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A B B M E A S U R E M E N T & A N A LY T I C S | U S E R G U I D E | I M/A K 1 / 1 4 R E V. N
AK101 and AK104
Gas analyzer systems for hydrogen-cooled alternators
For more information
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AK101 and AK104
gas analyzer systems
A Data Sheet is also available for free download
from:
www.abb.com/analytical
or by scanning this code:
Data Sheet
AK100 Series
ATEX compliant gas analyzer system
for hydrogen-cooled alternators
Measurement made easy
Search for or click on
DS/AK100-EN
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Table of Contents
Related Manuals for ABB AK101
Summary of Contents for ABB AK101
- Page 1 A B B M E A S U R E M E N T & A N A LY T I C S | U S E R G U I D E | I M/A K 1 / 1 4 R E V. N AK101 and AK104...
- Page 2 Electrical safety Health and safety This equipment complies with the requirements of CEI/IEC To ensure that our products are safe and without risk to health, 61010-1:2001-2 ‘Safety Requirements for Electrical Equipment the following points must be noted: for Measurement, Control and Laboratory Use’. If the •...
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Page 3: Table Of Contents
2.1.1 Range Display ......... 3 Range 1 Operating Page ........30 Model 006540203 or 006548000 Range 2 Operating Page – AK101 only ..... 30 Katharometer Analyzer Panel ......4 Range 3 Operating Page – AK101 only ..... 30 Model 4234 500/4234 501 Power Supply Units (PSU) ........ -
Page 4: Introduction
The ultimate responsibility for any particular installation lies with the installing user/contractor. This manual gives the installation, operating and maintenance information for the Company's range of Models AK101 and AK104 Intrinsically Safe Gas Analyzer Systems, normally used with hydrogen cooled electrical power generators. -
Page 5: Description
Note. CO is refered to throughout this manual as the adjustment, Model AK101 is equipped with a range selector purge gas. However, other gases such as Argon or switch – see Fig. 2.1. Model AK104 is a single display for Nitrogen may be used instead. -
Page 6: Model 006540203 Or
...2 DESCRIPTION 2.2 Model 006540203 or 006548000 2.3 Model 4234 500/4234 501 Katharometer Analyzer Panel – Fig. 2.2 Power Supply Units (PSU) – Fig. 3.3 Refer also to IM/6517-6518 for further details. Refer also to IM/4234500 for further details. Each panel comprises a metering valve, a drying chamber, a Caution. -
Page 7: Preparation
Manufactured by: N4006 A B B L i m i t e d Oldends Lane, Stonehouse, Glos. England GL10 3TA ABB L i m i t e d Oldends Lane, Stonehouse, Glos. England GL10 3TA Model No. Type No. Unique Serial No. -
Page 8: Model 4234 Power Supply Unit
Product Code Watts ✔ Serial No.: Year Manuf. Year Manufacture: N4006 Manufactured by: Voltage: ABB L i m i t e d Frequency: 50/60Hz Oldends Lane, Stonehouse, Power Rating: Glos. England GL10 3TA Manufactured by: N4006 ABB Limited Oldends Lane, Stonehouse, Glos. -
Page 9: Ak100 Ordering Information
Gas Sample Flow Alarm (only available with Cubicle option) Not fitted One flow alarm fitted AK103 and AK104 (single gas analysis panel versions) Two flow alarm fitted AK101 and AK102 (dual gas analysis panel versions) Katharometer Power Supply *** None... -
Page 10: Mechanical Installation
4 MECHANICAL INSTALLATION 4.1 Locating and Mounting System Items 4.1.1 Models AK101 and AK104 Display Unit – Fig. 4.1 Note. The display unit be located in the area of the application plant in a sheltered interior environment. must safe The display unit is designed for panel-mounting in a position to suit reading of the displays and with access to the rear for electrical interconnections. -
Page 11: Katharometer Analyzer Panel
4 MECHANICAL INSTALLATION… 4.1.2 Katharometer Analyzer Panel – Fig. 4.2 Refer also to IM/6517-6518 for further details. Note. The panel may be located in the hazardous area (Zone 0, 1 or 2) of the application plant in a sheltered interior environment. -
Page 12: Model 4234 Power Supply Unit
…4 MECHANICAL INSTALLATION 4.1.3 Model 4234 Power Supply Unit – Fig. 4.3 Refer also to IM/4234500 for further details. Note. The unit be located in the area of the application plant in a sheltered interior environment. must safe 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.) Ensure a clearance of at least 100 (4) at both ends of the unit for acces to the cable... -
Page 13: Cubicle Mounted System
4 MECHANICAL INSTALLATION… 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. Ensure any vertical surface on which the cubicle is to be mounted is robust and suitable for the purpose. -
Page 14: Sample Gas Interconnections
…4 MECHANICAL INSTALLATION Earth Point (Ground) (NOT intrinsically safe earth) To Cubicle Earth Low Flow Alarm Relay 1 (if fitted) (NOT intrinsically safe earth) E SCR S1 S2 0V 0V -12V+12V CH 1 N COM NC NO Power Supply Power Supply Unit 1 Unit 2 (if fitted) LOW FLOW... -
Page 15: Electrical Installation
5 ELECTRICAL INSTALLATION 5.1 Electrical Interconnections – Fig. 5.1, 5.2, 5.3 and 5.4 Fig. 5.1 AK101 System Diagram... - Page 16 …5 ELECTRICAL INSTALLATION Fig. 5.2 AK104 System Diagram...
- Page 17 5 ELECTRICAL INSTALLATION... Fig. 5.3 AK101 Low Flow Alarm Option System Diagram...
- Page 18 …5 ELECTRICAL INSTALLATION Fig. 5.4 AK104 Low Flow Alarm Option System Diagram...
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Page 19: Model 6553 Display Unit
Terminal Blocks for for Katharometer Zero Pots. Power and Signal Intrinsically Safe Circuits Conventional Circuits (TB6 not fitted to AK104) (TB3 not fitted to AK104) Fig. 5.5 Location of Components Inside Case (Rear View) – Models AK101 and AK104 Display Units... - Page 20 ...5 ELECTRICAL INSTALLATION...
- Page 21 5 ELECTRICAL INSTALLATION...
- Page 22 ...5 ELECTRICAL INSTALLATION...
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Page 23: Katharometer Analyzer Panel
5 ELECTRICAL INSTALLATION... Make the wiring connections in accordance with the information given in the wiring diagram Fig. 5.6 and Section 5.1. Refer Fig. 5.7 for connections to cubicle-mounted display unit. Caution. The integrity of the fail-safe operation of the zener diode safety barrier devices depends on an Intrinsically Safe Earth connection which must not have a resistance greater than 0.1 to the application plant earth (ground). -
Page 24: Model 4234 Power Supply Unit
...5 ELECTRICAL INSTALLATION 5.1.3 Model 4234 Power Supply Unit – Fig. 5.9 Refer also to IM/4234500 for further details. 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. -
Page 25: Intrinsically Safe Requirements
These are AK101 – see Fig. 5.1 and Fig. 5.3 listed below and detailed in Fig. 5.1. AK104 – see Fig. 5.2 and Fig 5.4 Items installed in safe areas must use cable suitably rated 5.2.3 Installing Remote Ancillary Items... -
Page 26: Setting Up
6 SETTING UP 6.2 Setting Sample Flow Note. CO is refered to throughout this manual as the When all tubing interconnections have been made and external purge gas. However, other gases such as Argon or parts of the sample system checked for leaks, carry out the Nitrogen may be used instead. -
Page 27: Electrical Checks
6 SETTING UP 6.3 Electrical Checks 6.3.2 Zener Diode Safety Barrier Devices Carry out the electrical checks detailed in Sections 6.3.1 and Zener diode safety barrier devices are fitted to the katharometer 6.3.2. system as detailed in Table 6.1 and are checked at the time of manufacture. -
Page 28: Controls & Displays
7 CONTROLS & DISPLAYS 7.1 Displays – Fig. 7.1 7.2 Switch Familiarization – Figs. 7.1 and 7.2 The 4689 (or CM30) digital display(s) mounted in the 6553 Display Unit comprises a 5-digit, 7-segment digital upper Advance to display line and a 16-character dot-matrix lower display line. The next page upper display line shows actual values of hydrogen purity, Page 1... -
Page 29: Start-Up
8 START-UP 8.3 Electrical Calibration Warning. When the apparatus is connected to its The instrument is factory calibrated for electrical voltage signal supply, terminals may be live and the opening of covers input. No adjustment is normally necessary for correct or removal of parts (except those to which access may functioning of the display unit. -
Page 30: Hydrogen
...8 START-UP 8.4.3 Hydrogen 2) Power up the monitor unit, and the purge gas katharometer unit by switching on the appropriate power supply unit. Note. Test for leaks in accordance with the 3) Set the range selector switch on the gas monitor unit to requirements of the responsible authority after making position (3). -
Page 31: Operation
24 hours of Note. Sections 9.1.1 and 9.1.2 only apply to the carrying out the calibration procedure. AK101. 1) Select position (3) of the range selector switch on the display 9.1.1 Purging of Hydrogen Coolant Gas unit. -
Page 32: Range 1 Operating
28. Access to Secure Parameters SECURITY CODE 9.3 Range 2 Operating Page – AK101 only Set to Range 2 the single Alarm Set Point value may be changed, this is displayed in the Operating Page %H2 IN * xxx.x... -
Page 33: Programming
RTX Type 4-20 0-20 Adjust RTX Span 0-10 Test Retrans (%) Secure Parameters 100.0 75.0 50.0 25.0 Range 85% -100 Range 80% -100 Alter Sec. Code Fig. 10.1 Overall Programming Chart for 6553 Display Unit (Range 1) – AK101 and AK104... - Page 34 Adjust RTX Zero 0-10 NOT IN USE Adjust RTX Span Test Retrans (%) Secure Parameters Alter Sec. Code *Note. Purge gas options include: (Carbon dioxide) (Nitrogen) (Argon) Fig. 10.2 Overall Programming Chart for 6553 Display Unit (Range 2) AK101 only...
- Page 35 Adjust RTX Span Test Retrans (%) Secure Parameters Alter Sec. Code Note. *Note. Purge gas options include: – 10.00mV. (Carbon dioxide) – 1.00mV. (Nitrogen) Argon – 10.00mV. (Argon) Fig. 10.3 Overall Programming Chart for 6553 Display Unit (Range 3) – AK101 only...
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Page 36: Range 1 (Upper Display)
...10 PROGRAMMING 10.1 Range 1 (UPPER DISPLAY) 10.1.1 Access to Secure Parameters A 5-digit code is used to prevent unauthorized access to the secure parameters. Security Code Enter the required code number, between 00000 and 19999, to gain access to the secure parameters. - Page 37 10 PROGRAMMING... …10.1.3 Set Up Outputs Page (UPPER DISPLAY) Continued from previous page Alarm 1 Set Point The Alarm 1 Set Point can be set to any value within the input range being displayed. The set point value is subject to hysteresis within the set point band as detailed above. A1 Set Point Set the alarm set point to the required value.
- Page 38 ...10 PROGRAMMING 10.1.4 Electrical Calibration Page (UPPER DISPLAY) Notes. 1) The 4689 instruments incorporate a two-point calibration sequence requiring both ELECTRICAL CAL zero and span inputs for a calibration. It is not possible to adjust the range zero or the range span scale points independently.
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Page 39: Range 2 (Lower Display) – Ak101 Only
10 PROGRAMMING... 10.2 Range 2 (LOWER DISPLAY) – AK101 only 10.2.1 Access to Secure Parameters A 5-digit code is used to prevent unauthorized access to the secure parameters. Security Code Enter the required code number, between 00000 and 19999, to gain access to the secure parameters. - Page 40 ...10 PROGRAMMING …10.2.3 Set Up Outputs Page (LOWER DISPLAY) – AK101 only Continued from previous page Purge Gas Relay Action For 'Fail-Safe' alarm operation the relay's alarm state must be the same as the power- down state, i.e. the relay is de-energized.
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Page 41: Electrical Calibration Page (Lower Display) – Ak101 Only
10 PROGRAMMING... 10.2.4 Electrical Calibration Page (LOWER DISPLAY) – AK101 only Notes. 1) The 4689 instruments incorporate a two-point calibration sequence requiring both zero and ELECTRICAL CAL span inputs for a calibration. It is not possible to adjust the range zero or the range span scale points independently. -
Page 42: Range 3
...10 PROGRAMMING 10.3 Range 3 10.3.1 Access to Secure Parameters (LOWER DISPLAY) – AK101 only A 5-digit code is used to prevent unauthorized access to the secure parameters. Security Code Enter the required code number, between 00000 and 19999, to gain access to the secure parameters. - Page 43 10 PROGRAMMING... …10.3.3 Set Up Outputs Page (LOWER DISPLAY) – AK101 only Continued from previous page Purge Gas Relay Action For 'Fail-Safe' alarm operation the relay's alarm state must be the same as the power-down state, i.e. the relay is de-energized.
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Page 44: Electrical Calibration Page (Lower Display) – Ak101 Only
...10 PROGRAMMING 10.3.4 Electrical Calibration Page (LOWER DISPLAY) – AK101 only Notes. 1) The 4689 instruments incorporate a two-point calibration sequence requiring both ELECTRICAL CAL zero and span inputs for a calibration. It is not possible to adjust the range zero or the range span scale points independently. -
Page 45: Maintenance
11 MAINTENANCE 11.2 Diagnostic Tests This section covers the requirements for fault finding, diagnostic tests and maintenance tasks. Warning. Warning. • These units are part of the certified intrinsically safe system. Appropriate safety precautions must be • Each unit of this system forms an integral part of a taken to prevent any incendive electrical discharges certified intrinsically safe system. -
Page 46: Changing Desiccant In Drying Chamber
...11 MAINTENANCE 11.3.3 Changing Desiccant in Drying Chamber 11.4 Repair Maintenance The need to change the desiccant in the drying chamber on the 11.4.1 Removing Liquid from Katharometer Analyzer panel depends on the condition of the Katharometer Measurement Block – Fig. 11.1 sample gas. -
Page 47: Removal/Replacement Of An Indicator Unit
Fuse, 500mA 250VAC rated F 20 x 5 mm ceramic cartridge HBC (1500A) 250VAC 0231 601 11.4.3 Error Messages Function selector switch AK101 006553 510 If the error message 'NV Memory Error' is displayed the contents Potentiometer (1k ), zero adjustment... -
Page 48: Certificates
13 CERTIFICATES CE Declaration of Conformity certificates are available from the Company on request or can be downloaded from our website: www.abb.com/analytical. EC Declaration of Conformity – Gas Monitor type 6553 EC Declaration of Conformity – Type 4234500/ 501 Power Supply Units EC Declaration of Conformity –... -
Page 49: Specification
14 SPECIFICATION... - Page 50 14 SPECIFICATION DS/AK100–EN Rev. N...
- Page 51 Notes Sales Service...
- Page 52 We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.