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4

MECHANICAL INSTALLATION…

Fig. 4.2 Installation Dimension and Interconnection Positions –

Model 006540203 or 006548000 Katharometer Analyser Panel

Note.

All dimensions nominal

millimetres unless indicated otherwise.

148

38

10

19

305

267

610

572

±

0.3

233

Outlet

Coupling for

Ø6 tube

(006548000)

or

Ø8 tube

(006540203)

19

Gland for Ø7 – 10.5 cable

4 fixing
holes Ø10

Coupling for

Ø6 tube

(006548000)

or

Ø8 tube

(006540203)

4.1.2

Katharometer Analyser Panels – Fig. 4.2

Caution.

Ensure that the correct panel, specifying zero gas 'Hydrogen' or 'CO2', is located at the required position and

ensure 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 a location
which subjects the katharometer unit to direct sunlight. When two katharometer panels are used they should be positioned 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 vertical surface
close to the sample tapping point. The installation dimensions for the panel is shown in Fig. 4.2.

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Summary of Contents for 6553 Series

Page 1: ...ser Systems for Intrinsically Safe Hydrogen Purge Gas Purity Measurement Instruction Manual Digital Displays 4689 500 501 and 4689 500 503Models Hydrogen Purity Purge Gas Monitor F1 95 0 H2 IN AIR 95 0 H2 IN AIR Range 1 2 3 Zero Zero ...

Page 2: ...nal conditions result in degraded process 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 manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part witho...

Page 3: ...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 23 8 4 1 Introduction 23 8 4 2 Purge Gas 23 8 3 2 Hydrogen 24 9 OPERATION 24 9 1 Normal 24 9 1 1 Purging of Hydrogen Coolant Gas 24 9 1 2 Filling with Hydrogen Coolant Gas 24 10 PROGRAMMING 26 10 1 Range 1 29 10 1 1 Access to Secure Parameters 29 10 1...

Page 4: ... combinations of similar equipment built to any earlier specifications are not covered by BASEFA certificate number BAS Ex 01E2044 This is particularly important where new replacement units are to be incorporated into existing installations covered by any earlier certification standards If in any doubt about the installation of particular combinations of certified equipment please contact the Comp...

Page 5: ...the katharometers in the hazardous area The adjustment access for a particular display is adjacent to the display and at the same level The monitor unit has a protective case which can be removed for access to the interior without removing the whole monitor unit from the panel The monitor also contains encapsulated zener barrier units to limit the electrical energy level that can be applied from t...

Page 6: ...hus any difference between the thermal conductivity of reference and sample gases causes an imbalance in the bridge this imbalance as a millivolt signal is indicated by the monitor unit Zener diodes are connected across the input connections from the power supply unit to the katharometer in order to limit the maximum voltage which could be developed across the filament bridge under external fault ...

Page 7: ...043 ABB L i m i t e d Oldends Lane Stonehouse Glos England GL10 3TA Code Serial No Voltage Watts Hz 50 60 Year Manuf Manufactured by Retaining Screw 0600 N4006 4689 Display Unit Ex Ex ABB Limited Oldends Lane Stonehouse Glos England GL10 3TA Katharometer Type 006548 ll 1 G EEx ia llC T4 Tamb 20 C to 55 C BAS 01 ATEX 1042 N4006 ABB L i m i t e d Oldends Lane Stonehouse Glos England GL10 3TA Type No...

Page 8: ... m i t e d Oldends Lane Stonehouse Glos England GL10 3TA Code Serial No Voltage Watts Year Manuf Manufactured by N4006 ABB Limited Oldends Lane Stonehouse 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 Intrinsic Safety Label 0600 Fig 3 3 Typical Identification Labels and Locations Model 4234 Power Supply Unit ...

Page 9: ...Air in Ar 0 100 H2 in Ar 80 100 H2 in Air E Range Selector Switch 0 Not fitted 2 Fitted with facilities for Remote Indication of Switch Position only upper display fitted 3 Fitted with two range switches upper and lower display remote indication of selected ranges F Additional Output Signal Not Used G Language 1 English 2 French 3 German 4 Polish H Type of Cubicle 1 Without Cubicle 2 Cubicle 2 x 3...

Page 10: ...s indicated otherwise Fig 4 1 Installation Dimensions and Interconnection Positions Model 6553 Gas Monitor Unit with Digital Displays 4 1 Locating and Mounting System Items 4 1 1 Model 6553 Gas Monitor Fig 4 1 The 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 dis...

Page 11: ...correct panel specifying zero gas Hydrogen or CO2 is located at the required position and ensure 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 a location which subjects the katharometer unit to direct sunlight When two katharometer panels are used they should be positioned...

Page 12: ...ns Cable Entry Not Used Output to Katharometer 3 0 Fig 4 3 Installation Dimension and Interconnection Positions Model 4234 Power Supply Unit 4 1 3 Model 4234 Power Supply Unit Fig 4 3 Caution The unit must be located in the safe area of the application plant in a sheltered interior environment The power supply unit has 4 fixing lugs and should be mounted on a suitable vertical surface The installa...

Page 13: ...n 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 4 MECHANICAL INSTALLATION Fig 4 4 Installation Dimensions Cubicle Hydrogen Purity Purge Gas Monitor ø12 Dimensions in mm Hazardous Area Cable Glands Safe Area Cable Glands Mains Power Cable Glands 478 600 515 140 80 80 340 382 630 40 H2 IN CO2 95 0 H2 IN AIR 95 0 4 Mo...

Page 14: ...oming sample gas temperature must not exceed the temperature given in Section 13 Ideally the sample gas temperature should be allowed to reach ambient temperature before entry to the Katharometer unit If there is a risk of significant particle contamination a suitable 1µm filter unit should be incorporated in the system before the sample gas enters the analyser system Compression couplings are sup...

Page 15: ...and either the inductance or the inductance to resistance L R ratio of the cables connected between a terminals 17 18 of the gas monitor Type 6653 and terminals 9 10 of a katharometer Type 0065XX b terminals 19 20 of the gas monitor and terminals 9 10 of a katharometer Type 0065XX c terminal 4 5 of barrier B1 of gas monitor Type 6653 and terminals 2 3 of a katharometer Type 0065XX must not exceed ...

Page 16: ...Block TB5 TB6 for Katharometer Zero Pots Intrinsically Safe Circuits Safety Earth Terminal TS1 Terminal Blocks for Power and Signal Conventional Circuits Range Switch L N E 16 1 TB1 TB3 TB4 TB5 TB6 B1 B2 B3 Warning Equipment in this system operates on a c mains supply voltage electricity Suitable safety precautions must be taken to avoid the possibility of electric shock Although certain instrumen...

Page 17: ...ns for Lower Display Connections for Upper Display L N E TB4 NO NC C Remote Range if fitted H 2 in CO 2 or Air in CO 2 Alarm 1 External bonding and earth Purge gas value Retransmit TB3 Monitor 17 18 19 20 B1 5 4 B2 5 4 TB5 TB6 TB1 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 Gas...

Page 18: ...r Mains Isolator Switch Mains In Live Neutral Earth 1 3 2 4 E 9 10 3 2 1 4 Katharometer H 2 in Air Katharometer Panel 1 9 10 6 3 1 4 Katharometer H 2 Air in CO 2 Katharometer Panel 2 Hazardous Area Warning I S Circuits It is imperative that wiring instructions are followed implicitly Earth continuity must be checked for correct bonding Note Katharometer Panel 1 is connected internally to the Upper...

Page 19: ...over of the katharometer unit 2 Remove cover to access the terminal block TB1 inside The electrical connections are made at the terminal block TB1 via the cable gland or any replacement gland to suit the intrinsically safe wiring requirements When the appropriate interconnections have been made if remote zero is to be used remove the 510R dummy remote zero resistor from across terminals 9 and 10 a...

Page 20: ...ade at terminal blocks TB1 and TB2 through the appropriate cable gland or any replacement gland to suit intrinsically safe wiring requirements Secure the incoming cable by the cable clips adjacent to the terminal blocks Replace the cover when wiring is complete 5 ELECTRICAL INSTALLATION TB1 T1 L N E F2 F3 Warning Hazardous Voltages There are no servicable parts in this unit Please return to the ma...

Page 21: ...a in Fig 5 3 5 2 2 Recommended Cables The choice of wiring cable is restricted due to the limitations imposed by the certification parameters see Notes 2a b and c in Fig 5 1 Cables manufactured to DEF STAN 61 12 Part 5 should comply but care should be taken over the number or cores included in the cable As can be seen there is a significant difference between the 2 core and 6 core cables The diame...

Page 22: ...been made and external parts of the sample system checked for leaks the suggested procedure is as follows 1 Arrange to supply calibration quality carbon dioxide gas through the gas analyser system at the normal working pressure of the application plant and within the limits given in Section 13 Caution Testing for leaks with carbon dioxide may not be considered an adequate check of gas tight integr...

Page 23: ... the cover on the unit 6 3 2 Zener Diode Safety Barrier Devices The zener diode safety barrier devices MTL 7055ac in the 6553 Monitor Unit are checked at the time of manufacture To ensure absolute safety when fitting a new instrument check that the barriers in the monitor are properly earthed by carrying out a routine test before using the analyser system Warning This unit is part of the certified...

Page 24: ... Choice Parameter X Y Z Select Parameter 1 Parameter 2 Parameter 3 Page X Parameter 4 Advance to next parameter or New value is automatically stored or Fig 7 1 Location of Controls and Displays Fig 7 2 Function of the Membrane Switches 7 1 Displays Fig 7 1 The displays comprise a 5 digit 7 segment digital upper display line and a 16 character dot matrix lower display line The upper display line sh...

Page 25: ... terminals may be live and the opening of covers or removal of parts except those to which access may be gained by hand is likely to expose live parts 8 1 Instrument Start Up In normal operation the instrument displays the Operating Page which is a general use page in which parameters are viewed only and cannot be altered Any changes to the operating parameters are implemented using the switches a...

Page 26: ...cate the purity of hydrogen used as a coolant The displays shows the percentage of hydrogen in air which should be safely in excess of the explosive limit at the hydrogen rich end There are no routine adjustments required to the gas analyser system after completion of start up procedures and putting on line in monitoring mode The system only requires minor adjustments to the metering valve to main...

Page 27: ... p U y a l p s i D e n i L r e w o L 1 m r a l A t n i o P t e S 2 m r a l A t n i o P t e S y a l p s i D l a u t c A n o i t c n u F y a l p s i D l a u t c A n o i t c n u F U p p e r D i s p l a y 1 x x x x e u l a V e l b a i r a V R I A N I 2 H y t i r u P n e g o r d y H R A R A 2 t i b i h n I E S U N I T O N t i b i h n I t i b i h n I t i b i h n I 3 t i b i h n I E S U N I T O N t i b i...

Page 28: ...2 Action EB EA A2 Setpoint RTX Type 4 20 0 20 0 10 0 0 Range 85 100 80 100 xxx x mV Span 10 00mV xxx x mV Zero 0 00mV ELECTRICAL CAL Calibrate NO YES NOT IN USE Operating Page Language Access to Secure Parameters UPPER INDICATOR LOWER INDICATOR UPPER DISPLAY RANGE 1 Note All parameter values shown on the upper display line are the default settings Set Up Outputs Page Electrical Calibration Page NO...

Page 29: ... Operating Parameters Secure Parameters Access to Secure Parameters Language UPPER INDICATOR Note All parameter values shown on the upper display line are the default settings LOWER DISPLAY RANGE 2 No Note Programming of the Language page Set Up Output page and the Electrical Calibration page should be carried out within Range 2 If circumstances require they can also be accessed from Range 3 scrol...

Page 30: ...CAL Adjust RTX Span Calibrate No Yes mV Zero 0 00mV xxx x mV Span 10 00mV xxx x Adjust RTX Zero Operating Page LOWER INDICATOR Set Up Outputs Page Electrical Calibration Page Operating Parameters Secure Parameters Access to Secure Parameters Language UPPER INDICATOR Note All parameter values shown on the upper display line are the default settings LOWER DISPLAY RANGE 3 No FIG 10 3 Overall Programm...

Page 31: ...at 00000 to allow access during commissioning but should be altered to a unique value known only to authorized operators see Access Page Advance to Language Selection 10 1 2 Language 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 Action For Fail safe alarm operation...

Page 32: ...cimal point position is set automatically The alarm LEDs are illuminated in the alarm condition Retransmission Output Type The 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 Output The instrument automatically transmits a test signal of 0 25 50 75 or 100 of the retransmis...

Page 33: ...ment display to stabilize Calibration Range Zero H2 IN AIR Proceed as described in Section 8 3 but apply a signal input equivalent to H2 IN AIR range zero 0 00 mV see table below Allow the instrument display to stabilize Calibration Range Span H2 IN AIR Apply a signal input equivalent to H2 IN AIR range span 10 0 mV see table below Allow the instrument display to stabilize Adjust Retransmission Ze...

Page 34: ...ing but should be altered to a unique value known only to authorized operators see Section 10 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 Page Header SET UP OUTPUTS Advance to next parameter Purge Gas Alarm Select Select the parameter on which the purge gas alarm is to operate Reprogram as required to agree with se...

Page 35: ...nput 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 required value Retransmission Output Type The 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 Output The instrument automati...

Page 36: ...xt parameter Calibration Range Zero H2 IN CO2 Proceed as described in Section 8 3 but apply a signal input equivalent to H2 IN AIR range zero 0 00 mV see table below Allow the instrument display to stabilize Advance to next parameter Calibration Range Span H2 IN CO2 Apply a signal input equivalent to H2 IN CO2 range span 10 0 mV see table below Allow the instrument display to stabilize Advance to ...

Page 37: ...evented 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 Section 10 3 3 Set Up Outputs Page Advance to Language Page 10 3 2 Language Page Advance to Set Up Outputs Page LOWER DISPLAY 10 3 Range 3 10 3 1 Access to Secure Parameters A 5 digit code...

Page 38: ...t 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 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 A...

Page 39: ... parameter Calibration Range Zero AIR IN CO2 Proceed as described in Section 8 3 but apply a signal input equivalent to AIR IN CO2 range zero 0 00 mV see table below Allow the instrument display to stabilize Advance to next parameter Calibration Range Span AIR IN CO2 Apply a signal input equivalent to AIR IN CO2 range span 10 0 mV see table below Allow the instrument display to stabilize Advance t...

Page 40: ... t s a l e h t d e s u V m d e t a r b i l a c a h t i w e r u d e c o r p t a e p e R e c r u o s e h t t c a t n o c s t s i s r e p m e l b o r p e h t f I y n a p m o C e g a s s e M n o i t a r b i l a C n o i t a n a l p x E n o i t c A g n i t a r b i l a C s t n e i c i f f e o c n o i t a r b i l a c w e n f o n o i t a r b i l a C e n o N s s a P n o i t a r b i l a C d e s u e r a s t n...

Page 41: ...riations of the ambient temperature Temperature changes can affect the sensitivity and reduce accuracy on sensitive ranges 11 1 7 Bridge Current The working current of the katharometer bridge is 350 mA supplied from the PSU This value must remain stable during normal operation as the katharometer output signal is approximately proportional to the cube of the bridge current 11 2 Diagnostic Tests Wa...

Page 42: ...ut a leak test in accordance with the requirements of the responsible authority m Power up the katharometer unit by switching on the appropriate PSU n Arrange to pass dry air or another suitable dry gas through the katharometer at the normal sample flowrate for 24 hours o Isolate the katharometer unit at its PSU p Make the remaining electrical connections at TB1 of the katharometer unit see Fig 5 ...

Page 43: ... cartridge 0231577 F1 400 mA cartridge 0231555 Katharometer Analyser Panel 006540 203 006548 000 Flowmeter 006525 460 0216 485 Valve metering 006525 480 0216 484 Coupling seal ring 006525 130 Katharometer unit H2 006539 960K or J 006548 001 Katharometer unit CO2 006539 960 Model 6553 Gas Monitor Unit Display unit 100 80 85 H2 in Air 4689 501 Display unit 80 85 100 H2 in Air 4689 503 Display unit 0...

Page 44: ...ately Environment Sheltered interior 0 to 90 RH b Model 006540 203 006548 000 Katharometer Analyser Panels Electrical Input 350 mA d c from 4234 PSU Signal Output 0 to 10 mV for H2 in air 85 to 100 H2 in air Accuracy 2 fsd each range Dead Time Typically 5 seconds Response Time Typically 40 s for 90 step change at katharometer Tubing and drying chamber introduce extra delays Ambient Temperature Max...

Page 45: ...1 Outline Dimensions 610 x 305 x 152 mm Weight 8 6 kg approximately Environment Sheltered interior d Power Supply Unit Model 4234 500 input 230 V a c 50 60 Hz Model 4234 501 input 115 V a c 50 60 Hz Fuse Ratings 250 mA high breaking capacity 1500 A ceramic 2 off 400 mA F 1 off dc Output stabilized 350 mA Load Conditions 0 to 14 Ω Ambient Temperature Range 20 to 55 C Supply Variations 6 V 4 Hz Regu...

Page 46: ...44 NOTES ...

Page 47: ...nalytics 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 Support We provide a comprehensive after sales service via a Worldwide Service Organization Contact one o...

Page 48: ...ned herein without notice Printed in UK 04 02 ABB 2002 ABB Limited Oldends Lane Stonehouse Gloucestershire GL10 3TA UK Tel 44 0 1453 826 661 Fax 44 0 1453 827 856 ABB Inc 2175 Lockheed Way Carson City NV 89706 USA Tel 1 0 775 883 4366 Fax 1 0 775 883 4373 ABB has Sales Customer Support expertise in over 100 countries worldwide www abb com ...

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