ABB AK102 User manual

Gas Analyzer Systems for
Hydrogen-cooled Alternators
AK102 and AK103
User Guide
IM/AK1/23_1

ABB
The Company
We are 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 UKAS Calibration Laboratory No. 0255 is just one of the ten flow calibration plants operated
by the Company and is indicative of our dedication to quality and accuracy.
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. 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 Company address on the back cover, together with servicing and spares information.
EN ISO 9001:2000
Cert. No. Q 05907
R
E
G
I
S
T
E
R
E
D
EN 29001 (ISO 9001)
Lenno, Italy – Cert. No. 9/90A
0255
Stonehouse, U.K.
Warning – Refer to the manual for instructions
Caution – Risk of electric shock
Protective earth (ground) terminal
Earth (ground) terminal
Direct current supply only
Alternating current supply only
Both direct and alternating current supply
The equipment is protected
through double insulation
Electrical Safety
This instrument complies with the requirements of CEI/IEC 61010-1:2001-2 "Safety requirements for electrical equipment for
measurement, control, and laboratory use". If the instrument is used in a manner NOT specified by the Company, the protection
provided by the instrument may be impaired.
Symbols
One or more of the following symbols may appear on the instrument labelling:
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 the
Technical Publications Department.

1
CONTENTS
1INTRODUCTION .......................................................... 2
2DESCRIPTION.............................................................. 3
2.1 Model 6553 Display Unit ..................................... 3
2.1.1 Range Display ....................................... 3
2.2 Model 006540203 or 006548000
Katharometer Analyzer Panel .............................. 4
2.3 Model 4234 500/4234 501
Power Supply Units (PSU)................................... 4
2.4 Remote Indicator/Controllers .............................. 4
3PREPARATION ............................................................. 5
3.1 Identification ....................................................... 5
3.1.1 Model 6553 Display Unit ....................... 5
3.1.2 Model 006540 203 or 006548 000
Katharometer Analyzer Panel ................ 5
3.1.3 Model 4234 Power Supply Unit ............. 6
3.1.4 AK100 Ordering Information .................. 7
4MECHANICAL INSTALLATION .................................... 8
4.1 Locating and Mounting System Items ................. 8
4.1.1 Model 6553 Display Unit ....................... 8
4.1.2 Katharometer Analyzer Panel ................ 9
4.1.3 Model 4234 Power Supply Unit ........... 10
4.1.4 Cubicle Mounted System .................... 11
4.2 Sample Gas Interconnections ........................... 12
5ELECTRICAL INSTALLATION .................................... 13
5.1 Electrical Interconnections ................................ 13
5.1.1 Model 6553 Display Unit ..................... 14
5.1.2 Model 006540 203 and 0065480 00
Katharometer Analyzer Panel .............. 17
5.1.3 Model 4234 Power Supply Unit ........... 18
5.2 Intrinsically Safe Requirements .......................... 19
5.2.1 Cable Requirements ............................ 19
5.2.2 Recommended Cables ....................... 19
5.2.3 Installing Remote Ancillary Items ......... 19
5.2.4 Full Intrinsically Safe Requirements ...... 19
6SETTING UP ............................................................... 20
6.1 Katharometer Analyzer Panel –
Filling the Drying Chamber ................................ 20
6.2 Setting Sample Flow ......................................... 20
6.3 Electrical Checks .............................................. 21
6.3.1 Power Supply Unit Output ................... 21
6.3.2 Zener Diode Safety Barrier Devices ..... 21
6.3.3 Checking System Earth ....................... 21
7CONTROLS & DISPLAYS .......................................... 22
7.1 Displays ............................................................ 22
7.2 Switch Familiarization ........................................ 22
8START-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
9OPERATION ............................................................... 25
9.1 Normal .............................................................. 25
9.1.1 Purging of Hydrogen Coolant Gas ....... 25
9.1.2 Filling with Hydrogen Coolant Gas ....... 25
9.2 Range 1 Operating Page .................................. 26
9.3 Range 2 Operating Page .................................. 26
9.4 Range 3 Operating Page .................................. 26
10 PROGRAMMING ........................................................ 28
10.1 Access to Secure Parameters ........................... 28
10.2 Language Page ................................................ 28
10.3 Set Up Outputs Page........................................ 29
10.4 Electrical Calibration Page ................................ 30
11 MAINTENANCE .......................................................... 31
11.1 General Maintenance ........................................ 31
11.1.1 Pressure .............................................. 31
11.1.2 Flow .................................................... 31
11.1.3 Leaks .................................................. 31
11.1.4 Vibration .............................................. 31
11.1.5 Contamination ..................................... 31
11.1.6 Ambient Temperature .......................... 31
11.1.7 Bridge Current .................................... 31
11.2 Diagnostic Tests ............................................... 31
11.2.1 Checking Output of the PSU ............... 31
11.2.2 Checking Integrity of Zener
Diode Safety Barrier Devices ............... 31
11.2.3 Checking the Katharometer Output ..... 31
11.3 Routine Maintenance ........................................ 31
11.3.1 Hydrogen Katharometer
Calibration ........................................... 31
11.3.2 Purge Gas Katharometer
Calibration ........................................... 31
11.3.3 Changing Desiccant in
Drying Chamber .................................. 32
11.4 Repair Maintenance .......................................... 32
11.4.1 Removing Liquid from Katharometer
Measurement Block ............................ 32
11.4.2 Removal/Replacement
of an Indicator Unit .............................. 33
11.4.3 Error Messages ................................... 33
12 SPARE PARTS LIST ................................................... 33
12.1 Consumables ................................................... 33
12.2 Routine Maintenance Parts ............................... 33
12.3 Repair Maintenance Parts ................................. 33
13 SPECIFICATION ......................................................... 34

2
Note. Argon may be used as an alternative purge gas
to the CO2referred to in this manual.
Caution. This operating manual applies only to those
systems that have been designed and constructed to
the standards specified in the schedules of the ATEX
certificates listed. The separate units to which these
certificates apply are clearly identifiable by model
numbers and the data on the identification and ATEX
certification labels fixed to them. Other combinations of
similar equipment built to any earlier specifications are
not covered by BASEEFA 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, contact
the Company for advice before proceeding.
It is essential that units are installed strictly in
accordance with the appropriate standards for
electrical equipment for use in flammable atmospheres.
Any deviation from the specified installation conditions,
or any unauthorized repair s 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 AK102 and
AK103 Intrinsically Safe Gas Analyzer Systems, normally used
with hydrogen cooled electrical 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 Display Unit, available in several variants. The
inputs to the unit are certified to code [EEx ia] IIC Tamb = –20
to 40°C under BAS 01 ATEX 7043 certificate with the unit
installed in the safe area only.
2) Model 006539-960K (or J) and 006548-001 Katharometer
Units that form part of an intrinsically safe Model 006540-
203 and 006548-000 Katharometer Analyzer Panel. These
units are certified to code EEx ia IIC T4 Tamb= –20 to 55°C
under BAS 01 ATEX 1042 certificate for installation in the
hazardous area (ZONE 0).
3) Model 4234 500 and 4234 501 constant current Power
Supply Unit provides the supply for one Katharometer Unit.
These power supply units have their output certified to code
[EEx ia] IIC Tamb= –20 to 55°C under BAS 01 ATEX 7041
certificate for installation in the safe area only.
If further information or assistance is required contact our
specialist staff at one of the addresses shown on the back cover
of this manual. Specialist training courses can also be arranged
at our Training Centre.
1INTRODUCTION
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0891:93005NEmetsyS

3
98.8
H2–CO2
UIIN
O
N
S
E
Hydrogen Purity
& Purge Gas Monitor
Range
Range Selector
Switches
Digital
Display
Units
1
2
3
1
2
3
Zero
Zero
Range
F1
F2
Zero
Adjustment
AK102
All the various system options comprise one or more of the
following units with the further option of fitting the display and
power supply units in a cubicle.
2.1 Model 6553 Display Unit
The display unit must be mounted in a safe area and is suitable
for panel mounting or installation into a control cubicle. The unit
houses one or two Model 4689 digital display units, each
equipped with a range selector switch and protected access for
zero adjustment –see Fig. 2.1.
The AK102 version is a dual 3-range instrument, designed to
provide 100% redundancy.
The AK103 version is a single 3-range instrument.
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 during 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. An alarm output and a
retransmission signal (4 to 20mA) are provided for
this switch position only.
Position (2) Percentage of Hydrogen in CO2/Argon by volume.
This range is for use in hydrogen filling or purging
operation. Alarm and retransmission signals are
inhibited in this switch 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 the
katharometer systems with relay action of the alarms 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 enable remote zeroing
of the katharometers mounted in the hazardous area. The
adjustment access for a particular display is adjacent to the
display and at the same level.
The 4689 has a protective case that can be removed for access
to the interior without removing the whole unit from the control
panel.
The 4689 contains encapsulated zener diode safety barrier
devices to limit the electrical energy that can be supplied from
the instrument circuits into the hazardous area. These devices
are located below the display units, on a rail that MUST be
earthed (grounded). A metal screening arrangement segregates
the connections made to equipment in the hazardous area. The
unit is protected on the mains input side by two fuses, one for
each circuit, accessible from the front of the panel.
Fig. 2.1 Model 6553 Display/Control Units
2DESCRIPTION
UIIN
O
N
S
E
Hydrogen Purity
& Purge Gas Monitor
Range Selector
Switche
Digital
Display
Unit
1
2
3
Zero
Range
F1
Zero
Adjustment
AK103

4
Electrical
Interconnections
Flow Gauge
Gas Sample
Outlet
Local Zero
Adjustment
Drying Chamber
Katharometer
Unit Case
Metering
Valve
Gas
Sample
Inlet
2.2 Model 006540203 or 006548000
Katharometer Analyzer Panel – Fig. 2.2
Each panel comprises a metering valve, a drying chamber, a
thermally lagged katharometer (Model 006539 or 006548) and a
flowmeter. 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 katharometer assembly incorporates a Wheatstone Bridge
comprising 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 4234
power supply unit (Model 4234 500 or 4234 501) is passed
through this bridge, the temperature of the platinum filaments
rises to a point of thermal equilibrium. Under conditions that 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 display unit.
Zener diodes are connected across the input connections from
the power supply unit to the katharometer 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 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 stabilized DC current output and must be mounted in the safe
area. There are two versions available:
Model 4234 500 for a nominal 230V AC supply voltage
Model 4234 501 for a nominal 115V AC supply voltage
The stabilized current output is current and voltage limited to
restrict the energy supply into the hazardous area.
The PSU 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 current output
cables to the hazardous area.
The circuit is protected by cartridge fuses. These fuses must
have a high breaking capacity (HBC) rating of 1500A to comply
with the terms of the certification.
2.4 Remote Indicator/Controllers
The 6553 Display Unit has retransmission outputs for
connection to indicator/controllers, 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 6540 203 and 6548 000 Katharometer Analyzer Panels
…2 DESCRIPTION

5
98.8
H2–CO2
UIIN
O
N
S
E
HydrogenPurity
&PurgeGasMonitor
Range
Zero
Zero
Range
1
2
3
1
2
3
F1
F2
Ex
ABB Limited
Stonehouse England GL10 3TA
TYPE 4689/502 (or 505)
SERIAL No. ......................
ABB Limited
Oldends Lane, Stonehouse,
Glos. England GL10 3TA
GAS MONITOR TYPE 6553
ll (1)G
[EEx ia] llC Tamb=–20C to + 40C
BAS 01 ATEX 7043
ABB Limited
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 Intrinsic
Safety Label
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.
Serial No.
Year of Manf.
Output
Zero Gas
Range
006548000
0600
Panel Reference No.
Model No.
Unique
Reference No.
Gas Type
Intrinsic
Safety Label
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 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 Section 3.1.4 to interpret the identification label code
and obtain a precise description of the 6553 Display Unit.
Note. Location of the identification label on the 4689
display unit is also shown in Fig. 3.1.
3.1.2 Model 006540 203 or 006548 000
Katharometer Analyzer Panel – Fig. 3.2
The panel is identified by the reference number label as shown in
Fig. 3.2. The identification and certification labels of the
individual katharometer units (fixed to the katharometer case)
are also shown in Fig. 3.2.
Fig. 3.1 Typical Identification Labels and Locations –
Model 6553 Display Unit
Fig. 3.2 Typical Identification Labels with Locations –
Model 006540 203 & 006548 000 Katharometer Analyzer
Panels (006548 shown)
3PREPARATION

6
Ex
ABB Li mi te 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
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

7
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3.1.4 AK100 Ordering Information
The equipment conforms with the requirements of ATEX directive for Class IIC gases to Code EEx ia IIC provided that the equipment
is installed in accordance with instructions provided.
3PREPARATION

8
366 (14.4)
Katharometer
Intrinsically
Safe Circuits
Signal
Conventional
Circuits
Cable
Entry
Mounting Panel
Thickness
6 (0.24) max.
346 (13.62)
30 (1.18)
Mounting Panel
Display Face
350 0.5 (13.780.2)
(Cutout)
Panel Cutout and
Mounting Requirements
Area For
Clamping
Cams
50
(1.97)
70
(2.76)
3 (0.12)
278 0.5 (10.940.2)
(Cutout)
%H2 IN CO2
95.0
290 (11.4) 30 (1.18) 227 (8.94)
%H2 IN AIR
95.0
Power
Input
123
123
Not Fitted
to AK103
3 (0.12)
4.1 Locating and Mounting 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 dimensions are shown in Fig. 4.1. The display unit is
secured to the panel by four adjustable cam brackets –two each side of the unit chassis.
Dimensions in mm (in.)
Fig. 4.1 Installation Dimensions – Model 6553 Display Unit
4MECHANICAL INSTALLATION

9
148 (5.83)
38(1.5)
10
(0.39)
19
(0.75)
305 (12)
267 (10.5)
610 (24)
572 0.3 (22.50.01)
233 (9.17)
Outlet
19 (0.75)
Gland for Ø7 to 10.5 (0.28 to 0.41) Cable
4 Fixing
Holes Ø10 (0.39)
Note. Coupling for
Ø6 (0.24) Tube (006548000) or
Ø8 (0.31) Tube (006540203)
See
Note
See
Note
4.1.2 Katharometer Analyzer Panel – Fig. 4.2
Note. 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 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 dimensions for the panel are shown in Fig. 4.2.
Fig. 4.2 Installation Dimension –
Model 006540203 or 006548000 Katharometer Analyzer Panel
Dimensions in mm (in.)
4MECHANICAL INSTALLATION…

10
140 (5.5) Centers
110 (4.33) Centers
170 (6.7) 111 (4.37)
120 (4.72)
All Holes Ø7.0 (0.28)
160 (6.3)
83
20 (0.79)
30
(1.18)
60 (2.36) Centers
Ensure a clearance of at least 100 (4) at
both ends of the unit for acces to the cable
glands and to minimize cable bends.
Mains Cable
Entry
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 Dimensions – Model 4234 Power Supply Unit
…4 MECHANICAL INSTALLATION

11
Hydrogen Purity
& Purge Gas Monitor
ø12 (0.47)
123
Hazardous Area
Cable Glands
Safe Area
Cable Glands
Mains Power
Cable Glands
478
(18.8)
600 (24.6)
140 (5.53)
80 (3.15)
80
(3.15)
340 (13.4)
382
(15.04)
%H2 IN CO2
95.0
%H2 IN AIR
95.0
4 Mounting Brackets
Ø10 (0.39) hole
123
515 (20.28) 40
(1.57)
630 (24.8)
110
(4.33)
Optional Mains Isolator
(not fitted to those systems that
require 100% redundancy)
4.1.4 Cubicle 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 to IP55
Weight of cubicle assembly 56kg (123lb) max.
Note. Isolator and MCBs not fitted to AK102 versions
(can be fitted to AK103 versions if specified).
4MECHANICAL INSTALLATION…
Dimensions in mm (in.)

12
12 34 56 78 91011 1213 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 LNE LNE
14 15 16 17 18 19 20 21 22 23 24 25 26
Note. The number of terminals, cable glands, low-flow alarms, PSU's and zener barriers
(flow alarms) vary according to ordering information details specified.
Relay No. 2
Relay No. 1
POWER
SUPPLY
UNIT No 1
POWER
SUPPLY
UNIT No 2
No. 1 No. 2
BARRIER FLOW
ALARM
E SCR S1 S2 0V 0V -12V+12V
CH 1
I N COM NC NO
E SCR S1 S2 0V 0V -12V+12V
CH 1
I N COM NC NO
1 2 1 2
3 4 3 4
Barriers
Low Flow Alarm
Relay 2 (if fitted)
Mains Power
Cable Glands
Earth Point (Ground) Low Flow Alarm
Relay 1 (if fitted)
Cable Glands for Cable
Terminations in
Hazardous Areas
Cable Glands for
Cable Terminations
in Safe Areas
To Cubicle Earth
Power Supply
Unit 2 (if fitted)
Power Supply
Unit 1
Terminal Block
MAINS
TERMINAL
BLOCK
KATHAROMETER
TERMINAL BLOCK LOW FLOW
ALARMS
ALARMS AND
RETRANS
4.2 Sample Gas 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 allowed to reach
ambient temperature before entry to the Katharometer unit.
If there is a risk of significant particle contamination incorporate a suitable 1µm filter unit 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 (0.31 in.) (Model 006540 203) or 6mm (0.24 in.) (Model 006548 000) outside diameter metal tube. It is
recommended that stainless steel tube is used.
The complete tubing system should be tested for leaks in accordance with the requirements of the responsible authority.
Fig. 4.5 Location of Main Components on Cubicle Backplate
…4 MECHANICAL INSTALLATION

13
Safe Area
See Note 9
Note 1 Apparatus which is unspecified except that it must not be supplied from nor contain in normal
or abnormal conditions a source of potential with respect to earth in excess of 250 volts r.m.s
or 250 volts d.c.
Note 2a The capacitance and either the inductance or the inductance to resistance (L/R) ratio of the
cable connected between the + and –terminals of the power supply Type 4234500/501 and
terminals 1 and 4 of a katharometer Type 0065XX must not exceed the following values:
Hazardous Area
See Notes 2 & 3
2
4
1
5
36
2
4
1
5
36
2
4
1
5
36
TB5
18
17
TB6
19
20
POWER SUPPLY
TYPE 4234 500/501
CERTIFIED [EEx ia] IIC
(–20CTa +55C)
CERTIFICATE No
BAS 01 ATEX 7041
-
+
2
1
3
2
1
3
RS1
RS2
B1
B2
B3
6553 Display/Control Unit
–
+
Indicator
4689
I1
–
+
Indicator
4689
I2
4 –
1+
9
10
3 –
2+
KATHAROMETER
TYPE 0065XXX
CERTIFIED EEx ia IIC T4
Tamb=–20C to +55C
CERTIFICATE No
BAS 01 ATEX 1042
3 –
2+
10
4 –
1+
6 –
9
KATHAROMETER
TYPE 0065XXX
CERTIFIED EEx ia IIC T4
Tamb=–20C to +55C
CERTIFICATE No
BAS 01 ATEX 1042
Junction boxes (if required) see note 6.
Location: Hazardous Area or Safe Area
See Note 1
See Note 1
Junction boxes (if required) see note 6.
Location: Hazardous or Safe Area
RV1
RV2
Display/Control Unit
Model 6553
CERTIFIED [EEx ia] IIC
Tamb=–20C to +40C
CERT No BAS 01 ATEX 7043
Group Capacitance
in F
Inductance
in mH
L/R ratio
in H/Ohm
IIC
IIB
IIA
7.5
99
999
0.02
0.06
0.16
20
60
160
or
Group Capacitance
in F
Inductance
in mH
L/R ratio
in H/Ohm
IIC
IIB
IIA
38
999
999
0.40
1.20
3.20
75
225
600
or
Group Capacitance
in F
Inductance
in mH
L/R ratio
in H/Ohm
IIC
IIB
IIA
38
999
999
0.20
0.60
1.60
40
120
320
or
Note 2b The capacitance and either the inductance or the inductance to resistance (L/R) ratio of the cables
connected between (a) terminals 17 & 18 of the display/control unit Type 6653 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
connected between 4 & 5 of barrier B2 plus terminal 4 of barrier B3 of display/control unit Type 6653
and terminals 2, 3 & 6 of a katharometer Type 0065XX, must not exceed the following values:
See Notes 2 & 3
Circuit A
Circuit B (see Note 8)
Note 3 The cable may be separate cables or may be installed as separate circuits within a type ‘A’or a type ‘B’
multicore cable as defined in EN50039(1980) subject to the following:
a. Each circuit shall be individually screened within a type ‘A’multicore cable.
b. The peak voltage of any other circuit within a type ‘B’multicore cable must not exceed 60 volts.
Note 4 The installation must comply with national requirements (e.g. in the UK EN60079-14:1997).
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 between the intrinsically safe and non-
intrinsically safe circuits.
This marking shall include the word SYST or SYSTEM, e.g.
‘BAS SYSTEM No Ex 01E2044’or ‘BAS No Ex 01E2044 SYST’
Note 6 A junction box, if used, must satisfy the requirements of Clauses 6.1 and 6.3.1 of EN50020:1994.
Note 7 Circuit A or Circuit B may be omitted.
Note 8 Circuit B may be identical to Circuit A.
Note 9 This item may or may not be fitted.
POWER SUPPLY
TYPE 4234 500/501
CERTIFIED [EEx ia] IIC
(–20CTa +55C)
CERTIFICATE No
BAS 01 ATEX 7041
-
+
See Note 10
Note 10 Zenner barriers (B1, B2 & B3) either MTL 7055ac BAS 99 ATEX 7285 or MTL 7755ac BAS 01 ATEX 7217
(MTL 7055ac barriers shown on diagram).
5.1 Electrical Interconnections – Fig. 5.1
Fig. 5.1 System Diagram
5ELECTRICAL INSTALLATION

14
Warning.
•Equipment in this system operates on AC mains
supply voltage electricity. Suitable safety
precautions must be taken to avoid the possibility of
electric shock.
Caution.
•Although certain instruments are fitted with internal
fuse protection, a suitably rated external protection
device, either a 3A fuse or miniature circuit breaker
(MCB) 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.
•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
AK100 Gas Analyzer system, that must be strictly observed.
Details of cable requirements, that 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 shown in Sections 5.1.1, 5.1.2 and 5.1.3.
Zero Adjustment
for Remote
Katharometers
(only 1 fitted to AK103)
Clamp
Cam
Mains Power
Supply Fuses
(only 1 fitted
to AK103)
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 161
TB1
TB2
TB3
TB4
TB5 TB6
B1 B2
TB2 not fitted
to AK103
TB4 not fitted
to AK103
TB6 not fitted
to AK103
5.1.1 Model 6553 Display Unit – Fig. 5.2
Caution. No connections must be made to the
hazardous area terminals (Terminal Blocks TB5 & TB6)
other than as specified in wiring diagram Fig. 5.3. The
appropriate cable requirements must be strictly
adhered to.
Remove the outer case from the back of the unit to gain access
to the terminal blocks.
Make electrical connections through the bottom of the unit into
the terminal blocks immediately above them –see Fig. 5.2.
The alarm and signal outputs on terminal blocks TB3 & TB4 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.
Refer Fig. 5.4 for connections to cubicle-mounted display unit.
Continued on page 17.
Fig. 5.2 Location of Components Inside Case (Rear View) – Models AK102 & AK103 Display Units
…5 ELECTRICAL INSTALLATION

15
External
power supply
TB2
1
2
3
4
5
6
7
8
9
10
Katharometer
Unit
Gas Panel 2
*
TB1
1
2
3
4
5
6
7
8
9
10
Katharometer
Unit
Gas Panel 1
TB1 TB2
Power Supply Unit 2
Model
4234
LNE
TB1 TB2
Power Supply Unit 1
LNE
External
power supply
Note. Interconnections
marked with MUST conform to the
intrinsically safe wiring requirements
given in the text.
All other wiring to suit power and signal
requirements
Outputs as required (upper and lower displays identical)
Zener diode safety
barrier devices
External dual
power supply
Connections for
Lower Display
Connections for
Upper Display
L N E
LNE
12345678910
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
+ –
12345678910111213141516
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.
Katharometer Gas Unit Panel 2 is connected internally within 6553 Gas Monitor to Lower Display.
B1
4 5
B2
4 5
MTL 7755ac MTL 7055ac
***
*
*
*
Note. Not applicable to AK103.
*
Model
4234
Monitor
Common
Range 3
Range 2
Range 1
+
–
+
–
+
–
+
–
+–+–
Fig. 5.3 Interconnection Wiring Diagram – Models AK102 & AK103 Intrinsically Safe Analyzer System using Dual 3-range Displays, as Separate Units
5ELECTRICAL INSTALLATION…

16
123456789
Katharometers
10 11 12 13 12345678910111213 23 24 25 2614 15 16 17 18 19 20 21 22
L N E E
Mains T/B6553 Outputs
Upper Display
6553 Outputs
Lower Display
N/O
Common
N/C
N/O
Common
N/C
N/O
Common
N/C
N/O
Common
N/C
Common
Range 3
Range 2
Range 1
Cubicle Terminal Blocks
+
–
+
–
H
2
in Air
Alarm 1
H
2
in Air
Alarm 2
H
2
in Air
Alarm 1
H
2
in Air
Alarm 2
Retransmission
Retransmission
Range Selector
Switch Position
Indicator
Range Selector
Switch Position
Indicator
23910 14
Katharometer
Panel 1
23910 14
Katharometer
Panel 2
Hazardous Area
Note. 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 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
Alarm Relays
23
142
3
14
L N E E
Common
N/C
N/O
Common
N/C
N/O
Relay 1
Relay 2 *
Ter minal
Box
Screen
Black
Red
White
Screen
Black
Red
White
Katharometer
H
2
& Air in CO
2
H
2
in Air
Katharometer
H
2
& Air in CO
2
H
2
in Air
++––
++––
*
*
*
*Note. Not available if single Model AK103 is fitted to the cubicle.
Common
Range 3
Range 2
Range 1
Fig. 5.4 Wiring Diagram for Cubicle-Mounted Display/Control Unit
…5 ELECTRICAL INSTALLATION

17
Zero Adjustment
Potentiometer
Measuring
Unit
Tubing
Connections
Terminal Block (TB1)
Dummy
Remote Zero
Resistor.
Remove When
Connecting
Remote Zero.
Mounting Pillars
10
9
12
11
10
9
8
7
6
5
4
3
2
1
Inlet Outlet
–
–
–
+
+
Caution. The integrity of the fail-safe operation of the zener diode safety barrier devices depends on a Safety Earth
connection which must not have a resistance greater than 1 to the application plant earth (gr ound).
Make the Earth (Ground) and Safety Earth connection at the stud (TS1) –see Fig. 5.2.
On completion of wiring and checks, replace the outer case and secure the clamping brackets to the mounting panel.
5.1.2 Model 006540 203 and 006548 000 Katharometer 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 gland to suit the intrinsically
safe wiring requirements. When the appropriate interconnections have been made, if remote zero is to be used, remove the 510
dummy remote zero resistor from across terminals 9 and 10 and set the zero adjustment potentiometer on the katharometer to the
approximate mid-point.
Replace the cover when wiring is complete.
Fig. 5.5 Location of Components Inside Case – Model 006539 and 006548 Type Katharometer Unit
5ELECTRICAL INSTALLATION…

18
TB1
T1
L N E
F2 F3
Warning. Hazardous Voltages.
There are no servicable parts in this unit.
Return to the manufacturer if faulty or seek
the services of a qualified engineer.
Switch off the mains supply and disconnect
it before removing the cover for any reason.
6
8
10
230 V
115 V
Output Current (mA) Links
350 C to X
250 D to X
180 E to X
NO connections should be made to
points A or B
TB2
–
+
F1
BA
CX
DE
M5 Earth Stud
Cable Gland for
AC Mains Input
Output
Current
Links
Cable Gland
Not Used
Cable Gland for
DC Output to
Katharometer
Mains Input
Terminal Block
DC Output
Terminal Block
Fuses*
*Refer to the 4234 manual for fuse details.
5.1.3 Model 4234 Power Supply Unit – Fig. 5.6
Caution. Do NOT connect mains supply to the power supply unit with the output terminals on open circuit.
Note. 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.
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 6 to 10 for 230V, or
link from tapping 8 to 10 for 115V.
Make electrical connections in accordance with the information given in the wiring diagrams Figs 5.1 and 5.3 and the cable details
in 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.
Replace the cover when wiring is complete.
Fig. 5.6 Location of Components Inside Case – Model 4234 Power Supply Unit
…5 ELECTRICAL INSTALLATION