H2Scan HY-ALERTA 1600 User manual

HY-ALERTATM 1600
Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
27215 Turnberry Lane, Unit A
Valencia, CA. 91355, USA
Tel: [phone] / Fax: [phone]
E-mail: [e-mail]
Website: http://www.h2scan.com

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 2 of 31
Our Mission
Deliver unsurpassed value and optimize green initiatives with our one of a kind
continuous hydrogen-specific sensing technology worldwide.
Our Value Propositions
Enable end-user customers to efficiently and effectively optimize:
Electric utility power transformer fleet and other oil-filled assets (Grid)
Petroleum refinery and other industrial process control
Facility and equipment safety to minimize downtime
...at a much lower total costs of ownership than the competition.
Our Strategic Objectives
H2scan's technology accepted as the new gold standard in hydrogen sensors.
H2scan's business recognized for innovation and ingenuity, high quality
products and systems, application -specific solutions, and exceptional customer
service and satisfaction.
H2scan's success results from teamwork, strategic partnerships and market
leadership leading to sales growth and improved profitability.

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 3 of 31
CONTENTS
1DESCRIPTION........................................................................................................................................5
2SPECIFICATIONS...................................................................................................................................5
3ATEX RATING.........................................................................................................................................6
4INSTALLATION.......................................................................................................................................7
4.1 Associated Equipment ..................................................................................................................7
4.2 Mounting .......................................................................................................................................8
4.3 Connections ..................................................................................................................................8
4.4 Settings .........................................................................................................................................9
5STARTUP................................................................................................................................................9
5.1 Settings .........................................................................................................................................9
6OPTIMUM UNIT PERFORMANCE.......................................................................................................10
7OPERATION .........................................................................................................................................10
7.1 Analog Output .............................................................................................................................10
7.2 Display ........................................................................................................................................10
7.3 Keypad........................................................................................................................................11
7.4 Configuration Menu.....................................................................................................................11
8SERIAL COMMUNICATION .................................................................................................................12
8.1 Software......................................................................................................................................12
8.2 Connection..................................................................................................................................12
8.3 Format and Settings....................................................................................................................12
8.4 Command Levels........................................................................................................................12
8.5 Command Summary...................................................................................................................13
9MAINTENANCE ....................................................................................................................................17
9.1 Cleaning......................................................................................................................................17
10 CALIBRATION.....................................................................................................................................17
10.1 Factory Calibration –...............................................................................................................17
10.2 Field Calibration......................................................................................................................17
11 FIELD CALIBRATION..........................................................................................................................17
11.1 Calibration Interval..................................................................................................................17
11.2 Gases......................................................................................................................................17
11.3 Gas Connection......................................................................................................................17
11.4 Procedure ...............................................................................................................................17
11.5 Calibration Using the Serial Interface.....................................................................................18
11.6 Calibration Using the Keypad.................................................................................................20
12 CLEAR FIELD CAL..............................................................................................................................20
12.1 Clear Field Cal Using the Serial Interface ..............................................................................20
12.2 Clear Field Cal Using the Keypad ..........................................................................................20
13 MESSAGES.........................................................................................................................................20
13.1 Warmup_XXX.........................................................................................................................20
13.2 Settle.......................................................................................................................................20
13.3 Wait_XXX ...............................................................................................................................20
13.4 htroff........................................................................................................................................20
13.5 Error_XXX...............................................................................................................................21
14 APPENDIX 1 FOXTERM SETUP........................................................................................................22
14.1 Foxterm Installation ................................................................................................................22
14.2 Foxterm setup.........................................................................................................................22
15 APPENDIX 2 - MENUS .......................................................................................................................23
16 APPENDIX 3........................................................................................................................................28
16.1 Control Drawing......................................................................................................................28
16.2 Serial Barrier Switch Settings for RS232 connection to PC...................................................31

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 4 of 31
IMPORTANT NOTICES
LIMITATION OF LIABILITY
IN THE EVENT OF A DEFECT IN A PRODUCT, H2SCAN SHALL NOT BE RESPONSIBLE FOR ANY
DIRECT, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING THEREFROM,
INCLUDING, BUT NOT LIMITED TO, LOSS OF REVENUE AND/OR PROFIT.
LIMITED WARRANTY
H2scan Limited Warranty. Each hydrogen instrument (“Product”) will conform, as to all substantial operational features, to the Product
specifications set forth this Manual and will be free of defects which substantially affect such Product’s performance for twelve (12) months
from the ship date for such Product.
Must Provide Notice of Defect. If you believe a Product is defective, you must notify H2scan in writing, within ten (10) days of receipt of such
Product, of your claim regarding any such defect.
Return Product to H2scan for Repair, Replacement or Credit. If the Product is found defective by H2scan, H2scan’s sole obligation under
this warranty is to either (i) repair the Product, (ii) replace the Product, or (iii) issue a credit for the purchase price for such Product, the
particular remedy to be determined [by H2scan] on a case-by-case basis.
Voided Warranty. H2scan’s 12 Month Limited Warranty is void for any of the following:
•The unit is opened and the manufacturing seal is broken
•Unauthorized repair work performed at the customer’s location or carried out by anyone other than H2scan’s factory trained
technicians
•Equipment or parts that have been tampered with, misused, neglected, mishandled, improperly adjusted, or modified in any way
without the written consent of H2scan.
•Equipment or parts that have been damaged due to shipping, misuse, accidents, mishandling, neglect, or problems with electrical
power sources.
•Repair work performed during the warranty period does not prolong the warranty period past the original period.
•System operation in incorrect or inappropriate environments.
•Usage that is not in accordance with system guidelines or an operator’s failure to follow manual instructions.
Limitation of Warranty. THE ABOVE IS A LIMITED WARRANTY AS IT IS THE ONLY WARRANTY MADE BY H2SCAN. H2SCAN MAKES
NO OTHER WARRANTY EXPRESS OR IMPLIED AND EXPRESSLY EXCLUDES ALL WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE. YOUR SOLE REMEDY HEREUNDER IS REPAIR OR REPLACEMENT OF THE PRODUCT
OR A CREDIT FOR THE PURCHASE PRICE FOR SUCH PRODUCT, THE PARTICULAR REMEDY TO BE DETERMINED BY H2SCAN
ON A CASE-BY-CASE BASIS. H2SCAN SHALL HAVE NO LIABILITY WITH RESPECT TO ITS OBLIGATIONS UNDER THIS
AGREEMENT FOR CONSEQUENTIAL, EXEMPLARY, OR INCIDENTAL DAMAGES EVEN IF IT HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH DAMAGES. THE STATED EXPRESS WARRANTY IS IN LIEU OF ALL LIABILITIES OR OBLIGATIONS OF
H2SCAN FOR DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE DELIVERY, USE OR PERFORMANCE OF THE
PRODUCTS.
Read and understand this operating manual before installing or using the unit. Only use cables from
H2scan with this unit. If this equipment is used in a manner not specified by H2scan, the protection
provided by this equipment may be impaired.
Hydrogen is flammable at 4% in air. Take indications seriously and be prepared to take action. In the event
of detection of 4% or higher of a hydrogen gas concentration there is a high probability of a hazard to
safety. Inform local emergency response personnel immediately.

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 5 of 31
1 DESCRIPTION
The HY-ALERTATM 1600 Intrinsically Safe Area Hydrogen Monitor is designed to detect and/or measure
hydrogen as a component of air. The hydrogen specific solid-state sensing element is housed in a
flameproof enclosure at the tip of the sensor tube, and ATEX certified for Zone 0 hazardous locations. The
electronics assembly housed in a metal housing, which is permanently attached to the sensor tube, is
ATEX certified for Zone 1 hazardous locations. The electronics contains all the circuitry necessary to
operate the sensor and provides calibrated hydrogen readings to a 4-20 mA analog and RS422 digital
outputs. The HY-ALERTATM 1600 has no cross sensitivity to other combustible gases, eliminating false
positive alarms and ensuring safety system reliability.
2 SPECIFICATIONS
Sensitivity Range:
0.4% to 5% hydrogen by volume at 1 ATM,
10% to 125% hydrogen lower flammable limit
Accuracy:
± (0.03 x indication + 0.2) percent hydrogen by volume
Example: accuracy at 1% H2is ±0.23% H2
Response Time:
T90 of 60 sec maximum
Temperature:
Ambient Operating:
Storage:
-20 to +40°C
-40 to +50°C
Sensor Input Voltage:
Range:
Intrinsically Safe:
5 VDC to 28 VDC
10 VDC, 6 W
Power Barrier Input Voltage:
Range:
Nominal:
20 VDC to 28 VDC
24 VDC
Analog Output:
Isolated, Loop Powered 4-20 mA
Serial Communication:
RS-422
Dimensions:
See following figure (dimensions in inches)
Weight:
1 lbs.
Enclosure Rating:
At least IP20, capable of meeting IP64
Dust-tight, protected against water spray from any direction
Approvals and Ratings:
0359
ITS07ATEX25634X
II 1 G, Ex ia II H2, db+db IIB T3 Ga
II 2 G, Ex ib II H2, ib db IIB T3 Gb
Calibration Period:
3 months
Product Life:
10 years

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 6 of 31
Figure 1: Dimensions (in inches)
3 ATEX RATING
The HY-ALERTA™ 1600 monitor is certified with a dual zone rating.
Electronics Assembly is Zone 1 (2 G Ex ib)
Probe Tip is Zone 0 (1 G Ex ib+d).

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 7 of 31
Figure 2: Hazardous Area and Associated Equipment
Table 1: Input and Output Parameters
Parameter
J1 Pins 2&3
(Power Supply)
J1 Pins 4&5
(4-20 mA loop)
J2 Pins 1&2, 3&4
(RS422 Rx&Tx)
Ui
11.5 V
26.7 V
3.7 V
li
3.27 A
91 mA
2.25 mA
Pi
9.41 W
611 mW
206 mW
Ci
0
68.2 nF
0
Li
0
0
0
Uo
n/a
n/a
5.9 V
Io
n/a
n/a
238 mA
Po
n/a
n/a
350 mW
Co
n/a
n/a
1000 uF
Lo
n/a
n/a
2.5 mH
Lo/Ro
n/a
n/a
404 uH/Ω
4 INSTALLATION
WARNING: IF THE UNIT IS INSTALLED IN A CLASSIFIED LOCATION THEN IT IS THE RESPONSIBILITY
OF THE USER AND INSTALLER TO MAKE CONNECTIONS TO RELATED EQUIPMENT IN A MANNER
CONSISTENT WITH THE LOCATION CLASSIFICATION.
4.1 ASSOCIATED EQUIPMENT
Only H2scan specified cables should be used with this Analyzer. The maximum length for
intrinsically safe operation of both the Power/Analog Cable and the Serial Interface Cable is 10
meters. Refer to the Appendix for Control Drawings.
When operated in a hazardous area, the HY-OPTIMA™ 1700 Analyzer must be connected to
appropriately certified barriers located in a non-hazardous area. The following barriers are approved
for use with this device for an Intrinsically Safe implementation:

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 8 of 31
Intrinsically Safe Power Barrier: H2scan’s custom designed barrier supplies 10VDC, 6W power to
the sensor.
Intrinsically Safe Analog Output Barrier (4mA to 20mA): GM International D1054S or
equivalent, One Channel Repeater Power Supply and Trip Amplifiers. Refer to the D1054S
Operating Manual for installation and configuration of this barrier.
Intrinsically Safe Serial Interface Barrier (RS422): GM International D1061S or equivalent,
RS422 / RS485 Fieldbus Isolating Repeater. Refer to the D1061S Operating Manual for installation
and configuration of this barrier. This barrier also requires a null modem cable for communication
between PC and Barrier.
4.2 MOUNTING
While the unit can be mounted in any orientation or position, it is important to consider the possible
sources and areas of accumulation of hydrogen gas. Typical installations are near the ceiling level
above equipment using or storing hydrogen. For earlier detection artificial means of accumulation
such as flat plates or inverted trays can be installed at lower heights to allow hydrogen to reach the
sensor more quickly.
WARNING: IT IS NOT THE INTENT OF THIS MANUAL TO SPECIFY MOUNTING LOCATION(S). IT IS THE
REPONSIBILITY OF THE USER AND INSTALLER TO DETERMINE THE PROPER LOCATION(S) FOR
HYDROGEN DETECTION BASED UPON THE PARTICULAR USES OF HYDROGEN AT THE
INSTALLATION SITE.
Mounting is achieved by 4 mounting tabs that can be rotated to align with flat, angled or moderately
curved surfaces. Mounting hardware should be a 4 mm screw (M4, #8 screw), appropriate for the
surface being mounted upon. The unit can be mounted in any orientation or position.
4.3 CONNECTIONS
Power/Analog Output - Connector 1
Supplied Cable –4 m (12 ft.) standard (Other lengths available).
Wire Color
Description
Red
+10 VDC
Black
10 VDC Return
White
+4 mA to 20 mA
Blue
4 mA to 20 mA Return
Bare
Case Ground
Serial Interface - Connector 2
Supplied Cable –4 m (12 ft.) standard (Other lengths available).

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 9 of 31
Wire Color
Description
Black
+TxD RS422
Blue
-TxD RS422
White
+RxD RS422
Brown
-RxD RS422
4.4 SETTINGS
Located on the front of the unit next to model number marking, a Status Indicator displays basic unit
functions as described below. Default amber and red Status Indicator LED settings are 1% and 2%
hydrogen by volume, respectively.
Status
Indicator Color
Normal operation / Hydrogen detected is below 1% hydrogen by volume
GREEN
Warm-up / Hydrogen detected between 1% and 2% hydrogen by volume
AMBER
Hydrogen detected above 2% hydrogen by volume / Unit fault detected
RED
The unit’s operational and output settings have been configured at the manufacturer with settings
specified at the time of purchase. Settings may be changed through the use of serial port.
WARNING: If settings are changed from those set by the manufacturer then it is the user’s
responsibility to understand the implications to the connecting equipment monitoring the unit.
5 STARTUP
Power must be applied to the unit before connecting the serial cable. Power is connected via the Power/
Analog signal connector. The serial cable can be connected any time after power has been applied to the
unit. Once power is applied, the unit executes a warm-up sequence lasting about 5 minutes. The status
LED will be amber in color during warm-up. It will become green, amber, or red when the unit is ready.
The following operations will be completed in this warm-up sequence:
Heat the sensor to operating temperature.
Perform the Power-On-Self-Test (POST).
The analyzer is designed to be exposed to air with no hydrogen most of the time. For optimal performance
keep any hydrogen exposure to the sensor to less than one hour. If the hydrogen exposure exceeds this
time, the sensor may need to be reconditioned by leaving it powered on in air for a few days.
5.1 SETTINGS
Located on the front of the unit next to model number marking, a Status Indicator displays basic unit
function as described below. Default amber and red Status Indicator LED settings are 1% and 2%
hydrogen by volume, respectively.
Status
Indicator Color
Normal operation / Hydrogen detected is below 1% hydrogen by volume
GREEN
Warm-up / Hydrogen detected between 1% and 2% hydrogen by volume
AMBER
Hydrogen detected above 2% hydrogen by volume / Unit fault detected
RED
The unit’s operational and output settings have been configured at the manufacturer with settings
specified at the time of purchase. Settings may be changed through the serial port.
WARNING:
IF SETTINGS ARE CHANGED FROM THOSE SET BY THE MANUFACTURER THEN IT IS THE USER’S
RESPONSIBILITY TO UNDERSTAND THE IMPLICATIONS TO THE CONNECTING EQUIPMENT
MONITORING THE UNIT.
Although the unit will respond to 90% or better of a concentration change within 60 seconds, the
signal will continue to settle. This period varies with concentration and other conditions. For best

HY-ALERTA™ 1600, Intrinsically Safe Area Hydrogen Monitor
OPERATING MANUAL
90000012 R8 Page 10 of 31
results in long-term monitoring, allow the unit to settle for a period of one (1) hour in the gas
composition being monitored prior to use.
6 OPTIMUM UNIT PERFORMANCE
For maximizing the performance of the sensor, the following steps are recommended.
Verify that all electrical connections and made as recommended. Switching the polarity can cause damage
to the unit. Ensure that the DC power supply utilized is appropriate and does not have large peak-to-peak
noise.
Perform a Field calibration after the installation and conditioning steps described in the Start-up section are
completed. DO NOT use 0% H2 as the lower calibration gas. Instead use hydrogen concentration that is
slightly lower than the expected lowest hydrogen concentration (for e.g. if 1% is the expected lowest H2
concentration, then use 0.5% H2 as the lower calibration gas.
For the second calibration gas use a concentration that is slightly higher than the expected maximum H2
concentration.
If the analyzer gets exposed to extended periods of H2, condition the sensor as described in the Start-up
section and follow-up with a Field calibration, if needed.
6.1 PRESSURE EFFECTS
The analyzer is hydrogen specific and sensitive to only the hydrogen partial pressure in the air.
Since changes in total gas pressure will affect the hydrogen partial pressure, they will also affect the
sensor readings. For instance, at one atmosphere pressure, a 2% H2 concentration will be reported
as 2% from the unit. At .9 atm, the reading will decrease to 1.8%.
Normal atmospheric pressure fluctuations may also manifest as small hydrogen changes.
At the factory, the units are typically calibrated at one atmosphere pressure.
Performing the field calibration will compensate for altitude induced inaccuracy.
7 OPERATION
7.1 ANALOG OUTPUT
The following parameters are set at the factory per customer specification at time of order, however
they are user configurable via the serial port.
The user can request for a specific output current or there are analog output ranges the user can
select from, which are listed below. The analog output the user selects is scaled to the user’s
hydrogen range of interest. All of this is initially set at the factory per customer specification at the
time of order. Below is the table for standard analog output current ranges:
Current Range
Selection
Analog Output
Range
Power-On Self
Diagnostic Output
Error Output
Standard
4 mA to 20 mA
22 mA
3 mA
Optional
0 mA to 20 mA
0 mA
20 mA
The selected Analog Output Range is scalable from the low to high levels of the hydrogen sensitivity
range. The user can change to another current range of the analog output in the field. Please refer
to the “I” command.
7.2 DISPLAY
The upper row of the LCD indicates a numerical value for the percent hydrogen concentration or
peak hydrogen value. The lower row of the LCD is used to display the hydrogen meter, a
logarithmic bar graph ranging from 0.001% (10 ppm) to 100% hydrogen by volume. An open box on