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ABB 6553 Series Instruction Manual

(atex) gas analyser systems for intrinsically safe hydrogen &purge gas purity measurement
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Instruction Manual
Model 6553 Series (ATEX)
Gas Analyser Systems for
Digital Displays
Intrinsically Safe Hydrogen &
4689 500/501
Purge Gas Purity
and
Measurement
4689 500/503Models

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Summary of Contents for ABB 6553 Series

  • Page 1 Instruction Manual Model 6553 Series (ATEX) Gas Analyser Systems for Digital Displays Intrinsically Safe Hydrogen & 4689 500/501 Purge Gas Purity Measurement 4689 500/503Models...
  • Page 2 Cert. No. Q5907 applications. As a part of ABB, a world leader in process automation technology, we offer customers application expertise, service and support worldwide. EN 29001 (ISO 9001) We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled service and support.

  • Page 3: Table Of Contents

    CONTENTS INTRODUCTION ............2 OPERATION ............... 24 Normal .............. 24 DESCRIPTION .............. 3 9.1.1 Purging of Hydrogen Coolant Gas ..24 Model 6553 Gas Monitor ........3 9.1.2 Filling with Hydrogen Coolant Gas ..24 2.1.1 Dual Range Display ....... 3 Model 006540203 or 006548000 PROGRAMMING ............

  • Page 4: Introduction

    1 INTRODUCTION The different units of the system are: Warning. This operating manual applies only to those systems which have been designed and constructed 1) The Model 6553 Gas Monitor Unit which is available in to the standards specified in the schedules of the ATEX several options.

  • Page 5: Description

    2 DESCRIPTION All the various system options consist of one or more of the With a second (lower) display fitted (4689500), this may be following units with the further option of fitting the monitor and dual range marked 0 to 100% hydrogen in carbon dioxide and 0 power supply units in a cubicle.

  • Page 6: Model 4234500/4234501 Power Supply Units (Psu)

    …2 DESCRIPTION Katharometer Local zero Gas sample unit case adjustment outlet Electrical interconnections Metering valve Flow gauge sample inlet Drying chamber Fig. 2.2 Location of Items – A Katharometer Analyser Panel When the intrinsically safe stabilized current from the 4234 The stabilized current output is current and voltage limited to power supply unit (model 4234500 or 4234501) is passed restrict the energy supply into the hazardous area.

  • Page 7: Preparation

    Glos. England GL10 3TA 006548000 ABB Limited St. Neots England PE19 3EU TYPE 4689/500 SERIAL No....... ABB L i m i t e d Oldends Lane, Stonehouse, Glos. England GL10 3TA Model No. Type No. Unique Serial No. 4689 Display Unit Reference No.

  • Page 8: Model 4234 Power Supply Unit

    Year Manuf. Manufactured by: N4006 A B B L i m i t e d Oldends Lane, Stonehouse, Glos. England GL10 3TA ABB Limited Oldends Lane, Stonehouse, Glos. England GL10 3TA Intrinsic TYPE 4234500/501 POWER SUPPLY UNITS Safety Label ll (1)G 0600 [EEx ia] llC (–20°C≤Ta≤55°C)

  • Page 9: Coding System

    3 PREPARATION 3.1.4 Coding System c t i l a i 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. The display unit and power supply units must be installed in a safe (non- hazardous) area, and katharometer panel may be mounted close to the sample point in the hazardous area.

  • Page 10: Mechanical Installation

    4 MECHANICAL 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.

  • Page 11: Katharometer Analyser Panels

    4 MECHANICAL INSTALLATION… 4.1.2 Katharometer Analyser Panels – Fig. 4.2 Caution. Ensure that the correct panel, specifying zero gas 'Hydrogen' or 'CO2', is located at the required position and ensure that the panel is of the correct pressure rating. The panel is located in the hazardous area (zone 0,1 or 2) of the application plant in a sheltered interior environment. Avoid a location which subjects the katharometer unit to direct sunlight.

  • Page 12: Model 4234 Power Supply Unit

    …4 MECHANICAL INSTALLATION 4.1.3 Model 4234 Power Supply Unit – Fig. 4.3 Caution. The unit must be located in the safe area of the application plant in a sheltered interior environment. The power supply unit has 4 fixing lugs and should be mounted on a suitable vertical surface. The installation dimensions are shown in Fig.

  • 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 either mounted 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.

  • Page 14: Sample Gas Interconnections

    …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 analyser 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.

  • Page 15: Electrical Installation

    5 ELECTRICAL INSTALLATION 5.1 Electrical Interconnections – Fig. 5.1 Fig. 5.1 System Diagram...

  • Page 16: Model 6553 Gas Monitor

    …5 ELECTRICAL INSTALLATION 5.1.1 Model 6553 Gas Monitor – Fig. 5.2 Warning. • Equipment in this system operates on a.c. mains supply Warning. No connections must be made to the voltage electricity. Suitable safety precautions must be hazardous area terminals (Terminal Blocks TB5 & TB6) other taken to avoid the possibility of electric shock.
  • Page 17 5 ELECTRICAL INSTALLATION…...
  • Page 18 …5 ELECTRICAL INSTALLATION...

  • Page 19: Model 006540203 And 006548000 Katharometer Analyser Panel

    5 ELECTRICAL INSTALLATION… 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 1R0 to the application plant earth (ground). 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.

  • Page 20: Model 4234 Power Supply Unit

    …5 ELECTRICAL INSTALLATION 5.1.3 Model 4234 Power Supply Unit – Fig. 5.6 Warning. Do NOT connect mains supply to the power supply unit with the output terminals on open circuit. Caution. Ensure that the power supply unit is correct for the mains supply voltage available. A nominal 115 V unit cannot be adapted for use with a nominal 230 V supply, or the other way around.

  • Page 21: Intrinsically Safe Requirements

    5 ELECTRICAL INSTALLATION 5.2 Intrinsically Safe Requirements 5.2.2 Recommended Cables These requirements relate to the interconnecting wiring made to The choice of wiring cable is restricted due to the limitations and from Model 6540 203 and 6548 000 Katharometer Analyser imposed by the certification parameters –...

  • Page 22: Setting Up

    6 SETTING UP 6.1 Katharometer Analyser Panel – Filling the Drying 6.2 Setting Sample Flow Chamber – Fig. 6.1 When all tubing interconnections have been made and external 1) Remove the drying chamber on the katharometer analyser parts of the sample system checked for leaks, the suggested panel by unscrewing the large knurled nut at the base of the procedure is as follows: chamber.

  • Page 23: Electrical Checks

    6 SETTING UP 6.3 Electrical Checks 6.3.2 Zener Diode Safety Barrier Devices Carry out the following electrical checks: The zener diode safety barrier devices (MTL 7055ac) in the 6553 Monitor Unit are checked at the time of manufacture. To ensure absolute safety when fitting a new instrument, check that the 6.3.1 Power Supply Unit Output barriers in the monitor are properly earthed by carrying out a...

  • Page 24: Controls & Displays

    7 CONTROLS & DISPLAYS 7.1 Displays – Fig. 7.1 7.2 Switch Familiarization – Fig. 7.2 The displays comprise a 5-digit, 7-segment digital upper display line and a 16-character dot-matrix lower display line. The upper Advance to display line shows actual values of hydrogen purity, hydrogen in next page carbon dioxide, air in carbon dioxide, alarm set points or Page 1...

  • Page 25: Startup

    8 STARTUP Warning. When the apparatus is connected to its Note. The 4600 Series instruments incorporate a two supply, terminals may be live, and the opening of covers or point calibration sequence requiring both zero and span removal of parts (except those to which access may be inputs for a calibration.

  • Page 26: Hydrogen

    9 OPERATION …8 STARTUP 9.1 Normal 8) Reset the range selector switch on the gas monitor to position 2. The top display continues to indicate NOT IN During normal operation the Model 6553 Gas Analyser System USE. is used to indicate the purity of hydrogen used as a coolant. The displays shows the percentage of hydrogen in air, which should 9) The bottom display indicates the selected measurement be safely in excess of the explosive limit at the hydrogen rich...
  • Page 27 9 OPERATION 1) Select position (3) of the range selector switch of the monitor unit. This causes the display units to indicate and have the functions given in Table 9.1. 2) When the changeover to introduce hydrogen into the application plant is made, select range (2) of the range selector switch on the monitor unit.

  • Page 28: Programming

    10 PROGRAMMING Note. The following programming pages apply to BOTH 4689 display units. UPPER DISPLAY (RANGE 1) Note. All parameter values shown on the upper display line are the default settings. Access to Secure Parameters SECURITY CODE UPPER INDICATOR Operating Page Language Set Up Outputs Page Electrical Calibration Page...
  • Page 29 10 PROGRAMMING… Note. Programming of the Language page, Set Up Output page and the Electrical Calibration page should be carried out within Range 2. If circumstances require, they can also be accessed from Range 3 scrolls. It is not necessary to work through the Set Up Output page and the Electrical Calibration page in Range 3 once they have been set up in Range 2.
  • Page 30 …10 PROGRAMMING LOWER DISPLAY (RANGE 3) Note. All parameter values shown on the upper display line are the default settings. Access to Secure Parameters SECURITY CODE LOWER INDICATOR Operating Page Language Electrical Calibration Page Set Up Outputs Page xxx. x %AIR IN CO2 English SET UP OUTPUTS...

  • Page 31: Access To Secure Parameters

    UPPER DISPLAY 10 PROGRAMMING… 10.1 Range 1 10.1.1 Access to Secure Parameters A 5-digit code is used to control access to secure parameters. Security Code Enter the required code number, between 00000 and 19999, to gain access to the secure parameters.
  • Page 32 UPPER DISPLAY …10 PROGRAMMING …10.1.1 Access to Secure Parameters 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 Setpoint Set the alarm set point to the required value.

  • Page 33: Electrical Calibration Page

    UPPER DISPLAY 10 PROGRAMMING… 10.1.4 Electrical Calibration Page Page Header ELECTRICAL CAL Note. The 4600 Series instruments incorporate a two point electrical calibration ELECTRICAL CAL sequence requiring both zero and span inputs for a calibration. It is not possible to adjust either the zero or the span scale points independently.

  • Page 34: Range 2

    LOWER DISPLAY …10 PROGRAMMING 10.2 Range 2 10.2.1 Access to Secure Parameters A 5-digit code is used to control access to the secure parameters. Security Code Enter the required code number, between 00000 and 19999, to gain access to the secure parameters.
  • Page 35 LOWER DISPLAY 10 PROGRAMMING… …10.2.3 Set Up Outputs Page 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. Relay Action For high alarm operation the relay must be Energized Below the alarm set point (EB).

  • Page 36: Electrical Calibration Page

    LOWER DISPLAY …10 PROGRAMMING 10.2.4 Electrical calibration page Page Header – ELECTRICAL CAL Note. The 4600 Series instruments incorporate a two point electrical calibration ELECTRICAL CAL sequence requiring both zero and span inputs for a calibration. It is not possible to adjust either the zero or the span scale points independently.

  • Page 37: Range 3

    LOWER DISPLAY 10 PROGRAMMING… 10.3 Range 3 10.3.1 Access to Secure Parameters A 5-digit code is used to control access to the secure parameters. Security Code Enter the required code number, between 00000 and 19999, to gain access to the secure parameters.

  • Page 38: Set Up Outputs Page

    LOWER DISPLAY …10 PROGRAMMING 10.3.3 Set Up Outputs Page Page Header – SET UP OUTPUTS SET UP OUTPUTS Advance to next parameter. Purge Gas Alarm Select Select the parameter on which the purge gas alarm is to operate. ALARM H2 IN CO2 Reprogram as required to agree with selected range: AIR IN CO2 i.e.

  • Page 39: Electrical Calibration Page

    LOWER DISPLAY 10 PROGRAMMING… 10.3.4 Electrical Calibration Page Page Header ELECTRICAL CAL Note. The 4600 Series instruments incorporate a two point electrical calibration ELECTRICAL CAL sequence requiring both zero and span inputs for a calibration. It is not possible to adjust either the zero or the span scale points independently.
  • Page 40 …10 PROGRAMMING i l a . . . i l a i l a c i f i l a i l a c i f b i l i l a c i f l i a i l a c i f t s i Table 10.1 Calibration Messages for Section 10.1.4 Upper Display Unit...

  • Page 41: Maintenance

    11 MAINTENANCE 11.1.7 Bridge Current Warning. The working current of the katharometer bridge is 350 mA • Each unit of this system forms an integral part of a supplied from the PSU. This value must remain stable during certified intrinsically safe system. Appropriate safety normal operation as the katharometer output signal is precautions must be taken to prevent any incendive approximately proportional to the cube of the bridge current.

  • Page 42: Purge Gas Katharometer Calibration

    …11 MAINTENANCE 11.3.2 Purge Gas Katharometer Calibration 11.4 Repair Maintenance Carry out a calibration check in accordance with Section 8.3. 11.4.1 Removing Liquid from Katharometer This task should be carried out before using the katharometer for Measurement Block – Fig. 11.1 monitoring a purging procedure.

  • Page 43: Removal/Replacement Of An Indicator Unit

    12 SPARE PARTS LIST 11 MAINTENANCE Note. It is possible that the zero reading may drift for Warning. Interference with unit several days after the removal of liquid. components implies acceptance of responsibility by that person for ensuring the continuing maintenance of intrinsic This task should be undertaken as required.

  • Page 44: Specification

    13 SPECIFICATION (a) Model 6553 Gas Monitor Unit Available Ranges: (a)100 to 80% or 100 to 85% H in air or 80 to 100% or 85 to 100% H in air (b) 0 to 100% hydrogen in carbon dioxide (c) 0 to 100% air in carbon dioxide Digital Display Units: in Air: 4689 501 or 4689 503...
  • Page 45 13 SPECIFICATION (c) Model 6548 000 Katharometer Analyser Panel Incorporating Model 6548 001 (H2 and CO2) Katharometer Unit Power Supply: 350 mA d.c., from 4234 PSU Signal Output: 0 to 10 mV for each range ±2% of scale span, each range Accuracy: Dead Time: Typically 5 seconds...
  • Page 46 NOTES...
  • Page 47 Fax: +44 (0)1453 827 856 Drives and Motors United States of America • AC and DC Drives, AC and DC Machines, AC motors to 1kV ABB Automation Inc. • Drive systems Tel: +1 (0) 755 883 4366 • Force Measurement •...
  • Page 48 ABB has Sales & Customer Support The Company’s policy is one of continuous product improvement and the right is reserved to modify the expertise in over 100 countries worldwide information contained herein without notice. Printed in UK (04.02) www.abb.com © ABB 2002 ABB Limited ABB Inc.

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