ABB 6553 Series User manual

Model 6553 Series
Gas Analyzer Systems for
Intrinsically Safe Hydrogen &
Purge Gas Purity Measurement
Instruction Manual
4689 502/502 Digital Displays
1
2
3
Range
1
2
3
Range
95.0
%H2 IN AIR
95.0
%H2 IN AIR
PurgeGasMonitor

ABB Automation
✶
Note.
Clarification of an instruction or additional information.
Information.
Further reference for more detailed information or
technical details.
AlthoughWarning hazardsarerelatedtopersonalinjury,andCaution hazardsareassociatedwithequipmentorpropertydamage,
it must be understood that operation of damaged equipment could, under certain operational 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 without prior approval of
Marketing Communications Department, ABB Automation.
The Company
ABB Automation is an established world force in the design and manufacture of
instrumentation for industrial process control, flow measurement, gas and liquid analysis and
environmental applications.
As a part of ABB, a world leader in process automation technology, we offer customers
application expertise, service and support worldwide.
We are committed to teamwork, high quality manufacturing, advanced technology and
unrivalled service and support.
The quality, accuracy and performance of the Company’s products result from over 100 years
experience, combined with a continuous program of innovative design and development to
incorporate the latest technology.
The NAMAS Calibration Laboratory (No. 0255) is just one of ten flow calibration plants
operated by the Company, and is indicative of ABB Automation’s dedication to quality
and accuracy.
BS EN ISO 9001
St Neots, U.K. – Cert. No. Q5907
Stonehouse, 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 or
death.
Caution.
Aninstruction that drawsattention to therisk of damageto
the product, process or surroundings.
Health and Safety
To 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 the
information given.
4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure
and/or temperature.
5. Chemicalsmustbestored awayfrom heat,protected fromtemperature extremesand powderskept dry.Normal safehandling 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 Company address on the back cover, together with servicing and spares information.
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1
CONTENTS
1INTRODUCTION.......................................................... 2
2DESCRIPTION............................................................. 3
2.1 Model 6553 Purge Gas Monitor .................... 3
2.1.1 Range Display ................................... 3
2.2 Model 6548 000
Katharometer Analyser Panel ....................... 4
2.3 Model 4234 Power Supply Unit..................... 4
2.4 Remote Indicator/Controllers ........................ 4
3PREPARATION............................................................ 5
3.1 Identification .................................................. 4
3.1.1 Model 6553 Monitor Unit ................. 5
3.1.2 Model 6548 000
Katharometer Analyser Panel ......... 5
3.1.3 Model 4234 Power Supply Unit ....... 5
3.1.4 Coding System ................................ 6
3.1.5 Ordering Code – 6553 Hydrogen
Purity and Purge Gas. ..................... 7
3.1.6 Option Combinations (6553/[X])...... 7
4MECHANICAL INSTALLATION… .............................. 8
4.1 Locating and Mounting System Items........... 7
4.1.1 Model 6553 Gas Monitor ................. 8
4.1.2 Katharometer Analyser Panel ......... 8
4.1.3 Model 4234 Power Supply Unit ....... 9
4.2 Sample Gas Interconnections..................... 10
5ELECTRICAL INSTALLATION ................................. 11
5.1 Electrical Interconnections .......................... 11
5.1.1 Model 6553 Gas Monitor ............... 11
5.1.2 Model 6548 000 Katharometer
Analyser Panel............................... 12
5.1.3 Model 4234 Power Supply Unit ..... 15
5.2 Intrinsically Safe Requirements .................. 15
5.2.1 Cable Requirements........................ 15
5.2.2 Recommended Cables .................. 16
5.2.3 Installing Remote Ancillary Items .. 16
5.2.4 Full Intrinsically Safe
Requirements ................................ 16
6SETTING UP.............................................................. 17
6.1 Katharometer Analyser Panel - Filling the
Drying Chamber – Fig.6.1 .......................... 17
6.2 Setting Sample Flow ................................... 17
6.3 Electrical Checks......................................... 18
6.3.1 Model 4234 Power
Supply Unit Output ........................ 18
6.3.2 Zener Barrier Units ........................ 18
6.3.3 Checking System Earth................. 18
7 CONTROLS & DISPLAYS........................................ 19
7.1 Displays ....................................................... 19
7.2 Switch Familiarization .................................... 19
8Start-up ..................................................................... 20
8.1 Instrument Start-Up ....................................... 20
8.2 Alarm Set Point .............................................. 20
8.2.1 Type of Alarm Action ..................... 20
8.2.2 Hydrogen alarm Set Point ............. 20
8.3 Electrical Calibration ...................................... 20
8.4 Gas Calibration .............................................. 21
8.4.1 Hydrogen Gas Calibration ............. 21
8.4.2 Purge Gas Check Reading............ 21
9OPERATION .............................................................. 22
9.1 Normal ....................................................... 22
9.1.1 Purging of Hydrogen
Coolant Gas................................... 22
9.1.2 Filling with Hydrogen
Coolant Gas................................... 22
10 PROGRAMMING ..................................................... 22
10.1 Range 1 (%H2 in Air)................................... 26
10.1.1 Access to Secure Parameters
(Range 1)....................................... 26
10.1.2 Language Page ............................. 26
10.1.3 Set Up Outputs Page..................... 26
10.1.4 Electrical Calibration Page ............ 28
10.2 Range 2 (%H2 in CO2) ............................... 29
10.2.1 Access to Secure Parameters
(Range 2)....................................... 29
10.2.2 Language Page ............................. 29
10.2.3 Set Up Outputs Page..................... 29
10.2.4 Electrical Calibration Page ............ 30
10.3 Range 3 (%Air in CO2) ............................... 31
10.3.1 Access to Secure Parameters
(Range 3)....................................... 31
10.3.2 Language Page ............................. 31
10.3.3 Set Up Outputs Page..................... 31
10.3.4 Electrical Calibration Page ............ 32
11 MAINTENANCE ...................................................... 33
11.1 General Maintenance.................................. 33
11.1.1 Pressure ........................................ 33
11.1.2 Flow ............................................... 33
11.1.3 Leaks ............................................. 33
11.1.4 Vibration ........................................ 33
11.1.5 Contamination ............................... 33
11.1.6 Ambient Temperature .................... 33
11.1.7 Bridge Current ............................... 33
11.2 Diagnostic Tests .......................................... 33
11.2.1 Checking Output of
4234 Power Supply Unit ................ 33
11.2.2 Checking Integrity of
Zener Barrier Units ........................ 33
11.2.3 Checking the Katharometer
Output ............................................ 33
11.3 Routine Maintenance .................................. 34
11.3.1 Hydrogen Katharometer
Calibration...................................... 34
11.3.2 Purge Gas Katharometer
Calibration...................................... 34
11.3.3 Changing Desiccant in
Drying Chamber ............................ 34
11.4 Repair Maintenance .................................... 34
11.4.1 Removing Liquid from Katharometer
Measurement Block....................... 34
11.4.2 Removal of a Display
Unit Chassis................................... 35
12 SPARE PARTS LIST ............................................... 35
12.1 Consumables ............................................... 35
12.2 Routine Maintenance Parts ......................... 35
12.3 Repair Maintenance Parts........................... 35
13 SPECIFICATION...................................................... 36
APPENDIX ..................................................................... 38

2
1INTRODUCTION
Warning. This operating manual applies only to
those systems which have been designed and
constructedtothestandardsspecifiedintheschedulesof
the BASEEFA certificates listed. The separate units to
which these certificates apply are clearly identifiable by
model numbers and the data on the identification and
BASEEFA certification labels fixed to them. Other
combinations of similar equipment built to any earlier
specifications are not covered by certificate number EX
77138. 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 Company for advice before proceeding.
Itis essential thatunitsare installed strictly in accordance
with the appropriate standards for electrical equipment
foruseinflammableatmospheres.Anydeviationfromthe
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 Model 6553
Intrinsically Safe Gas Analyzer Systems, normally used with
hydrogen cooled electrical power generators.
The complete 6553 analyzer system uses a combination of
three different units. Each unit is independently certified by
BASEEFA (EECS) for use as part of an intrinsically safe
system to the standards of SFA.3012:1972 for use in
association with Group IIC (hydrogen) hazardous
atmospheres.The different units of the system are:
1) The Model 6553 Gas Monitor Unit which is available in
several options. The inputs to these units are certified to
code Ex (ia) IIC under BASEEFA certificate Ex 77124/B/S
with the unit installed in the safe area only.
2) The Model 6548-001 Katharometer Unit which forms part
of an intrinsically safe Model 6548-000 Katharometer
Analyzer Panel. The 6548-001 unit is certified to code
Ex (ia) IIC T5 under BASEEFA certificate Ex 76179/B for
installation in the hazardous area.
3) The Model 4234 constant current Power Supply Unit,
whichprovidesa suitablesupplyforonekatharometerunit.
These units have their output certified to code Ex (ia) IIC
under BASEEFA certificate Ex 76180/B/S for installation in
the safe area only.
The complete gas monitoring system, if installed in
accordance with the certificate schedules and the
requirementsgiveninthismanual,isitselfcertifiedintrinsically
safe to an overall code Ex (ia) IIC under the system certificate
number Ex 77138.
If further information or assistance is required, Company
specialist staff, service centres or worldwide organization may
be contacted through the most convenient address given on
the back cover of this manual. Specialist training courses can
also be arranged by our Training Centre.

3
2DESCRIPTION 2DESCRIPTION…2DESCRIPTION…
The Model 4689 displays are dedicated variants of the
Company's Model 4600 Series Indicator/Controllers. With this
special variant (4689), the displays and alarm indicators on the
front panel remain the same but software control is specific to the
Katharometer systems.The relay action of the alarms is fixed as
'fail safe'. All user programmable data can be protected from
unauthorized alteration by a programmable 5-digit security
number.
The zero adjustments on the front panel of the monitor allow
remote zeroing of 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 katharometer panel.
The monitor also contains encapsulated zener barrier units to
limit the electrical energy level that can be applied from the
instrument circuits into the hazardous area.These zener barrier
units are located below the display units, on a bus-bar which
MUST be earthed (grounded). A metal screening arrangement
segregates the connections made to equipment in the
hazardous area.A main fuse is fitted inside the monitor case for
the electricity supply line.
All the various system options consist of one or more of the
following units with the further option of fitting the monitor and
power supply units in a cubicle.Specific information relating to
a cubicle option will be supplied separately.
2.1 Model 6553 Purge Gas Monitor
The Purge Gas Monitor is a Unit suitable for panel mounting or
in a control cubicle in the safe area. The various monitor
options use one or two digital displays with protected access
for zero adjustments and may also have a range selector
switch or switches - see Fig. 2.1.
Fig. 2.1 Model 6553 Gas monitor
%H2 IN AIR
95.0
123
123
%H2 IN AIR
95.0
Remote
Zero
Adjustment
Purge Gas Monitor
Kent-Taylor
Range
Switches
2.1.1 Range Display
A selector switch for each display provides independent
parameter selection as follows:
Position (1) Percentage of Hydrogen in Air by volume.
This is the hydrogen purity measurement of the
coolant gas under normal operation of the
system. The display covers a range of 85 to
100% or 80 to 100% hydrogen in air depending
on the range selected.Alarm output and a value
retransmission signal (4 to 20 mA) are provided
for this switch position only.
Position (2) Percentage of Hydrogen in Carbon Dioxide by
volume.
This range is for use in hydrogen purging
operation. Alarm and retransmission signal are
inhibited in this switch position.
Position (3) Percentage of Air in Carbon Dioxide by volume.
This range is for use in carbon dioxide purging
operation. Alarm and retransmission signal are
inhibited in this switch position.
A further option of providing remote indication of range
selector switch may be available dependent on the number of
alarms specified.

4
…2 DESCRIPTION
2.2 Model 6548 000
Katharometer Analyser Panel – Fig. 2.2
Each panel comprises a metering valve, a drying chamber, a
thermallylaggedkatharometertype6548001and aflowmeter.
These items are mounted on a flat panel suitable for fixing to a
vertical surface close to the sample point.The katharometers
are calibrated for the hydrogen purity measurement as well as
hydrogen in carbon dioxide and air in carbon dioxide.
Each sealed katharometer assembly incorporates aWheatstone
Bridge made up of fine glass coated platinum filaments.One pair
of parallel arms is sealed in the reference gas and the other pair
exposed to the sample gas.
When the intrinsically safe stabilized current from the power
supply unit (Model 4234) is passed through this bridge, the
temperature of the platinum filaments rises to a point of thermal
equilibrium. Under conditions which are arranged to give
minimum radiation and convection heat transfer, the equilibrium
temperature depends on the thermal conductivity of the gas
surrounding the filament. Thus 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.
Zenerdiodesareconnectedacross theinputconnectionsfrom
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 conditions.The current is
limited to a safe value under fault conditions by the power
supply unit.
2.3 Model 4234 Power Supply Unit – Fig. 3.3
Warning. Do NOT connect mains supply to the
power supply unit with the output terminals on open
circuit.This causes premature component failure.
Caution. Ensure that the power supply unit is
correct for the mains supply voltage available. A nominal
110V unit cannot be adapted for use with a nominal 240V
supply, or the other way around.
In order to operate a katharometer unit in the hazardous area,
one Model 4234 Power Supply Unit is required for each
katharometer.The PowerSupplyUnitsuppliesastabilized350
mA d.c. signal, and must be mounted in the safe area.There
are two separate versions available for either a nominal 110-
120V a.c. or 200-220/240V a.c. supply voltage.The stabilized
current output is current and voltage limited to restrict the
energy supply into the hazardous area.
The model 4234 is housed in a metal case fitted with lugs for
wall/panel mounting. Cable gland entries are provided at
opposite ends of the case for supply voltage input and
stabilized output cables to the hazardous area. The printed
circuit board assembly and diode heat sink are mounted on a
metal chassis and separate labelled terminal blocks are used
for making electrical interconnections.
Thecircuitisprotectedbyacartridgefuse.Thisfusemusthave
ahighbreakingcapacity(h.b.c.)ratingof4000Atocomplywith
the terms of the certification.
2.4 Remote Indicator/Controllers
The 6553 monitor unit has provision for retransmission values
and ancillary indicator/controllers may be connected to these
outputs, providing that they are installed in the safe area and the
installation conforms to the requirements given in Section 5.1.
Fig. 2.2 Location of Items – Model 6548 000 Katharometer Analyzer Panel
Electrical
interconnections
Flow gauge
Gas sample
outlet
Coarse zero
adjustment
Drying chamber
Katharometer
unit case
Metering
valve
Gas
sample
inlet

5
3PREPARATION
Fig. 3.1 Typical Identification Labels and Locations –
Model 6553 Gas Monitor Unit with Digital Displays
3PREPARATION…
✶
Note. Although the display units may be marked as
'4600' on their front panels, they are special units for this
monitor and a standard Model 4600 cannot be used.The
precise identity of the display unit is given on the
identification label shown in Fig.3.1.
3.1.2 Model 6548 000
Katharometer Analyser Panel – Fig. 3.2
The identification of a panel is given by the panel reference
number label as shown in Fig. 3.2. The identification and
certificationlabelsoftheindividualkatharometerunits(fixedto
the katharometer case) are also shown in Fig.3.2.
3.1 Identification
It is essential that installers and users clearly identify the
various units of the monitoring system as follows:
3.1.1 Model 6553 Monitor Unit – Fig. 3.1
The 6553 monitor is available in several options, these being
defined by the code number as given in Section 3.1.4.
The identification and certification labels are fixed to the
outside of the monitor case as shown in Fig. 3.1.The precise
interpretation of the identification code gives information on
the 6553 system as shown in Section 3.1.5.
Fig. 3.2Typical Identification Labels with Locations –
Model 6548 000 Katharometer Analyzer Panel
ASEA BROWN BOVERI
ABB Kent-Taylor Ltd
Oldends Lane, Stonehouse
Glos, England GL10 3TA
Code No. 6553–6131101101
Serial No. GBXXXXX
Voltage. 110–120
Hz. 50–60
Watts. 30
95.0
%H2IN AIR
PurgeGasMonitor
Kent-Taylor
ABB Kent-Taylor Limited
PURGE GAS MONITOR TYPE 6553
Ex (ia) IIC/BAS No.Ex77124/B/S
SFA3012
Ex
%H2 IN AIR
95.0
Retaining
Screw
ASEA BROWN BOVERI
ABB Kent-Taylor Ltd
St. Neots England PE19 3EU
TYPE 4689/502
SERIAL No. X
XXX X XXX
Range
1
2
3
Range
1
2
3
6548000
Panel Reference No.
ABB Kent-Taylor Ltd
Ex (ia) IIC T5
Ex 76179/B
SFA 3012
Katharometer Type 6548001
Ex
Intrinsic Safety Label (UK)
(Katharometer Unit)
ABB Kent-Taylor Ltd
Stonehouse, England
Type No. 006548001
Contract No. V60127
Serial No. XXXXXX
Range 85–100%
Output 0–10mV
Zero Gas 85% H
2 IN N 2
Model No.
Unique
Reference No.
Gas Type
(Hydrogen in Air Katharometer Unit)
ASEA BROWN BOVERI

6
…3 PREPARATION
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. 3.3Typical Identification Labels and Locations –
Model 4234 Power Supply Unit
Ex
ABB Kent-Taylor Limited
POWER SUPPLY UNITTYPE 004234000
Issue 5
Ex (ia) IIC/BAS.NoEx76180/B/S
SFA 3012
1972
MAX. L/R 20uH/Ω
Intrinsic
Safety Label
(UK)
ABB Kent-Taylor Ltd
Oldens Lane Stonehouse
Gloucs England GL10 3TA
Cat.No. 004234000
Serial No. XXXXXXX
Voltage. 110-120
Hz. 50-60
Watts. 10
Model No.
Unique
Reference No.

7
3PREPARATION
3.1.4 Coding System 6553/ X X X X X X X X X X
ABCDEFG HJ K
Features of Upper Indicator
Scale of Upper Indicator
Features of Lower Indicator
Scale of Lower Indicator
Range selector Switch
Not used
Fitted with Labels
Cubicle Type
Special Features
Mains Supply
The equipment conforms with the requirements of SFA 3012 for class IIC gases to Code Ex (ia) IIC provided that the equipment
is installed in accordance with instructions provided.The display unit and power supply units must be installed in a safe (non-
hazardous) area, and gas analysis panels may be mounted close to the sample point in the hazardous area.
3.1.5 Ordering Code – 6553 Hydrogen Purity and Purge Gas.
AFeatures of Upper Indicator
6Two alarms + retrans. 4–20mA
BScale of Upper Indicator
1100–85% H2in Air
2100–80% H2in Air
30–100% Air in CO2, 0–100% H2in CO2,
85–100% H2in Air
40–100% Air in CO2, 0–100% H2in CO2,
80–100% H2in Air
585–100% H2in Air
680–100% H2in Air
CFeatures of Lower Indicator
0Indicator Not Fitted
3Two alarms + retrans. 4–20mA
DScale of Lower Indicator
0Indicator Not Fitted
10–100% Air in CO2, 0–100% H2in CO2
2100–85% H2in Air
3100–80% H2 in Air
40–100% Air in CO2,0–100% H2 in CO2,
85–100% H2 in Air
50–100% Air in CO2,0–100% H2 in CO2,
80–100% H2 in Air
685–100% H2in Air
780–100% H2in Air
ERange Selector Switch
0Not fitted
2Fitted, with facilities for Remote
Indication of Switch Position – upper
ind.
3Fitted with two range switches, upper
and lower indicator + remote ind.
FAdditional Output Signal – Not Used
GFitted with Labels
1English
2French
3German
HType of Cubicle
1Without Cubicle.
4Purge Cubicle (D1)(with purity)
5Purity Cubicle (D2 or D3)(Purity only)
JSpecial Features
0None
9Fitted
KMains Supply
1110V, 50/60Hz
2220V, 50/60Hz
3240V, 50/60Hz
3.1.6 Option Combinations (6553/[X])
The digit decode is shown in Section 3.1.5.
[X] Purity only:
top ind.
3-Range:
top ind.
only
Std. purge
system 2 x purity display 2 x 3 ranges
Purity top :
3 ranges
lower
A666666
B1,2,5,6 3,4 1,2,5,6 1,2,5,6 3,4 1,2,5,6
C003333
D0012,3,6,7 4,5 4,5
E022033
F000000
G1 to 3 1 to 3 1 to 3 1 to 3 1 to 3 1 to 3
H1,5 1,5 1,4 1,5 1,4 1,4
J0,9 0,9 0,9 0,9 0,9 0,9
K1,3 1,3 1,3 1,3 1,3 1,3

8
4MECHANICAL INSTALLATION…
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 displays and with access to the rear to enable
wiring interconnections to be made.The panel preparation requirements and installation dimensions are shown in Fig. 4.1.The
monitor is secured to the panel by two clamping brackets at opposite corners of the monitor chassis.
362
Katharometer
intrinsically
safe circuits
Power and signal
conventional
circuits
Cable
entries
Mounting panel
thickness range
345
0-20
Cable entry
point
Mounting panel
display face
95
350 ±0.5
25.5
3View on display face of
mounting panel requirements
Area for
clamping
brackets
95 50
3
274
278 ±0.5
290 30 272
Monitor
case
123
123
%H2 IN AIR
95.0
%H2 IN AIR
95.0
Purge Gas Monitor
Kent-Taylor
Fig. 4.1 Installation Dimensions and Interconnection Positions – Model 6553 Gas Monitor Unit with Digital Displays
✶
Note. All dimensions nominal
millimeters unless indicated otherwise.

9
4MECHANICAL INSTALLATION…
4.1.2 Katharometer Analyser Panel – Fig. 4.2
Caution. Ensure that the panel is operated at the correct gas pressure.
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.
✶
Note. All dimensions nominal
millimeters unless indicated otherwise.
Fig. 4.3 Installation Dimensions and Interconnection Positions – Model 4234 Power Supply Unit
✶
Note. All dimensions nominal
millimeters unless indicated otherwise.
Fig. 4.2 Installation Dimension and Interconnection Positions – Model 6548 000 Katharometer Analyzer Panel
4.1.3 Model 4234 Power Supply Unit – Fig. 4.3
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 installation dimensions are
shown in Fig.4.3.
283
50 160 ±1
230
194 ±0.5
148
26
Power in
2 Glands for Ø7 10.5 cable
Regulated
power ouput
10.5
20
26
55
135
Gland positions for
alternative orientation of unit
148
38
10
19 305
267 ±0.3
Coupling for
Ø6 tube
Inlet
98
610
572 ±0.3
112
179233
Outlet Coupling for
Ø6 tube
19
Gland for Ø7 – 10.5 cable
4 fixing
holes Ø10

10
…4 MECHANICAL INSTALLATION
4.2 Sample Gas Interconnections
Warning. A hazardous mixture of hydrogen in air
could develop in the event of leakage from the sample
gas system. Katharometer analyzer panels should be
located in a ventilated area.
The sample pressure must not exceed the value given in
Section 13.
The incoming sample gas temperature must not exceed the
temperature given in Section 13.
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 analyzer system.
Compression couplings are supplied at the sample inlet and
outlet to the katharometer panel.These couplings are suitable
for connecting 8mm outside diameter metal tube. It is
recommended that stainless steel tube is used.
The complete tubing system should be tested for leaks in
accordancewith the requirementsofthe responsibleauthority.

11
5ELECTRICAL INSTALLATION
5.1.1 Model 6553 Gas Monitor – Fig. 5.1
Warning. No connections must be made to the
hazardous area terminals (Terminal Block 2) other than
as specified in wiring diagram Fig. 5.3. The appropriate
cable requirements must be also satisfied.
Removetheoutercasefromthebackoftheunittogainaccess
to the cable glands and terminal blocks.
The electrical connections are made through the appropriate
cable gland at the bottom of the unit into the terminal block
immediately above them.There are separate cable glands for
wires to the hazardous and safe areas – see Fig. 5.1.
The alarm and signal outputs on terminal block 1 (TB 1),
betweenTB1 - 1 andTB1 - 16, may be connected as required.
The availability of signal outputs vary with the particular 6553
system. Refer to Fig. 5.3 for details.
Make the wiring connections in accordance with the
information given in the wiring diagram Fig. 5.3 and Section
5.1.
Fig. 5.1 Location of Components Inside Case (Rear View) – Model 6553 Gas Monitor Unit with Digital Displays
5ELECTRICAL INSTALLATION…
5.1 Electrical Interconnections
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 instruments are fitted with internal
fuse protection, a suitably rated external protection
device, e.g. a 3A fuse or miniature circuit breaker
(m.c.b.), must also be fitted by the installer.
•The proper electrical connections and wiring standards
must be achieved to establish the intrinsic safety of the
system, as certified.
•The a.c.input and intrinsically safe d.c.output wiring must
be routed separately from non-intrinsically safe wiring.
Fig.5.4 shows the interconnecting wiring requirements for the
gas analyser system, which must be strictly observed.Details
of cable requirements, which must be strictly adhered to, are
also 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 local
electrical standards for intrinsically safe circuits.
The separate units of the analyzer system must be
interconnected as follows:
Zero adjustment
for remote
katharometers
Clamp
brackets
Type : 4689
top display unit
Type : 4689
bottom display
unit
Zener barriers
Terminal block (TB2)
for katharometer
intrinsically safe circuits
Safety earth
terminal (TS1)
Terminal block
for power and signal
conventional circuits
Upper display
3-way mains
supply terminal
block
Selector
Switches
116 17 32
Area for
Barriers
Fuses
Upper display
TB1
Lower display
3-way mains
supply terminal
block
Lower display
TB3
TB2

12
…5 ELECTRICAL INSTALLATION
5.1.2 Model6548 000KatharometerAnalyserPanel
Electrical connections are made inside the katharometer unit
(6548 001) on the analyzer panel – see Fig.5.2.
Remove the cover of the katharometer unit to gain access to
the terminal block (TB1) inside.
Make the electrical connections to the Gas Monitor in
accordance with the information given in wiring diagram Fig.
5.3 and Section 5.2.
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
interconnectionshavebeenmade,ifremotezeroisto be used,
remove the 510R dummy load resistor from across terminals 9
and 10 and set the zero adjustment on the katharometer to the
approximate mid-point.
Replace the cover on completion of wiring up.
Fig. 5.2 Location of Components Inside Case – Model 6548 001 Katharometer Unit
Zero adjustment
Measuring
unit
Tubing
connections
Terminal block (TB1)
Dummy
load
resistor
Mounting pillars
10
9
10
9
Inlet Outlet
Caution.The integrity of the fail-safe operation of
the zener barrier units depends on a Safety Earth
connectionwhichmustnothavearesistancegreaterthan
1R0 to the application plant earth (ground).
Make the Earth (Ground) and Safety Earth connection at the
stud (TS1) – see Fig. 5.1.
On completion of wiring and checks, replace the outer case
and secure the clamping brackets to the mounting panel.

13
5ELECTRICAL INSTALLATION…
Fig. 5.3 Interconnection Wiring Diagram – Model 6553 Intrinsically Safe Analyzer System using two three range displays, as separate units
6553/6
Monitor Unit
123 45678910111213141616 TB2
No user connections
External
power supply
Basic reference code for system:6553/6XX110X0XX
1 2 3 4 5 6 7 8 9
10
Katharometer
unit 2
1 2 3 4 5 6 7 8 9
10
Katharometer
unit 1
TB1 TB2
Power Supply Unit 2
4234
LNE
TB1 TB2
Power Supply Unit 1
4234
LNE
External
power supply
Warning. Interconnections
marked with MUST conform to the
intrinsically safe wiring requirements given in the text. All other wiring to suit power and signal requirements.
External dual power supply
X = As specified
+–
+ –
Lower Display TB
Upper Display TB
L N E
LNE
1234567891011 12 13 14 15 16 TB3
NO NC NO NC
COM COM
Remote Range
(if fitted)
Outputs as required (upper and lower displays similar)
Alarms retransmit
+ –
Not used
12345678910111213141516TB1
External
bonding
and
earth
TS1
*
Switch Position 13 14 15 16
1 X X 2 X X 3 X X
Terminal
*
Labelled 17 - 32

14
…5 ELECTRICAL INSTALLATION
Fig. 5.4 System Diagram. System Cert. Ex76181/1 dated Dec 1988
Unspecified safe area equipment
(in accordance with Note 5)
See Note 5
L
N
E
–
+
H2 in Air
H2 in CO2
CO2 in Air
4689 502
Indicator
L
N
E
–
+
See Note 3 See Note 2
Power Supply
type 004234000
Issue 5
Certified Ex(ia)IIC
by BASEEFA.
Cert. No. Ex 76180/B/S
see Note 5
L
N E
Notes 1The total capacitance and inductance or inductance to resistance
ratio (L/R) of the cables connected to the output terminals (hazardous area) of the analyser and power supply unit must not exceed the following values::
Terminal boxes (if required) must confirm to BASEEFA standard SFA 3012 clause 6.3. May be located in hazardous or safe area. BASEEFAcertified 5v 10Ωshunt zener diode barriers of like polarity, certified Ex(ia)IIC. MTL 105+ve The installation must conform to the BASEEFAInstallation Conditions, issue 6 dated 1 September 1976. Safe area equipment must not contain a source of potential relative to earth in excess of 250V rms or 250v d.c.
2 3 4 5
1
2
3
1
2
3
Group Capacitance
µFInductance
µHL/R ratio
µH/Ohm
IIA IIB
IIC
24
9 3
200
75 25
160
60 20
Hazardous area
See Note 1
-
+
L
N E-
+
Power Supply
type 004234000
Issue 5
Certified Ex(ia)IIC
by BASEEFA.
Cert. No. Ex 76180/B/S
see Note 5
5v 10Ω
24
13
5v 10Ω
24
13
5v 10Ω
24
13
5v 10Ω
2 13
4
Katharometer
type 006539960
issue J or K
OR
Katharometer
type 006548001
Certified Ex ia IIC T5
BASEEFA
Cert. No. Ex 76179/B
4 –
1+
9
10
3 –
2+
2+
9
10 4 –
1+
3 –
Katharometer
type 006539960
issue J or K
OR
Katharometer
type 006548001
Certified Ex ia IIC T5
BASEEFA
Cert. No. Ex 76179/B
H2 in Air
H2 in CO2
CO2 in Air
4689 502
Indicator

15
5ELECTRICAL INSTALLATION…
5.2 Intrinsically Safe Requirements
These requirements relate to the interconnecting wiring made
to and from Model 6548 000 Katharometer Analyzer Panel in
the hazardous area, and those for remote ancillary items
connected to the system.
5.2.1 Cable Requirements
The interconnecting cables between the various units of the
gas analysis system are subject to stringent limitations
becauseoftherequirementsoftheintrinsicsafetycertification.
These are listed below and detailed in Fig. 5.4.
All cables entering the hazardous area must be kept separate
from cables in the safe area. Cables entering the hazardous
area must not be run with other cables, and terminations must
have an earthed screen to separate them from connections for
other circuits.The detailed requirements are as follows:
1) Connections between Model 6548 000 Katharometer
Analyzer Panel and Model 4234 Power Supply Unit.
All cables from the Katharometer in the hazardous area
must have an inductance/resistance ratio not exceeding
18µH/Ω, (for Group IIC gases). There is a further
requirement that the maximum resistance of this
interconnecting cable is limited to 2Ω. This may place a
limitation on the length of the total cable run.
Fig. 5.5 Location of Components Inside Case – Model 4234 Power Supply Unit
Spare fuse
FS1
Input
terminals
(TB1)
Cable clamp Voltage selection
terminals (TB3) Cable clamp
Output
terminals
(TB2)
R103
C101 R101 D102 R104 RV101
D101
R102
TR101
Z101
D103
C102 C103
TR102
5.1.3 Model 4234 Power Supply Unit – Fig. 5.5
Warning. Do NOT connect mains supply to the
power supply unit with the output terminals on open
circuit.This causes premature component failure.
Caution. Ensure that the power supply unit is
correct for the mains supply voltage available. A nominal
110V unit cannot be adapted for use with a nominal 240V
supply, or the other way around.
Remove the cover of the unit to gain access to the terminal
blocks inside.
Locatetheterminalblock(TB3)adjacenttothetransformerT1.
To ensure the correct transformer tapping is used for the
incoming mains supply, adjust the brown wire, if necessary, to
the appropriately marked TB3 terminal to either 110 or 120V
(200, 220 or 240V, for alternative power supply unit).
Make electrical connections in accordance with the
information given in the wiring diagram Fig. 5.3 and Section
5.2.1.
The electrical connections are made 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.
Fit the cover on completion of wiring up.

16
…5 ELECTRICAL INSTALLATION
Single sheathed conducting cables should be twisted
together to reduce their mutual inductance, and routed
separately from cabling for non-intrinsically safe circuits in
the safe area.
2) Connections between Model 6548 000 Katharometer
Analyzer Panel and Model 6553 Gas Monitor Unit.
Katharometer to display unit cables, carrying the output
signals through zener barrier units inside the monitor unit,
are subject to of a maximum inductance/resistance ratio of
18µH/Ω(for group IIC gases).These wires are indicated by
ain Fig. 5.3.
No special requirements are necessary to limit the choice
of cable for the interconnection between the katharometer
zero adjustment controls and the monitor unit.
5.2.2 Recommended Cables
The limitations imposed restrict the choice of wiring cable to a
few types. 'Pyrotenax' meet the requirements of less than
18µH/Ωwith their mineral insulated cable type PCC 2L1.
The Company should be consulted with information on any
other cables proposed for use in the installation of this system.
Detailed cable specifications of the above mentioned type is
available from:
Pyrotenax Limited
Hedgeley Road
Hebburn-on-Tyne
County Durham
Telephone: [phone]
5.2.3 Installing Remote Ancillary Items
Any indicator/controllers, or other electrical equipment,
connectedtoTB1oftheModel6553GasMonitorUnitmustnotbe
supplied from, nor contain, a potential source greater than 250V
d.c.or 250V r.m.s.with respect to earth.
5.2.4 Full Intrinsically Safe Requirements
For systems to be modified or used with other gases the full
BASEEFA requirements must be complied with as follows:
1) The total Capacitance and Inductance or Inductance to
Resistance ratio (L/R) of the cables connecting the
katharometer unit to the hazardous area terminals of the
monitor 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 areas must
conform to BASEEFA Standard SFA.3012, Clause 6.3.
3) The overall installation must conform to the BASEEFA
installation conditions, Issue 6 (September 1976) – see
Fig. 5.4.
Table 5.1 6553 – Intrinsically Safe Wiring Requirements
Gas Group Capacitance
µF Inductance mH
Inductance/
Resistance
µH/Ω
IIA 4.8 0.152 144
IIB 1.8 0.057 54
IIC 0.6 0.019 18

17
When the gas analyzer system has been correctly installed in
accordance with the requirements for intrinsic safety given in
Section 5.2, carry out the following setting-up procedures:
6.1 Katharometer Analyser Panel - Filling the
Drying Chamber – Fig. 6.1
1) Remove the drying chamber on the katharometer analyzer
panel by unscrewing the large knurled nut at the base of
the chamber.Pull the chamber down and out of the sealing
groove to remove it from the panel.
2) Open a container of fresh granular calcium chloride,
immediately fill, and prepare to replace, the drying chamber.
✶
Note. The capacity of the drying chamber is about
140ml.To fill the chamber, approximately 100g of calcium
chloride is required.
3) Replace the drying chamber in its sealing groove and
reposition the chamber to enable it to be secured and
sealed by hand tightening the knurled nut.
4) Carry out an approved leak testing procedure before
passing sample gas through the system.
Fig. 6.1 Katharometer Analyzer Panel
6.2 Setting Sample Flow
When all tubing interconnections have 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 analyzer system at the normal working
pressure of the application plant and within the limits given
in Section 13.
2) Gradually open the metering valve on the katharometer
panel to pressurize the complete system to the maximum
pressure given in Section 13.
Caution. Testing for leaks with carbon dioxide
may not be considered an adequate check of gas tight
integrity in respect of the more penetrating hydrogen gas.
Consideration may be given to the use of a gas , such as
helium, which has penetrating properties nearer to that of
hydrogen.
3) Slowly open the metering valve to give a nominal flowrate
of gas of 100 to 150 ml.min-1. Do not exceed the maximum
flowrate given in Section 13.
4) Set the flowrate and shut off the calibration gas external to
the analyzer system.
5) Repeat this procedure for each katharometer analyzer
panel, as required.
6SETTING UP 6SETTING UP…
Electrical
interconnections
Flow gauge
Gas sample
outlet
Coarse zero
adjustment
Drying chamber
Katharometer
unit case
Metering
valve
Gas
sample
inlet

18
…6 SETTING UP
6.3.2 Zener Barrier Units
The zener barriers 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 bycarrying outa routine testbeforeusingthe
analyzer system.
Warning.
•This unit is part of the certified intrinsically safe
system.Appropriate safety precautions must be taken
to prevent any incendive electrical discharges in the
hazardous area when carrying out this task.
•If these tests reveal a faulty zener barrier, the barrier
MUST be replaced by a new unit. The barrier is a
sealed unit and no repair is permitted. The correct
zener barriers are certified intrinsically safe to EX (ia)
IIC and no 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 barrier
unit.
4) Using a low voltage ohmmeter, measure the resistance
between terminals 1 and 3.This must be less than 18.15Ω.
If in excess of this value - change the barrier.
5) Using a low voltage ohmmeter, ensure that the resistance
between terminals 2 and 4 of the barrier unit and the
application plant safety earth is less than 1Ω.
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 Earth
Check that the resistance between earth terminals on the
analyser system and the application plant system safety earth
does not exceed one ohm.
6.3 Electrical Checks
Carry out the following electrical checks:
6.3.1 Model 4234 Power Supply Unit Output
Warning. This unit is part of the certified
intrinsically safe system. Appropriate safety precautions
must be taken to prevent any incendive electrical
discharges in the hazardous area when carrying out this
task
Testing the output may only be carried out with the hazardous
area cable disconnected and a dummy load resistor fitted
across the output.Never operate the unit to supply an open
circuit.
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 at
terminals TB2+ and TB2–.
4) Connect a 10Ω(2W ±5%) dummy load resistor across
terminals TB2+ and TB2–.
Warning. Ensure that proper electrical safety
precautions are taken at all times when undertaking this
procedure.
5) Switch on the power supply unit and check that it is stable
at 350mA.
6) On completion of tests isolate the unit, remove the dummy
load resistor and reconnect the output wires to the
hazardous area.
7) Replace the cover on the unit.