TB2+ and TB2–.

4) Connect a 10 Ω (2 W ±5%) dummy load resistor acrossterminals TB2+ and TB2–.

Warning. Ensure that proper electrical safetyprecautions are taken at all times when undertaking thisprocedure.

5) Switch on the power supply unit and check that it is stableat 350 mA.

6) On completion of tests, isolate the unit, remove the dummyload resistor and reconnect the output wires to thehazardous area.

7) Replace the cover on the unit.

6.3.2 Zener Barrier UnitsThe zener barriers in the 6553 Monitor Unit are checked at thetime of manufacture. To ensure absolute safety when fitting anew instrument, check that the barriers in the monitor areproperly earthed by carrying out a routine test before using theanalyzer system.

Warning.• This unit is part of the certified intrinsically safe system.

Appropriate safety precautions must be taken toprevent any incendive electrical discharges in thehazardous area when carrying out this task.

• If these tests reveal a faulty zener barrier, the barriermust be replaced by a new unit. The barrier is a sealedunit and no repair is permitted. The correct zenerbarriers are certified intrinsically safe to EX (IA) IIC andno other type may be substituted.

1) Electrically isolate the 6553 monitor unit.

2) Remove the outer case from the monitor.

3) Disconnect the cable connected to terminal 3 of the barrierunit.

4) Using a low voltage ohmmeter, measure the resistancebetween terminals 1 and 3. This must be less than18.15 Ω. If in excess of this value – change the barrier.

5) Using a low voltage ohmmeter, ensure that the resistancebetween terminals 2 and 4 of the barrier unit and theapplication plant safety earth is less than 1 Ω.

6) Connect the wire to terminal 3 on the barrier unit.

7) Fit the outer case to the 6553 Monitor Unit.

6.3.3 Checking System EarthCheck the resistance between earth terminals on the analyzersystem and the application plant system safety earth does notexceed one ohm.

…6 SETTING UP

19

7.1 Displays – Fig. 7.1The displays comprise a 5-digit, 7-segment digital upperdisplay line and a 16-character dot-matrix lower display line.The upper display line shows actual values of hydrogen purity,hydrogen in carbon dioxide, air in carbon dioxide, alarm setpoints or programmable parameters. The lower display lineshows the associated units or programming information.

7.2 Switch Familiarization – Fig. 7.1 and 7.2

%H2 IN AIR

AlarmL.E.D.'s

UpperDisplay Line

LowerDisplay Line

Membrane Switches

A – Advancing to Next Page

Parameter 1Parameter 2Parameter 3Parameter 4

Page 1Parameter 1Parameter 2Parameter 3

Page 2

Advance tonext page

For majorityof parameters

or

B – Moving Between Parameters

C – Adjusting and Storing a Parameter Value

New value isautomatically stored

Parameter Value Adjust

D – Selecting and Storing a Parameter Choice

Parameter XYZ

Select

Parameter 1

Parameter 2Parameter 3

Page X

Parameter 4

Advance tonext parameter

or

New value isautomatically storedor

7 CONTROLS & DISPLAYS …7 CONTROLS & DISPLAYS

Fig. 7.1 Location of Controls and Displays

Fig. 7.2 Function of the Membrane Switches

20

Warning. When the apparatus is connected to itssupply, terminals may be live, and the opening of covers orremoval of parts (except those to which access may begained by hand) is likely to expose live parts.

8.1 Instrument Start-upIn normal operation the instrument displays the OperatingPage which is a general use page in which parameters areviewed only and cannot be altered. Any changes to theoperating parameters are implemented using the switches asdescribed in Section 7.2. To alter or program a parameter referto Section 10. A 5-digit Security Code is used to preventunauthorized access to programmable parameters. The valueis preset at 00000 to allow access during commissioning butshould be altered to a unique value, known only to authorizedoperators, as described in the Access Page.

When all the required wiring connections and electrical checkshave been correctly made, the power supplies to the variousunits may be switched on as follows:

1) Switch on the supply voltage to the 4234 Power SupplyUnit.

2) Switch on the supply voltage to the 6553 Monitor unit.

8.2 Alarm Set-points

8.2.1 Type of Alarm ActionThe alarm elay coil is energized during normal non-alarm relaystates and is de-energized upon recognition of an alarmcondition, thereby providing ‘fail-safe’ alarms. i.e. with Alarm 1set point = 95.0, when the display is indicating greater than95.0 (plus hysteresis), then Alarm Relay 1 is energized andAlarm 1 LED is OFF. When the display indicates less than 95.0(minus hysteresis), then Alarm Relay 1 is de-energized andAlarm 1 LED is ON. This operating mode ensures that, in theevent of a mains power failure, an alarm condition is signalled.

8.2.2 Hydrogen Alarm Set PointIt is suggested that the hydrogen alarm set-points should bebased on a reducing percentage of hydrogen as it is displacedby air entering the application plant. This can be achieved bysetting Alarm 1 and Alarm 2 to give ample warning of thedevelopment of a potentially explosive mixture. Factorysettings are Alarm 1 = 95.0 and Alarm 2 = 90.0.

1) Access the programming pages (Section 10) and input thealarm set-points in accordance with the information givenin Section 10.1.2.

8.3 CalibrationBefore putting the system on-line, carry out a calibration checkon the zero input signal using calibrarion sample gas. Themaximum input signal for the full range reading is presetduring manufacture and sealed. These sealed adjustmentsmust not be altered by users.

Note. The 4600 Series instruments incorporate atwo point calibration sequence requiring both zero andspan inputs for a calibration. It is not possible to adjusteither the range zero or the range span scale pointsindependently.

The local coarse ‘zero’ adjusters on the katharometer units inthe hazardous area are redundant when this adjustment istransferred to the gas monitor unit. The potentiometers in thekatharometer units should be set to the midpoint oninstallation, and sealed off. A summary of the system functionsand calibration data is given in Table 8.1.

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8 STARTUP

Table 8.1 System Functions and Calibration Settings (Dual Range Display System)

21

8.3.1 Purge GasWhen a purge gas katharometer forms part of the 6553system, the startup procedure is as follows:

1) Arrange to pass calibration quality carbon dioxide throughthe (CO2) katharometer, on the appropriate katharometeranalyzer panel. The gas should be at the normal workingpressure of the sample gas. This gives the correct flowrateof purge/sample gas as set previously.

2) Power up the monitor unit, and the purge gas katharometerunit by switching on the appropriate power supply unit.

3) Set the range selector switch on the gas monitor unit toposition (3).

4) The top display unit indicates NOT IN USE.

5) The bottom display unit indicates the selectedmeasurement parameter – percentage by volume of air incarbon dioxide (%AIR IN CO2) – on its lower display line.The upper display line indicates a value for the parameter.

6) With carbon dioxide calibration gas passing through thesample system at the normal flowrate, the upper line of thebottom display unit should stabilize within 2 hours to read0.0

7) If necessary, refer to Section 10.3.3 for a full calibrationsequence.

Note. A coarse zero adjustment facility is availableat the bottom ‘zero’ potentiometer adjacent to the displayunit. Adjustment is made by inserting a screwdriverthrough the hole behind the small escutcheon plate.

8) Reset the range selector switch on the gas monitor toposition 2. The top display continues to indicate NOT INUSE.

9) The bottom display indicates the selected measurementparameter – percentage by volume of hydrogen in carbondioxide (%H2 IN CO2) – on the lower line. The upper lineindicates a value for the parameter.

10)With carbon dioxide continuing to pass through the samplesystem, the upper line of the bottom display unit shouldstabilize within a few minutes to read 0.0.


Note. No adjustment of the bottom zeropotentiometer is necessary. As any adjustment requiredwill already have been made while calibrating the ‘air incarbon dioxide’ range.

8.3.2 Hydrogen

Warning. Test for leaks in accordance with therequirements of the responsible authority after makingany hydrogen connections.

1) Arrange to pass calibration quality hydrogen gas throughthe (H2) Katharometer Unit on the appropriatekatharometer analyzer panel, at the normal workingpressure of the sample gas system. This should give thecorrect flowrate of gas, as set previously.

2) Power up the monitor unit, and the hydrogen katharometerunit by switching on the appropriate power supply unit.

3) If fitted, set the range selector switch on the monitor unit toposition (1).

4) The hydrogen display unit indicates the measurementparameter – percentage by volume of hydrogen in air(%H2 IN AIR) – on the lower line. The upper line indicatesa value for the parameter.

5) If fitted, the purge gas display unit indicates NOT IN USE.

6) With hydrogen calibration gas passing through the samplesystem at the normal flowrate, the upper line of the topdisplay should stabilize within 2 hours to read 100.0.


Note. A coarse zero adjustment facility is available atthe top 'zero' potentiometer. Adjustment is made byinserting a screwdriver through the hole behind the smallescutcheon plate.

…8 STARTUP

22

9.1 NormalDuring normal operation the Model 6553 Gas AnalyzerSystem is used to indicate the purity of hydrogen used as acoolant. The top display shows the percentage of hydrogen inair, which should be safely in excess of the explosive limit atthe hydrogen rich end.

There are no routine adjustments required to the gas analyzersystem after completion of start-up procedures and putting on-line in monitoring mode. The system only requires minoradjustments to the metering valve to maintain the requiredflowrate and the carrying out of safety routines.

A summary of the functions and status of the system for thedifferent range selector switch positions is shown in Table 9.1.

9.1.1 Purging of Hydrogen Coolant GasWhen the hydrogen coolant has to be removed from theapplication plant, it would be wasteful and dangerous torelease the coolant gas directly into the atmosphere. So it isnecessary to ensure that the system is outside of the explosivelimits for air in hydrogen before allowing air into the system.

Initially, inert purge gas (carbon dioxide) is introduced into thesystem. When the hydrogen concentration is safely below theexplosive limit, air is introduced into the system to completelydisplace the other two gases.

The Model 6553 Gas Analyzer System provides all thenecessary indications and output signals to enable thisoperation to be carried out safely.

With respect to the operation of the gas analyzer system, theprocedure is as follows:

Warning. Suitable safety procedures will apply tothe operation of the gas cooling and sample system.

1) Power up the purge gas katharometer and carry out acalibration check on the katharometer in accordance withthe information given in Section 8.3.

2) Select position (2) of the range selector switch on themonitor unit. This causes the display units to indicate andhave the functions given in Table 9.1.

3) Commence the purging operation.

4) When the changeover to introduce air into the applicationplant is made, select position (3) of the range selectorswitch on the monitor unit. This causes the display units toindicate and have the functions given in Table 9.1.

9.1.2 Filling with Hydrogen Coolant GasThis procedure is a reversal of the purging procedure.Initially, inert purge gas (carbon dioxide) is introduced into theapplication plant until the air content is safely below theexplosive limit for air in hydrogen. When this limit is reached,hydrogen is gradually introduced into the system to displacethe other two gases.

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9 OPERATION

Table 9.1 Functions and Status of Display Units for Different Range Selector Switch Positions

23

With respect to the operation of the gas analyzer system, theprocedure is as follows:

Warning. Suitable safety precautions will apply tothe operation of the gas cooling and sample systems.

1) Power up the monitor unit and hydrogen and purge gaskatharometers.

2) Carry out separate calibration check procedures on thekatharometers in accordance with the information given inSection 8.3.

Note. Commence the filling operation within 24hours of carrying out the calibration procedure.

3) Select position (3) of the range selector switch of themonitor unit. This causes the display units to indicate andhave the functions given in Table 9.1.

4) When the changeover to introduce hydrogen into theapplication plant is made, select range (2) of the rangeselector switch on the monitor unit. This causes the displayunits to indicate and disable functions as given in Table 9.1.

5) When the bottom display indicates that hydrogen filling iscomplete, arrange to pass the sample gas alternatelythrough the hydrogen and purge gas katharometers.

6) Make alternate selections of the reading from eachkatharometer by operating the range selector switch on themonitor unit between positions (1) and (2).

7) When both readings stabilize at the required value, shutdown the purge gas katharometer and position the rangeselector switch at (1). The hydrogen measurementanalyzer system is on-line in monitoring mode.

UPPER INDICATORRANGE 1

9.2 Operating Page – Range 1 (Read Only)

The measured %H2 IN AIR is displayed.

Alarm 1 Set PointThe set point value is programmable – see Set Up Outputs Page.

Alarm 2 Set PointThe set point value is programmable – see Set Up Outputs Page.

Advance to Security Code Page

When Range 1 is selected, %H2 IN AIR measurement is shown on the upper indicator, andthe lower indicators ‘NOT IN USE’.

Alarm 1 Setpoint

Alarm 2 Setpoint

0 0 0 0 0SECURITY CODE

Range 1

xxx . x%H2 IN AIR

xxx . x

xxx . x

NOT IN USE

Ranges 2 and 3

–––––

9 OPERATION…

24

9.3 Operating Page – Range 2 (Read only)

With Range 2 selected, %H2 IN CO2 measurement is shown on the lower indicator, and theupper indicator shows ‘NOT IN USE’.

The measured %H2 IN CO2 is displayed.

LOWER INDICATORRANGE 2

Advance to Access to Secure Parameters.

9.4 Operating Page – Range 3 (Read only)

With Range 3 selected, the upper indicator shows ‘NOT IN USE’, and the lower indicatorshows %AIR IN CO2 measurement.

The measured %AIR IN CO2 is displayed


Advance to Access to Secure Parameters.

NOT IN USE

Range 1

–––––

00000SECURITY CODE

Range 2

xxx.x%H2 IN CO2

NOT IN USE

Range 1

–––––

xxx.x%AIR IN CO2

00000SECURITY CODE

Range 3

…9 OPERATION

25

10 PROGRAMMING 10 PROGRAMMING…

Fig. 10.1 Overall Programming Chart for Display 4689 503

YESYES

RANGE 1

Operating Page

LOWER INDICATOR

English

SECURITY CODE

Alarm 1 Setpoint

%H2 IN AIR

Alarm 2 Setpoint

NOT IN USE

SET UP OUTPUTS

A1 Action EA

A2 Action EB

A1 Setpoint

Language

Set Up Outputs Page

Access toSecure Parameters

Operating Parameters

Secure Parameters

xxx.x

xxx.x

A2 Setpoint

RTX Type 4-20

Test Retrans.(%)

Range 85%-100%

Alter Sec. Code

ELECTRICAL CAL

Calibrate NO

mV Span(10.00mV)

Electrical CalibrationPage

xxx.x

xxx.x

Deutsch

EB

EA

0-200-10

100.075.050.025.00.0

80%-100%Adjust RTX Span

Adjust RTX Zero

mV Zero (0.00mV)

NO

xxx.x

xxx.x

xxx.x

xxx.x

YES

UPPER INDICATOR

26

Note. All parameter values shown onthe upper display are the Companystandard settings.

Operating PageLOWER INDICATOR

SET UP OUTPUTS%H2 IN CO2

ALARM H2 IN CO2

ELECTRICAL CAL

or

mV Zero (0.00mV)

mV Span(10.00mV)

Set Up Outputs Page Electrical Calibration Page


Secure Parameters

xxx.x

xxx.x

xxx.x

NOT IN USE

SECURITY CODE


Relay Action EA

Alarm Setpoint

Test Retrans (%)

Alter Sec. Code

Calibrate No

Adjust RTX Zero

Adjust RTX Span

xxx.x

Yes

xxx.xAIR IN CO2

EB

RTX Type 4-20

0-200-10

English

Language

Deutsch

No

RANGE 2

SPT. %H2 IN CO2

xxx.x

UPPER INDICATOR

…10 PROGRAMMING

Fig. 10.2 Overall Programming Chart for Display 4689 500

27

Operating PageLOWER INDICATOR

SET UP OUTPUTS%AIR IN CO2

ALARM H2 IN CO2

ELECTRICAL CAL

or

mV Zero (0.00mV)

mV Span(10.00mV)

Set Up Outputs Page Electrical Calibration Page


Secure Parameters

xxx.x

xxx.x

xxx.x

NOT IN USE

SECURITY CODE


Relay Action EA

Alarm Setpoint

Test Retrans (%)

Alter Sec. Code

Calibrate No

Adjust RTX Zero

Adjust RTX Span

xxx.x

Yes

xxx.xAIR IN CO2

EB

RTX Type 4-20

0-200-10

English

Language

Deutsch

No

RANGE 3

SPT. %AIR IN CO2

xxx.x

UPPER INDICATOR

Note. All parameter values shownon the upper display are the Companystandard settings.

10 PROGRAMMING…

FIG. 10.3 Overall Programming Chart for Display 4689 500

28

10.1 Range 1 UPPER INDICATORRANGE 110.1.1 Access to Secure Parameters

A 5-digit code is used to control access to secure parameters.

Security CodeEnter the required code number, between 00000 and 19999, to gain access to the secureparameters. If an incorrect value is entered, access to subsequent programming pages isprevented and the display reverts to the Operating page.

Note. The security code is preset at ‘00000’ to allow access during commissioningbut should be altered to a unique value, known only to authorized operators – seeAccess Page.

Advance to Language Selection.

10.1.2 Langauge Selection

Set the language required. Subsequent displays change to the language selected.

Advance to Set up Outputs Page.

10.1.3 Set Up Outputs Page

Page Header – SET UP OUTPUTS

Alarm 1 ActionFor ‘Fail-safe’ alarm operation the relay’s alarm state must be the same as the power-downstate, i.e. the relay is de-energized.For high alarm operation the relay must be Energized Below the alarm set point (EB).For low alarm operation the relay must be Energized Above the alarm set point (EA).The alarm l.e.d.s are illuminated in the alarm condition.Select the required alarm action from the following table:

The set point band is defined as the actual value of the set point plus or minus 1% of the setpoint value. Alarm action occurs if the input value is above or below the set point band. If theinput moves within the set point band the last alarm action is maintained.

…continued

…10 PROGRAMMING

Security Code

English

Deutsch

English

Deutsch

SET UP OUTPUTS

SET UP OUTPUTS

ALARM H2 IN CO2

AIR IN CO2

mralAnoitcA

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BE NO FFO desigrene-eD desigrenE

AE FFO NO desigrenE desigrene-eD

29

continued…

Alarm 1 Set PointThe Alarm 1 Set Point can be set to any value within the input range being displayed. The set pointvalue is subject to hysteresis within the set point band as detailed above.

Set the alarm set point to the required value.

Alarm 2 ActionRepeat as for Alarm 1 Action above.

Alarm 2 Set PointRepeat as for Alarm 1 Set Point above.The decimal point position is set automatically. The alarm LEDs are illuminated in the alarmcondition.

Retransmission Output TypeThe retransmission output is assigned to the hydrogen purity range.

Select the retransmission output current range required (4 to 20 mA , 0 to 20 mA or 0 to 10 mA)

Test Retransmission OutputThe instrument automatically transmits a test signal of 0, 25, 50, 75 or 100% of theretransmission range. The % test signal selected is shown on the upper line of the display.

Example – for the range of 0 to 20 mA and 50% retransmission test signal, 10 mA is transmitted.

Select the required retransmission test signal.

Alter Security CodeSet the security code to a value between 00000 and 19999.

Advance to Electrical Calibration Page.

10 PROGRAMMING…

A1 Setpoint

ELECTRICAL CAL

Test Retrans. (%)

Alter Sec. Code

A2 Setpoint

A2 Action EA

EB

RTX Type 4-20

0-200-10

Range 85%-100%

80%-100%

xxxxx

100.075.050.025.00.0

30

…10 PROGRAMMING

10.1.4 Electrical Calibration Page

Page Header ELECTRICAL CAL

Note. The 4600 Series instruments incorporate a two point electrical calibrationsequence requiring both zero and span inputs for a calibration. It is not possible to adjusteither the zero or the span scale points independently.

CalibrationProceed as described in Section 8.3 Calibration, but apply a signal input equivalent to rangezero (0.0 mV). Allow the instrument display to stabilize.

Calibration Range Zero %H2 IN AIRProceed as described in Section 8.3, but apply a signal input equivalent to %H2 IN AIR rangezero (0.00 mV) – see table below. Allow the instrument display to stabilize.

Calibration Range Span %H2 IN AIRApply a signal input equivalent to %H2 IN AIR range span (10.0 mV) – see table below. Allowthe instrument display to stabilize.

Adjust Retransmission ZeroSet the milliammeter reading to 4 mA.

Note. 4 mA is retransmitted as ‘zero’ and is not affected by the retransmission typeselected in Section 10.1.3.

Adjust Retransmission SpanSet the milliammeter reading to 20 mA.

Note. 20 mA is retransmitted as ‘span’ and is not affected by the retransmission typeselected in Section 10.1.3.

Return to Operating Page.

ELECTRICAL CAL

Calibrate NO

Adjust RTX Zero

xxx.x

Adjust RTX Span

%H2 IN AIR

xxx.xYES

mV Zero (0.00mV)

xxx.x

mV Span (10.00mV)

xxx.x

xxx.x

NO

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%H2 RIAni

)1( poT 1 H%58 2 N%51/ 2 H%58 2 riA%51/ H%001 2 %001

%H2 OCni 2

)2( mottoB 1 OC%001 2 0.0 - 0.001

%OCniRIA 2

)3( mottoB 2 OC%001 2 0.0 - 0.001


31

10.2 Range 2

10.2.1 Access to Secure Parameters

Security Code

English

Deutsch

English

Deutsch

SET UP OUTPUTS

SET UP OUTPUTS

ALARM H2 IN CO2

AIR IN CO2

10 PROGRAMMING…


A 5-digit code is used to control access to the secure parameters.


Note. The security code is preset at ‘00000’ to allow access during commissioningbut should be altered to a unique value, known only to authorized operators – see Section10.2.3 Set Up Outputs Page.

Advance to Language Page.

10.2.2 Language Page


Advance to Set Up Outputs Page.

10.2.3 Set Up Outputs Page


Advance to next parameter.

Purge Gas Alarm SelectSelect the parameter on which the purge gas alarm is to operate.

Reprogram as required to agree with selected range:i.e. for Range 2 select %H2 IN CO2

Range 3 select %AIR IN CO2.

continued…

32

…continued

Purge Gas Relay ActionFor ‘Fail-safe’ alarm operation the relay’s alarm state must be the same as the power-downstate, i.e. the relay is de-energized.For high alarm operation the relay must be Energized Below the alarm set point (EB).For low alarm operation the relay must be Energized Above the alarm set point (EA).The alarm l.e.d.s are illuminated in the alarm condition.Select the required alarm action from the following table:


Purge Gas Alarm Set PointThe alarm set point can be set to any value within the input range being displayed. The setpoint value is subject to hysteresis within the set point band as detailed above.


Retransmission Output TypeThe retransmission output is assigned to the purge gas concentration.

Select the retransmission output current range required (4 to 20 mA, 0 to 20 mA or 0 to 10 mA).

Test Retransmission OutputThe instrument automatically transmits a test signal of 0, 25, 50, 75 or 100% of the retransmissionrange selected above. The % test signal selected is shown on the upper display.

Example – for a selected range of 0 to 20 mA and 50% retransmission test signal, 10 mA istransmitted.


Alter Security CodeSet the security code to a value between 00000 and 19999.

Advance to Electrical Calibration Page.ELECTRICAL CAL

Test Retrans. (%)

Alter Sec. Code

Alarm Setpoint

Relay Action EA

EB

RTX Type 4-20

0-200-10

xxxxx

100.075.050.025.00.0

mralAnoitcA


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noitcAyaleRtupnIrof

tnioPteSwoleB



…10 PROGRAMMING

33

10.2.4 Electrical calibration page

Page Header – ELECTRICAL CAL




Calibration Range Zero %H2 IN CO2Proceed as described in Section 8.3, but apply a signal input equivalent to %H2 IN AIR rangezero (0.00 mV) – see table below. Allow the instrument display to stabilize.


Calibration Range Span %H2 IN CO2Apply a signal input equivalent to %H2 IN CO2 range span (10.0 mV) – see table below. Allowthe instrument display to stabilize.






Return to Operating Page

ELECTRICAL CAL

xxx.xmV Zero (0.00mV)

xxx.xmV Span (10.00mV)

%H2 IN CO2

Calibrate NO

xxx.xYES

Adjust RTX Zero

xxx.x

Adjust RTX Span

NO

10 PROGRAMMING…

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%H2 RIAni

)1( poT 1 H%58 2 N%51/ 2 H%58 2 riA%51/ H%001 2 %001

%H2 OCni 2

)2( mottoB 1 OC%001 2 0.0 - 0.001

%OCniRIA 2

)3( mottoB 2 OC%001 2 0.0 - 0.001


34

10.3 Range 3 LOWER INDICATORRANGE 3

10.3.1 Access to Secure ParametersA 5-digit code is used to control access to the secure parameters.


Note. The security code is preset at ‘00000’ to allow access during commissioningbut should be altered to a unique value, known only to authorized operators – see Section10.3.3 Set Up Outputs Page.

Advance to Language Page.

10.3.2 Language Page


Advance to Set Up Outputs Page

Security Code

English

Deutsch

English

Deutsch

SET UP OUTPUTS

…10 PROGRAMMING

35

10.3.3 Set Up Outputs Page LOWER INDICATORRANGE 3



Purge Gas Alarm SelectSelect the parameter on which the purge gas alarm is to operate.Reprogram as required to agree with selected range:i.e. for Range 2 select H2 IN CO2

Range 3 select AIR IN CO2.

Purge Gas Relay ActionFor ‘Fail-safe’ alarm operation the relay’s alarm state must be the same as the power-downstate, i.e. the relay is de-energized.For high alarm operation the relay must be Energized Below the alarm set point (EB).For low alarm operation the relay must be Energized Above the alarm set point (EA).The alarm l.e.d.s are illuminated in the alarm condition.Select the required alarm action from the following table:


Purge Gas Alarm Set PointThe alarm set point can be set to any value within the input range being displayed. The setpoint value is subject to hysteresis within the set point band as detailed above.


Retransmission Output TypeThe retransmission output is assigned to the purge gas concentration.

Select the retransmission output current range required (4 to 20 mA, 0 to 20 mA or 0 to 10 mA).

Test Retransmission OutputThe instrument automatically transmits a test signal of 0, 25, 50, 75 or 100% of the retransmissionrange selected above. The % test signal selected is shown on the upper display.Example – for a selected range of 0 to 20 mA and 50% retransmission test signal, 10 mA istransmitted.


Alter Security Code

Set the security code to a value between 00000 and 19999.

Advance to Electrical Calibration Page.

mralAnoitcA


tnioPteSevobA


tnioPteSwoleB

noitcAyaleRtupnIrof

tnioPteSevobA

noitcAyaleRtupnIrof

tnioPteSwoleB



ELECTRICAL CAL

Test Retrans. (%)

Alter Sec. Code

Alarm Setpoint

Relay Action EA

EB

RTX Type 4-20

0-200-10

xxxxx

100.075.050.025.00.0

SET UP OUTPUTS

ALARM H2 IN CO2

AIR IN CO2

10 PROGRAMMING…

36

10.3.4 Electrical Calibration Page LOWER DISPLAYRANGE 3Page Header ELECTRICAL CAL




Calibration Range Zero %AIR IN CO2Proceed as described in Section 8.3, but apply a signal input equivalent to %AIR IN CO2range zero (0.00 mV) – see table below. Allow the instrument display to stabilize.


Calibration Range Span %AIR IN CO2Apply a signal input equivalent to %AIR IN CO2 range span (10.0 mV) – see table below.Allow the instrument display to stabilize.






Return to Operating Page.

ELECTRICAL CAL

xxx.xmV Zero (0.00mV)

xxx.xmV Span (10.00mV)

%AIR IN CO2

Calibrate NO

xxx.xYES

Adjust RTX Zero

xxx.x

Adjust RTX Span

NO

…10 PROGRAMMING

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tinUyalpsiDdetceleS

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lennahC






%H2 RIAni

)1( poT 1 H%58 2 N%51/ 2 H%58 2 riA%51/ H%001 2 %001

%H2 OCni 2

)2( mottoB 1 OC%001 2 0.0 - 0.001

%OCniRIA 2

)3( mottoB 2 OC%001 2 0.0 - 0.001


37

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ssaPnoitarbilaC desuerastneiciffeocnoitarbilacwenehT enoN

liaFlaCRIA-2HdnaderongierastneiciffeocnoitarbilacwenehT

erastneiciffeocnoitarbilacdoognwonktsaleht.desu

VmdetarbilacahtiwerudecorptaepeR.ecruos

ehttcatnoc,stsisrepmelborpehtfIynapmoC

egasseMnoitarbilaC noitanalpxE noitcA

...gnitarbilaC stneiciffeocnoitarbilacwenfonoitarbilaC enoN

ssaPnoitarbilaC desuerastneiciffeocnoitarbilacwenehT enoN

liaFlaC2OC-2HliaFlaC2OCRIA

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VmdetarbilacahtiwerudecorptaepeR.ecruos

ehttcatnoc,stsisrepmelborpehtfIynapmoC

…10 PROGRAMMING

Table 10.1 Katharometer Calibration Messages for Section 10.1.3 Upper Display Unit

Table 10.2 Katharometer Calibration Messages for Sections 10.2.3 and 10.3.3 Lower Display Unit

38

Warning.• Each unit of this system forms an integral part of a

certified intrinsically safe system. Appropriate safetyprecautions must be taken to prevent any incendiveelectrical discharges in the hazardous area whencarrying out any of the following tasks.

• Equipment in this system operates on a.c. mains supplyvoltage electricity. Suitable precautions must be takento avoid the possibility of electric shock.

• The maximum pressure and temperature specified forparticular parts of the system must not be exceeded.

The katharometer unit and its associated equipment aredesigned for stable and accurate operation over long periods.

This section covers the requirements for fault finding,diagnostic tests and maintenance tasks.

11.1 General Maintenance11.1.1 PressureThe operation of the katharometer units is not affectedsignificantly by changes in pressure providing that they arewithin the pressure limits given in Section 13.

11.1.2 FlowThe katharometer zero balance and sensitivity areindependent of the sample flowrate, as the sample gassensing system depends on molecular diffusion. But thespeed of response is affected by the flowrate. This means thatthe flow resistance of the drying chamber is a compromisebetween obtaining speed of response, and avoiding a rapiddegradation of the desiccant.

11.1.3 LeaksThere is an inherent safety requirement that there are no leaksinto or out of the sample system. Any leaks could also affectthe correct operation of the katharometer unit.

11.1.4 VibrationThe katharometer unit will tolerate reasonable levels ofmechanically induced vibration. Pulsations due to unsteadysample flow can affect the katharometer filaments and causeerrors due to excessive cooling.

11.1.5 ContaminationContamination in the sample system can arise from oil orsuspended particles, or from erosion of material from thesample system upstream of the katharometer unit.

11.1.6 Ambient TemperatureThe calibration of the katharometer is not significantly affectedby variations of the ambient temperature. Temperaturechanges can affect the sensitivity and reduce accuracy onsensitive ranges.

11.1.7 Bridge CurrentThe working current of the katharometer bridge is 350 mAsupplied from the power supply unit. This value must remainstable during normal operation as the katharometer outputsignal is approximately proportional to the cube of the bridgecurrent.

11.2 Diagnostic Tests

11.2.1 Checking Output of 4234 Power Supply UnitCarry out the test procedure given in Section 6.3.1.

11.2.2 Checking Integrity of Zener Barrier UnitsCarry out the test procedure given in Section 6.3.2.

11.2.3 Checking the Katharometer Output

Warning.• This unit is part of the certified intrinsically safe system.

Appropriate safety precautions must be taken toprevent any incendive discharges in the hazardousarea when carrying out this task.

• Ensure that the proper electrical safety precautions aretaken at all times when undertaking this procedure.

The procedure is as follows:

1) Electrically isolate the monitor unit.

2) Remove the outer cover from the 6539 960 katharometer unit.

3) With the katharometer operating, check if the voltageacross terminals TB1 - 1 and TB1 - 4 is not above 4 V with350 mA passing. If the voltage is above this value it is likelythat one or more filaments of the bridge is broken.

4) With the katharometer operating, check that the voltageacross terminals TB1 - 1 and TB1 - 4 is below 2.8 V with350 mA passing. If the voltage is below this value and thereis no zero adjustment available, it is likely that there is anaccumulation of liquid within the katharometer block.

5) If the reading from the test made at step 3 is unstable whenthe katharometer block is tapped gently, this could indicatethat a filament is damaged but not open circuit.

If any of these tests indicate that the katharometer is faulty thecomplete katharometer unit must be returned for repair orreplacement.

The sensitivity adjusters of katharometer units are sealed andmust not be tampered with.

11.3 Routine Maintenance

11.3.1 Hydrogen Katharometer CalibrationCarry out a calibration check in accordance with Section 8.3.

This task should be carried out at intervals of 3 months of on-line use.

11.3.2 Purge Gas Katharometer CalibrationCarry out a calibration check in accordance with Section 8.3.

This task should be carried out before using the katharometerfor monitoring a purging procedure.

11 MAINTENANCE

39

11.3.3 Changing Desiccant in Drying ChamberThe need to change the desiccant in the drying chamber onthe katharometer analyzer panel depends on the condition ofthe sample gas.

It is recommended that the analyzer system is monitoredregularly during the initial phase of operation for indicationsthat the desiccant is exhausted. Then a suitable maintenanceinterval for this task can be established.

As the desiccant degrades, the white grains can be seen tohave a yellowish tinge and the granular form becomes moreconsolidated. If liquid contamination occurs the desiccantbecomes brown and consolidated.

Warning. Suitable safety precautions will apply tothe operation of the gas cooling and sample systems.

1) Isolate the sample gas system from the main system.Carry out a limited hydrogen purging operation on thesample system in accordance with the instructions of theresponsible authority.

2) Carry out the procedure given in Section 6.2.

3) After purging any residual air from the sample system inaccordance with the requirements of the responsibleauthority, allow hydrogen to pass through the katharometeragain.

This task should be undertaken on the basis of instrumentresponse or at intervals of one year.

11.4 Repair Maintenance

11.4.1 Removing Liquid from KatharometerMeasurement BlockIf tests indicate that there is likely to be an accumulation ofliquid in the measurement block, it may be removed using thefollowing procedure:

1) Electrically isolate the defective katharometer at its powersupply unit.

2) Isolate the gas sample system to the particularkatharometer from the main gas cooling system. Purge thesample system of hydrogen in accordance with therequirements of the responsible authority.

Warning. The thermal insulation inside the casemust not be damaged or removed.

3) Remove the cover of the katharometer unit and dismantlethe internal sample system tubing.

4) Remove the fixing screws which secure the mountingpillars to the case – see Fig. 5.2.

5) Disconnect the interconnecting wiring at terminal blockTB1.

Caution. Do not insert any type of probe into thegas system of the measurement block or use compressedair to blow through the system.

6) Remove the measuring unit from the case and tilt at 45° tothe horizontal. This will allow any liquid to drain from themeasurement block – see Fig. 11.1.

7) Pour a small quantity of rectified spirit (ethanol) through themeasurement block. Allow as much liquid as possible todrain out. Assist this by gentle shaking. Repeat thisprocedure several times until all evidence of contaminationis removed.

8) Fit the measuring unit into its case. Replace the fixingscrews and remake the electrical interconnections atterminals TB1 - 1 and TB1 - 4.

9) Fit the internal sample gas tubing.

10)Make the sample gas tube interconnection couplings.

11) Replace the desiccant in the drying chamber inaccordance with the procedure given in Section 11.3.3.

12)Carry out a leak test in accordance with the requirementsof the responsible authority.

13)Power up the katharometer unit by switching on theappropriate power supply unit.

14)Arrange to pass dry air or another suitable dry gas throughthe katharometer at the normal sample flowrate for 24hours.

11 MAINTENANCE…

Fig. 11.1 Removing Liquid from theKatharometer Block

40

15)Isolate the katharometer unit at its power supply unit.

16)Make the remaining electrical connections at TB1 of thekatharometer unit – see Fig. 5.3.

17)Replace the cover of the katharometer unit.

18)Power up the katharometer unit from its power supply unit.

19)Carry out a calibration procedure in accordance withSection 8.3.

Note. It is possible that the zero reading may drift forseveral days after the removal of liquid.

This task should be undertaken as required.

11.4.2 Removal of a Display Unit ChassisThe procedure is as follows:

1) Electrically isolate the gas monitor unit.

2) Release the retaining screw through the display facia andcarefully withdraw the chassis from its edge connectorsand out through the front panel – see Fig. 3.1.

3) Fit the chassis by carefully inserting and pressing firmlyinto position before tightening the retaining screw.

4) Power up the monitor unit and carry out a calibration inaccordance with Section 8.3.

This task should be undertaken as required.

Warning. Interference with any unit or itscomponents implies acceptance of responsibility by thatperson for ensuring the continuing maintenance ofintrinsic safety requirements. Unauthorized repair, spareparts or incorrect assembly may render any unit unfit foruse within a hazardous area.

Note. Although the digital display units may bemarked 4600 on their display facia, they are dedicatedvariants which are not interchangeable with theCompany’s standard 4600 Controller/Display. Thesededicated display units are identified (4689 500 or4689 503) as shown in Fig. 3.1.

When ordering a 6539 960 katharometer unit, it is necessaryto specify the zero gas in association with the Company partnumber. See the typical identification label shown in Fig. 3.2.

12.1 ConsumablesDescription Part No.Model 6540 203 and 6548 000 KatharometerAnalyzer PanelsGranular anhydrous Ca Cl2 Locally sourced

12.2 Routine Maintenance PartsDescription Part No.Model 4234 Power Supply UnitFuse, 500 mA/≥4000 A hbc cartridge 002417 005

Model 6553 Gas Monitor UnitFuse, 500 mA a/s 1.25x 0.25 in glass cart. 0231 596Function selector switch, 3 position., 2 wafer 0234 710Function selector switch, 3 position., 3 wafer 0234 711Potentiometer (1 kΩ), zero adjustment 002569 036

Katharometer Analyzer Panel 6540 203 6548 000Seal, top of drying chamber .......... 002310 012 002310 012Seal, bottom of drying chamber .... 006519 160 0211 035Gauze, drying chamber ................. 006525 700 006548 018Katharometer Unit, coupling seal sleeve .................... 006525 130

12.3 Repair Maintenance PartsDescription Part No.Model 4234 Power Supply UnitNominal 110 V unit 004234 001Nominal 230 V unit 004234 002

Katharometer Analyzer Panel 6540 203 6548 000Flowmeter, 50 to 250 ml/min .......006540 460 0216 485Valve, metering ............................006540 361 0216 484Katharometer unit (H2) ......... 006539 960(H2) 006548 001Katharometer unit (CO2) .... 006539 960(CO2)

Model 6553 Gas Monitor UnitDisplay unit (H2) 4689 503Display unit (CO2) 4689 500Zener barrier unit 0248 299

egasseMrorrE noitanalpxE

rorrEyromeMVNelitalov-nonehtfostnetnocehT

daerneebtonsahyromem*.purewopgnirudyltcerroc

hctiwsdnasdnoces01tiaw,FFOhctiws,tluafyfitceroT*.ynapmoCehttcatnoc,stsisreptluafehtfI.niagaNO

…11 MAINTENANCE 12 SPARE PARTS LIST

Table 11.1 Error Messages

41

(a) Model 6553 Gas Monitor Unit BASEEFA Certificate No. Ex 77124/B/S

Available Ranges: (a) 80% to 100% or 85% to 100% hydrogen in air(b) 0 to 100% hydrogen in carbon dioxide(c) 0 to 100% air in carbon dioxide

Digital Display Units:%H2 in Air: 4689 503%Air in CO2 / %H2 in CO2: 4689 500

Range Selector Switch Positions (when fitted): (1) Percentage by volume, hydrogen in air(2) Percentage by volume, hydrogen in carbon dioxide(3) Percentage by volume, air in carbon dioxide

Accuracy (display units): ±0.25% of scale span

Ambient Temperature Range: 0 to 45°C

Power Supply : 110/120 or 200/220/230 V ac, 50/60 Hz (2 separate versions)

Power Consumption : 30 VA approximately

Outline Dimensions: 290 x 362 x 272 mm

Weight : 12 kg approximately

Environment : Sheltered interior, 0 to 90% RH

(b) Model 6540 203 Katharometer Analyzer Panel BASEEFA Certificate No. Ex 76179/BIncorporating Model 6539 960 (H2) or 6539 960 (CO2) Katharometer Unit

Power Supply: 350 mA d.c., from 4234 PSU

Signal Output: 0 to 10 mV for each range

Accuracy: ±2% of scale span, each range

Dead Time: Typically 5 seconds

Response Time: Typically 40 s for 90% step change at katharometer. Tubingand drying chamber introduce extra delays.

Ambient Temperature: Maximum of 50°C

Sample Connections: Compression couplings, 8 mm outside diameter tube.

Sample Pressure: Minimum, 125 mm H2OMaximum, 0.35 bar (g)

Normal Sample Flowrate: 100 to 150 ml min–1

Maximum Gas Flowrate: 250 ml min–1

Minimum Gas Flowrate: 50 ml min–1


Weight: 8.6 kg approximately

Environment: Sheltered interior

13 SPECIFICATION 13 SPECIFICATION…

42

(c) Model 6548 000 Katharometer Analyzer Panel BASEEFA Certificate No. Ex 76179/BIncorporating Model 6548 001 (H2 and CO2) Katharometer Unit

Power Supply: 350 mA d.c., from 4234 PSU

Signal Output: 0 to 10 mV for each range

Accuracy: ±2% of scale span, each range

Dead Time: Typically 5 seconds

Response Time: Typically 40 s for 90% step change at katharometer. Tubingand drying chamber introduce extra delays.

Ambient Temperature: Maximum of 50°C

Sample Connections: Compression couplings, 6 mm tube

Sample Pressure: Minimum, 125 mm H2OMaximum, 10 bar (g)

Normal Sample Flowrate: 100 to 150 ml min–1

Maximum Gas Flowrate: 250 ml min–1

Minimum Gas Flowrate: 50 ml min–1


Weight: 8.7 kg approximately.


(d) Model 4234 Power Supply Unit BASEEFA Certificate No. Ex. 76180/B/S

Input Voltage: 110/120 V or 200/220/230 V a.c., 50/60 Hz (2 separateversions)

Fuse Rating: 500 mA hbc (high breaking capacity ≥4000 A)

d.c. Output: 350 mA stabilized

Load Conditions: 1 katharometer – 13 Ω maximumInterconnecting cable – 2 Ω maximum

Ambient Temperature Range: – 5 to +50°C

Supply Variations: ±6% (V)

±4% (Hz)

Regulation: Within ±0.8% for:(i) Load var. of ±15%(ii) Supply var. of ±6%(iii) Ambient temperature variation of ±10°C

Ripple: Less than 1 mA r.m.s.

Stability: Within ±0.7% of initial setting, over period of 1 month with loadresistance, supply voltage and ambient temperature atnominal stated values


Weight: 3.8 kg approximately


…13 SPECIFICATION

43

A1.1 Model 4234 Power Supply UnitTwo different power supply units are available to suit differentsupply voltages. See Spare Parts List.

A1.1.1 Functional DescriptionA circuit diagram for each type is shown in Fig. A1 (230 V),Fig. A2 (110 V).

A stable supply voltage is produced across zener diodes Z3and Z4 by utilizing the forward slope resistance of zenerdiodes Z1 and Z2 in the full-wave rectifier bridge connected tothe secondary winding of transformer T1. A reference voltageis produced across C103 by zener diode Z101 in conjunctionwith R101, with diode D103 providing temperaturecompensation. This reference voltage is applied to the base ofTR101, which is used to drive the power transistor TR102 toproduce a constant current output of 350 mA. The small presetpotentiometer RV101 is used to provide a fine adjustment forthe current output.

The output current is restricted by inviolate resistors whichensure that the requirements of the intrinsic safety certificationare met, even under a ‘2-fault’ condition.

Warning. This unit is part of the certifiedintrinsically safe system, Appropriate safety precautionsmust be taken to prevent any incendive electricaldischarges in the hazardous area when carrying outmaintenance tasks.

A1.1.2 Fault Finding

Caution. Do not operate this unit without anelectrical load on the output.

If testing indicates that this unit is defective, further fault findingmay be carried out based on the typical test point values givenin Table A1. There are several test points available on the unit.Reference should be made to Figs. A1, A2 and the markingson the circuit boards for the location of test points andcomponents.

Note. The primary winding of the transformer T1incorporates a thermal cutout device to preventoverloading under fault conditions. Sufficient time mustbe allowed for this to cool and reset after a fault hasoccurred, and before continuing further testing.

A1.1.3 Parts List

Repair Maintenance Parts

Description Part No.ResistorR101, 910R, ±2%, 0.5 W, metal oxide -R102, 3k3, ±2%. 0.5 W, metal oxide -R103, 4R7, ±1%, 9 W, wirewound -R104, 100R, ±2%, 0.5 W, metal oxide -

Variable resistorRV 101, 1k0, Spectrol Reliance, CW51 -

CapacitorC101, 1000 µF, 16 V, elect., Mullard 0175 15102 -C102, 1000 µF, 16 V, elect., Mullard 0175 15102C103, 100 µF, 16 V, elect, Mullard 0165 14101 -

TransistorTR101, BC 108, Mullard -TR 102, 2N 3766, Motorola -

DiodeD101, BYX 36 - 600, Mullard -D102, BYX 36 - 600, Mullard -D103, AAZ - 15, Mullard -

Zener diodeZ1, BZY93C9V1, Mullard -Z2, BZY93C9V1. Mullard -Z3, BZY93C9V1, Mullard -Z4, BZY93C9V1, Mullard -Z101, BZY88C3V3, Mullard -

FuseFS1, 500 mA, hbc cartridge, Belling Lee L693 -

TransformerT1, 110 - 120 V primary 4234 130T1, 200 - 220 - 230 V primary 4234 140

tnioPtseTegatloV

VmroF snoitidnoC

1PT 1.9 .c.d V0ottcepserhtiW




5PT 0.5 .c.dgnisuV0ottcepserhtiW

01 Ω daolymmud


1T 1.9 .c.a yradnocestA

APPENDIX

Table A1 Test Point Values – Model 4234 PowerSupply Unit

44

TB

1T

B3

HR

CF

S1

500m

A

FS

2

500m

A(s

pare

)

L N E

Pow

erIn

put

The

rmal

Trip

0V

240V

220V

200V

T1

1 2

Z1

Z2

0AZ

227

0AZ

227

0AZ

227

Z3

Z4

D10

1B

YX

36-6

00D

102

BY

X36

-600

TP

19.

1V

63

C10

110

00µ

16V

C10

210

00µ

16V

TP

23.

5V

R10

191

0R R10

410

0R

RV

101

1K

TP

33.

0V R10

33K

3

C10

310

0µ16

V

Z10

1B

ZY

88C

3V3

D10

1A

AZ

15

TR

101

BC

108

TR

102

2N37

66

TP

5*5

.0V

TP

42.

4VT

P6

1.7V

4 5

0V

TB

2 + –

R10

34R

7

Out

put

PC

B C

ompo

nent

Lay

out

*Mea

sure

d w

ith a

10R

load

.

…APPENDIX

Fig

. A1

Po

wer

Su

pp

ly U

nit

Mo

del

423

4 –

Ove

rall

Cir

cuit

(20

0/22

0/23

0V V

ersi

on

)

45

TB

1T

B3

HR

CF

S1

500m

A

FS

2

500m

A(s

pare

)

L N E

Pow

erIn

put

The

rmal

Trip

0V

120V

110V

T1

1 2

Z1

Z2

0AZ

227

0AZ

227

0AZ

227

Z3

Z4

D10

1B

YX

36-6

00D

102

BY

X36

-600

TP

19.

1V

63

C10

110

00µ

16V

C10

210

00µ

16V

TP

23.

5V

R10

191

0R R10

410

0R

RV

101

1K

TP

33.

0V R10

33K

3

C10

310

0µ16

V

Z10

1B

ZY

88C

3V3

D10

1A

AZ

15

TR

101

BC

108

TR

102

2N37

66

TP

5*5

.0V

TP

42.

4VT

P6

1.7V

4 5

0V

TB

2 + –

R10

34R

7

Out

put

PC

B C

ompo

nent

Lay

out

*Mea

sure

d w

ith a

10R

load

.

Fig

. A2

Po

wer

Su

pp

ly U

nit

Mo

del

423

4 –

Ove

rall

Cir

cuit

(11

0/12

0 V

ersi

on

)

…APPENDIX

PRODUCTS & CUSTOMER SUPPORT

ProductsAutomation Systems

• for the following industries:– Chemical & Pharmaceutical– Food & Beverage– Manufacturing– Metals and Minerals– Oil, Gas & Petrochemical– Pulp and Paper

Drives and Motors• AC and DC Drives, AC and DC Machines, AC motors to 1kV• Drive systems• Force Measurement• Servo Drives

Controllers & Recorders• Single and Multi-loop Controllers• Circular Chart , Strip Chart and Paperless Recorders• Paperless Recorders• Process Indicators

Flexible Automation• Industrial Robots and Robot Systems

Flow Measurement• Electromagnetic Magnetic Flowmeters• Mass Flow Meters• Turbine Flowmeters• Wedge Flow Elements

Marine Systems & Turbochargers• Electrical Systems• Marine Equipment• Offshore Retrofit and Referbishment

Process Analytics• Process Gas Analysis• Systems Integration

Transmitters• Pressure• Temperature• Level• Interface Modules

Valves, Actuators and Positioners• Control Valves• Actuators• Positioners

Water, Gas & Industrial Analytics Instrumentation• pH, conductivity, and dissolved oxygen transmitters and

sensors• ammonia, nitrate, phosphate, silica, sodium, chloride,

fluoride, dissolved oxygen and hydrazine analyzers.• Zirconia oxygen analyzers, katharometers, hydrogen purity

and purge-gas monitors, thermal conductivity.

Customer SupportABB Automation provides a comprehensive after sales servicevia our Worldwide Service Organization. Contact one of thefollowing offices for details on your nearest Service and RepairCentre.

United KingdomABB Automation LimitedTel: +44 (0)1480 475321Fax: +44 (0)1480 470787

United States of AmericaABB Automation Inc.Instrumentation DivisionTel: +1 215-674-6000Fax: +1 215-674-7183

Client Warranty

Prior to installation, the equipment referred to in this manualmust be stored in a clean, dry environment, in accordance withthe Company's published specification. Periodic checks must bemade on the equipment's condition.

In the event of a failure under warranty, the followingdocumentation must be provided as substantiation:

1. A listing evidencing process operation and alarm logs at timeof failure.

2. Copies of operating and maintenance records relating to thealleged faulty unit.

IM/6

5535

00/3

Issu

e 4

The Company’s policy is one of continuous productimprovement and the right is reserved to modify theinformation contained herein without notice.

© ABB 2001 Printed in UK (02.01)

ABB Automation LtdStonehouse,Gloucestershire. GL10 3TAUKTel: +44 (0)1453-826661Fax: +44 (0)1453-827856

ABB Automation Inc125 E. County Line RoadWarminster, PA 18974USATel: +1 215-674-6000Fax: +1 215-674-7183

ABB Automation has Sales & Customer Supportexpertise in over 100 countries worldwide

www.abb.com/automation

model 6553 series instruction manual gas analyser systems ... · zero zero hydrogen purity &...

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