ABB AK102, User Manual

Page 1: ...Gas Analyzer Systems for Hydrogen cooled Alternators AK102 and AK103 User Guide IM AK1 23_1 ...

Page 2: ...of high pressure and or temperature 5 Chemicals must be stored away from heat protected from temperature extremes and powders kept dry Normal safe handling procedures must 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 be obtained from the...

Page 3: ...3 Checking System Earth 21 7 CONTROLS DISPLAYS 22 7 1 Displays 22 7 2 Switch Familiarization 22 8 START UP 23 8 1 Instrument Start Up 23 8 2 Alarm Set Point 23 8 2 1 Type of Alarm Action 23 8 2 2 Hydrogen alarm Set Point 23 8 3 Electrical Calibration 23 8 4 Gas Calibration 24 8 4 1 Introduction 24 8 4 2 Gas Range Calibration 24 9 OPERATION 25 9 1 Normal 25 9 1 1 Purging of Hydrogen Coolant Gas 25 ...

Page 4: ...power generators A complete AK100 Analyzer system uses a combination of three different units Each unit is certified independently for use as part of an intrinsically safe system to meet the standards of the ATEX directive 9 94 EC for use in association with Group IIC hydrogen hazardous atmospheres in accordance with the following standards The different units of the system are 1 Model 6553 Displa...

Page 5: ...ch position Position 3 Percentage of Air in CO2 Argon by volume This range is for use in carbon dioxide or argon filling or purging operations Alarm and retransmission signals are inhibited in this switch position A further option of providing remote indication of range selector switch may be available depending on the number of alarms specified The 4689 Display Units provide software specific to ...

Page 6: ...ometer in order to limit the maximum voltage that could be developed across the filament bridge under external fault conditions Under fault conditions the current is limited to a safe value by the power supply unit 2 3 Model 4234 500 4234 501 Power Supply Units PSU Fig 3 3 Caution Do not connect the mains supply to the PSU with the output terminals open circuit Caution Ensure that the PSU is corre...

Page 7: ...ntial that installers and users clearly identify the various units of the monitoring system as follows 3 1 1 Model 6553 Display Unit Fig 3 1 Several versions of the 6553 Display Unit are available and are defined by the code number explained in Section 3 1 4 Identification and certification labels are fixed to the outside of the display unit case as shown in Fig 3 1 Use the ordering code table in ...

Page 8: ...Glos England GL10 3TA TYPE 4234500 501 POWER SUPPLY UNITS ll 1 G EEx ia llC 20 C Ta 55 C BAS 01 ATEX 7041 Ex Intrinsic Safety Label 0600 3 1 3 Model 4234 Power Supply Unit Fig 3 3 The identification and certification labels are fixed to the outside of the unit case as shown Fig 3 3 Typical Identification Labels and Locations Model 4234 Power Supply Unit 3 PREPARATION ...

Page 9: ... r o t a c i d n i y l p p u s r e w o p d n a s B C M s u l p r o t a l o s i s u l p e l c i b u c h t i W 0 1 2 3 n o i t p o e l c i b u C h t i w e l b a l i a v a y l n o m r a l A w o l F e l p m a S s a G d e t t i f t o N s n o i s r e v l e n a p s i s y l a n a s a g e l g n i s 4 0 1 K A d n a 3 0 1 K A d e t t i f m r a l a w o l f e n O s n o i s r e v l e n a p s i s y l a n a s a g...

Page 10: ...nting System Items 4 1 1 Models AK102 and AK103 Display Unit Fig 4 1 Note The display unit must be located in the safe area of the application plant in a sheltered interior environment The display unit is designed for panel mounting in a position to suit reading of the displays and with access to the rear for electrical wiring interconnections The panel preparation requirements and installation di...

Page 11: ... plant in a sheltered interior environment Avoid a location that subjects the katharometer unit to direct sunlight When two katharometer panels are used locate them in positions that have the same ambient temperature The katharometer unit is fixed to the panel that has fixing holes at each corner for mounting on a suitable vertical surface close to the sample tapping point The installation dimensi...

Page 12: ...ry Not Used Output to Katharometer 3 0 0 12 20 0 79 30 1 18 30 1 18 4 1 3 Model 4234 Power Supply Unit Fig 4 3 Note The unit must be located in the safe area of the application plant in a sheltered interior environment The power supply unit has four fixing lugs for mounting on a suitable vertical surface The installation dimensions are shown in Fig 4 3 Dimensions in mm in Fig 4 3 Installation Dime...

Page 13: ... Mounted System Figs 4 4 and 4 5 The cubicle must be located in a safe area of the application plant and mounted either on the base using four M10 fixings or to a vertical surface using the four fixing brackets on the back plate Overall dimensions of the cubicle are given in Fig 4 4 and the principal base case components are shown in Fig 4 5 Fig 4 4 Installation Dimensions Cubicle Cubicle sealed t...

Page 14: ... Interconnections Note A hazardous mixture of hydrogen in air could develop in the event of leakage from the sample gas system Mount katharometer analyzer panels in a ventilated area The sample pressure must not exceed 0 35 bar Gauge for Model 6540 203 or 10 bar Gauge for Model 6548 000 The incoming sample gas temperature must not exceed 55 C 131 F Ideally the sample gas temperature should be allo...

Page 15: ... and terminals 9 10 of a katharometer Type 0065XX b terminals 19 20 of the display control unit and terminals 9 10 of a katharometer Type 0065XX c terminal 4 5 of barrier B1 of display control unit Type 6653 and terminals 2 3 of a katharometer Type 0065XX must not exceed the following values Note 2c The capacitance and either the inductance or the inductance to resistance L R ratio of the cables c...

Page 16: ...103 3 way Mains Supply Terminal Blocks Type 4689 Upper Display Unit Type 4689 Lower Display Unit AK102 only Zener Diode Safety Barrier Devices Only Barrier B1 Fitted to Model AK103 Terminal Block TB5 TB6 for Katharometer Zero Pots Intrinsically Safe Circuits Safety Earth Terminal TS1 Terminal Blocks for Power and Signal Conventional Circuits Range Switch Range Switch AK102 only L N E 16 1 TB1 TB2 ...

Page 17: ...er Display L N E L N E 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TB4 NO NC NO NC COM COM Remote Range if fitted H 2 in Air Alarm 1 H 2 in Air Value Retransmission 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 External bonding and earth TS1 H 2 in Air Alarm 2 TB3 17 18 19 20 B1 4 3 B2 4 3 TB5 TB6 TB1 TB2 Note Katharometer Gas Unit Panel 1 is connected internally within 6553 Gas Monitor to Upper Display Katha...

Page 18: ...ive that wiring instructions are followed implicitly Earth continuity must be checked for correct bonding Note Katharometer Panel 1 is connected internally to the Upper Display of the 6553 Display Control Unit Katharometer Panel 2 is connected internally to the Lower Display of the 6553 Display Control Unit 14 15 16 17 18 19 20 21 22 23 24 Optional Low Flow Alarms Ex ia llC T4 Optional Low Flow Al...

Page 19: ...ometer Analyzer Panel To gain access to the connection terminal block TB1 1 Remove four screws in the cover of the katharometer unit 2 Remove cover Make the electrical connections to the Display Unit in accordance with the information given in wiring diagrams in Figs 5 3 5 4 and 5 5 and Section 5 2 The electrical connections are made at the terminal block TB1 via the cable gland or any replacement...

Page 20: ...t the power supply unit is correct for the mains supply voltage available A nominal 115V unit cannot be adapted for use with a nominal 230V supply or vice versa Remove the cover of the unit to gain access to the terminal blocks inside Identify the terminal block TB1 adjacent to the transformer T1 and ensure the correct transformer tapping is used for the incoming mains supply i e link from tapping...

Page 21: ...osed by the certification parameters Care must be taken to ensure that the specification of the cable required for interconnection lengths is such that the certification parameter limits are not exceeded see Notes 2a b and c in Fig 5 1 Cables manufactured to DEF STAN 61 12 Part 5 should comply but care must be taken over the number or cores included in the cable there is a significant difference b...

Page 22: ...t an approved leak testing procedure before passing sample gas through the system 6 2 Setting Sample Flow When all tubing interconnections have been made and external parts of the sample system checked for leaks carry out the following procedure 1 Supply calibration quality CO2 or Argon through the gas analyzer system at the normal working pressure of the application plant and within the following...

Page 23: ...vices The zener diode safety barrier devices MTL7755ac or MTL7055ac in the 6553 Display Unit are checked at the time of manufacture To ensure absolute safety when fitting a new instrument check that the barriers in the display unit are properly earthed by carrying out a routine test before using the analyzer system Warning This unit is part of the certified intrinsically safe system Appropriate sa...

Page 24: ...ameter 1 Parameter 2 Parameter 3 Page X Parameter 4 Advance to next parameter or New value is automatically stored or 7 2 Switch Familiarization Figs 7 1 and 7 2 Fig 7 1 Location of Controls and Displays Fig 7 2 Function of the Membrane Switches 7 CONTROLS DISPLAYS 7 1 Displays Fig 7 1 The display mounted in the 6553 panel comprises a 5 digit 7 segment digital upper display line and a 16 character...

Page 25: ...larm 1 LED is OFF When the display indicates less than 95 0 minus hysteresis Alarm Relay 1 is de energized and Alarm 1 LED is ON This operating mode ensures that an alarm condition is signalled in the event of a mains power failure Repeat the above procedure for Alarm Relay 2 set point 90 0 8 2 2 Hydrogen Alarm Set Point It is recommended that the hydrogen alarm set points are based on a reducing ...

Page 26: ...for leaks in accordance with the requirements of the responsible authority for site safety after making any hydrogen connections Note The procedure outlined here is not normally necessary as the ranges have been set at the factory 1 Select Range 1 Pass an 85 H2 15 N2 gas mixture through the katharometer and allow the reading to stabilize Adjust the katharometer zero potentiometer or remote zero if...

Page 27: ...2 H 2 r A r o s a G e g r u P t i b i h n I 3 x x x x e u l a V e l b a i r a V O C N I R I A 2 r A r o s a G e g r u P t i b i h n I 9 1 Normal During normal operation the AK100 Gas Analyzer System is used to indicate the purity of hydrogen used as a coolant The display shows the percentage of hydrogen in air which should be safely in excess of the explosive limit at the hydrogen rich end There a...

Page 28: ...grammmable see Section 10 3 Set Up Outputs Page Alarm 2 Set Point The set point value is programmmable see Section 10 3 Set Up Outputs Page Advance to Access to Secure Parameters on page 28 9 4 Range 3 Operating Page Range 3 is selected only during purging and refilling operations and the Operating Page indicates the percentage of Air in the CO2 or Argon purge gas Access to the programming pages i...

Page 29: ...eter values shown on the upper display line are the default settings Range 2 Selected Operating Page H2 IN CO2 Range 3 Selected Operating Page AIR IN CO2 Alarm 2 Setpoint Note With the range selector switch set to either Range 2 or Range 3 only the respective Operating Page is displayed Pressing the and keys has no effect Alarm 1 Set Point Alarm 2 Set Point RTX Type 0 10 0 20 4 20 Notes Access to ...

Page 30: ...0 to allow access during commissioning but should be altered to a unique value known only to authorized operators see Alter Security Code parameter in Set Up Outputs Page Advance to Language Page Note Access to the programming pages is possible only with Range 1 selected 10 1 Access to Secure Parameters A 5 digit code is used to prevent unauthorized access to the secure parameters 10 2 Language Pa...

Page 31: ...smission output range required 4 to 20mA 0 to 20mA or 0 to 10mA Advance to next parameter RTX Range The retransmission signal can be selected to be ranged 85 to 100 H2 in Air or 80 to 100 H2 in Air This option is only available with the range switch in position 1 Advance to next parameter Test Retransmission Output The instrument transmits a test signal of 0 25 50 75 or 100 of the retransmission r...

Page 32: ...livolt source see Section 8 3 and apply a signal input equivalent to range zero 250 00mV Allow the instrument display to stabilize Advance to next parameter Calibration Range Span 100 H2 in Air Apply a signal input equivalent to range span 10 00mV Allow the instrument display to stabilize Advance to next parameter Adjust Retransmission Zero Adjust the retransmission zero e g 4 00mA to the appropri...

Page 33: ...tive ranges 11 1 7 Bridge Current The working current of the katharometer bridge is 350mA supplied from the PSU This value must remain stable during normal operation as the katharometer output signal is proportional to the cube of the bridge current 11 2 Diagnostic Tests Warning Each of the units in the system are part of the certified intrinsically safe system Appropriate safety precautions must ...

Page 34: ...e gas sample system to the particular katharometer from the main gas cooling system Purge the sample system of hydrogen in accordance with the requirements of the responsible authority Caution The thermal insulation inside the case must not be damaged or removed c Remove the cover of the katharometer unit and dismantle the internal sample system pipework d Remove the fixing screws securing the mou...

Page 35: ...rinsically safe application Note Although the digital display units may be marked 4600 on their display facia they are dedicated variants which are not interchangeable with the Company s standard 4600 Controller Display These dedicated display units are identified 4689 502 as shown in Fig 3 1 on page 5 When ordering a katharometer unit it is necessary to specify the zero gas and range in associati...

Page 36: ...o for H2 Purity One for Purge Gas AK102 Four H2 Purity AK103 Two H2 Purity AK104 Two H2 Purity Relay contacts Single pole changeover Rating 250V AC 250V DC max 3A AC 3A DC max Loading non inductive 750VA 30W max inductive 75VA 3W max Insulation 2kV RMS contacts to earth ground Remote range indication Rating 250V AC 300V AC max 150mA AC 150mA AC max No of set points AK101 Three Two for H2 Purity On...

Page 37: ...arometer Analyzer Panel Approvals CENELEC approved EEx ia IIC Tamb 20 C to 55 C BASEEFA Certificate No BAS 01 ATEX 1042 II 1 G Model 6540 203 incorporating Model 6539 960 H2 or Model 6539 960 CO2 Katharometer Unit Model 6548 000 incorporating Model 6548 001 H2 and CO2 Katharometer Unit Power Supply 350mA DC from 4234500 or 4234501 power supply unit Signal Output 0 to 10mV for each range Accuracy 2...

Page 38: ...36 NOTES ...

Page 39: ...trumentation 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 Support We provide a comprehensive after sales service via a Worldwide Service Organization Contact one of the follow...

Page 40: ...ments 9716 S Virginia St Ste E Reno Nevada 89521 USA Tel 1 775 850 4800 Fax 1 775 850 4808 ABB has Sales Customer Support expertise in over 100 countries worldwide www abb com The Company s policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice Printed in UK 06 04 ABB 2004 ...