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A B B ME A SUR EMENT & A N A LY TIC S | USER GU IDE | IM/A K 1/14 R E V. N

AK101 and AK104

Gas analyzer systems for hydrogen-cooled alternators

Measurement made easy

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Data Sheet
AK100 Series
ATEX compliant gas analyzer system
for hydrogen-cooled alternators

DS/AK100-EN

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AK101 and AK104
gas analyzer systems

Summary of Contents for 006539-960J

Page 1: ...ernators Measurement made easy For more information A Data Sheet is also available for free download from www abb com analytical or by scanning this code Search for or click on Data Sheet AK100 Series ATEX compliant gas analyzer system for hydrogen cooled alternators DS AK100 EN AK101 and AK104 gas analyzer systems ...

Page 2: ... in full or part without prior approval of the Technical Publications Department Health and safety To ensure that our products are safe and without risk to health the following points must be noted The relevant sections of these instructions must be read carefully before proceeding Warning labels on containers and packages must be observed Installation operation maintenance and servicing must only...

Page 3: ...ectrical Calibration 27 8 4 Gas Calibration 27 8 4 1 Introduction 27 8 4 2 Purge Gas 27 8 4 3 Hydrogen 28 9 OPERATION 29 9 1 Normal 29 9 1 1 Purging of Hydrogen Coolant Gas 29 9 1 2 Filling with Hydrogen Coolant Gas 29 9 2 Range 1 Operating Page 30 9 3 Range 2 Operating Page AK101 only 30 9 4 Range 3 Operating Page AK101 only 30 10 PROGRAMMING 31 10 1 Range 1 UPPER DISPLAY 34 10 1 1 Access to Secu...

Page 4: ...iation from the specified installation conditions or any unauthorized repairs or adjustments can invalidate the safety assurances given by the certification of the unit The ultimate responsibility for any particular installation lies with the installing user contractor This manual gives the installation operating and maintenance information for the Company s range of Models AK101 and AK104 Intrins...

Page 5: ...ng operations Alarm output and a value retransmission signal 4 to 20mA are provided Each display defaults to NOT IN USE when not selected A further option of providing remote indication of range selector switch may be available depending on the number of alarms specified The 4689 or CM30 digital displays provide software specific to the katharometer systems with relay action of the alarms fixed as...

Page 6: ...ther details Caution Do not connect the mains supply to the PSU with the output terminals open circuit Caution Ensure that the PSU 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 To operate a katharometer unit in the hazardous area one Model 4234 PSU is required for each katharometer The PSU supplies a stabili...

Page 7: ...essential 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 unit case as shown in Fig 3 1 Use the ordering code table in Sect...

Page 8: ... Supply Unit Fig 3 3 Refer also to IM 4234500 for further details The identification and certification labels are fixed to the outside of the unit case as shown 3 PREPARATION Fig 3 3 Typical Identification Labels and Locations Model 4234 Power Supply Unit Fig 3 4 Typical Identification Labels and Locations cubical option incorporating 6553 display unit and 4234 power supply unit Product Code Seria...

Page 9: ...only CO2 Argon Nitrogen AK101 only 0 1 2 3 Gas Analysis Panel None Low pressure flame traps for vent to atmosphere 0 35barg 5 psi max High pressure for closed loop 10barg 145 psi max 0 2 3 Cubicle Without cubicle With cubicle plus isolator With cubicle plus isolator plus MCBs and power supply indicators 0 2 3 Gas Sample Flow Alarm only available with Cubicle option Not fitted One flow alarm fitted...

Page 10: ...ounting System Items 4 1 1 Models AK101 and AK104 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 interconnections The panel preparation requirements and installation dimensi...

Page 11: ...arometer Analyzer Panel Fig 4 2 Refer also to IM 6517 6518 for further details Note The panel may be located in the hazardous area Zone 0 1 or 2 of the application 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 uni...

Page 12: ...ray Not Used Gray Output to Katharometer 3 0 0 12 20 0 79 30 1 18 30 1 18 Blue 4 1 3 Model 4234 Power Supply Unit Fig 4 3 Refer also to IM 4234500 for further details 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 ...

Page 13: ...lant and mounted either on the base using four M10 fixings or to a vertical surface using the four fixing brackets on the back plate Ensure any vertical surface on which the cubicle is to be mounted is robust and suitable for the purpose Rawlbolts or similar heavy duty fixings must be used Overall dimensions of the cubicle are given in Fig 4 4 and the principal base case components are shown in Fi...

Page 14: ... INSTALLATION Fig 4 5 Location of Main Components on Cubicle Backplate PSU 1 TO KATH 1 TB18 1 2 3 4 5 6 7 8 9 10 11 13 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 L N E E L N E E 38 39 40 41 42 43 44 45 46 47 48 49 Note The number of terminals cable glands low flow alarms PSU s and zener barriers flow alarms vary according to ordering information details specified B6...

Page 15: ...65XX Note 2c The capacitance and either the inductance or the inductance to resistance L R ratio of the cables connected between 3 4 of barrier B2 plus terminal 4 of barrier B3 of gas monitor type 6553 and terminals 2 3 6 of a katharometer Type 0065XX must not exceed the following values See Notes 2 3 for cable details Circuit A Circuit B see Note 8 Note 3 The cable may be separate cables or may b...

Page 16: ...e B multicore cable must not exceed 60 volts Note 4 The installation must comply with national requirements Note 5 The system must be marked with a durable label The label should appear on or adjacent to the principal item of electrical apparatus in the system or at the interface be intrinsically safe circuits This marking shall include the word SYST or SYSTEM e g BAS SYSTEM No Ex 01E2044 or BAS N...

Page 17: ...I S Earth Zener Diode Safety Barrier MTL 767 CERT No BAS 01 ATEX 7202 IEC Ex BAS 05 0019 Hazardous Area 1 4 2 3 Junction boxes if required see note 7 Location Hazardous or Safe Area 16 14 15 16 Screen TB JB Terminal Box See Note 5 GIR Low Flow Sensor Red White Black 1 3 4 2 Circuit B Floscan Relay Module See Note 6 B4 B5 Screen Red White Black I S Earth Zener Diode Safety Barrier MTL 767 CERT No B...

Page 18: ...IA 0 58 3 55 14 1 45 7 22 14 66 263 544 or Safe Ar Circuit A ea Floscan Relay Module See Note 6 B4 Screen Red White Black I S Earth Zener Diode Safety Barrier MTL 767 CERT No BAS 01 ATEX 7202 IEC Ex BAS 05 0019 Hazardous Area 1 12V S 1 4 2 3 16 14 15 16 Screen TB JB Terminal Box See Note 5 GIR Low Flow Sensor Red White Black 1 3 4 2 Note 4 The cables may be separate cables or may be installed as s...

Page 19: ...ctrical connections and wiring standards must be achieved to establish the intrinsic safety of the system as certified AC input intrinsically safe DC output and non intrinsically safe wiring must all be routed separately Fig 5 1 shows the interconnecting wiring requirements for the AK10x Gas Analyzer system that must be strictly observed Details of cable requirements that must be strictly adhered ...

Page 20: ...5 16 TB4 NO NC COM Remote Range AK101 only H 2 in Purge Gas or Air in Purge Gas Alarm 1 Purge Gas Value Retransmission 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 External bonding and earth TB3 Monitor 17 18 19 20 B1 4 3 B2 4 3 TB5 TB6 TB2 Note Katharometer Gas Unit Panel 1 is connected internally within 6553 Gas Monitor to Upper Display Katharometer Gas Unit Panel 2 is connected internally within 6553...

Page 21: ...ring to suit power and signal requirements Zener diode safety barrier devices L N E 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TB4 External bonding and earth TS1 Monitor 17 18 B1 4 3 TB5 TB2 Note Katharometer Gas Unit Panel 1 is connected internally within 6553 Gas Monitor to Upper Display MTL 7755ac NO NC COM Alarm 1 H 2 in Air NO NC COM Alarm 2 H 2 in Air H 2 in Air Value Retransmit Fig 5 6a Interco...

Page 22: ...atharometer H 2 Air in CO 2 H 2 in Air Note I S Circuits It is imperative that wiring instructions are followed implicitly Earth continuity must be checked for correct bonding Warning The case mounted Instrinsically Safe Earth stud see Fig 4 5 must be connected to the plant High Integrity Earth The maximum resistance from this earth stud to the plant High Integrity Earth must be 0 1 Ω This earth i...

Page 23: ...ckets to the mounting panel 5 1 2 Model 006540 203 and 006548 000 Katharometer Analyzer Panel Refer also to IM 6517 6518 for further details 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 6 5 7 and 5...

Page 24: ...Ensure that 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 Check voltage link is set to correct supply voltage see Fig 5 9 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 trans...

Page 25: ... of a maximum inductance resistance ratio of 79 H for group IIC gases Refer also to Fig 5 1 Note 2d or Fig 5 2 Note 2c These wires are indicated by a in Fig 5 6 and Fig 5 6a 3 Connections between model 006540203 or 006548000 Katherometer Analyzer panels and Model 6553 Display Unit Kathrometer 9 and 10 to 6553 Display Unit terminals TB5 and TB6 cables are subject to a maximum inductance resistance ...

Page 26: ...tions 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 limits Model 6540 203 125mm H2O min to 0 35bar gauge max Model 6548 000 125mm H2O min to 10bar gauge max Note In some instances test...

Page 27: ...orrectly earthed by carrying out an appropriate test before using the katharometer system Warning The zener diode safety barrier devices are certified intrinsically safe and form part of the certified intrinsically safe system Appropriate safety precautions MUST be taken to prevent any incendive electrical discharges in the hazardous area when testing the barriers If the tests identify a faulty ba...

Page 28: ...ter 2 Parameter 3 Page X Parameter 4 Advance to next parameter or New value is automatically stored or 7 1 Displays Fig 7 1 The 4689 or CM30 digital display s mounted in the 6553 Display Unit comprises a 5 digit 7 segment digital upper display line and a 16 character dot matrix lower display line The upper display line shows actual values of hydrogen purity hydrogen in air air in carbon dioxide al...

Page 29: ...ng of the development of a potentially explosive mixture Factory settings are Alarm 1 95 0 and Alarm 2 90 0 The procedure is as follows Access the programming pages Section 10 and set the alarm 8 3 Electrical Calibration The instrument is factory calibrated for electrical voltage signal input No adjustment is normally necessary for correct functioning of the display unit If electrical calibration ...

Page 30: ... read 0 0 11 If necessary refer to Section 10 2 3 for a full calibration sequence Note No adjustment of the lower zero potentiometer is necessary as any adjustment required will already have been made while calibrating the Air in purge gas range 8 4 3 Hydrogen Note Test for leaks in accordance with the requirements of the responsible authority after making any hydrogen connections 1 Pass calibrati...

Page 31: ... n I 2 x x x x e u l a v e l b a i r a V H 2 n i y t i r u P s a G e g r u P d e r i u q e r s A e l b a l i a v a t o N 3 x x x x e u l a v e l b a i r a V n i r i A y t i r u P s a G e g r u P d e r i u q e r s A e l b a l i a v a t o N 4 0 1 K A e h t o t e l b a c i l p p a t o N Table 9 1 Functions and Status of Display Units for Different Range Selector Switch Positions 9 1 Normal During nor...

Page 32: ...set point value is programmmable see Section 10 3 Set Up Outputs Page Advance to Access to Secure Parameters on page 28 9 3 Range 2 Operating Page AK101 only Set to Range 2 the single Alarm Set Point value may be changed this is displayed in the Operating Page 9 4 Range 3 Operating Page AK101 only Set to Range 3 the single Alarm Set Point value may be changed this is displayed in the Operating Pag...

Page 33: ...ecure Parameters Note All parameter values shown on the upper display line are the default settings Alarm 2 Setpoint RTX Type 4 20 0 20 0 10 100 0 75 0 50 0 25 0 0 0 EB A1 Action EA Yes NOT IN USE Lower Display EB A2 Action EA A1 Setpoint A2 Setpoint Range 85 100 mV Zero 0 00mV xxx x xxx x mV Span 10 00mV xxx x Test Retrans Range 80 100 Note The following programming pages apply to both display un...

Page 34: ...Yes NOT IN USE Upper Display EB Relay Action EA Alarm Setpoint Test Retrans mV Zero 0 00mV xxx x xxx x mV Span 10 00mV xxx x Alter Sec Code H2 IN SPT H2 IN Note Programming of the Language page Set Up Outputs page and the Electrical Calibration page should be carried out within Range 2 If circumstances require they can also be accessed from Range 3 It is not necessary to work through the Set Up Ou...

Page 35: ...e upper display line are the default settings RTX Type 4 20 0 20 0 10 AIR IN Alarm H2 IN Alarm Setpoint Yes NOT IN USE Upper Display EB Only when AIR IN selected in Set Up Outputs page Relay Action EA Test Retrans mV Zero 0 00mV xxx x xxx x mV Span Alter Sec Code AIR IN SPT AIR IN xxx x xxx x see Note Note CO2 10 00mV N2 1 00mV Argon 10 00mV 10 PROGRAMMING Fig 10 3 Overall Programming Chart for 65...

Page 36: ...rs 10 1 2 Language Page Security Code Enter the required code number between 00000 and 19999 to gain access to the secure parameters If an incorrect value is entered access to subsequent programming pages is prevented and the display reverts to the Operating Page Note The security code is preset at 00000 to allow access during commissioning but should be altered to a unique value known only to aut...

Page 37: ...ion Output Type The retransmission output is assigned to the hydrogen purity range Select the retransmission output range required 4 to 20mA 0 to 20mA or 0 to 10mA Advance to next parameter Test Retransmission Output The instrument transmits a test signal of 0 25 50 75 or 100 of the retransmission range The test signal selected is shown on the upper line of the display Example for the range 0 to 2...

Page 38: ...bration Range Zero 80 or 85 H2 in Air Apply a signal input equivalent to H2 IN AIR range zero 0 00mV Allow the instrument to stabilize Advance to next parameter Calibration Range Span 100 H2 in Air Apply a signal input equivalent to H2 IN AIR 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 t...

Page 39: ...Enter the required code number between 00000 and 19999 to gain access to the secure parameters If an incorrect value is entered access to subsequent programming pages is prevented and the display reverts to the Operating Page Note The security code is preset at 00000 to allow access during commissioning but should be altered to a unique value known only to authorized operators see Alter Security C...

Page 40: ...nt value Alarm action occurs if the input value is above or below the set point band If the input moves within the set point band the last alarm action is maintained Purge Gas Alarm Set Point The alarm set point can be set to any value within the input range being displayed The set point value is subject to hysteresis within the set point band as detailed above Set the alarm set point to the requi...

Page 41: ...gnal input equivalent to H2 IN PURGE GAS range zero 0 00mV Allow the instrument to stabilize Advance to next parameter Calibration Range Span 100 H2 in CO2 Apply a signal input equivalent to H2 IN PURGE GAS 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 appropriate zero value The ret...

Page 42: ...e Enter the required code number between 00000 and 19999 to gain access to the secure parameters If an incorrect value is entered access to subsequent programming pages is prevented and the display reverts to the Operating Page Note The security code is preset at 00000 to allow access during commissioning but should be altered to a unique value known only to authorized operators see Alter Security...

Page 43: ...s the actual value of the set point 1 of the set point value Alarm action occurs if the input value is above or below the set point band If the input moves within the set point band the last alarm action is maintained Purge Gas Alarm Set Point The alarm set point can be set to any value within the input range being displayed The set point value is subject to hysteresis within the set point band as...

Page 44: ...libration Range Zero 0 Air in CO2 Proceed as described in Section 8 3 Calibration but apply a signal input equivalent to AIR IN CO2 range zero 0 00mV Allow the instrument to stabilize Advance to next parameter Calibration Range Span 100 Air in CO2 Apply a signal input equivalent to AIR IN CO2 range span 10 00mV N2 range span 1 00mV Argon range span 10 00mV Allow the instrument display to stabilize...

Page 45: ...rrent 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 These units are part of the certified intrinsically safe system Appropriate safety precautions must be taken to prevent any incendive electrical discharges in the hazar...

Page 46: ...r at its PSU b Isolate the 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 fixin...

Page 47: ... These dedicated display units are identified 4689 500 501 or 503 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 association with the Company part number See the typical identification label shown in Fig 3 2 on page 5 12 1 Consumables Description 12 2 Routine Maintenance Parts Description Part No Model 6553 Display unit Fuse 500...

Page 48: ...le from the Company on request or can be downloaded from our website www abb com analytical EC Declaration of Conformity Gas Monitor type 6553 EC Declaration of Conformity Type 4234500 501 Power Supply Units EC Declaration of Conformity Katharometers type 006539 and 006548 ...

Page 49: ...47 14 SPECIFICATION d d ...

Page 50: ...48 14 SPECIFICATION DS AK100 EN Rev N d d d d ...

Page 51: ...Notes Sales Service ...

Page 52: ...ights in this document and in the subject matter and illustrations contained therein Any reproduction disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB ABB 2018 ABB Limited Measurement Analytics Oldends Lane Stonehouse Gloucestershire GL10 3TA UK Tel 44 0 1453 826 661 Fax 44 0 1453 829 671 Email instrumentation gb abb ...

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