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Top Level Drawing No.: HD0212G01I/O Manual No.: HA0313G01 Rev. B

Gas Station Instruction Manual

PacificorpCarbon Generating StationUnit 1

UTILITY SYSTEMS

1 HA0313G01 Rev. B

ContentsGeneral Description ............................................................................................................................ 5

Mechanical Installation & Considerations ......................................................................................... 7Mounting ......................................................................................................................................... 7Lifting ............................................................................................................................................. 7Enclosure Sealing ............................................................................................................................ 7Piping .............................................................................................................................................. 7

Electrical Installation & Considerations .......................................................................................... 10Conduit Seals ................................................................................................................................ 10

Getting Started ................................................................................................................................... 11Power Connections ....................................................................................................................... 11Signal Connections ....................................................................................................................... 14Contact Connections .................................................................................................................... 16Special Consideration ................................................................................................................... 16Pressure Test ................................................................................................................................. 18Apply Power – System Power-Up ................................................................................................ 19Generator Drying – During Generator Shutdown or While on Turning Gear ............................. 20Purge Operation – CO2 Purge of Air ........................................................................................... 21Purge Operation – H2 Purge of CO2 ........................................................................................... 23Generator Ramp-Up – Build to Rated Pressure ............................................................................ 25Normal Operation – Monitor H2 Purity in Air ............................................................................. 26Generator Purge – CO2 Purge of H2 ........................................................................................... 28Generator Purge – Air Purge of CO2 ........................................................................................... 30

Appendix ATransmet I.S., Intrinsically Safe Dewpoint TransmitterSho-Rate “50” Model 1350E and Sho-Rate “50” Model 1355E Sizes 1-6Parker Filtration 8000 Series Compressed Air and Gas In-Line FiltersInstallation, Operation & Maintenance Instructions for Roots Blower, Model 204-CS-YLX

2HA0313G01 Rev. B

FiguresFigure 1 - Outline, Major Component Location ................................................................................................... 6Figure 2 - Flange/Door Location .......................................................................................................................... 8Figure 3 - Lifting Guide ........................................................................................................................................ 9Figure 4 - Customer Interface ........................................................................................................................... 12Figure 5 - TB-2 .................................................................................................................................................. 13Figure 6 - TB-3 and TB-4 .................................................................................................................................. 15Figure 7 - TB-1 .................................................................................................................................................. 17Figure 8 - Purge CO2 to Remove Air ................................................................................................................ 22Figure 9 - Purge H2 to Remove CO2 ................................................................................................................ 24Figure 10 - Normal Operation ............................................................................................................................ 27Figure 11 - Purge CO2 to Remove H2 .............................................................................................................. 29Figure 12 - Purge Air to Remove CO2 .............................................................................................................. 31

3 HA0313G01 Rev. B

LIMITED WARRANTYEnvironment One Corporation warrants the instrument described herein to be free fromdefects in material and factory workmanship, and agrees to repair such instruments which,under normal use and service, disclose the defect to be the fault of the Environment OneCorporation’s manufacturing.

Environment One Corporation’s obligation under this Warranty relates to the original pur-chaser and is limited to a return of the purchase price, or, at Environment One Corporation’ssole discretion, to the repair or replacement of the instrument or any of its parts, which, in ouropinion and upon examination, proves to be defective. For this Warranty to be in effect, anymaterial or part alleged to be defective is to be returned to Environment One with our priorwritten approval, fully insured and transportation prepaid by the purchaser, within 12 monthsfrom date of delivery.

This Warranty shall not apply to an instrument that has been 1) subjected to misuse, negli-gence or accident; 2) connected, installed, operated or adjusted other than in accordancewith instructions furnished by Environment One Corporation; 3) repaired modified or workedon by someone not authorized by Environment One Corporation, so that in our judgementthe performance or reliability of the instrument has been impaired.

We reserve the right to make replacement with equivalent merchandise and to makechanges at any time in the specification, design or construction of the instrument withoutincurring obligation to make any commensurate changes in units previously delivered.

Environment One Corporation assumes no liability for consequential or contingent damagesfor a defective instrument covered by this Warranty, failure of delivery in whole or part, or forany other cause. This Warranty and the writing attached to it constitute the understanding ofthe buyer and seller so that no terms, conditions or agreements purporting to modify theterms hereof shall be binding unless made in writing and signed by an authorized agent ofthe home office of Environment One Corporation.

WARNINGThis equipment operates at voltage levels that can be hazardous to maintenance personnel.“Safety Considerations” should be read before installation or service. These instructions donot purport to cover all details or variations in equipment nor to provide for every possiblecontingency to be met in connection with installation, operation or maintenance. Shouldfurther information be desired or should particular problems arise that are not coveredsufficiently for the Purchaser’s purposes, refer the matter to Environment One Corporation.

4HA0313G01 Rev. B

SAFETY CONSIDERATIONSTHE SYSTEM ELECTRONICS ENCLOSURE AND AUXILIARY ELECTRONICS ENCLO-SURE CONTAIN 120 VAC AND/OR 460 3P. THIS VOLTAGE APPEARS AT THE AC POWERSTRIP AND VARIOUS OTHER POINTS. EQUIPMENT OPERATION INVOLVES A FLAM-MABLE GAS (HYDROGEN) UNDER PRESSURE. APPROPRIATE MEASURES MUST BETAKEN TO PREVENT LEAKS AND AVOID SOURCES OF IGNITION.

ALL ELECTRICAL CONNECTIONS BETWEEN THE SYSTEM ELECTRONICS, CUS-TOMER INTERFACE AND DISPLAY/CONTROL PANELS SHOULD BE TESTED ANDVERIFIED TO BE CORRECT. ALL WIRING SHOULD BE IN ACCORDANCE WITHCENELEC STANDARD EN50014.

ALL GAS CONNECTIONS TO THE SENSOR CELL MUST BE LEAK CHECKED PRIOR TOAPPLYING AC POWER.

CHECK FOR LEAKS AT ALL TUBING AND MECHANICAL CONNECTIONS INSIDE THESENSOR CELL ENCLOSURE. IF LEAKS ARE FOUND, DETERMINE THE CAUSE ANDREPAIR. REPEAT THE LEAK CHECK UNTIL THE SYSTEM IS DETERMINED TO BE LEAKTIGHT.

5 HA0313G01 Rev. B

General Description

Environment One’s (E/One’s) Gas Station was developed in response to electric powergenerator owners’ and operators’ interest in a flexible, more cost-efficient approach to gasmonitoring and control systems for hydrogen-cooled generators.

The E/One Gas Station is a modular concept that combines selected technologies that relateto a hydrogen-cooled generator’s gas system into a single, comprehensive skid. EachE/One Gas Station is configured to the particular requirements of the site, whether theapplication is part of an original equipment scope of supply, or a retrofit project.

The Pacificorp, Carbon Plant, Unit 2 Gas Station is a four-module configuration, consistingof:

· One Generator Gas Manifold (GGM) module for the supply, control and monitoring ofprimary generator gas (H2, CO2 and Air)

· Two redundant Generator Gas Analyzer (GGA) modules for monitoring gas purity

· One Generator Gas Dryer (GGD) module for removal of contaminants and moisture fromhydrogen.

· The Gas Station also has a Drip Leg Panel, a System Electronics Enclosure and aCustomer Interface Enclosure

See Figure 1, Outline/Major Component Location.

6HA0313G01 Rev. B

Figure 1 - Outline, Major Component Location

GAS

GGA

GGM

GGA

GGD

7 HA0313G01 Rev. B

Mechanical Installation & Considerations

These instructions provide details to facilitate equipment installation. The exact location of theGas Station should be in accordance with recommendations made by the generator manu-facturer, power plant management or their authorized representatives.

Proper training of individuals involved with mechanical connections and other installationactivities is the responsibility of plant management. Contact Environment One for additionalinstallation instruction and/or if plant management requires additional detail, beyond thatwhich is covered in this document, to ensure safe and proper installation.

Environment One recommends that all wiring and related mechanical installation be inaccordance with Cenelec Standard EN50014. All wiring must be in accordance with localcodes and requirements of the local authority that has responsibility.

All gas connections to the Gas Station are to be leak tested in accordance with local codesand professional practice before continuing.

CAUTION! Care must be taken when removing the covers of explosion proof enclo-sures to avoid damage (scratches, etc.) to the sealing surfaces. Do not remove oropen covers from the enclosures unless power is removed from the customer inter-face and the system is free of hydrogen (or explosive gas mixtures).

Prior to applying power to the Gas Station, ensure that the local power source used matchesthe power rating on the respective module nameplate. Power must be removed from the GasStation if the main electronic enclosures will be opened for any reason.

Mounting

The location chosen should be such that the equipment will not be subject to extremes ofdust, temperature, vibration or shock. It should be accessible for service, with adequateclearance. Fasteners used should be compatible with the mounting surface to support theweight of the assembly. Refer to Figures 1 and 2.

Lifting

The Gas Station is designed to be lifted and moved by a forklift. Confirm that the forklift’srating is adequate for the Gas Station’s weight (approximately 3,250 lbs.). Never lift the GasStation from cable, plumbing or other exterior surfaces. See Figure 3, Lifting Guide.

Enclosure Sealing

The Gas Station is configured as a NEMA 3R application. Use RTV sealant to seal areaswhere flanges penetrate the top of the enclosure. Failure to seal these areas can result inwater entering the Gas Station enclosure.

Piping

Piping connections should be in accordance with Figure 2, Flange/Door Location. Gasconnections are made through 13 1-inch 150# raised face flanges and one 3/4-inch 150#raised face flange located at the top and rear of the Gas Station. Electrical connections aremade through four 3/4-inch conduit provisions at the rear of the Gas Station.

8HA0313G01 Rev. B

Figure 2 - Flange/Door Location

9 HA0313G01 Rev. B

Figure 3 - Lifting Guide

10HA0313G01 Rev. B

Electrical Installation & Considerations

These instructions provide details to facilitate equipment installation. The exact location of theGas Station should be in accordance with recommendations made by the generator manu-facturer, power plant management, or their authorized representatives.

Proper training of individuals involved with wiring and other installation activities is the respon-sibility of plant management. Contact Environment One for additional installation instructionand/or if plant management requires additional detail, beyond that which is supplied in thisdocument, to assure safe and proper installation.

Prior to applying power to the Gas Station, ensure that the local power source used matchesthe power rating on the respective module nameplate and consistent with E/One specifica-tions. Reference should be made to figures in this section to assure power connections aremade in accordance with the Gas Station’s design parameters.

Environment One recommends that all wiring be in accordance with Cenelec StandardEN50014. All wiring must be in accordance with local codes and requirements of the localauthority that has responsibility.

CAUTION! Care must be taken when removing the covers of explosion proof enclo-sures to avoid damage (scratches, etc.) to the sealing surfaces. Do not remove oropen covers from the enclosures unless power is removed from the customer inter-face and the system is free of hydrogen (or explosive gas mixtures).

Power must be removed from the Gas Station if the main electronic enclosures are openedfor any reason.

Plant management is responsible for providing overload protection of the 460 3P lines.

Conduit Seals

The Gas Station’s electrical system includes explosion-proof seals. These fittings must befilled with proper sealing compound and fiber (Crouse-Hinds Chico “A” sealing compoundand Chico “X” fiber). Failure to comply with this requirement is a safety violation. It is theresponsibility of plant management to ensure electrical installation is in accordance withsafety guidelines.

11 HA0313G01 Rev. B

Getting Started

The following sections provide instructions pertaining to initial customer connections andpower up of the Gas Station. It is recommended that power connections be made andconfirmed as being in accordance with instructions prior to actual application of power.

Prior to power being applied to the Gas Station, plant management should consider advisingthe control room, as some contacts and/or alarms may annunciate as part of the systembeing configured. This could especially occur with the GGM and GGA subsystems, as theyrelate to main gas supply pressures and gas purity levels.

Power Connections

1. Locate TB-2 in the Customer Interface enclosure as indicated in Figure 4, CustomerInterface.

2. Connect 120VAC Line (1), Neutral (2) and Ground (3) as indicated in Figure 5, TB-2.

3. Connect 460 3P, L1, L2, L3 and Ground for the GGD motor/blower as indicated in Figure5, TB-2.

4. Connect 460 3P, L1, L2, L3 and Ground for the GGD heaters as indicated in Figure 5, TB-2.

12HA0313G01 Rev. B

Figure 4 - Customer Interface

49 8VDC output to (de-foaming tank level switch)

47 8VDC output to water detector switch

45 8VDC output to (seal oil pressure switch)

43 8VDC output To (Hydrogen cold gas thermostat)

41 8VDC output To (Hydrogen bottle pressure switch)

48 (de-foaming tank level high) dc input from (de-foaming tank level switch)

42 (Hydrogen temperature high) dc input from (Hydrogen cold gas thermostat)

40 (Hydrogen bottle pressure low) dc input from (Hydrogen bottle pressure switch)

21 NC

37 NO

38 Comm (Annunciator Alarm)

53 external 125VDC return

52 (Hydrogen side level low)


50 (Vacuum pump off)

46 (Water detector high)

44 (seal oil pressure low)

39 NC

23 Comm (Analyzer 2 Alarm)

26 Comm (Analyzer 1 Normal)


32 Comm (Dew point High)

35 Comm (Horn relay)

36 NC

31 NO

33 NC

34 NO

30 NC

28 NO

22 NO

25 NO

27 NC

24 NC

5 Comm (Analyzer 2 Trouble)

11 Comm (Dryer Trouble)


8 Comm (Annunciator Trouble)

14 Comm (Analyzer 1 Warning)


13 NO

19 NO

15 NC

16 NO

18 NC

12 NC

6 NC

7 NO

9 NC

10 NO

10 L3

13 spares

8 "-"

6 SHIELD

5 "-"

3 SHIELD 2 "-"

7 "+" CASE PRESSURE 4-20mA

4 "+" OUTLET DEW POINT 4-20mA

1 "+" INLET DEW POINT 4-20mA

17 " "

15 SHIELD

14 "-"

12 SHIELD 11 "-"

16 "+" ANALYZER 2 PURITY 4-20mA


10 "+" FAN DIFFERENTIAL PRESSURE 4-20m 9 SHIELD

TB-3

12

14

15

16

11

2 L2(neut)

3 GND

4 L1

6 L3

7 GND

8 L1

5 L2 (motor 460V 3ph, 0.6hp)

9 L2 (heater 460V 3ph, 1200W)

(system 120V 1ph, )

DO NOT EXTERNALLY EXCITE 4-20mA OUTPUTS

***CAUTION***

DO NOT EXCEED CONTACT RATINGS

120VAC 0.5 AMP

30 VDC 1 AMP

125 VDC 0.005 AMP (resistve)

***CAUTION***

13 HA0313G01 Rev. B

5 L2 (motor 460V 3ph, 0.6hp)

(system 120V 1ph,

9 L2 (heater 460V 3ph, 1200W

6 L3

12

11

10 L3

8 L1

7 GND

2 L2(neut)

4 L1

3 GND

1 L1(line)

Figure 5 - TB-2

14HA0313G01 Rev. B

Signal Connections


2. NOTE: These 4-20 mA signals are internally energized. DO NOT APPLY EXTERNALPOWER TO THESE SIGNALS. IF THESE SIGNALS ARE EXTERNALLY ENER-GIZED SYSTEM FAILURE MAY RESULT. See Figure 6, TB-3 and TB-4.

3. Connect signals from TB-3 to the power plant control room or plant data acquisitionsystem.

15 HA0313G01 Rev. B

Figure 6 - TB-3 and TB-4

6 SHIELD

7 "+" CASE PRESSURE 4-20mA



10 "+" FAN DIFFERENTIAL PRESSURE 4-20mA

17 "-"

15 SHIELD

12 SHIELD

9 SHIELD

8 "-"

11 "-"

14 "-"

4 "+" OUTLET DEW POINT 4-20mA

1 "+" INLET DEW POINT 4-20mA

3 SHIELD

5 "-"

2 "-"

16HA0313G01 Rev. B

Contact Connections


2. Observe contact ratings as indicated in Figure 7, TB-1.

3. Connect contacts from TB-1 to power plant control room.

Special Consideration

· E/One has provided “source” information regarding each signal/contact.

· E/One recommends that plant management review the specific nomenclature beingused by the control room regarding Gas Station signals/contacts.

· E/One believes that an exchange of this information is consistent with end-user satisfac-tion and E/One’s capacity to provide field support.

· Essentially, if E/One is aware of how the control room references our specific signals/contacts, E/One can maintain cross-reference information within its Service group,which will facilitate field support.

17 HA0313G01 Rev. B

Figure 7 - TB-1

43 8VDC output To (Hydrogen cold gas thermostat)

49 8VDC output to (de-foaming tank level switch)

47 8VDC output to water detector switch

45 8VDC output to (seal oil pressure switch)

48 (de-foaming tank level high) dc input from (de-foaming tank level switch)

54 (seal oil pump off) dc input from seal oil pump pressure switch 55 external 125VDC return


52 (Hydrogen side level low)


50 (Vacuum pump off)

46 (Water detector high)

44 (seal oil pressure low)

41 8VDC output To (Hydrogen bottle pressure switch)

42 (Hydrogen temperature high) dc input from (Hydrogen cold gas thermostat)

40 (Hydrogen bottle pressure low) dc input from (Hydrogen bottle pressure switch

6 NC

24 NC



32 Comm (Dew point High)

35 Comm (Horn relay)

31 NO

33 NC

34 NO

30 NC

28 NO

25 NO

27 NC

37 NO

38 Comm (Annunciator Alarm)

39 NC

36 NC

11 Comm (Dryer Trouble)

8 Comm (Annunciator Trouble)



13 NO

15 NC

16 NO

12 NC

7 NO

9 NC

10 NO

21 NC


22 NO

20 Comm (Analyzer 1 Alarm)19 NO

18 NC

5 Comm (Analyzer 2 Trouble)

2 Comm (Analyzer 1 Trouble)3 NC

4 NO

18HA0313G01 Rev. B

Pressure Test

Environment One recommends that all gas connections be tested for leaks prior to systemstart-up. Site personnel should consult plant management for pressure testing proceduresthat have been approved for this category of equipment. E/One recommends using Leak Teksolution, or equivalent. Do not exceed 160 psi during pressure tests.

If required, contact Environment One for information relating to in-process and final testprocedures that have been conducted as part of the system’s manufacture.

19 HA0313G01 Rev. B

Apply Power – System Power-Up

When plant personnel have inspected all electrical connections and conduit seals andconcluded that installation has been in accordance with instructions, power should be ap-plied to the Gas Station.

Please note E/One’s earlier comment that prior to applying power plant management shouldconsider advising the control room, as some contacts and/or alarms may annunciate as partof the system’s initialization. This could especially occur with the GGM and GGA sub-systems, as they relate to main gas supply pressures and gas purity levels.

When power is applied:

· All discrete LED’s will illuminate on each of the four Gas Station Modules

· Each module will perform its initial power-up check

· Both of the GGA modules, upon successfully completing their power-up check, will read“Configure Valves” at the function menu display (LCD). Upon configuring the valves totheir proper orientation, press Enter.

· The GGA modules will default to Normal mode (H2 in Air). Select the proper mode ifNormal (H2 in Air) is not the desired mode.

· The GGD module, upon successfully completing its power-up check, will read “PressEnter to Begin Drying.”

· The GGM module, upon successfully completing its power-up check, will read “GGM byE/One.”

20HA0313G01 Rev. B

Generator Drying – During Generator Shutdown or While on TurningGear

While the generator is showdown, or when it is on turning gear prior to ramp-up, E/Onerecommends that the GGD be utilized to minimize moisture in the generator.

To begin GGD operation:

1. Confirm that mechanical and electrical installation has been completed in accordancewith this manual and that incremental plant checks, to the extent there are any, havebeen completed.

2. Apply power

3. The GGD module, upon successfully completing its power-up check, will read “PressEnter to Begin Drying.” Press Enter on the menu and the GGD will commence its dryeroperation.

21 HA0313G01 Rev. B

Purge Operation – CO2 Purge of Air

· Confirm GGA Modules valves areconfigured appropriately and that theGGA is in Air in CO2 purge mode

· Confirm IV1/3 is in “on” position toallow Air to be vented from the gen-erator

· Confirm DV1/22 in vertical position, toallow Air to be vented from the gen-erator

· Confirm IV9/24 is in “on” position toallow in CO2

· Confirm DV2/23 in horizontal to allowin CO2

· Confirm IV12/33 is in “on” position to monitor case pressure

· Confirm IV13/34 is in “on” position to monitor CO2 supply pressure

· Continue to introduce CO2 until Air in CO2 nears zero percent purity on the GGA mod-ules.

GGA

22HA0313G01 Rev. B

Figure 8 - Purge CO2 to Remove Air

23 HA0313G01 Rev. B

Purge Operation – H2 Purge of CO2

· Confirm GGA Modules’ valves areconfigured appropriately and that theGGA is in H2 in CO2 purge mode

· Confirm spool piece is oriented forflow from IV6/25A to IV7/25B

· Confirm IV9/24 is in “off” position tostop flow of CO2

· Confirm DV2/23 in vertical position toremove CO2 pressure

· Confirm DV1/22 in horizontal positionto assure separation of CO2 and H2

· Confirm IV1/3 is in the “on” position toallow CO2 to be vented from genera-tor

· Confirm IV6/25A is in the “on” position to allow H2 in

· Confirm IV7/25B is in the “on” position to allow in H2

· Confirm IV2/9 in “on” position to allow in H2

· Confirm IV3/10 in “on” position to allow in H2

· Confirm P1 reads increasing ramp of pressure

· Confirm IV11/42 is in “on” position to monitor H2 supply pressure

· Confirm IV12/33 is in “on” position to monitor case pressure

· Continue to introduce H2 until H2 reaches >95 percent purity on the GGA module

· NOTE: IV8 may be opened/throttled to expedite H2 fill process, but this should only bedone when H2 in CO2 purity >75 percent on the GGA modules

GGA

24HA0313G01 Rev. B

Figure 9 - Purge H2 to Remove CO2

25 HA0313G01 Rev. B

Generator Ramp-Up – Build to Rated Pressure

· Confirm that mechanical and electrical installation has been completed in accordancewith this manual and that incremental plant checks, to the extent there are any, havebeen completed.

· Apply power to the Gas Station

· Confirm that the Manifold and GGA modules are configured according to Purge Operation– CO2 Purge of Air

· Upon completion of Purge Operation – CO2 Purge of Air process, and H2 purge of CO2process, confirm that the Manifold and GGA modules are configured according to NormalOperation – H2 in Air

· Monitor GGM and GGA modules for stabilization of case and differential pressure, andhydrogen purity, in accordance with plant standard operating procedures (SOP).

26HA0313G01 Rev. B

Normal Operation – Monitor H2 Purity in Air

· Confirm GGA Modules’ valves areconfigured appropriately and that theGGA is in Normal H2 in Air mode

· Confirm spool piece is oriented forflow from IV6/25A to IV7/25B

· Confirm IV6/25A is in “on” position

· Confirm IV7/25B is in “on” position

· Confirm IV2/9 is in “on” position


· Confirm DV1/22 is in horizontalposition

· Confirm DV2/23 is in vertical position

· Confirm IV1/3 is in “off” position

· Monitor GGM module for case anddifferential pressure

· Monitor GGA module for maintenance of H2 purity

13 spares1415

16

5 L2 (motor 460V 3ph, 0.6hp)

(system 120V 1ph, )

9 L2 (heater 460V 3ph, 1200W)

6 L3

12

11

10 L3

8 L1

7 GND

2 L2(neut)

4 L1

3 GND

1 L1(line)

27 HA0313G01 Rev. B

Figure 10 - Normal Operation

28HA0313G01 Rev. B

Generator Purge – CO2 Purge of H2

· Confirm GGA modules’ valves areconfigured appropriately and that theGGA’s are in H2 in CO2 purge mode

· Confirm spool piece is oriented forflow from IV5/8 to IV4/7

· Confirm IV6/25A is in “off” position tostop H2 supply flow and isolate spoolpiece

· Confirm IV7/25B is in “off” position toisolate spool piece

· Confirm that IV4/7 is closed andisolating the spool piece

· Confirm that IV5/8 is closed andisolating the spool piece

· Confirm DV2/23 is in horizontal position to allow CO2 flow into the generator

· Confirm DV1/22 is in vertical position to allow H2 to purge through vent line

· Confirm IV1/3 is in “on” position to allow venting of H2



· Confirm CO2 supply pressure at GGM module meets plant standard operating policy

· Open IV9/24 to initiate CO2 fill

· Monitor GGA modules until H2 purity nears 0%

· Upon reaching desired H2 in CO2 purity level, close IV9/24 to stop CO2 flow

GGA

29 HA0313G01 Rev. B

Figure 11 - Purge CO2 to Remove H2

30HA0313G01 Rev. B

Generator Purge – Air Purge of CO2

· Confirm that GGA modules’ valvesare configured appropriately and thatthe GGA’s are in Air in CO2 purgemode

· Confirm that the orientation of thespool piece allows flow from IV5/8 toIV4/7

· Confirm DV2/23 is in horizontalposition

· Confirm DV1/22 is in vertical position



· Confirm IV9/24 is in “off” position

· Monitor GGA modules until Air in CO2 purity nears 100 percent

CAUTION! Reconfirm IV6/25A and IV7/25B are in the “off” position.

GGA

31 HA0313G01 Rev. B

Figure 12 - Purge Air to Remove CO2

32HA0313G01 Rev. B

Generator Gas Analyzer Module (GGA)

Installation and Operation Manual

HA0291P01 Rev. A

UTILITY SYSTEMS

1 HA0291P01 Rev. A

ContentsIntroduction .......................................................................................................................................... 6

Specifications ....................................................................................................................................... 7

System Description .............................................................................................................................. 8Gas Analyzers (Sensor Cell, HC0021G02, Controller PCB HD0082G07, I/O PCB HD0122G04,Display PCB HD0138G01) ............................................................................................................. 8GGA Display Panel ........................................................................................................................ 8Sensor Cell Assembly ...................................................................................................................... 9Flow Indicator with Metering Valve ............................................................................................... 9Purifier ............................................................................................................................................ 9Moisture Indicator .......................................................................................................................... 9

Installation ......................................................................................................................................... 10Mounting ....................................................................................................................................... 10Lifting ........................................................................................................................................... 10

Electrical Connections ....................................................................................................................... 11Contacts/Signals ........................................................................................................................... 11Circuit Protection ......................................................................................................................... 12

System Operation .............................................................................................................................. 13GGA Initialization ........................................................................................................................ 13Flow Calibration .......................................................................................................................... 13

GGA Menu Displays ......................................................................................................................... 14Navigating the LCD Display ........................................................................................................ 14LCD Menu Display — Two Modes of Operation .......................................................................... 14Menu Profile ................................................................................................................................. 14

Menu Navigation Tutorial ................................................................................................................. 15Activating the Menu ..................................................................................................................... 15Navigating the Menu in Scrolling Mode (GGA Default) .............................................................. 15Disabling Scrolling More ............................................................................................................... 15Navigating the Menu in Non-Scrolling Mode ............................................................................... 15Function (FN) Menu ..................................................................................................................... 16Purge Menu ................................................................................................................................... 16Log Menu ...................................................................................................................................... 16Setup Menu ................................................................................................................................... 17Test Menu ...................................................................................................................................... 17View Menu .................................................................................................................................... 18

2HA0291P01 Rev. A

Procedures ......................................................................................................................................... 19Setting the Alarm Level ................................................................................................................ 19Setting the Warning Level ............................................................................................................. 19Gas Calibration ............................................................................................................................ 19About the Faults Log .................................................................................................................... 20About the Power Log .................................................................................................................... 21

Modes of Operation .......................................................................................................................... 22Startup .......................................................................................................................................... 22Startup Problems .......................................................................................................................... 22Suspended Operation .................................................................................................................... 22Purge Operation - H2 in CO2 ....................................................................................................... 22Purge Operation - Air in CO2 ....................................................................................................... 23Normal Operation ......................................................................................................................... 23

Maintenance ...................................................................................................................................... 24Daily .............................................................................................................................................. 24Weekly ........................................................................................................................................... 24Every Six Months .......................................................................................................................... 24When the Generator is Down ....................................................................................................... 24

Component Replacement Instructions ............................................................................................. 25Removing a Gas Analyzer Sensor ................................................................................................. 25Removing a Processor Circuit Board ............................................................................................ 25Removing the Input/Output (I/O) Circuit Board ........................................................................... 25Removing Moisture Indicator ....................................................................................................... 26Removing Gas Purifier Cartridge ................................................................................................ 26Removing the Flow Meter ............................................................................................................ 27

Parts Lists .......................................................................................................................................... 28Recommended GGA Spare Parts (Stocked by Customer) ............................................................ 28Recommended GGA Replacement Parts (Stocked by E/One) ...................................................... 28

3 HA0291P01 Rev. A

FiguresGGA Figure 1 - GGA Display Panel .................................................................................................................. 31GGA Figure 2 - GGA Valve Panel ..................................................................................................................... 32GGA Figure 3 - Back Side of GGA Valve Panel ............................................................................................... 33GGA Figure 4 - GGA Wiring Assembly Details ................................................................................................. 34GGA Figure 5 - GGA Piping Schematic ............................................................................................................ 35GGA Figure 6 - Calibrate N2 ............................................................................................................................. 36GGA Figure 7 - Calibrate CO2 .......................................................................................................................... 37GGA Figure 8 - Calibrate H2 ............................................................................................................................. 38GGA Figure 9 - Purge Air in CO2 ..................................................................................................................... 39GGA Figure 10 - Purge H2 in CO2 ................................................................................................................... 40GGA Figure 11 - Normal H2 in Air .................................................................................................................... 41

4HA0291P01 Rev. A

5 HA0291P01 Rev. A

Generator Gas Analyzer (GGA) ModuleImportant Information

THIS EQUIPMENT OPERATES AT VOLTAGE LEVELS THAT CAN BE HAZARDOUS TOPERSONNEL. READ THE SECTION ABOUT SAFETY CONSIDERATIONS BEFOREINSTALLING OR SERVICING.

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONSIN EQUIPMENT NOR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE METIN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE.

SHOULD FURTHER INFORMATION BE DESIRED, OR SHOULD PARTICULAR PROB-LEMS ARISE THAT ARE NOT COVERED SUFFICIENTLY FOR THE PURCHASER’SPURPOSES, REFER THE MATTER TO ENVIRONMENT ONE CORPORATION.

IT IS THE RESPONSIBILITY OF SITE MANAGEMENT TO ASSURE THAT ONLY TRAINED/QUALIFIED PERSONNEL OPERATE AND/OR SERVICE THIS EQUIPMENT.

PROPER PIPING PRACTICES ARE TO BE OBSERVED TO AVOID POTENTIAL OILCONTAMINATION OF THE SENSOR CELL. SHOULD CONTAMINATION OCCUR, ANA-LYZER OUTPUT MAY NOT CORRESPOND TO DESIGN SPECIFICATIONS. CONTACTENVIRONMENT ONE FOR SUPPORT.

Generator Gas Analyzer (GGA) ModuleSafety Considerations

THE SYSTEM ELECTRONICS ENCLOSURE AND CUSTOMER INTERFACE ENCLOSURECONTAINS 115 1PH, AND OR VOLTAGES UP TO 460 VOLTS AC 3PH. THIS VOLTAGEAPPEARS AT THE AC POWER STRIP AND VARIOUS OTHER POINTS. EQUIPMENTOPERATION INVOLVES A FLAMMABLE GAS (HYDROGEN) UNDER PRESSURE. APPRO-PRIATE MEASURES MUST BE TAKEN TO PREVENT LEAKS AND AVOID SOURCES OFIGNITION.

WHEN ALL ELECTRICAL CONNECTIONS TO THE SYSTEM ELECTRONICS, SENSORAND DISPLAY PANEL ARE COMPLETED AND TESTED, ENSURING THAT ALL SEALFITTINGS ARE FILLED WITH AN APPROVED SEALING COMPOUND AND FIBER IS NEC-ESSARY. (CROUSE-HINDS CHICO “A” SEALING COMPOUND AND CHICO-”X” FIBER OREQUIVALENT.)

FAILURE TO COMPLY WITH THIS REQUIREMENT IS A SAFETY VIOLATION. IT IS THERESPONSIBILITY OF PLANT MANAGEMENT TO ASSURE ELECTRICAL INSTALLATION ISIN ACCORDANCE WITH SAFETY GUIDELINES.

ALL WIRING MUST BE IN ACCORDANCE WITH LOCAL CODES. ALL GAS CONNEC-TIONS TO THE PANEL MUST BE LEAK CHECKED PRIOR TO APPLYING AC POWER.

CHECK FOR LEAKS AT ALL TUBING AND MECHANICAL CONNECTIONS. IF LEAKS AREFOUND, DETERMINE THE CAUSE AND REPAIR. REPEAT THE LEAK CHECK UNTIL THEPANEL IS DETERMINED TO BE LEAK TIGHT.

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Introduction

Modern high-capacity turbine generators use hydrogen gas as a cooling medium. Tworeasons for using hydrogen are 1) hydrogen has the best heat transfer characteristics of anygas; and 2) the low atomic weight of hydrogen makes it the lightest and, therefore, has thelowest density of any stable gas (10 percent that of air at a purity of 98 percent), resulting inthe lowest windage losses.

The Generator Gas Analyzer (GGA) is designed to monitor the purity of cooling gas requiredto ventilate the conducting and rotating parts of hydrogen cooled generators.

The GGA can be configured to return the analyzed gas sample to the generator (closed-loopvacuum-type system) or vent the analyzed gas sample out to a safe vent line (scavengingtype system) .

Environment One’s microprocessor-controlled GGA, with its triple-range sensor cell, iscapable of measuring 70 to 100 percent H2 in Air, 0 to 100 percent H2 in CO2 and 0 to 100percent Air in CO2.

Each GGA continuously analyzes the generator cooling gas, displays gas purity in real timeand has a corresponding 4-20 mA output. In the event that the gas purity falls to a warning oralarm level, a visual indication is given and alarm contacts are switched.

The GGA’s triple-range sensor cell also monitors purge gases used during generator start-up, shutdown and maintenance. Purge gas purity is displayed and a corresponding 4-20 mAoutput is provided for H2 in CO2 or Air in CO2.

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Specifications

Input Voltage (see nameplate) 120 Vac 50/60 Hz220 Vac 50/60 Hz (optional)

Ambient Temperature 32 F to 125 F (0 C to 52 C)

Maximum Pressure 100 psi

Ambient Location Hydrogen gas presence

Gas Analyzer Switchable - Triple Range

Sensing Unit (70 to 100% H2 in Air) (4-20 mA)(0 to 100% H2 in CO2) (4-20 mA)(0 to 100% Air in CO2) (4-20 mA)

Accuracy +/- 1% of full scale @ 80-100% H2 in Air

Outputs 4-20 mA current output

Alarm Levels Alarm and warning levels are adjustable

Relay Contact Rating 30V/1A DC 120V/0.5A AC

125V/0.005A (Resistive) DC

Data Retention Lithium battery-supported RAM10 years minimum

Indicators AC power, Trouble, Normal (H2 in Air),Purge (H2 in CO2), Purge (Air in CO2),Calibrate H2, Calibrate CO2, CalibrateN2, one 3-character LED numericdisplay, one 16-character LCD display

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System Description

The GGA Module is designed for use on hydrogen-cooled generators. It is designed to oper-ate in hazardous areas, using several explosion/flameproof technologies, including but notlimited to intrinsic safety, explosion/flame proof enclosures, conduit seals and glands.

The GGA analyzes and, in real time, displays the hydrogen gas purity on built-in numericdisplays. The major components of the GGA Module include:

• 1 completely independent, generator gas analyzer (GGA)

• 1 hydrogen gas flow indicator with metering valves

• 1 hydrogen gas purifier

• 1 moisture indicator

• Numerous isolation valves

• 1 local display panel that indicate gas purity and specific operating conditions

Gas Analyzers (Sensor Cell, HC0021G02, Controller PCBHD0082G07, I/O PCB HD0122G04, Display PCB HD0138G01)Each analyzer is comprised of a sensor cell, controller PCB, an I/O PCB and a displaypanel. The sensor cell is located in an explosionproof enclosure on the back of the GGAmodule (GGA Figure 3). The controller PCB and I/O PCB is housed in the main junction box;local display panels are mounted on the front of the panel (GGA Figure 1).

The analyzer provides purity monitoring, calibration, mode selection, sensor unit control,alarm electronics, data logging, system inputs/outputs and sensing unit linearization. See(GGA Figure 1) for display panel features and functions.

Fail-safe operation of the Gas Analyzer is ensured by:

1. On power-up, the GGA must execute and pass qualifying self-tests. Failure in any testresults in termination of operation and annunciation of the condition causing the failure.

2. Following power-up and/or system reset, the GGA is continuously supervised by anindependent watchdog monitor that serves to reset it should its operation become erratic.

3. The GGA is completely self-supervised and continuously checks itself for legal processorfunctioning, internal voltages, analog-to-digital conversion accuracy, and integrity ofcabling as well as relay operation. Any faults are immediately annunciated as “trouble” onthe display and accompanied by a change in the corresponding relay state.

GGA Display PanelThe display panel provides control of all functions of the GGA as well as complete annuncia-tion of the status of the GGA Display Panel (GGA Figure 1). Functions are accessed bymeans of a four-button membrane-switch keypad and 16-character Liquid Crystal Display(LCD). See GGA Menu Display for a description of the menu.

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The display panel provides Light Emitting Diodes (LED’s) to annunciate the Normal (H2 inair), Purge (H2 in CO2 and air in CO2), and Calibrate (H2, CO2 and N2) GGA states. Inaddition, they indicate Warning, Alarm and Trouble conditions. A green LED indicates ACPower.

To permit a system level initialization (“cold start”), a momentary push-button, located behindthe GGA display panel (GGA Figure 1) in the upper right hand corner, may be pressed. Sinceall calibration constants are stored in non-volatile memory, these values will not be lostshould the system be initialized or should it lose, then regain, AC power.

Sensor Cell Assembly

The sensor cell assembly is comprised of a sampling thermistor and a reference thermistor— both operated at very low power in a self-heated mode — embedded in a temperature-regulated cell block. Gas purity is derived as a function of the thermal conductivity of the gasmixture to the heat output of the thermistors under known constraints.

Flow Indicator with Metering Valve

A low-flow gas indicator with a needle type metering valve is used to adjust the hydrogen gasflow through the sensing unit (GGA Figure 2).

The direct reading scale, with a range of 100 to 900 cc/min, is calibrated with hydrogen.

Note: Flow indication changes with different gases. For hydrogen, the flow should be set for500 cc/min.

Purifier

A gas purifier removes foreign matter from the hydrogen stream. Removal of oil, water andparticles above 12 microns is accomplished through the use of molecular sieve materialsand special filters (GGA Figure 3). The filters are available as replaceable cartridges,HA0012P02.

Moisture Indicator

The moisture indicator indicates the downstream presence of moisture in the hydrogenstream (GGA Figure 2). The units are supplied with a dyed silica gel, which graduallychanges from blue (at relative humidity less than 4 percent) to pink (at relative humidityhigher than 40 percent). These devices are replaceable.

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Installation

Follow the installation instructions to ensure proper installation of the equipment. The exactlocation of the GGA Module should be in accordance with the recommendations made byEnvironment One or its authorized representative.

Mounting

The GGA Module is designed to be mounted to a frame with 4 3/8" bolts (typically an Environ-ment One Gas Station).

Choose a location that is not subject to extremes of dust, temperature, vibration or shock.The panel should be accessible for service, with adequate clearance to open the enclosureand display panel doors (GGA Figure 2).

Lifting

The GGA module should be lifted by the panel. To avoid damage or leaks, never lift the GGAmodule by its tubing.

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Electrical Connections

Prior to applying power to the GGA Module, ensure that the local power source matches thepower rating on the GGA nameplate.

The GGA Module is shipped with all isolation and metering valves closed. All gas lines mustbe connected to the GGA Module and leak-tested before continuing.

Electrical connections are made through four 3/4-inch male conduit unions at the top, bottomor side of the panel (GGA Figure 3 and Appendix Figure 3). System power requirements are120 or 220 volts AC (systems are supplied for specifically 120 V or 220 V). The AC powersource should be reliable and not subject to severe transients. Total load maximum is 100watts.

Electrical connections, located inside of the main junction box, are accessed by removing 323/4" hex captive bolts. Two guide studs are provided for assistance in removal/replacement.

CAUTION! Do not scratch sealing surfaces on the main junction box. The main junc-tion box lid weighs 50 lbs (22.7 kg) and is hinged. Take precautions during removal.Prior to opening the main junction box, remove power from the GGA and ensure thesystem is free of hydrogen.

Wire routing should be in accordance with Appendix Figure 3. This ensures that noise gener-ated from the AC power and contacts does not interfere with the signals. Connections aremade to barrier-type terminal strips (Appendix Figure 3).

Contacts/Signals

The GGA includes alarm and status relays (GGA Figure 4 and Appendix Figure 4). They are:

• Normal Relay Both a normally open and a normally closed contact (single-pole, double-throw configuration) is provided and a normal H2 in Air condition is signaled by an ener-gized relay.

• Warning Relay Both a normally open and a normally closed contact (single-pole, double-throw configuration) is provided and a warning is signaled by an energized relay.

• Alarm Relay Both a normally open and a normally closed contact (single-pole, double-throw configuration) is provided and an alarm is signaled by an energized relay.

• Trouble Relay Both a normally open and a normally closed contact (single-pole, double-throw configuration) is provided and Trouble is signaled by a de-energized relay.

4-20 mA output signals are provided for gas purity (GGA Figure 4 and Appendix Figure 4).The 4-20 mA signals for the analyzer correspond to 70 to 100 percent in Normal mode (H2 inair) and 0 to 100 percent in Purge modes (H2, CO2 and Air in CO2).

Analyzer output signals are internally powered. These signals are not to be powered byexternal systems.

See GGA Figure 4 and Appendix Figure 4 for locations of signals on terminal block and fordescription of conditions where relays are activated.

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Circuit Protection

The GGA is individually fused. A half-amp slo-blow fuse, located on the Input/Output PCB,provides circuit protection.

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System Operation

The GGA’s main purpose is to analyze and display the hydrogen gas purity of hydrogencooled generators.

GGA Initialization

With system power on, press the RESET push-button on the backside of the DISPLAYPANEL (GGA Figure 1). Reset the GGA module.

The GGA DISPLAY PANEL will respond with (a) all discrete LED’s lit; (b) all segments andthe tenths place decimal point of the GAS PURITY display lit; and (c) all pixels of the LCDdisplay on.

Once communication has been established with the rest of the system, (a) all discreteLED’s, except AC POWER and TROUBLE, will turn off; (b) all segments of the GAS PURITYdisplay will turn off; and (c) the display will echo the results of cold-start initialization.

• GGA Ver 2.0E-7

• CHECKSUM OK

• POWER OK

• RELAY TEST …

• … PASSED

• ADC CALIBRATED

• Tcell = XX.X 0C (where XX.X is the instantaneous cell block temperature).

For an indeterminate period (normally not exceeding 15 minutes for a cold start), the LCD willdisplay the real-time temperature of the sensor cell block. When the temperature rises to55.0 C +/- 5.0 C, the system will advance and the display will indicate: NORMAL (H2/AIR),CONFIGURE VALVES. In response to this prompt, permit the sample gas to flow through thesensor then press the ENTER key. This is the NORMAL mode of operation.

For a first time installation, it is essential that a gas sensor calibration be performed on thesystem. Also, the faults log should be cleared. See Calibration under Setup Menu and ClearFaults Log under Log Menu for specific information.

Flow Calibration

See GGA Figure 5 for piping component location and GGA Figures 6 through 11 for valveconfigurations.

1. With the GGA system in normal operation, manually close all isolation valves and meter-ing valves.

2. Set analyzer Cell flow. Open isolation valves; adjust the flow meter/metering valve for aflow of approximately 500 SCCM.

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GGA Menu Displays

The following sections provide definitions and user information regarding the various menusthat are accessible via the GGA’s LCD display. It is strongly recommended that users famil-iarize themselves with this section. Forward additional questions to Environment One.

Navigating the LCD Display

Four keys control menu operation: FN, ENTER, UP ARROW and DOWN ARROW.

• The FN key activates and exits the menu.

• The ENTER key selects an item from the menu.

• The UP ARROW and DOWN ARROW keys change the selection displayed.

LCD Menu Display — Two Modes of Operation

The menu has two modes of operation, scrolling and non-scrolling.

• In scrolling mode, the selection shown on the LCD changes automatically every twoseconds.

• In non-scrolling mode, the UP ARROW and DOWN ARROW keys must be used tochange the selection.

Scrolling the default mode. Users can change modes by reviewing the SETUP MENU sec-tion in the following pages.

Menu Profile

Six menus are available: Function, Log, Purge, Setup, Test and View. The Function menu isthe top-level menu; all other menus are accessed through this menu.

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Menu Navigation Tutorial

Activating the Menu

1. Press FN to start the menu. The LCD should display the prompt FUNCTION MENU.

2. Press FN again to turn off the menu.

Navigating the Menu in Scrolling Mode (GGA Default)

1. Press FN to start the menu. The LCD should display the prompt FUNCTION MENU.After two seconds, the prompt should change to GO TO LOG MENU.

2. When the prompt shows GO TO VIEW MENU, press the ENTER key.

3. The LCD should display the prompt VIEW MENU.

4. Wait until the prompt shows VIEW CALIBRATION, then press the ENTER key. Thedisplay should show Vref=N.NNN where N.NNN is the calibration value for the referencethermistor.

5. Press the FN key. The prompt will be restored to VIEW CALIBRATION.

6. Press FN again. The prompt will be restored to GO TO VIEW MENU.

7. Press FN a third time. The LCD will display GGA BY E/ONE as the menu is deactivated.

Disabling Scrolling More

1. Press FN to start the menu.

2. Wait until the prompt shows GO TO SETUP MENU and press ENTER.

3. Wait until the prompt shows SET SCROLL OFF and press ENTER.

4. The prompt will flash SET SCROLL OFF.

5. Press FN to return to the beginning of the menu.

Navigating the Menu in Non-Scrolling Mode

1. The LCD should display the prompt FUNCTION MENU. Press the DOWN ARROW keyuntil the prompt shows GO TO VIEW MENU and press the ENTER key.

2. The LCD should display the prompt VIEW MENU. Press the DOWN ARROW key untilthe prompt shows VIEW CALIBRATION and press the ENTER key. The display shouldshow Vref=N.NNN VDC where N.NNN is the calibration value for the reference thermistor.



5. Press FN a third time. The LCD will display GGA BY E/ONE.

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Function (FN) Menu

• GO TO LOG MENU Select this item to enter the Log Menu. The Log Menu containsselections to view and clear the fault and power logs. The Log Menu also includes aselection to view the software version number.

• GO TO PURGE MENU Select this item to enter the Purge Menu. The Purge Menuincludes selections to change to a different range for purge operations. The availablealternate ranges are hydrogen in carbon dioxide and air in carbon dioxide.

• GO TO SETUP MENU Select this item to enter the Setup Menu. The Setup Menuincludes selections for calibration and configuration. Items that an be configured includethe Warning level, Alarm level, operating mode and menu scroll rate. The Setup menualso includes selections to calibrate the reference values for hydrogen, nitrogen andcarbon dioxide.

• GO TO TEST MENU Select this item to enter the Test Menu. The Test Menu containsselections to test the power supplies, keypad, relays, solenoids, bar graphs and the 4-20mA outputs.

• GO TO VIEW MENU Select this item to enter the View Menu. The View Menu containsselections to view the calibration constants, cell temperature, thermistor voltages and A/D converter voltages.

Purge Menu

• PURGE (H2/CO2) Select this item to change the range from hydrogen in air to hydrogenin carbon dioxide. See Purge Operation for more information.

• PURGE (AIR/CO2) Select this item to change the range from hydrogen in air to air incarbon dioxide. See Purge Operation for more information.

Log Menu

• SHOW FAULTS LOG Select this item to view the Faults Log. See About the Faults Logfor more information.

• CLEAR FAULTS LOG Select this item to clear the Faults Log. When selected, theCLEAR FAULTS LOG prompt will flash for two seconds before clearing the Faults Log. Ifthe FN key is pressed while the prompt is still flashing, clearing the log will be canceled.See About the Faults Log for more information.

• SHOW POWER LOG Select this item to view the Power Log. See About the Power Logfor more information.

• CLEAR POWER LOG Select this item to clear the Power Log. When selected, theCLEAR POWER LOG prompt will flash for two seconds before clearing the Power Log. Ifthe FN key is pressed while the prompt is still flashing, clearing the log will be canceled.See About the Power Log for more information.

• SHOW PROGRAM ID Select this item to display the program identification and revisionlevel in the format GGA Rev. X.X. This manual was written for software version 2.0E.

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Setup Menu

• CALIBRATE H2 Select this item to calibrate the GGA with 100 percent hydrogen gas.See Gas Calibration for more information.

• CALIBRATE CO2 Select this item to calibrate the GGA with 100 percent carbon dioxidegas. See Gas Calibration for more information.

• CALIBRATE N2 Select this item to calibrate the GGA with 100 percent nitrogen gas. SeeGas Calibration for more information.

• ALARM LEVEL Select this item to change the alarm level. See Setting the Alarm Levelfor more information.

• WARNING LEVEL Select this item to change the warning level. See Setting the WarningLevel for more information.

• STOP MONITORING This item is to be used for troubleshooting and is displayed whenthe monitoring is turned on. Select this item to turn off monitoring. When selected, theSTOP MONITORING prompt will flash STOPPING for two seconds before monitoring issuspended. If the FN key is pressed while it is flashing, the command will be cancelled.See Suspended Operation for more information.

• START MONITORING This item is displayed when the scrolling is turned on. Select thisitem to turn monitoring on. When selected, the START MONITORING prompt will flashSTARTING for two seconds before monitoring begins. If the FN key is pressed while theprompt is flashing, the command will be canceled. See Normal Operation for moreinformation.

• SET SCROLL OFF This item is displayed when the scrolling is turned on. Select thisitem to turn off scrolling. When scrolling is inactive, the displayed menu items will notchange until a menu key (UP ARROW, DOWN ARROW, FN or ENTER) is pressed.

• SET SCROLL ON This item is displayed when the scrolling is turned off. Select this itemto turn on scrolling. When scrolling is active, the displayed menu items will change onceevery two seconds.

Test Menu

• CONTACT TEST Select this item to start an interactive test of the relay contacts. TheGGA will place all relays except one in a de-energized condition. The LCD will display thename of the single relay that is still energized. Use the arrow keys to change which relayis energized. Press the FN or ENTER keys to terminate the test.

• KEYPAD TEST Select this item to start an interactive test of the keypad. The LCD willdisplay the prompt PRESS ANY KEY at the start of the test. Test the keypad by pressing,one at a time, all of the keys on the keypad, reserving the FN key for last. The LCD willecho the name of each key as it is pressed. The test will terminate when the FN key ispressed.

• OUTPUT TEST Select this item to start an interactive test of the bar graphs and 4-20mA outputs. The GGA will clear the numeric displays, set the 4-20 mA outputs to 4 mAand display CURRENT=4 mA on the LCD display at the start of the test. Use the arrow

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keys to increase or decrease the current in 1 mA steps. Press FN or ENTER to terminatethe test.

• POWER TEST Select this item to test the power supplies. When Power Test is selected,the GGA will display the voltage for each power supply in the format <nominalvalue>=<present value>. An example of the 12-volt power supply is +12 VOLTS=12.1.The GGA will scroll through all five power supply voltages. The voltages are displayed fortwo seconds each.

• RELAY TEST Select this item to test all of the relays. The LCD will display RELAY TEST.The system will cause each relay to be energized. If no errors are detected, the LCD willdisplay RELAYS PASS. If an error is detected, the LCD will display the failure mode andthen list the names of the malfunctioning relays. The failure modes are STUCK ON andSTUCK OFF. See Table 5 for a list of the probable cause(s) of the error(s).

View Menu

• VIEW CALIBRATION Select this item to display the calibration values for the sensor cell.The format for the displayed values is “Vnn=X.XXX VDC” where Vnn is the symbol andX.XXX is the voltage of a calibration constant. The symbols for the four calibration con-stants are: Vref for the reference thermistor; Vn2 for nitrogen gas; Vh2 for hydrogen gas;and Vco2 for carbon dioxide. Use the UP ARROW key or DOWN ARROW key to scrollthrough the calibration constants. Press the FN key to return to the VIEW MENU.

• VIEW TCELL Select this item to view the cell temperature in real time. The temperatureis displayed in the format “Tcell=XX.XC” where XX.X is the temperature in degreesCentigrade.

• VIEW CELL VOLTS Select this item to view the thermistor voltages in real time. Thevoltages are displayed in the format s=X.XXX r=X.XXX where s stands for the samplethermistor and r stands for the current value of the reference thermistor voltage.

• VIEW 12BIT ADC Select this item to display the voltage at each of the four input of the12-bit A/D converter. Use the UP ARROW or DOWN ARROW to scroll through all fourchannels. Press the FN key to return to the View Menu.

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Procedures

Setting the Alarm Level

The Alarm level determines what ratio of hydrogen to air will trigger an Alarm indication. TheAlarm level is expressed as a percent. An Alarm indication is given when the purity dropsbelow the value of the Alarm level and remains there for at least one minute after a Warningis indicated. An Alarm will only occur if the GGA is in Normal mode. The factory default valuefor the alarm level is 85 percent. The Alarm level can be changed by selecting ALARM LEVELfrom the Setup Menu.

When ALARM LEVEL is selected, the Alarm level is displayed on the LCD display. Press theUP ARROW to increase the level; press the DOWN ARROW to decrease the level. The levelcannot be increased beyond the Warning level or decreased below 80 percent. Press theENTER key to save your changes and return to the Setup Menu. Press the FN key to discardchanges and return to the Setup Menu.

Setting the Warning Level

The Warning level determines what ratio of hydrogen to air will trigger a Warning indication.The Warning level is expressed in percent. A Warning indication is given when the puritydrops below the value of Warning level and remains there for at least one minute. A Warningwill only occur if the GGA is in Normal mode. The factory default value for the Warning level is90 percent. The Warning level can be changed by selecting WARNING LEVEL from theSetup Menu.

When WARNING LEVEL is selected, the Warning level is displayed on the LCD display.Press the UP ARROW key to increase the level; press the DOWN ARROW key to decreasethe level. The Warning level cannot be increased beyond 99 percent or decreased below theAlarm level. Press the ENTER key to save your changes and return to the SETUP MENU.Press the FN key to discard the changes and return to the SETUP MENU.

Gas Calibration

1. Begin hydrogen gas calibration by selecting CALIBRATE H2 from the Setup Menu.

2. In response to the prompts CALIBRATE H2, CONFIGURE VALVES, permit the hydrogencalibration gas to flow through the sensor. With the calibration gas flowing the LCD willdisplay the voltage output of the reference cell sensor in the format Vref=X.XXX VDC.Press the FN key to cancel the calibration at this point, if desired; this will permit a returnto the main menu. If desired to continue the calibration, observe the reference voltageand, if it appears stable (i.e., a final change of not greater than 1 to 2 mV per minute),press the ENTER key.

3. The LCD will display the voltage output of the sample cell sensor in the format“Vcell=X.XXXVDC.” Again, the calibration may be terminated by pressing FN. If it iscontinued, observe the sample cell voltage as it adjusts to the flowing H2 calibration spangas. When it appears stable (i.e., a final change of not greater than 1 mV per minute,which occurs within approximately 15 minutes) press the ENTER key. The LCD willdisplay H2 CALIBRATED. This concludes H2 calibration.

The display will scroll the prompts CALIBRATE H2, CALIBRATE CO2 and CALIBRATE N2.

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Press the Fn key on the GGA to return to the main menu or to continue gas calibration, waituntil the display scrolls to the prompt CALIBRATE CO2 and press the ENTER key.

1. Begin carbon dioxide gas calibration by selecting CALIBRATE CO2 from the Setup Menu.

2. In response to the prompts CALIBRATE CO2, CONFIGURE VALVES, permit the CO2calibration gas to flow through the sensor. With the calibration gas flowing, the LCD willdisplay the voltage output of the reference cell sensor in the format Vref=X.XXX VDC. Ifdesired to cancel the calibration at this point, press the Fn key; this will permit a return tothe main menu. If desired to continue the calibration, observe the reference voltage and, ifit appears stable (i.e., a final change of not greater than 1 to 2 mV per minute), press theENTER key.

3. The LCD will display the voltage output of the sample cell sensor in the formatVcell=X.XXX VDC. Again, the calibration may be terminated by pressing FN. If it is contin-ued, observe the sample voltage as it adjusts to the flowing CO2 calibration zero gas.When it appears stable (i.e., a final change of not greater than 1 to 2 mV per minute,which occurs within approximately 15 minutes), press the ENTER key. The LCD willdisplay CO2 CALIBRATED. This concludes CO2 calibration.

4. Begin nitrogen gas calibration by selecting CALIBRATE N2 from the SETUP MENU.

5. In response to the prompts CALIBRATE N2, CONFIGURE VALVES, permit the nitrogencalibration gas to flow through the sensor. With the calibration gas flowing the LCD willdisplay the voltage output of the reference cell sensor in the format Vref=X.XXX VDC. Ifdesired to cancel the calibration at this point, press the Fn key; this will permit a return tothe main menu. If desired to continue the calibration, observe the reference voltage and, ifit appears stable (i.e., a final change of not greater than 1 to 2 mV per minute) press theENTER key.

6. The LCD will display the voltage output of the sample cell sensor in the formatVcell=X.XXX VDC. Again, the calibration may be terminated by pressing Fn. If it is contin-ued, observe the sample voltage as it adjusts to the flowing N2 calibration zero/span gas.When it appears stable (i.e., a final change of not greater than 1 to 2 mV per minute,which occurs within approximately 15 minutes) press the ENTER key. The LCD willdisplay N2 CALIBRATED. This concludes N2 calibration.

7. Press the Fn key to return to the main menu. This concludes the gas sensor calibrationof the GGA system.

About the Faults Log

The Faults log traps these error conditions: I/O Read Error, I/O Write Error, Unverified Alarm,Flow Fault and Power Fault.

• An I/O Read Error is logged when a read error is detected in the communication channelthat connects the processor and I/O board.

• An I/O Write Error is logged when a write error is detected in the communication channelthat connects the processor and I/O board.

• A Tcell Fault is logged when the temperature of the sensor cell drifts out of specificationduring normal operating mode.

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• A Power Fault is logged when the measured voltage of one or more of the power suppliesis out of specification.

About the Power Log

The Power log records the minimum and maximum voltage of each power supply. Thevoltage is sampled once every two seconds.

When SHOW POWER LOG is selected, the GGA displays the minimum and maximum foreach power supply in the format <nominal value>=<minimum value>,<maximum value>. Anexample for the 12-volt power supply is +12V=11.8,12.1. Use the UP ARROW key or DOWNARROW key to scroll through the five power supply voltages. Press the FN key to return tothe LOG MENU.

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Modes of Operation

Startup

The GGA initializes all relays to the de-energized position.

The GGA executes a “power-on self-test” (POST) to verify its proper operation. It verifies itssoftware by checksum testing the contents of its read-only memory (ROM). It tests all of itspower supplies and all of its relays. It checks the cell temperature and waits until it reaches55.0 C +/- 5.0 C.

The POST will take about 20 seconds to complete if no errors are encountered and the cellis at its normal operating temperature. At the conclusion of the POST, the GGA display panelwill flash NORMAL (H2/AIR), CONFIGURE VALVES. Verify the valve configuration and thenpress the ENTER key for normal operation or the FN key for suspended operation.

Startup Problems

Immediately after power-up, the GGA begins searching for a display. If the local display ispresent and functioning properly, the search will complete in less than one tenth of a second.If the GGA cannot communicate with the local display, LINKING… may appear on the LCD. Ifthe GGA cannot find a local display within four seconds, it will assume one is present andproceed with the POST.

The GGA verifies its software by checksum testing the contents of its read-only memory(ROM). If it finds a problem, it will stop the POST process and flash BAD CHECKSUM on theLCD. The FN key may be pressed to allow the GGA to continue the POST process. How-ever, proper operation cannot be guaranteed if this error is present.

The GGA will annunciate any problems it finds with the power supplies or relays. The pres-ence of one or more of these faults will not stop the POST process. However, they should becorrected as soon as possible because they indicate a hardware problem.

The GGA requires that the cell temperature reach 55.0 C +/- 5.0 C before enabling NORMALOPERATION. The POST will wait until the cell temperature falls within this range beforeproceeding. The test can be bypassed by pressing the ENTER key.

Suspended Operation

When the GGA is in suspended operation, it will not monitor the gas concentration or gener-ate any alarms or warnings. The Trouble LED will be illuminated whenever the GGA is in thismode of operation. The numerical displays will be blank and the 4-20 mA output will indicatezero percent gas purity.

Purge Operation - H2 in CO2

When the GGA is in purge hydrogen in carbon dioxide operation it will display the concentra-tion of hydrogen in CO2. It will not generate any alarms or warnings. The GGA will display themeasured purity on the numerical displays. The measured purity is also available through a4-20 mA output. The 4-20 mA current output of the GGA corresponds to 0 to 100 percent gaspurity.

23 HA0291P01 Rev. A

Purge Operation - Air in CO2

When the GGA is in “purge air in carbon dioxide” operation, it will display the concentration ofair in CO2. It will not generate any alarms or warnings. The GGA will display the measuredpurity on the numerical displays. The measured purity is also available through a 4-20 mAoutput. The 4-20 mA current output of the GGA corresponds to 0 to 100 percent gas purity.

Normal Operation

Note: It is important to verify that the generator fan pressure and generator fan suction linesconnecting the GGA to the generator are filled with hydrogen before placing the system intoNormal operation.

When the GGA is in Normal operation, it will display the concentration of the hydrogen in air. Itwill indicate a warning or alarm condition if it is out of specification. The GGA monitors thegas purity with a thermal conductivity cell. The GGA will display the measured purity on thenumerical displays. The measured purity is also available through a 4-20 mA output. The 4-20 mA current output of the GGA corresponds to 70 to 100 percent gas.

24HA0291P01 Rev. A

Maintenance

The GGA Module is designed for reliable, trouble-free operation. Periodic checks and mainte-nance are easy. Following the required maintenance checks will ensure safe, trouble-freeoperation of this equipment.

Daily

1. Check and adjust the GGA Module flow rates; see Flow Calibration.

2. Check hydrogen purity.

Weekly

1. Visually inspect the moisture indicator. A blue medium indicates dry hydrogen, while apink medium indicates excessive moisture in the hydrogen gas sample that may affectthe stability of the GGA. Replace or regenerate the Moisture Indicator and replace theGas Purifier if the medium is pink. Refer to Removal of Moisture Indicators and GasPurifiers.

2. Check the purifier by closing the isolation valves, release pressure within purifier housingby setting the selector valve SV1 to vent and opening isolation valves IV10 and IV14, thenremove the housing by hand and check for fluid

It is advisable to have a container available to collect any fluid contained within the purifier.

CAUTION! The purifiers may contain hydrogen gas; use proper safety precautions.

Every Six Months

1. Check analyzer power and calibration voltages.

2. Calibrate Generator Gas Analyzer, as necessary.

3. Run diagnostics.

When the Generator is Down

During periods when the generator is shut down, it is recommended that either a) power bemaintained to the GGA; or b) the GGA be isolated by placing all isolation valves in “off” posi-tion.

25 HA0291P01 Rev. A

Component Replacement Instructions

The hydrogen analyzer, input/output circuit board, processor circuit boards, power suppliesand intrinsically safe barriers are located inside the main junction box. Prior to opening themain junction box, remove power from the GGA and ensure the system is free of hydrogen.

To gain access to the inside of the main junction box for service, remove the 32, 3/4-inchcaptive bolts. Two guide studs assist with removal/replacement of the hinged lid.

CAUTION! Do not scratch sealing surfaces on the main junction box. The main junc-tion box lid weighs 50 lbs (22.7 kg) and is supported by two hinges. Take precautionsduring removal.

Removing a Gas Analyzer Sensor

To remove a hydrogen analyzer from a flameproof enclosure:

1. Disconnect AC input power.

2. Manually close isolation valves.

3. Remove the cover of the junction box (right-hand thread).

4. Remove the 12-pin cable connector from the sensor circuit board.

5. Remove inlet and outlet tubing connections from the analyzer with a 7/16-inch wrench.

6. Remove mounting hardware (4 slotted screws).

7. To reinstall sensor cell, reverse above process, then leak check.

Removing a Processor Circuit Board

To remove a processor circuit board from the main junction box:


2. Close isolation valves.

3. Remove the main junction box cover.

4. To remove the processor board, disconnect the 9-pin display cable, the 26-pin ribboncable and remove the 4 nuts (11/32).

5. Install the new processor board in reverse order.

6. Check that pin #1 on the connectors is properly aligned.

Removing the Input/Output (I/O) Circuit Board

1. Disconnect AC input power. To avoid electric shock or fire hazards, confirm all sources ofexternal excitation, including power supplied to the relay contacts, are removed.

26HA0291P01 Rev. A

2. Close Isolation valves.


4. Remove the processor board. Disconnect the 9-pin display cable, the 26-pin ribbon cableand 4 nuts (11/32).

5. Remove the 4 slotted screws that hold the board in place.

6. Remove all wiring connections to the terminal blocks on the I/O board.

7. Disconnect power supply connections to the I/O board.

8. Disconnect the analyzer cell, 12-pin connector.

9. The I/O board can now be removed. Install the new I/O board in reverse order.

Removing Moisture Indicator

The moisture indicator is located on the front of the panel (GGA Figure 2). To remove mois-ture indicators:


2. Manually close all isolation valves.

3. Unscrew moisture indicator by hand.

4. Replace moisture indicator by screwing in the replacement by hand.

5. Open isolation valves.

6. Perform leak check.

7. Reconnect AC input power.

Removing Gas Purifier Cartridge

The gas purifier is located on the back of the panel (GGA Figure 3).



3. Release pressure within purifier housing by setting the selector valve SV1 to vent andopening IV10, IV14.

4. Remove the purifier housing by hand (right-hand thread).

5. Remove purifier cartridge by hand (right-hand thread).

6. Replace cartridge.

7. Re-secure the purifier housing

27 HA0291P01 Rev. A

8. Set selector valve (SV1) to return.

9. Open isolation valves



Removing the Flow Meter



3. Remove tubing fittings and locking nuts from the back of the flowmeter.

4. Withdraw flowmeter from the front side of the GGA Module.

5. To install replacement, reverse above process.

6. Use caution not to exceed 10 foot pounds torque on threaded fittings.



28HA0291P01 Rev. A

Parts Lists

Recommended GGA Spare Parts (Stocked by Customer)

Item Description Part Number Description

MI1 Replacement Plug HA0013P02 Moisture indicator replacement plug

Purifier Cartridge HA0012P02 Purifier cartridge

I/O PCB HD0122G01 I/O PCB

Processor PCB HD0082G07 Processor PCB

Analyzer Cell HC0021G02 Analyzer cell assembly

Recommended GGA Replacement Parts (Stocked by E/One)


Flow-meter FM1 HA0040P01 100 to 900cc/min H2 flow-meter w/metering valve

Isolation Valve HA0011P01 1/4" female isolation ball valve, SS

3 way Selector Valve HA0116P01 1/4" female selector valve, SS

12 VDC Power Supply HA0027P01 12 VDC power supply

Display PCB HD0138G01 Display PCB

Display Panel HB0026G01 Display panel

Moisture Indicator MI1 HA0013P01 1/4" NPT, male/female moistureindicator

29 HA0291P01 Rev. A

Figures

The figures that follow depict the GGA and its components. All references in this documentrefer to the following figures.

Contact Environment One with questions that relate to any of the figures in the Appendix.

30HA0291P01 Rev. A

31 HA0291P01 Rev. A

GGA Figure 1 - GGA Display Panel

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32HA0291P01 Rev. A

GGA Figure 2 - GGA Valve Panel

33 HA0291P01 Rev. A

GGA Figure 3 - Back Side of GGA Valve Panel

34HA0291P01 Rev. A

GGA Figure 4 - GGA Wiring Assembly Details

35 HA0291P01 Rev. A

GGA Figure 5 - GGA Piping Schematic

36HA0291P01 Rev. A

GGA

GGA Figure 6 - Calibrate N2

37 HA0291P01 Rev. A

GGA Figure 7 - Calibrate CO2

GGA

38HA0291P01 Rev. A

GGA Figure 8 - Calibrate H2

GGA

39 HA0291P01 Rev. A

GGA Figure 9 - Purge Air in CO2

GGA

40HA0291P01 Rev. A

GGA Figure 10 - Purge H2 in CO2

GGA

41 HA0291P01 Rev. A

GGA Figure 11 - Normal H2 in Air

GGA

42HA0291P01 Rev. A

Generator Gas Dryer (GGD)


HA0296P01 Rev. A

UTILITY SYSTEMS

1 HA0296P01 Rev. A


Specifications ....................................................................................................................................... 7

System Description .............................................................................................................................. 8Left Column Pressure Transmitter .................................................................................................. 8Right Column Pressure Transmitter ................................................................................................ 8Outlet Pressure Transmitter ............................................................................................................ 8Control Gas Pressure Transmitter .................................................................................................. 8

Electrical Connections ......................................................................................................................... 9Contacts/Signals ............................................................................................................................. 9Circuit Protection ........................................................................................................................... 9

System Operation .............................................................................................................................. 10GGD Initialization ........................................................................................................................ 10

GGD Menu Displays ......................................................................................................................... 11Navigating the LCD Display ........................................................................................................ 11LCD Display Menu – Two Modes of Operation ............................................................................ 11Menu Profile ................................................................................................................................. 11

Menu Navigation Tutorial ................................................................................................................. 12Activating the Menu ..................................................................................................................... 12Navigating the Menu in Scrolling Mode (GGD default) ............................................................... 12Disabling Scrolling Mode .............................................................................................................. 12Navigating the Menu in Non-Scrolling Mode ............................................................................... 12Function (FN) Menu ..................................................................................................................... 13Log Menu ...................................................................................................................................... 13Setup Menu ................................................................................................................................... 13Test Menu ...................................................................................................................................... 14Tools Menu .................................................................................................................................... 15View Menu .................................................................................................................................... 15

Procedures ......................................................................................................................................... 17Sensor Calibration ........................................................................................................................ 17Setting the Dew Point Alarm Level .............................................................................................. 17Setting the Desired Dew Point Level ............................................................................................ 17Setting the Minimum Drying Time ................................................................................................ 18Setting the Maximum Drying Time ............................................................................................... 18Clearing a Heater Fault ............................................................................................................... 18About the Faults Log .................................................................................................................... 18About the Power Log .................................................................................................................... 19

2HA0296P01 Rev. A

Modes of Operation .......................................................................................................................... 20Startup .......................................................................................................................................... 20Startup Problems .......................................................................................................................... 20Manual Operation ......................................................................................................................... 20Manual Column Regeneration ...................................................................................................... 20Manual Column Venting ............................................................................................................... 21Manual Column Drying ................................................................................................................ 21Normal Operation ......................................................................................................................... 22

Maintenance and Repair ................................................................................................................... 23Maintenance, Repair and Adjustments ......................................................................................... 23Daily .............................................................................................................................................. 24Weekly ........................................................................................................................................... 24Monthly ......................................................................................................................................... 24Quarterly ....................................................................................................................................... 24Semi-Annually ............................................................................................................................... 24Annually ........................................................................................................................................ 25Desiccant Replacement Procedure ................................................................................................ 25Heater Installation Procedure ....................................................................................................... 27Heater Check Out Procedure ........................................................................................................ 28Inlet Switching Valve Disassembly ................................................................................................ 28Exhaust Switching Valve Disassembly .......................................................................................... 29Purge and Outlet Check Valve Disassembly ................................................................................. 30

Troubleshooting ................................................................................................................................. 32

Component Replacement Instructions ............................................................................................. 34Removing a Pressure Transducer .................................................................................................. 34Removing a Processor Circuit Board ............................................................................................ 34Removing the Input/Output (I/O) Circuit Board ........................................................................... 34

Parts Lists .......................................................................................................................................... 36Recommended GGD Spare Parts (Stocked by Customer) ............................................................ 36Recommended GGD Replacement Parts (Stocked by E/One) ...................................................... 36

3 HA0296P01 Rev. A

FiguresGGD Figure 1 - Dryer Module and System Piping ............................................................................................ 40GGD Figure 2 - Generator Gas Dryer Display/Valve Panel .............................................................................. 41GGD Figure 3 - Menu Tree ............................................................................................................................... 42GGD Figure 4 - Sweep Ports ............................................................................................................................ 43GGD Figure 5 - Element and Heater Tube ........................................................................................................ 44GGD Figure 6 - Heater and Heater Tube .......................................................................................................... 45GGD Figure 7 - Inlet Switching Tube ................................................................................................................ 46GGD Figure 8 -Exhaust Switching Valve .......................................................................................................... 47GGD Figure 9 -Purge and Outlet Check Valve ................................................................................................. 48

4HA0296P01 Rev. A

5 HA0296P01 Rev. A

Generator Gas Dryer (GGD) SystemImportant Information





Generator Gas Dryer (GGD) SystemSafety Considerations

THE SYSTEM ELECTRONICS ENCLOSURE AND CUSTOMER INTERFACE ENCLOSURECONTAIN 115 AND 460 VOLTS AC. THIS VOLTAGE APPEARS AT THE AC POWER STRIPAND VARIOUS OTHER POINTS. EQUIPMENT OPERATION INVOLVES A FLAMMABLEGAS (HYDROGEN) UNDER PRESSURE. APPROPRIATE MEASURES MUST BE TAKENTO PREVENT LEAKS AND AVOID SOURCES OF IGNITION.

ALL ELECTRICAL CONNECTIONS BETWEEN THE SYSTEM ELECTRONICS, CUS-TOMER INTERFACE AND DISPLAY/CONTROL PANEL SHOULD BE TESTED AND VERI-FIED TO BE CORRECT.

ALL WIRING MUST BE IN ACCORDANCE WITH LOCAL CODE AND/OR CENELEC STAN-DARD EN50014.

ALL GAS CONNECTIONS TO THE PANEL MUST BE LEAK CHECKED PRIOR TO APPLY-ING AC POWER.


6HA0296P01 Rev. A

Introduction

7 HA0296P01 Rev. A

Specifications

System ElectronicsInput Voltage 115 VAC Two PhaseInput Frequency 47 to 63 HzInput Power 30 WInrush Current 0.5 A

HeaterInput Voltage 460 VAC Three PhaseInput Frequency 60 HzInput Power 1800 WInrush Current 3.5 A

MotorInput Voltage 460 VAC Three PhaseInput Frequency 60 HzInput Power 1800 WInrush Current 3.5 A



Ambient Location Class 1, Division 1, Group B

Outputs, Relays 5A @ 250VAC5A @ 30VDCDew Point High, NO and NC100mA@125VDCTrouble, NO and NC

Outputs, Signal 4-20 mA current output (self-powered)Input Dew PointOutlet Dew Point

8HA0296P01 Rev. A

System Description

The major components of the GGD include:

• 1 generator gas dryer

• 2 column pressure sensors

• 1 outlet pressure sensor

• 1 control gas pressure sensor

• 1 local display panel

• 1 system electronics

Left Column Pressure Transmitter

A pressure transmitter provides a signal to the GGD indicating the pressure in the left col-umn. The pressure range is 0 to 100 pounds per square inch.

Right Column Pressure Transmitter

A pressure transmitter provides a signal to the GGD indicating the pressure in the left col-umn. The pressure range is 0 to 100 pounds per square inch.

Outlet Pressure Transmitter

A pressure transmitter provides a signal to the GGD indicating the pressure at the outlet ofthe column and the inlet of the motor. The pressure range is 0 to 100 pounds per squareinch.

Control Gas Pressure Transmitter

A pressure transmitter provides a signal to the GGD indicating the control gas pressure usedto operate the pneumatic valves. The pressure range is 0 to 100 pounds per square inch.

9 HA0296P01 Rev. A


Contacts/Signals

The GGD includes alarm and status relays (GGD Figure 3). They are:

• Dew Point High Relay Both a normally open and a normally closed contact (single pole,double throw configuration) is provided and an Alarm is signaled by an energized relay.

• Trouble Relay Both a normally open and a normally closed contact (single pole, doublethrow configuration) is provided and Trouble is signaled by an de-energized relay.

• 4-20 mA output signals are provided for the inlet and outlet dew points (GGD Figure 3).

• The 4-20 mA signals for the dew point correspond to –80 to +20 degrees Centigrade.

• The 4-20 mA output signals are internally powered. These signals are not to bepowered by the Mark V, Mark VI.

See Figure 3 for locations of signals on terminal block. See GGD Figures 9 and 10 for de-scription of conditions where relays are activated.

Circuit Protection

The 115 VAC provided to the GGD is individually fused. A half-amp slo-blow fuse, located onthe Input/Output PCB, provides circuit protection.

The 460 VAC three-phase current is not fused. An external three-pole 5-ampere circuitbreaker must be provided for the power supplied to the motor and the power supplied to theheater.

10HA0296P01 Rev. A

System Operation

The GGD’s main purpose is to remove water vapor from hydrogen gas. This section de-scribes system operation.

GGD Initialization

Apply system power to the GGD. The GGD DISPLAY PANEL will respond with (a) all discreteLED’s lit; (b) all segments and the tenths place decimal point of the seven segment LEDdisplays lit; and (c) all pixels of the LCD display on.

Once communication has been established with the rest of the system, (a) all discreteLED’s, except the AC POWER and TROUBLE, will turn off; (b) all segments of the sevensegment LED displays will turn off; and (c) the display will echo the results of cold startinitialization:

· GGD Ver 1.0A-7

· CHECKSUM OK

· POWER OK

· RELAY TEST …

· … PASSED

· I/O BOARD OK

· 12BIT ADC TEST

· … PASSED

TO START DRYER/PRESS ENTER. In response to this prompt verify that all valves areconfigured for proper operation and then press the ENTER key to start drying in normalmode. Press the Fn key to continue without starting the dryer.

· TESTING …

· LEFT COLUMN

· L=XX.X°C YY.Y PSI

· STARTING ...

· WAIT …

· GGD by E/ONE

After initialization, the Faults log should be cleared. See CLEAR FAULTS LOG under LOGMENU for specific instructions.

11 HA0296P01 Rev. A

GGD Menu Displays

The following sections provide definitions and user information in regards to the variousmenus that are accessible via the GGD’s LCD display. It is strongly recommended thatusers familiarize themselves with this section. Forward additional questions to EnvironmentOne.



· The FN key activates the menu and exits the menu.

· The ENTER key selects an item from the menu.

· The UP ARROW and DOWN ARROW keys change the selection displayed.

LCD Display Menu – Two Modes of Operation


· In scrolling mode, the selection shown on the LCD changes automatically every twoseconds.

· In non-scrolling mode, the UP ARROW and DOWN ARROW keys must be used tochange the selection.

Scrolling is the default mode. Users can change modes by reviewing the SETUP MENUsection in the following pages.

Menu Profile

Six menus are available: Function, Log, Setup, Test, Tools and View. The Function menu isthe top-level menu; all of the other menus are accessed through this menu.

12HA0296P01 Rev. A


Activating the Menu

1. Press FN to start the menu. The LCD should display the prompt <FUNCTION MENU>.

2. Press FN again to turn it off.

Navigating the Menu in Scrolling Mode (GGD default)

1. Press FN to start the menu. The LCD should display the prompt <FUNCTION MENU>.After two seconds the prompt should change to GO TO LOG MENU.

2. Wait until the prompt GO TO LOG MENU appears and press the ENTER key.

3. The LCD should display the prompt <LOG MENU>.

4. Wait until the prompt SHOW PROGRAM ID appears and press the ENTER key. Thedisplay should show GGD VER 1.0A-7.

5. Press the FN key. The prompt will be restored to SHOW PROGRAM ID.

6. Press FN again. The prompt will be restored to GO TO LOG MENU.

7. Press FN a third time. The LCD will display “GGD by E/One” as the menu is deactivated.

Disabling Scrolling Mode


2. Wait until the prompt GO TO SETUP MENU appears and press ENTER.

3. Wait until the prompt SET SCROLL OFF appears and press ENTER.




1. The LCD should display the prompt <FUNCTION MENU>. Press the DOWN ARROWkey until the prompt GO TO LOG MENU appears and press the ENTER key.

2. The LCD should display the prompt <LOG MENU>. Press the DOWN ARROW key untilthe prompt SHOW PROGRAM ID appears and press the ENTER key. The display shouldshow GGD VER 1.0A-7.



5. Press FN a third time. The LCD will display “GGD by E/One.”

13 HA0296P01 Rev. A

Function (FN) Menu

· GO TO LOG MENU Select this item to enter the LOG MENU. The log menu containsselections to view and clear the fault and power logs. The log menu also includes aselection to view the software version number.

· GO TO SETUP MENU Select this item to enter the SETUP MENU. The setup menuincludes selections for calibration and configuration. Items that can be configured includesensor calibration, alarm levels, the operating mode and the menu scroll rate. The setupmenu also includes selections to calibrate the pressure sensors.

· GO TO TEST MENU Select this item to enter the TEST MENU. The test menu containsselections to test the power supplies, the keypad, the relays, and the 4-20 mA outputs.

· GO TO TOOLS MENU Select this item to enter the TOOLS MENU. The tools menucontains selections to manually operate the dryer.

· GO TO VIEW MENU Select this item to enter the VIEW MENU. The view menu containsselections to view column temperatures and pressures, dryer status, valve status, andthe A/D converter voltages.

Log Menu

· SHOW FAULTS LOG Select this item to view the faults log. See About the Fault Log formore information.

· CLEAR FAULTS LOG Select this item to clear the faults log. When selected the CLEARFAULTS LOG prompt will flash for two seconds before clearing the faults log. If the FNkey is pressed while it is still flashing, clearing of the log will be canceled. See About theFault Log for more information.

· SHOW POWER LOG Select this item to view the power log. See About the Power Logfor more information.

· CLEAR POWER LOG Select this item to clear the power log. When selected, theCLEAR POWER LOG prompt will flash for two seconds before clearing the power log. Ifthe FN key is pressed while it is still flashing, clearing of the log will be canceled. SeeAbout the Power Log for more information.

· SHOW PROGRAM ID Select this item to display the program identification and revisionlevel in the format GGD Rev X.X. This manual was written for software version 1.0A.Press the FN key to stop displaying the program identification.

Setup Menu

· SETUP SENSORS Select this item to calibrate the pressure sensors and to set theirhigh and low alarm points. See Sensor Calibration for more information.

· DEWPOINT ALARM Select this item to change the alarm level. The dryer will energizethe Dew Point High relay when the inlet dew point rises above the alarm level. SeeSetting the Dew Point Alarm Level for more information.

· DESIRED DEWPOINT Select this item to change the desired dew point level. The dryer

14HA0296P01 Rev. A

will switch columns and start regenerating when the outlet dew point rises above thedesired dew point. See Setting the Desired Dew Point Level for more information.

· SET MIN DRY TIME Select this item to change the minimum drying time. The dryer willnot switch columns and start regeneration until the column has been drying for theminimum drying time. The switch will be blocked even if the outlet dew point is greaterthan the desired dew point. See Setting the Minimum Drying Time for more information.

· SET MAX DRY TIME Select this item to change the maximum drying time. Once acolumn has been drying for the maximum drying time it will switch columns and startregenerating. The switch will occur even if the outlet dew point is less than the desireddew point. However, the minimum drying time will override the maximum drying time. SeeSetting the Maximum Drying Time for more information.

· STOP MONITORING This item is displayed when the dryer is turned off. Select it tostart the dryer. When selected the START MONITORING prompt will flash STARTING fortwo seconds before the dryer starts. If the FN key is pressed while it is still flashing, thecommand will be canceled.

· START MONITORING This item is displayed when the monitoring is currently turned off.Select it to turn monitoring on. When selected the START MONITORING prompt will flashSTARTING for two seconds before monitoring begins. If the FN key is pressed while it isstill flashing, the command will be canceled. See Normal Operation for more information.

· SET SCROLL OFF This item is displayed when the scrolling is currently turned on.Select it to turn scrolling off. When scrolling is inactive the displayed menu items will notchange until a menu key (UP ARROW, DOWN ARROW, FN or ENTER) is pressed.

· SET SCROLL ON This item is displayed when the scrolling is currently turned off.Select it to turn scrolling on. When scrolling is active, the displayed menu items willchange once every two seconds.

Test Menu

· CONTACT TEST Select this item to start an interactive test of the relay contacts. TheGGD will place all relays except one in a de-energized condition. The LCD will display thename of the single relay that is still energized. Use the arrow keys to change which relayis energized. Press the FN or ENTER keys to terminate the test.

· KEYPAD TEST Select this item to start an interactive test of the keypad. The LCD willdisplay the prompt PRESS ANY KEY at the start of the test. Test the keypad by pressing,one at a time, all of the keys on the keypad, reserving the FN key for last. The LCD willecho the name of each key as it is pressed. The test will terminate when the FN key ispressed.

· OUTPUT TEST Select this item to start an interactive test of the 4-20 mA outputs. TheGGD will set the 4-20 mA outputs to four milliamps and display CURRENT=4mA on theLCD display at the start of the test. Use the arrow keys to increase or decrease thecurrent in one milliamp steps. Press FN or ENTER to terminate the test.

· POWER TEST Select this item to test the power supplies. When POWER TEST isselected, the GGD will display the voltage for each power supply in the format <nominal

15 HA0296P01 Rev. A

value>=<present value>. An example for the 12-volt power supply is +12 VOLTS =12.1.The GGD will scroll through all five power supply voltages. The voltages are displayed fortwo seconds each.

· RELAY TEST Select this item to test all of the relays. The LCD will display RELAY TEST… The system will cause each relay to be energized. If no errors are detected, the LCDwill display RELAYS PASS. If an error is detected, the LCD will display the failure modeand then list the names of the malfunctioning relays. The failure modes are STUCK ONand STUCK OFF. See Table 5 for a list of the probable cause(s) of these errors.

Tools Menu

· SET TO MANUAL Select this item to place the dryer in manual mode. This selection isonly present when you are in automatic mode.

· SET TO AUTOMATIC Select this item to place the dryer in automatic mode. This selec-tion is only present when you are drying in manual mode.

· REGEN RIGHT COL Select this item to regenerate the right column. This selection isonly present when you are in manual mode.

· REGEN LEFT COL Select this item to regenerate the left column. This selection is onlypresent when you are in manual mode.

· VENT RIGHT COL Select this item to vent the right column. This selection is onlypresent when you are in manual mode.

· VENT LEFT COL Select this item to vent the left column. This selection is only presentwhen you are in manual mode.

· DRY WITH RIGHT Select this item to start drying with the right column. This selection isonly present when you are in manual mode.

· DRY WITH LEFT Select this item to start drying with the left column. This selection isonly present when you are in manual mode.

· STOP REGEN Select this item to stop regeneration. This selection is only present whenthe dryer is regenerating in manual mode.

· STOP DRYING Select this item to stop the blower motor. This selection is only presentwhen the blower is on and you are in manual mode.

View Menu

· VIEW COLUMN Select this item to display the column, outlet or control gas temperatureand pressure. Press the FN key to return to the VIEW MENU.

· VIEW VALVES Select this item to display valve status. The LCD will display an indicatorfor each valve energized. The indicators are: RV, LV, RD, LD and M. RV indicates theright vent valve is open; LV indicates the left vent valve is open; RD indicates that the inletvalve to the right column is open; LD indicates that the inlet valve to the left column isopen; M indicates that the blower motor is on. Press the FN key to return to the VIEWMENU.

16HA0296P01 Rev. A

· VIEW STATUS Select this item to display dryer status. The LCD will display one of thefollowing status indicators: DISABLED, NORMAL OPERATION, CHANGEOVER, VENT-ING, HEATING, REGENERATING, COOLING or HEATER FAULT. Press the FN key toreturn to the VIEW MENU.

· VIEW 12BIT ADC Select this item to display the voltage at each of the 12 inputs of the12-bit A/D converters. Use the UP ARROW key or DOWN ARROW key to scroll throughall 12 channels. Press the FN key to return to the VIEW MENU.

• VIEW COUNTERS Select this item to display the internal usage counters. There are fourcounters: THIS DRY, THIS REGEN, LAST DRY and LAST REGEN. THIS DRY indicateshow long the current column has been drying in hours. THIS REGEN indicates how longthe current regeneration has been active in minutes. (If the dryer is not regenerating, thiscounter will read zero.) LAST DRY indicates how long the previous column dried. LASTREGEN indicates how long the last regeneration took in minutes. Use the UP ARROWkey or DOWN ARROW key to scroll through all four counters. Press the FN key to returnto the VIEW MENU.

17 HA0296P01 Rev. A

Procedures

Sensor Calibration

The GGD uses four pressure sensors: Left Column Pressure, Right Column Pressure,Outlet Pressure and Control Gas Pressure. All four sensors use the same setup procedure.Three operations can be performed on each sensor: SET GAIN, SET ZERO and RESET.

· RESET The gain and zero points for the sensor can be reset to the factory default valuesby selecting RESET.

· SET ZERO The zero point for the sensor can be changed with this function.

When SET ZERO is selected, the current pressure will be displayed on the LCD display. Theactual pressure present at the sensor input should be zero before zeroing the sensor. Pressthe UP ARROW key to increase it by 0.1; press the DOWN ARROW key to decrease it by0.1. Press the UP ARROW and DOWN ARROW keys as required to make the displayedpressure match the actual pressure present at the sensor input. Press the ENTER key tosave your changes and return to the SENSOR MENU. Press the FN key to discard thechanges and return to the SENSOR MENU.

· SET GAIN The gain of the sensor can be changed with this function.

When SET GAIN is selected, the current pressure will be displayed on the LCD display. Zerothe sensor before setting the gain. Press the UP ARROW key to increase it by 0.1; press theDOWN ARROW key to decrease it by 0.1. Press the UP ARROW and DOWN ARROWkeys as required to make the displayed pressure match the actual pressure present at thesensor input. Press the ENTER key to save your changes and return to the SENSOR MENU.Press the FN key to discard the changes and return to the SENSOR MENU.

Setting the Dew Point Alarm Level

· DEWPOINT ALARM If the dew point exceeds the dew point alarm level the DEW POINTHIGH relay will activate.

When DEWPOINT ALARM is selected, the dew point alarm level will be displayed on theLCD display. Press the UP ARROW key to increase it; press the DOWN ARROW key todecrease it. Press the ENTER key to save your changes and return to the SENSOR MENU.Press the FN key to discard the changes and return to the SENSOR MENU.

Setting the Desired Dew Point Level

· DESIRED DEWPOINT If the outlet dew point rises above the desired dew point level thedryer will switch columns and start regenerating.

When DESIRED DEWPOINT is selected, the desired dew point level will be displayed on theLCD display. Press the UP ARROW key to increase it; press the DOWN ARROW key todecrease it. Press the ENTER key to save your changes and return to the SENSOR MENU.Press the FN key to discard the changes and return to the SENSOR MENU.

18HA0296P01 Rev. A

Setting the Minimum Drying Time

· MIN DRY TIME The dryer will not switch columns and start regeneration until the columnhas been drying for the minimum drying time. The switch will be blocked even if the outletdew point is greater than the desired dew point level or the maximum drying time hasbeen exceeded.

When SET MIN DRY TIME is selected, the minimum drying time will be displayed on theLCD display. Press the UP ARROW key to increase it; press the DOWN ARROW key todecrease it. Press the ENTER key to save your changes and return to the SENSOR MENU.Press the FN key to discard the changes and return to the SENSOR MENU.

Setting the Maximum Drying Time

· MAX DRY TIME Once a column has been drying for the maximum drying time, it willswitch columns and start regenerating. The switch will occur even if the outlet dew pointis less than the desired dew point level. However, the minimum drying time will overridethe maximum drying time.

When SET MAX DRY TIME is selected, the maximum drying time will be displayed on theLCD display. Press the UP ARROW key to increase it; press the DOWN ARROW key todecrease it. Press the ENTER key to save your changes and return to the SENSOR MENU.Press the FN key to discard the changes and return to the SENSOR MENU.

Clearing a Heater Fault

The dryer must be in manual mode before you can clear a HEATER FAULT. Select SET TOMANUAL from the TOOLS MENU to enter manual mode. If SET TO MANUAL does notappear on the TOOLS MENU, then you are already in manual mode.

The TROUBLE LED will be illuminated and the TROUBLE RELAY de-energized (asserted)whenever the GGD is in manual mode.

The RESET HEATER will be the only option shown on the TOOLS MENU when a HEATERFAULT is present. The RESET HEATER prompt will be followed by a number between 1 and3. The number corresponds to the fault type:

• Fault #1 is an overheat fault. Its presence indicates that the column temperature ex-ceeded 225 C during the regeneration processes.

• Fault #2 is the heating rate fault. It indicates that the column did not reach 60 C within 20minutes of the heater temperature beginning to rise.

• Fault #3 is a heating response fault. It indicates that the column did not rise at least 10 Cwithin 20 minutes of the heater being energized.

Select RESET HEATER to clear the fault. The dryer will respond with the prompt HEATERRESET.


The Faults log traps these error conditions: I/O Read Error, I/O Write Error, Sensor Fault,and Power Fault.

19 HA0296P01 Rev. A

· An I/O Read Error is logged when a read error is detected in the communication channelthat connects the processor and I/O board.

· An I/O Write Error is logged when a write error is detected in the communication channelthat connects the processor and I/O board.

· A Temperature Fault is logged when the temperature of either column is less than 0 C orgreater than 52 C unless the dryer is regenerating. The upper limit for the inactive columnis raised to 215 C during regeneration.

· A Pressure Fault is logged when the pressure of either column is less than 10 PSI orgreater than 90 PSI unless the column is being vented. The upper limit for a column is 5psi while venting. There is no lower limit on a venting column. Also, a Pressure Fault islogged when the control pressure drops below 33 PSI.

· A Motor Fault is logged when the output temperature exceeds 100 C.

· A Heater Fault is logged when the temperature of a heated column does not match theexpected temperature profile. A fault is logged if the temperature does not rise fastenough or if the column temperature exceeds 225 C. Both column heaters are disableduntil the fault condition is cleared. The heaters must be reset through the TOOLS MENUbefore this fault can be cleared.

· A Sensor Fault is logged when the output of a sensor is outside of the expected rangeduring normal operating mode.

· A Power Fault is logged when the measured voltage of one or more of the power suppliesis out of specification.

About the Power Log


When SHOW POWER LOG is selected, the GGD will display the minimum and maximumfor each power supply in the format <nominal value>=<minimum value>,<maximum value>.An example for the 12-volt power supply is +12V=11.8,12.1. Use the UP ARROW key orDOWN ARROW key to scroll through the five power supply voltages. Press the FN key toreturn to the LOG MENU.

20HA0296P01 Rev. A

Modes of Operation

Startup

The GGD initializes all relays to the de-energized position.

The GGD executes a “power-on self-test” (POST) to verify its proper operation. It verifies itssoftware by checksum testing the contents of its read-only memory (ROM). It tests all of itspower supplies and all of its relays.

The POST will take about 20 seconds to complete if no errors are encountered. At theconclusion of the POST the GGD display panel will alternately flash TO START DRYER andPRESS ENTER. If the ENTER key is pressed, the GGD will start drying in automatic mode. Ifthe FN key is pressed, the dryer will not start and it will enter manual operation instead.

Startup Problems

Immediately after power-up, the GGD begins searching for a display. If the local display ispresent and functioning properly, the search will complete in less than one tenth of a second.If the GGD cannot communicate with the local display, LINKING … may appear on the LCD.If the GGD cannot find a local display within four seconds, it will assume one is present andproceed with the POST.

The GGD verifies its software by checksum testing the contents of its read-only memory(ROM). If it finds a problem, it will stop the POST process and flash BAD CHECKSUM on theLCD. The FN key may be pressed to allow the GGD to continue the POST process. How-ever, proper operation cannot be guaranteed if this error is present.

The GGD will annunciate any problems it finds with the power supplies or relays. The pres-ence of one or more of these faults will not stop the POST process. However, they should becorrected as soon as possible because they indicate a hardware problem.

Manual Operation

When the GGD is in manual mode all automatic responses are disabled and you can manu-ally control the dryer. You can start or stop the drying processes. You can switch whichcolumn is drying. You can start or stop regenerating a column. You can start or stop ventinga column.

The TROUBLE LED will be illuminated and the TROUBLE RELAY de-energized (asserted)whenever the GGD is in manual operation.

Select SET TO MANUAL from the TOOLS MENU to enter manual mode. If SET TO MANUALdoes not appear on the TOOLS MENU then you are already in manual mode.

Manual Column Regeneration

The dryer must be in manual mode before you can begin a manual regeneration. Select SETTO MANUAL from the Tools menu to enter manual mode. If SET TO MANUAL does notappear on the Tools menu, then you are already in manual mode.

21 HA0296P01 Rev. A


Select REGEN RIGHT COL or REGEN LEFT COL from the Tools menu to start regenera-tion. REGEN RIGHT COL will not appear on the menu if you are drying with the right columnor regenerating/venting either column. REGEN LEFT COL will not appear on the menu if youare drying with the left column or regenerating/venting either column.

Once REGEN RIGHT COL or REGEN LEFT COL has been selected, the dryer will respondby flashing STARTING … on the LCD display. (The prompt CHANGING COLUMN mayprecede the STARTING … prompt under certain circumstances.) Once regeneration begins,the Tools menu will refresh.

Manual Column Venting



Select VENT RIGHT COL or VENT LEFT COL from the TOOLS MENU to start venting.VENT RIGHT COL will not appear on the menu if you are drying with the right column orregenerating/venting either column. VENT LEFT COL will not appear on the menu if you aredrying with the left column or regenerating/venting either column.

Once VENT RIGHT COL or VENT LEFT COL has been selected the dryer will respond byflashing VENTING… on the LCD display. (The prompt CHANGING COLUMN may precedethe VENTING… prompt under certain circumstances.) Once venting starts, the Tools menuwill refresh.

Manual Column Drying



Select DRY WITH RIGHT or DRY WITH LEFT from the Tools menu to start drying with theindicated column. DRY WITH RIGHT will not appear on the menu if you are drying, regener-ating or venting the right column. DRY WITH LEFT will not appear on the menu if you aredrying, regenerating or venting the left column.

The dryer will respond in one of two ways to the selection of DRY WITH RIGHT or DRYWITH LEFT, depending on its current status. The dryer will display CHANGING COLUMN onthe LCD display if the dryer is currently drying and you have elected to switch to a differentcolumn. It will display TESTING … on the LCD display if the dryer is not currently drying. (Theprompt CHANGING COLUMN may precede the TESTING… prompt under certain circum-stances.) Following the TESTING… prompt, the dryer will display the column selected andits temperature and pressure. Once drying starts, the Tools menu will refresh.

22HA0296P01 Rev. A

Normal Operation

When the GGD is in normal operation, it will manage column changeover and regenerationautomatically. It will use the values of the minimum drying time, maximum drying time anddesired dew point to determine how often to change and regenerate a column.

The GGD will display the inlet and outlet dew points on the numerical displays. It will energizethe dew point high relay if the inlet dew point is greater than the dew point alarm level. Theinlet and outlet dew points are also available through two 4-20 mA outputs.

The 4-20 mA current output corresponds to –80 to +20 degrees centigrade.

REMINDER! Should the system go into trouble, access the menu items SHOWFAULTS LOG and SHOW POWER LOG for more information.

23 HA0296P01 Rev. A

Maintenance and Repair

Maintenance, Repair and Adjustments

WARNING! Ensure that the dryer and any associated pre-filters and after-filters arevalve isolated, and fully depressurized before attempting to remove or disassembleany components or subassemblies. Failure to do so may result in serious personalinjury and/or equipment damage.

WARNING! All vents, exhaust, and purge connections must be piped to a safe loca-tion. Failure to do so may create a hazard that could cause serious personal injuryand/or equipment damage.

WARNING! The entire system must be purged of all air prior to any start up (or re-start) procedure following shutdowns for maintenance and/or whenever Oxygen mayhave been introduced into the system. Failure to do may result in serious personalinjury and/or equipment damage. (Refer to the Hydrogen Sweep Procedure in Mainte-nance, Repair and Adjustments.)

CAUTION! A leak test must be performed at regular intervals to assure the integrity ofequipment and make certain that no hazard exists due to hydrogen leakage. Refer tothe weekly preventative maintenance section for leak test procedure.

(GGD Figure 4) Sweep Ports “A” and “B” are recommended for sweep. Connect sweep toremove Hydrogen as follows:

1. De-energize the Hydrogen Coolant Purifier’s electrical system.

2. Open Purifier’s Bypass Valve (if Purifier system has been so equipped).

3. Close and lockout the Purifier’s Inlet and Outlet Block Valves (customer supplied).

4. Connect Sweep Port B to customer vent.

5. Open Sweep Port B. Allow the Purifier to bleed down to 3 to 5 PSIG.

6. Close Sweep Port B.

7. Pressurize the Purifier with an inert gas (Nitrogen, Carbon Dioxide, etc.), to 60 PSIGthrough Sweep Port A.

8. Close Sweep Port A and repeat steps 5 though 7 two more times.

9. Close Sweep Port A.

10. Using a LOL meter, check for a satisfactory quality (< 20% LEL) of gas at the Pre-filterand After-filter Drain Valves and both chamber pre-start up valves.

11. After achieving a satisfactory quality (< 20% LEL) of gas, open Sweep Port B and allowthe Purifier to bleed down to zero PSIG.

12. Close Sweep Ports A and B. The Purifier may now be serviced.

24HA0296P01 Rev. A

Daily

WARNING! The entire system requires a specific start up procedure each and everytime the equipment has been shutdown for maintenance and/or any period of time.The entire system must be purged of all air prior to any start up using the start uppurge procedure detailed in the manual. Failure to do so may result in serious per-sonal injury and/or equipment damage.

1. Check operation of pre-filter drain. Manual drain valve MUST be operated daily to maintainfilter efficiency and prevent premature desiccant failure.

2. Check Blower oil levels as instructed in the Blower Installation & Lubrication InstructionSection.

Weekly

1. Check the following operating conditions: purge rate, inlet pressure, inlet flow rate andinlet temperature.

When checking purge rate, refer to Dryer Specification & Performance Data Sheet andRotameter Calibration Data Sheet.

2. Check pressure drop (differential pressure) across Dryer and Blower.

3. Check dryer operation and switching valves.

4. Leak test the dryer and associated piping to maintain a non-hazardous area.

Monthly

Change blower lubricating oil after every 1500 hours of blower operation. Refer to the BlowerInstallation & Lubrication Instruction Section for oil specifications and instructions.

Quarterly



Inspect the Pilot Gas Filter Cartridge and replace if the used cartridge appears clogged, dirty,or excessively corroded.

Semi-Annually

WARNING! The entire system requires a specific start up procedure each and everytime the equipment has been shutdown for maintenance and/or any period of time.

25 HA0296P01 Rev. A

The entire system must be purged of all air prior to any start up using the start uppurge procedure detailed in the manual. Failure to do so may result in serious per-sonal injury and/or equipment damage.


1. Inspect the Pre-filter Cartridge for clogging, excessive corrosion, cracked or damagedend seals or high pressure drop (differential pressure). Replace cartridge if necessary.

2. Inspect the After-filter Cartridge for clogging, excessive corrosion, cracked or damagedend seals or high pressure drop (differential pressure). Replace cartridge if necessary.

Annually



1. Disassemble, clean and inspect the Outlet and Purge Check Valve Assemblies. Replaceall damaged or worn parts.

2. Disassemble, clean and inspect the Inlet Switching and Purge Exhaust Switching Valves.Replace all damaged or worn parts.

3. Remove the desiccant fill port flanges and desiccant retaining screens from the top ofeach desiccant chamber. Visually inspect the desiccant through each chamber’s fill port.Replace desiccant if it appears badly broken or discolored.

4. Heaters: After an initial three years of operation, one or two heaters should be pulled fromeach chamber and inspected for warpage or cracks developing in the heater sheath. Ifany of these conditions are observed, all the heaters should be replaced. This inspectionof the heaters should now become part of the annual preventative maintenance to pre-vent heater burnout.

Note: Heater burnout may cause damage to the heater tube sheath causing extensive downtime and costly repairs.

Desiccant Replacement Procedure

WARNING! The GGD has been designed to process pure Hydrogen gas only. NoOxygen must be present within the gas being processed. Failure to keep the Hydro-gen free of Oxygen may result in serious personal injury and/or equipment damage.

26HA0296P01 Rev. A


CAUTION! Before attempting to change the desiccant, make sure that the desiccantis fully cooled.

CAUTION! Dryer models covered within the scope of this manual are designed to usea specific desiccant. Use of any other size or type may reduce efficiency or damagethe dryer.

WARNING! Ensure that the dryer is de-energized, valve isolated and fully depressur-ized before attempting to remove or disassemble any dryer component or subassem-bly. Failure to do so may result in serious personal injury and/or equipment damage.

CAUTION! Prior to installing desiccant, review all applicable Material Safety DataSheets and container warnings. Safety Data Sheets may be obtained from the manu-facturers Safety Coordinator. Exercise all necessary precautions for your health andwelfare.

WARNING! A static electric charge can build up when pouring desiccants or drypowders. Proper grounding should be observed when pouring from a container (bag,drum, etc.).

WARNING! Do not transfer desiccant under pressure. Malfunction or improper use ofequipment can propel beads with enough velocity to penetrate skin.

WARNING! Used desiccant material must be handled with special care. Desiccant isan absorbent material. Used desiccant may contain chemicals and/or gases that arehazardous, toxic and/or flammable. It is recommended that all used desiccant beanalyzed to determine content before disposal. Exercise proper care and proce-dures during handling and storage of used materials. All containers must be properlylabeled and disposed of in accordance with local, state, and federal regulations.

1. Remove the desiccant fill port flanges and internal desiccant retaining screens installedin the top of each desiccant chamber.

2. Remove desiccant drain port flanges, located in the front of the chamber, and draindesiccant into suitable disposable containers.

3. Use a flashlight to inspect each chamber through its respective fill port to ensure that alldesiccant has been drained. LIGHT tapping on the chamber wall with a soft-faced malletmay be required to assist in the removal of lingering desiccant.

4. Replace gaskets and reinstall desiccant drain port flanges.

5. Refer to the Dryer Specification and Performance Data Sheet for quantity of desiccantrequired for each desiccant chamber.

6. Utilizing an appropriately sized funnel, fill each chamber with desiccant until the specifiedquantity has been installed. LIGHT tapping on the chamber wall with a soft-faced mallet

27 HA0296P01 Rev. A

should yield additional free space to allow installation of the specified quantity. DO NOTTAMP OR RAM DESICCANT.

Note: Do not be alarmed if the specified quantity of desiccant cannot be installed in eachchamber. Desiccant levels will settle after approximately two to three weeks of normal opera-tion. Following this “settling” period, desiccant should be added as necessary to return levelsto the BOTTOM of each chamber’s retaining screen (when installed).

7. Replace gaskets and reinstall the fill port flange and integral desiccant retaining screen ineach desiccant chamber, and torque flange bolts to a reasonable limit.

Heater Installation Procedure


1. Turn off power to the dryer. Main switch should be locked in “OFF” position and/or clearlytagged that it must not be turned on except by authorized personnel.

2. Prior to opening the main junction box, remove power from the dryer and ensure that thesystem is free of hydrogen.

3. Disconnect wiring to element(s) to be replaced.

4. Remove the cable gland and coupling retaining element in heater tube. Slide the elementdown and out of the heater tube, bending it to facilitate removal. If element does not bend,cut it off.

5. Grasp replacement element at the end opposite the lead wires and bend the tip in ap-proximately an 18 inch radius until an angle of about 90 degrees is reached. As theelement is inserted into the heater tube, straighten the element where it enters the wellwhile continuing to bend the element further along its length until it is completely inserted(GGD Figure 5).

6. Upon fully inserting the uncoiled heater into the heater tube, observe that a small rod isattached to one of the ends of the heater element (GGD Figure 6). This rod will just fitinside the heater tube. The two ends of the heater element must be located where therod is centered in the conduit coupling that connects to the heater tube.

7. Once the heater element is fully inserted up into the heater tube, tighten the conduitcoupling onto the heater tube threads and secure the cable gland. The heater element isnow firmly secured in the heater tube.

8. All that remains is to reconnect the cable leads in the main junction box. Ensure that thecable glands are properly tightened.

9. Replace the junction box cover.

28HA0296P01 Rev. A

Heater Check Out Procedure

WARNING! The entire system must be purged of all air prior to any start up (or re-start) procedure following shutdowns for maintenance and/or whenever Oxygen mayhave been introduced into the system. Failure to do so may result in serious per-sonal injury and/or equipment damage. (Refer to the Hydrogen Sweep Procedure inMaintenance, Repair and Adjustments.)

To check heaters use the following procedure:

Refer to the wiring schematic drawing in the drawing pocket of this manual.

1. Check to see if nominal voltage (see specification sheet) is supplied.

2. With a clamp-on amp meter, check the amperage on each heater leg. The amperageshould be equal within 10%.

3. If low amperage is found on one leg of heaters, de-energize the electrical circuit, depres-surize system, and vent off hydrogen from system. Open and purge the dryer withcarbon dioxide or nitrogen and check each of the three legs for continuity, with an ohmmeter. A burned out heater will be indicated by an open continuity circuit.

Inlet Switching Valve Disassembly


WARNING! Ensure that the dryer is de-energized, valve isolated, and fullydepressurized before attempting toremove or disassemble any dryer com-ponent or subassembly. Failure to do somay result in serious personal injuryand/or equipment damage.

Note: Removal of valve body [15] from thedryer manifold is not required unless re-placement of square O-rings [16] or valvebody is necessary.

Note: GGD Figure 7 illustrates one-half ofinlet switching valve only. Disassembly ofopposite half (not shown exploded), isidentical.

1. Clean and inspect all valve hardwareupon disassembly. Replace all softwareand any hardware which appearsdamaged or abnormally worn.

Inlet Switching Valve

Item Description Total

1 Sockethead Cap Screw 83 Valve Cover 24 O-Ring 45 Poppet Shaft 26 Piston Seal 47 Valve Bonnet 28 Rod Scraper 210 O-Ring 411 Seal Retainer 212 Valve Seat Seal 213 Retaining Disc 214 Seal Nut 215 Valve Body 116 Square O-Ring 217 Sockethead Cap Screw 418 Tube Compression Elbow 2

29 HA0296P01 Rev. A

2. Clean and inspect valve seat located inside the valve body [15]. As previously noted, thiscan be accomplished without removing the valve body [15] from the dryer manifold.

3. Apply an ultra-thin film of O-ring lubricant (good for 400 F compatible with silicone/viton)to items [4], [6], [10], and [16] before reassembly. DO NOT APPLY LUBRICANT TO THEVALVE SEAT SEAL [12].

4. The U-cup piston seal [6] has been fitted with a cut O-ring. Ensure that the U-cup pistonseal is installed on the valve piston [5] as shown. The open side of the U-cup piston seal[6] must face the valve cover [3] upon reassembly.

IMPORTANT! Due to potential damage of screwed fasteners from over torquing,fatigue, and corrosion, maintain the following procedure. Inspect internal threads forconformity to ensure no damage was caused during previous assembly and/ ordisassembly, and remove all foreign debris. Install the new bolts provided in therepair kit and torque as follows:

Size Torque

1/4 - 20 30 - 40 inch lbs. (3.4 - 4.5 Nm)5/16-18 130-135 inch lbs. (14.7-15.3 Nm)3/8-16 240 - 245 inch lbs. (27.1 - 27.7 Nm)1/2-13 525 - 550 inch lbs. (59.3 - 62.2 Nm)

Nm = Newton-meters

Exhaust Switching Valve Disassembly


WARNING! Ensure that the dryer is de-energized, valve isolated, and fully depressur-ized before attempting to remove or disassemble any dryer component or subassem-bly. Failure to do so may result in serious personal injury and/or equipment damage.

Note: Removal of valve body [15] from the dryer manifold is not required unless replace-ment of square O-rings [16] or valve body is necessary.

Note: GGD Figure 8 illustrates one-half of exhaust switching valve only. Disassembly of theopposite half (not shown exploded) is identical.

1. Clean and inspect all valve hardware upon disassembly. Replace all software and anyhardware that appears damaged or abnormally worn.

2. Clean and inspect the valve seat located inside the valve body [15]. As previously noted,this can be accomplished without removing the valve body [15] from the dryer manifold.

3. Apply an ultra-thin film of O-ring lubricant (good for 400 F compatible with silicone/viton)to items [4], [6], [10] and [16] before reassembly. DO NOT APPLY LUBRICANT TOTHE VALVE SEAT SEAL [12].

30HA0296P01 Rev. A

4. The U-cup piston seal [6] has been fittedwith a cut O-ring. Ensure that the U-cuppiston seal is installed on the valvepiston [5] as shown. The open side ofthe U-cup piston seal [6] must face thevalve cover [3] upon reassembly.

IMPORTANT! Due to potential damage ofscrewed fasteners from over torquing,fatigue, and corrosion, maintain thefollowing procedure. Inspect internalthreads for conformity to ensure nodamage was caused during previousassembly and/ or disassembly, andremove all foreign debris. Install thenew bolts provided in the repair kit andtorque as follows:

Size Torque

1/4 - 20 30 - 40 inch lbs.(3.4 - 4.5 Nm)

5/16-18 130-135 inch lbs.(14.7-15.3 Nm)

3/8-16 240 - 245 inch lbs. (27.1 - 27.7 Nm)1/2-13 525 - 550 inch lbs. (59.3 - 62.2 Nm)

Nm = Newton-meters

Purge and Outlet Check Valve Disassembly


WARNING! Ensure that the dryer is de-energized, valve isolated, and fully depressur-ized before attempting to remove or disassemble any dryer component or subassem-bly. Failure to do so may result in serious personal injury and/or equipment damage.

Note: DO NOT remove poppet guides [18] from the outlet check valve cover [14] unlesswear or damage necessitates replacement.

1. Clean and inspect all valve hardware upon disassembly (GGD Figure 9). Replace allsoftware and any hardware which appears damaged or abnormally worn. Closely inspectvalve poppets [25], check balls [8], purge adjusting valve [12] and associated mating-sealing surfaces for any faults which could prevent positive sealing.

2. Apply an ultra-thin film of O-ring lubricant (good for 400 F compatible with silicone/viton)to items [6], [7], [10], [11], [16], [17], and [23]. DO NOT APPLY LUBRICANT TO CHECKBALLS [8] OR VALVE POPPETS [25].

IMPORTANT! Due to potential damage of screwed fasteners from over torquing,

Exhaust Switching Valve


1 Sockethead Cap Screw 83 Valve Cover 24 O-Ring 45 Poppet Shaft 26 Piston Seal 47 Valve Bonnet 28 Rod Scraper 210 O-Ring 411 Seal Retainer 212 Valve Seat Seal 213 Retaining Disc 214 Seal Nut 215 Valve Body 116 Square O-Ring 217 Sockethead Cap Screw 418 Tube Compression Elbow 2

31 HA0296P01 Rev. A

fatigue, and corrosion, maintain thefollowing procedure. Inspect internalthreads for conformity to ensure nodamage was caused during previousassembly and/or disassembly, and re-move all foreign debris. Install the newbolts provided in the repair kit andtorque as follows:

Size Torque

1/4 - 20 30 - 40 inch lbs.(3.4 - 4.5 Nm)

5/16-18 130-135 inch lbs.(14.7-15.3 Nm)

3/8-16 240 - 245 inch lbs.(27.1 - 27.7 Nm)

1/2-13 525 - 550 inch lbs.(59.3 - 62.2 Nm)

Nm = Newton-meters

Purge & Outlet Check Valve


1 Pipe Plug 22 Sockethead Cap Screw 43 Sockethead Cap Screw 44 Flow Block 16 O-Ring 17 O-Ring 28 Check Ball 29 Purge Block 110 O-Ring 211 O-Ring 112 Purge Adjusting Valve 113 Valve Guide 114 Check Valve Cover 115 Valve Housing 116 O-Ring 217 O-Ring 118 Poppet Guide 219 Valve Spring 223 Square O-Ring 225 Valve Poppet 226 Valve Seat 1

32HA0296P01 Rev. A

Troubleshooting

WARNING! Your Model 25HCP (Hydrogen Coolant Purifier) has been designed toprocess pure Hydrogen gas only. No Oxygen must be present within the gas beingprocessed. Failure to keep the Hydrogen free of Oxygen may result in serious per-sonal injury and/or equipment damage.


WARNING! All vent, exhaust, and purge connections must be piped to a safe location.Failure to do so may create a hazard that could cause serious personal injury and/orequipment damage.

CAUTION! A leak test must be performed at regular intervals to assure the integrity ofthe equipment and to make certain that no hazard exists due to Hydrogen leakage.Refer to the weekly preventative maintenance section for leak test procedure.

CAUTION! This equipment has been designed for installation in a non-hazardousarea as described by the National Electrical Code. Installation of this equipment in ahazardous location may result in personal injury and/or equipment damage.

WARNING! Some of the following troubleshooting checks require entering the dryercontrol system enclosure while the dryer’s electrical supply is energized. Therefore,a potential shock hazard exists. These checks should be conducted by a qualifiedelectrical technician or a Pneumatic Products Authorized Field Service EngineerONLY. The dryer’s electrical power supply must be de-energized before any electri-cal maintenance or repair work is conducted.

Problem Possible Cause Remedy

1. Insufficient or excessive purgegas flow for regeneration.

2. Inlet gas dew point higher thanthe design conditions.

3. Liquids entering the dryer wetgas inlet.

Dew Point 1. Check purge flow required and adjustpurge adjusting valve.

2. Check the dew point of the gas beingdried and allow time for moisture pull down.

3a. Check the incoming line. Inspect pre-filter and be certain that the liquid has beendrained.

3b. Check pre-filter gasket for good sealintegrity.

33 HA0296P01 Rev. A

Problem Possible Cause Remedy

4. Desiccant broken and coatedwith oil.

5. Incomplete regeneration of bed.

6. Back pressure in regenerationchamber.

Dew Point 4. Replace desiccant and correct thesource of trouble. Check pre-filter.

5a. Check heaters.

5b. Check purge setting..

6. Refer to Back Pressure in RegenerationChamber of section of this table.

1. Exhaust valve fails to close.Failure toRepressurize

1. Inspect exhaust valve and clean.

1. Filters dirty.ExcessivePressureDrop in Filters

1. Replace as required.

1. Desiccant retaining screens areclogged or fouled.

2. Heavier gas than hydrogen ispresent.

3. Inlet pressures below designpressure.

ExcessivePressure Dropin Dryer

1. Inspect and clean.

2. Check the gas that is being dried.

3. Increase inlet pressure to design pres-sure.

1. No input power.

2. Pilot gas failure.

Failure toSwitch

1. Check wiring, fuses and/or powersource.

2. Check solenoid valves for open circuitcoil or inoperative valve.

1. Check valves are leaking.

2. Excessive purge flow.

3. Leaking inlet switching valves.

4. Exhaust valve not fully open.

5. Too much purge flow.

Back Pressureon Regenerat-ing Chamber

1. Inspect check valves in outlet and purgeblocks, then clean.

2. Check required purge flow.

3. Inspect valves and clean or replaceparts, if required.

4. Remove valve bonnet and clean outdust. Wipe poppet shaft clean.

5. Adjust purge flow per specificationsheets.

34HA0296P01 Rev. A


The pressure sensors, input/output circuit board, processor circuit boards, power suppliesand intrinsically safe barriers are located inside the main junction box. To gain access to theinside of the main junction box for service, remove the 32 3/4-inch captive bolts. Two guidestuds assist with removal/replacement.

CAUTION! Do not scratch sealing surfaces on the main junction box. The main junc-tion box lid weighs 50 lbs (22.7 kg). Take precautions during removal. Prior to open-ing the main junction box, remove power from the GAS STATION and ensure thesystem is free of hydrogen.

Removing a Pressure Transducer

To remove a pressure transducer from a flameproof enclosure:



3. Remove the cover of the main junction box.

4. Disconnect the three wires that connect the pressure transducer to the I/O board.

5. Unscrew the pressure sensor from the flame arrestor.

6. To reinstall a pressure sensor, reverse above process, and then leak check.





3. Disconnect the 20-pin ribbon cable and 4 nuts (11/32).

4. Remove the processor board.


6. Check that pin #1 on the ribbon connector is properly aligned.




3. Disconnect the 20-pin ribbon cable and 4 nuts (11/32).

4. Remove the processor board.

35 HA0296P01 Rev. A

5. Remove the 4 standoffs that hold the board in place.




36HA0296P01 Rev. A

Parts Lists

Recommended GGD Spare Parts (Stocked by Customer)


Inlet Cartridge DA0103P03 Inlet cartridge

Outlet Cartridge DA0103P02 Outlet cartridge

Desiccant DA0118P01 Desiccant

Blower Hydraulic Oil DA0119P01 Blower hydraulic oil

Ball Valve Rebuild Kit DA0120P01 Ball valve rebuild kit

Recommended GGD Replacement Parts (Stocked by E/One)


Blower Assembly HC0084P04 Blower assembly

Isolation Valve HA0011P01 1/4" female isolation ball valve, SS

Dew Point Transmitter DB0100P01 Dew point transmitter

Temperature Probe DA0104P01 Temperature transmitter

Display PCB DD0107G01 Display PCB X

Processor Control PCB HB0026G01 Processor control PCB X

Inlet/Outlet Filter Body DA0103P01 Inlet/Outlet filter body

Inlet Cartridge DA0103P03 Inlet cartridge

Outlet Cartridge DA0103P02 Outlet cartridge

Control Solenoids DA0100P01 Four-way solenoid coil

Purge Solenoid Valve GA0224P03 Skinner solenoid valve

37 HA0296P01 Rev. A

Figures

38HA0296P01 Rev. A

39 HA0296P01 Rev. A

GGD Figure 1 - Dryer Module and System Piping

40HA0296P01 Rev. A

GGD Figure 2 - Generator Gas Dryer Display/Valve Panel

41 HA0296P01 Rev. A

GGD Figure 3 - Menu Tree

SETUP MENU

VIEW MENU

LOG MENUFUNCTION MENU

TOOLS MENU

SHOW FAULTS LOG

CLEAR FAULTS LOG

SHOW POWER LOG

CLEAR POWER LOG

SHOW PROGRAM ID

SET PASSWORD

SETUP SENSORS

DEWPOINT ALARM

DESIRED DEWPOINT

SET MIN DRY TIME

SET MAX DRY TIME

SET SCROLL ON

SET SCROLL OFF

START MONITORING

STOP MONITORING

CONTACT TEST

RELAY TEST

POWER TEST

OUTPUT TEST

KEYPAD TEST

VIEW 12BIT ADC

TEST MENU

VIEW STATUS

VIEW VALVES

VIEW COLUMN

REGEN LEFT COL.

REGEN RIGHT COL.

VENT LEFT COL.

VENT RIGHT COL.

DRY WITH LEFT

DRY WITH RIGHT

SET TO AUTOMATIC

SET TO MANUAL

STOP DRYING

STOP REGEN

OUTLET PRES

LEFT COL PRES

RIGHT COL PRES

CONTROL PRES

SET GAIN

SET ZERO

RESET

SET GAIN

SET ZERO

RESET

SET GAIN

SET ZERO

RESET

SET GAIN

SET ZERO

RESET

42HA0296P01 Rev. A

GGD Figure 4 - Sweep Ports

43 HA0296P01 Rev. A

GGD Figure 5 - Element and Heater Tube

44HA0296P01 Rev. A

GGD Figure 6 - Heater and Heater Tube

45 HA0296P01 Rev. A

GGD Figure 7 - Inlet Switching Tube

46HA0296P01 Rev. A

GGD Figure 8 -Exhaust Switching Valve

47 HA0296P01 Rev. A

GGD Figure 9 -Purge and Outlet Check Valve

48HA0296P01 Rev. A

Generator Gas Manifold (GGM)


HA0298P01 Rev. A

UTILITY SYSTEMS

1 HA0298P01 Rev. A


Specifications ....................................................................................................................................... 7

System Description .............................................................................................................................. 8Hydrogen Supply Pressure Transmitter ........................................................................................... 8Case Pressure Transmitter .............................................................................................................. 8Carbon Dioxide Supply Pressure Transmitter ................................................................................ 8Differential Pressure Transmitter .................................................................................................... 8

Installation ........................................................................................................................................... 9

Electrical Connections ....................................................................................................................... 10Contacts/Signals ........................................................................................................................... 10Circuit Protection ......................................................................................................................... 10

System Operation .............................................................................................................................. 11GGM Initialization ........................................................................................................................ 11

GGM Menu Displays ........................................................................................................................ 12Navigating the LCD Display ........................................................................................................ 12LCD Display Menu – Two Modes of Operation ............................................................................ 12Menu Profile ................................................................................................................................. 12

Menu Navigation Tutorial ................................................................................................................. 13Activating the Menu ..................................................................................................................... 13Navigating the Menu in Scrolling Mode (GGM default) .............................................................. 13Disabling Scrolling Mode .............................................................................................................. 13Navigating the Menu in Non-Scrolling Mode ............................................................................... 13Function (FN) Menu ..................................................................................................................... 14Log Menu ...................................................................................................................................... 14Setup Menu ................................................................................................................................... 14Test Menu ...................................................................................................................................... 15View Menu .................................................................................................................................... 15

Procedures ......................................................................................................................................... 16Sensor Calibration and Alarm Levels ........................................................................................... 16About the Faults Log .................................................................................................................... 17About the Power Log .................................................................................................................... 17

Modes of Operation .......................................................................................................................... 18Startup .......................................................................................................................................... 18Startup Problems .......................................................................................................................... 18

2HA0298P01 Rev. A

Suspended Operation .................................................................................................................... 18Normal Operation ......................................................................................................................... 18

Maintenance ...................................................................................................................................... 20Daily .............................................................................................................................................. 20Weekly ........................................................................................................................................... 20Every Six Months .......................................................................................................................... 20

Component Replacement Instructions ............................................................................................. 21Removing a Pressure Transducer .................................................................................................. 21Removing a Processor Circuit Board ............................................................................................ 21Removing the Input/Output (I/O) Circuit Board ........................................................................... 21

Spare Parts ......................................................................................................................................... 22Recommended GGM Spare Parts (Stocked by Customer) ........................................................... 22Recommended GGM Replacement Parts (Stocked by E/One) ...................................................... 22

3 HA0298P01 Rev. A

FiguresGGM Figure 1 - Generator Gas Manifold Piping Schematic ............................................................................. 25GGM Figure 2 - Generator Gas Manifold Display/Valve Panel ........................................................................ 26GGM Figure 3 - Menu Tree ............................................................................................................................... 27

4HA0298P01 Rev. A

5 HA0298P01 Rev. A

Generator Gas Manifold (GGM) SystemImportant Information





Generator Gas Manifold (GGM) SystemSafety Considerations

THE SYSTEM ELECTRONICS ENCLOSURE AND CUSTOMER INTERFACE ENCLOSURECONTAIN 115 AND OR 230 VOLTS AC. THIS VOLTAGE APPEARS AT THE AC POWERSTRIP AND VARIOUS OTHER POINTS. EQUIPMENT OPERATION INVOLVES A FLAM-MABLE GAS (HYDROGEN) UNDER PRESSURE. APPROPRIATE MEASURES MUST BETAKEN TO PREVENT LEAKS AND AVOID SOURCES OF IGNITION.

ALL ELECTRICAL CONNECTIONS BETWEEN THE SYSTEM ELECTRONICS, CUS-TOMER INTERFACE AND DISPLAY/CONTROL PANEL SHOULD BE TESTED AND VERI-FIED TO BE CORRECT.

ALL WIRING MUST BE IN ACCORDANCE WITH LOCAL CODE AND/OR CENELEC STAN-DARD EN50014.

ALL GAS CONNECTIONS TO THE PANEL MUST BE LEAK CHECKED PRIOR TO APPLY-ING AC POWER.


6HA0298P01 Rev. A

Introduction

The Generator Gas Manifold assembly consists of the Manifold and the GGM Module. TheManifold is used for the supply, regulation and monitoring of hydrogen gas pressures to thegenerator, as well as the supply of carbon dioxide and air during purge cycles (GGM Figure1).

The GGM Module provides continuous numeric display of:

· Hydrogen Supply Pressure

· Case Pressure

· Fan Differential Pressure

· Carbon Dioxide Supply Pressure

The GGM Module also contains an integral annunciator section for:

· High Hydrogen Supply Pressure

· Low Hydrogen Supply Pressure

· High Carbon Dioxide Pressure

· Low Carbon Dioxide pressure

· High Fan Differential Pressure

· Low Fan Differential Pressure

· Hydrogen Bottle Low Pressure

· Hydrogen High Temperature

· Seal Oil Pump Low Pressure

· Seal Oil Pump Off

· Defoaming Tank Level

· Vacuum Pump Off

· Hydrogen Side Level Low

· Water Detector High

Other displays include AC Power, Trouble and LCD Menu/Interface Panel.

7 HA0298P01 Rev. A

Specifications

Input Voltage 85 VAC to 250 VACInput Frequency 47 to 63 HzInput Power 10 WInrush Current 0.5 A



Ambient Location Class 1, Division 1, Group B

Sensor AccuracyH2 Supply Pressure +/- 2% of full scaleCase Pressure +/- 2% of full scaleFan Differential Pressure +/- 2% of full scaleCO2 Supply Pressure +/- 2% of full scale

Inputs, Switch 0 to 9 VDC opto-isolated

Outputs, Relays 5A @ 250VAC5A @ 30VDC

Audible, NO and NC 100mA@125VDCAlarm, NO and NCTrouble, NO and NC

Outputs, Signal 4-20 mA current output (self-powered)Case PressureFan Differential Pressure

8HA0298P01 Rev. A

System Description

The major components of the GGM include:

• 1 generator gas manifold

• 1 hydrogen supply pressure sensor

• 1 case pressure sensor

• 1 fan differential pressure transmitter

• 1 carbon dioxide supply pressure sensor

• 1 local display panel

• 1 system electronics

Hydrogen Supply Pressure Transmitter

A pressure transmitter provides a signal corresponding to the hydrogen supply pressurenumerical display. The pressure range is 0 to 100 pounds per square inch. Some units maybe equipped with a special range.

Case Pressure Transmitter

A pressure transmitter provides an output signal corresponding to the hydrogen supplypressure. The case pressure is indicated on a numerical display and available as a 4-20 mAoutput. The 4-20 mA output corresponds to 0 to 100 pounds per square inch. Some unitsmay be equipped with a special range.

Carbon Dioxide Supply Pressure Transmitter

A pressure transmitter provides a signal to the GGM carbon dioxide pressure numericaldisplay. The pressure range is 0 to 100 pounds per square inch. Some units may beequipped with a special range, if desired.

Differential Pressure Transmitter

A differential pressure transmitter provides an output signal corresponding to the generatorfan differential pressure (Appendix Figure 5). The differential pressure is indicated on anumerical display and available as a 4-20 mA output. The 4-20 mA output corresponds to 0 to30 inches H2O. Some units may be equipped with a special range, if desired.

9 HA0298P01 Rev. A

Installation

The GGM arrives at the power plant already installed within the Gas Station. There are nospecial installation instructions regarding this module beyond gas pressure and electricalconnection checks that are called out in the following sections of this manual.

10HA0298P01 Rev. A


Contacts/Signals

The GGM includes alarm and status relays (Appendix Figure 4). They are:

• Audible Relay Both a normally open and a normally closed contact (single pole, doublethrow configuration) is provided and an Alarm is signaled by an energized relay.

• Alarm Relay Both a normally open and a normally closed contact (single pole, doublethrow configuration) is provided and an Alarm is signaled by an energized relay.

• Trouble Relay Both a normally open and a normally closed contact (single pole, doublethrow configuration) is provided and Trouble is signaled by an de-energized relay.

• 4-20 mA output signals are provided for Case Pressure and Fan Differential Pressure(GGM Figure 2).

• The 4-20 mA signals for Case Pressure correspond to 0 to 100 psi.

• The 4-20 mA signals for Fan Differential Pressure correspond to 0 to 30 inches of water.

The 4-20 mA output signals are internally powered. These signals are not to bepowered by central control system of the power plant (see Electrical Connections).

Circuit Protection

Each GGM is individually fused. A half-amp slo-blow fuse, located on the Input/Output PCB,provides circuit protection.

11 HA0298P01 Rev. A

System Operation

This section describes system operation.

GGM Initialization

With system power on, press the RESET push-button on the backside of the DISPLAYPANEL (GGM Figure 2). The GGM DISPLAY PANEL will respond with (a) all discrete LED’s lit;(b) all segments and the tenths place decimal point of the seven segment LED displays lit;and (c) all pixels of the LCD display on.

Once communication has been established with the rest of the system, (a) all discreteLED’s, except the AC POWER and TROUBLE, will turn off; (b) all segments of the sevensegment LED displays will turn off; and (c) the display will echo the results of cold startinitialization:

· GGM Ver 1.0A-7

· CHECKSUM OK

· POWER OK

· RELAY TEST …

· … PASSED

· I/O BOARD OK

· NORMAL OPERATION will flash for two seconds then the display will clear and the GGMwill begin normal operation.

After initialization, the Faults log should be cleared. See CLEAR FAULTS LOG under LOGMENU for specific instructions.

12HA0298P01 Rev. A

GGM Menu Displays

The following sections provide definitions and user information in regards to the variousmenus that are accessible via the GGM’s LCD display. It is strongly recommended thatusers familiarize themselves with this section. Forward additional questions to EnvironmentOne. Refer to the GGM Menu Tree (GGM Figure 3).



• The FN key activates the menu and exits the menu.

• The ENTER key selects an item from the menu.

• The UP ARROW and DOWN ARROW keys change the selection displayed.

LCD Display Menu – Two Modes of Operation


• In scrolling mode, the selection shown on the LCD changes automatically every twoseconds.

• In non-scrolling mode, the UP ARROW and DOWN ARROW keys must be used tochange the selection.

Scrolling is the default mode. Users can change modes by reviewing the SETUP MENUsection in the following pages.

Menu Profile

Five menus are available: Function, Log, Setup, Test and View. The Function menu is thetop-level menu; all of the other menus are accessed through this menu.

13 HA0298P01 Rev. A


Activating the Menu

1. Press FN to start the menu. The LCD should display the prompt <FUNCTION MENU>.

2. Press FN again to turn it off.

Navigating the Menu in Scrolling Mode (GGM default)

1. Press FN to start the menu. The LCD should display the prompt <FUNCTION MENU>.After two seconds the prompt should change to GO TO LOG MENU.

2. Wait until the prompt GO TO LOG MENU appears and press the ENTER key.

3. The LCD should display the prompt <LOG MENU>.

4. Wait until the prompt SHOW PROGRAM ID appears and press the ENTER key. Thedisplay should show GGM VER 1.0A-7.



7. Press FN a third time. The LCD will display “GGM by E/One” as the menu is deactivated.

Disabling Scrolling Mode


2. Wait until the prompt GO TO SETUP MENU appears and press ENTER.

3. Wait until the prompt SET SCROLL OFF appears and press ENTER.




1. The LCD should display the prompt <FUNCTION MENU>. Press the DOWN ARROWkey until the prompt GO TO VIEW MENU appears and press the ENTER key.

2. The LCD should display the prompt <VIEW MENU>. Press the DOWN ARROW key untilthe prompt VIEW CALIBRATION appears and press the ENTER key. The display shouldshow Vref=N.NNN VDC where N.NNN is the calibration value for the reference thermistor.



5. Press FN a third time. The LCD will display “GGM by E/One.”

14HA0298P01 Rev. A

Function (FN) Menu

· GO TO LOG MENU Select this item to enter the LOG MENU. The log menu containsselections to view and clear the fault and power logs. The log menu also includes aselection to view the software version number.

· GO TO SETUP MENU Select this item to enter the SETUP MENU. The setup menuincludes selections for calibration and configuration. Items that can be configured includesensor calibration, alarm levels, the operating mode and the menu scroll rate. The setupmenu also includes selections to calibrate the pressure sensors.

· GO TO TEST MENU Select this item to enter the TEST MENU. The test menu containsselections to test the power supplies, the keypad, the relays, and the 4-20 mA outputs.

· GO TO VIEW MENU Select this item to enter the VIEW MENU. The view menu containsa selection to view the A/D converter voltages.

Log Menu

· SHOW FAULTS LOG Select this item to view the faults log. See About the Fault Log formore information.

· CLEAR FAULTS LOG Select this item to clear the faults log. When selected, the CLEARFAULTS LOG prompt will flash for two seconds before clearing the faults log. If the FNkey is pressed while it is still flashing, clearing of the log will be canceled. See About theFault Log for more information.

· SHOW POWER LOG Select this item to view the power log. See About the Power Logfor more information.

· CLEAR POWER LOG Select this item to clear the power log. When selected theCLEAR POWER LOG prompt will flash for two seconds before clearing the power log. Ifthe FN key is pressed while it is still flashing, clearing of the log will be canceled. SeeAbout the Power Log for more information.

· SHOW PROGRAM ID Select this item to display the program identification and revisionlevel in the format GGM Rev X.X. This manual was written for software version 1.0A.Press the FN key to stop displaying the program identification.

Setup Menu

· SETUP SENSORS Select this item to calibrate the pressure sensors and to set theirhigh and low alarm points. See Sensor Calibration and Alarm Levels for more informa-tion.

· STOP MONITORING This item is used for troubleshooting and is displayed when themonitoring is currently turned on. Select it to turn monitoring off. When selected theSTOP MONITORING prompt will flash STOPPING for two seconds before monitoring issuspended. If the FN key is pressed while it is still flashing, the command will be can-celed. See Suspended Operation for more information.

· START MONITORING This item is displayed when the monitoring is turned off; select itto turn monitoring on. When selected, the START MONITORING prompt will flash

15 HA0298P01 Rev. A

STARTING for two seconds before monitoring begins. The command will be canceled ifthe FN key is pressed while it is flashing. See Normal Operation for more information.

· SET SCROLL OFF This item is displayed when the scrolling is currently turned on.Select it to turn scrolling off. When scrolling is inactive the displayed menu items will notchange until a menu key (UP ARROW, DOWN ARROW, FN or ENTER) is pressed.

· SET SCROLL ON This item is displayed when the scrolling is currently turned off.Select it to turn scrolling on. When scrolling is active, the displayed menu items willchange once every two seconds.

Test Menu

· CONTACT TEST Select this item to start an interactive test of the relay contacts. TheGGM will place all relays except one in a de-energized condition. The LCD will display thename of the single relay that is still energized. Use the arrow keys to change which relayis energized. Press the FN or ENTER keys to terminate the test.

· KEYPAD TEST Select this item to start an interactive test of the keypad. The LCD willdisplay the prompt PRESS ANY KEY at the start of the test. Test the keypad by pressing,one at a time, each key on the keypad, reserving the FN key for last. The LCD will echothe name of each key as it is pressed. The test will terminate when the FN key ispressed.

· OUTPUT TEST Select this item to start an interactive test of the 4-20 mA outputs. TheGGM will set the 4-20 mA outputs to four milliamps and display CURRENT=4mA on theLCD display at the start of the test. Use the arrow keys to increase or decrease thecurrent in one milliamp steps. Press FN or ENTER to terminate the test.

· POWER TEST Select this item to test the power supplies. When POWER TEST isselected, the GGM will display the voltage for each power supply in the format <nominalvalue>=<present value>. An example for the 12-volt power supply is +12 VOLTS =12.1.The GGM will scroll through all five power supply voltages. The voltages are displayed fortwo seconds each.

· RELAY TEST Select this item to test all of the relays. The LCD will display RELAY TEST… The system will cause each relay to be energized. If no errors are detected, the LCDwill display RELAYS PASS. If an error is detected, the LCD will display the failure modeand then list the names of the malfunctioning relays. The failure modes are STUCK ONand STUCK OFF. See Table 5 for a list of the probable cause(s) of these errors.

View Menu

· VIEW CALIBRATION Select this item to display the calibration values for the sensor cell.The format for the displayed values is “Vnn=X.XXX VDC” where Vnn is the symbol andX.XXX is the voltage of a calibration constant. The symbols for the four calibration con-stants are: Vref for the reference thermistor, Vn2 for nitrogen gas, Vh2 for hydrogen gasand Vco2 for carbon dioxide. Use the UP ARROW key or DOWN ARROW key to scrollthrough the calibration constants. Press the FN key to return to the VIEW MENU.

· VIEW 12-BIT ADC Select this item to display the voltage at each of the 12 inputs of the12-bit A/D converters. Use the UP ARROW key or DOWN ARROW key to scroll throughall 12 channels. Press the FN key to return to the VIEW MENU.

16HA0298P01 Rev. A

Procedures

Sensor Calibration and Alarm Levels

The GGM uses four pressure sensors: Hydrogen Supply Pressure, Case Pressure, FanDifferential Pressure, and Carbon Dioxide Supply Pressure.

All four sensors use the same setup procedure, except for the Carbon Dioxide SupplyPressure, which does not have alarm points. Five operations can be performed on eachsensor: SET GAIN, SET ZERO, RESET, HIGH ALARM and LOW ALARM.

To perform any of these setup procedures, press the FN key when the LCD display indicates“GGM by E/One” and select SETUP. Then select the procedure you wish to perform bypressing ENTER when that prompt appears.

· RESET The gain and zero points for the sensor can be reset to the factory default valuesby selecting RESET.

· SET ZERO The zero point for the sensor can be changed with this function.

When SET ZERO is selected, the LCD display will display the current pressure. The actualpressure present at the sensor input should be zero before zeroing the sensor.

Press the UP ARROW key to increase it by 0.1; press the DOWN ARROW key to decreaseit by 0.1. Press the UP ARROW and DOWN ARROW keys as required to make the dis-played pressure match the actual pressure present at the sensor input. Press the ENTERkey to save your changes and return to the SENSOR MENU. Press the FN key to discard thechanges and return to the SENSOR MENU.

· SET GAIN The gain of the sensor can be changed with this function.

When SET GAIN is selected, the current pressure will be displayed on the LCD display. Zerothe sensor before setting the gain. Press the UP ARROW key to increase it by 0.1; press theDOWN ARROW key to decrease it by 0.1. Press the UP ARROW and DOWN ARROWkeys as required to make the displayed pressure match the actual pressure present at thesensor input. Press the ENTER key to save your changes and return to the SENSOR MENU.Press the FN key to discard the changes and return to the SENSOR MENU.

· HIGH ALARM If the pressure exceeds the high alarm level, the HIGH LED will illuminateand the ALARM and AUDIBLE relays will activate.

When HIGH ALARM is selected, the high alarm level will be displayed on the LCD display;press the UP ARROW key to increase it. Press the DOWN ARROW key to shift the value tothe left (multiply by 10 and drop the highest digit). Press the ENTER key to save yourchanges and return to the SENSOR MENU. Press the FN key to discard the changes andreturn to the SENSOR MENU.

· LOW ALARM If the pressure drops below the low alarm level, the LOW LED will illumi-nate and the ALARM and AUDIBLE relays will activate.

When LOW ALARM is selected, the low alarm level will be displayed on the LCD display.

17 HA0298P01 Rev. A

Press the UP ARROW key to increase it; press the DOWN ARROW key to shift the value tothe left (multiply by 10 and drop the highest digit). Press the ENTER key to save yourchanges and return to the SENSOR MENU. Press the FN key to discard the changes andreturn to the SENSOR MENU.


The Faults log traps these error conditions: I/O Read Error, I/O Write Error, Sensor Fault andPower Fault.

· An I/O Read Error is logged when a read error is detected in the communication channelthat connects the processor and I/O board.

· An I/O Write Error is logged when a write error is detected in the communication channelthat connects the processor and I/O board.

· A Sensor Fault is logged when the output of a sensor is outside of the expected rangeduring normal operating mode.

A Power Fault is logged when the measured voltage of one or more of the power supplies isout of specification.

About the Power Log


When SHOW POWER LOG is selected, the GGM will display the minimum and maximumfor each power supply in the format <nominal value>=<minimum value>,<maximum value>.An example for the 12-volt power supply is +12V=11.8,12.1. Use the UP ARROW key orDOWN ARROW key to scroll through the five power supply voltages. Press the FN key toreturn to the LOG MENU.

18HA0298P01 Rev. A

Modes of Operation

Startup

The GGM initializes all relays to the de-energized position.

The GGM executes a “power on self-test” (POST) to verify its proper operation. It verifies itssoftware by checksum testing the contents of its read-only memory (ROM). It tests all of itspower supplies and all of its relays.

The POST will take about 20 seconds to complete if no errors are encountered. At theconclusion of the POST the GGM display panel will flash NORMAL OPERATION for twoseconds and then enter normal operation. If the FN key is pressed while NORMAL OPERA-TION is flashing, the GGM will enter suspended operation instead.

Startup Problems

Immediately after power-up, the GGM begins searching for a display. If the local display ispresent and functioning properly, the search will complete in less than one tenth of a second.If the GGM cannot communicate with the local display, LINKING… may appear on the LCD. Ifthe GGM cannot find a local display within four seconds, it will assume one is present andproceed with the POST.

The GGM verifies its software by checksum testing the contents of its read-only memory(ROM). If it finds a problem, it will stop the POST process and flash BAD CHECKSUM on theLCD. The FN key may be pressed to allow the GGM to continue the POST process. How-ever, proper operation cannot be guaranteed if this error is present.

The GGM will annunciate any problems it finds with the power supplies or relays. The pres-ence of one or more of these faults will not stop the POST process. However, they should becorrected as soon as possible because they indicate a hardware problem.

Suspended Operation

When the GGM is in suspended operation, it will display the pressure and monitor the switchinputs. It will indicate any alarms on the display but the ALARM and AUDIBLE relays will notenergize. Alarms will not latch in suspended operation.

The TROUBLE LED will be illuminated and the TROUBLE RELAY de-energized (asserted)whenever the GGM is in suspended operation.

Normal Operation

When the GGM is in normal operation, it will display the pressure and monitor the switchinputs. When an alarm comes in, it will indicate so on the display and energize the ALARMand AUDIBLE relays. Once an alarm is detected, it will persist until the RESET button ispressed.

Pressing the RESET or SILENCE button will deactivate the AUDIBLE RELAY.

The GGM will display the hydrogen supply pressure, the case pressure, the fan differentialpressure and the carbon dioxide supply pressure on the numerical displays. The case

19 HA0298P01 Rev. A

pressure and fan differential pressure are also available through a 4-20 mA outputs.

The 4-20 mA current output for the case pressure corresponds to 0 to 100 pounds persquare inch.

The 4-20 mA current output for the fan differential pressure corresponds to 0 to 30 inches ofwater.

The GGM will display an alarm if any of the pressures are outside of specified limits or if anannunciator section alarm is asserted.

REMINDER! Should the system go into trouble, access the menu items SHOWFAULTS LOG and SHOW POWER LOG for more information.

20HA0298P01 Rev. A

Maintenance

Daily

1. Check operation of the hydrogen gas regulator PR2 for proper regulation of hydrogenpressure.

Weekly

1. Leak test the manifold assembly to ensure safe operation of the equipment.

Every Six Months

1. Calibrate pressure sensors per the Procedures section when the generator is down.

21 HA0298P01 Rev. A


The pressure sensors, I/O circuit board, processor circuit boards, power supplies andintrinsically safe barriers are located inside the main junction box. To gain access to theinside of the main junction box for service, remove the 32 3/4-inch captive bolts. Two guidestuds assist with removal/replacement.

CAUTION! Do not scratch sealing surfaces on the main junction box. The main junc-tion box lid weighs 50 lbs (22.7 kg). Take precautions during removal. Prior to open-ing the main junction box, remove power from the Gas Station and ensure the systemis free of hydrogen.

Removing a Pressure Transducer

To remove a pressure transducer from a flameproof enclosure:



3. Remove the cover of the main junction box.

4. To reinstall a pressure sensor, reverse above process, then leak check.





4. Disconnect the 20-pin ribbon cable and remove the 4 nuts (11/32).


6. Check that pin #1 on the ribbon connector is properly aligned.




4. Remove the processor board. Disconnect the 20-pin ribbon cable and 4 nuts (11/32).

5. Remove the 4 slotted screws that hold the board in place.




22HA0298P01 Rev. A

Spare Parts

Recommended GGM Spare Parts (Stocked by Customer)


Pressure Sensor HA0276P03 Pressure sensor

Gasket Set Spool HA0289P02 Manifold spool gaskets

Ball Valve Rebuild Kit DA0121P01 Ball valve rebuild kit

Recommended GGM Replacement Parts (Stocked by E/One)


DP Transmitter HA0058P08 Differential pressure transmitter

Display PCB HD0085G03 Display PCB X

Processor Control PCB HA0279G01 Processor control PCB X

I/O Board Assembly HD0224G01 I/O board PCB X

Manifold Ball Valve HA0217P03 Ball valve

Manifold 3-Way Ball Valve HC0114P01 3-Way ball valve

23 HA0298P01 Rev. A

Figures

24HA0298P01 Rev. A

25 HA0298P01 Rev. A

GGM Figure 1 - Generator Gas Manifold Piping Schematic

26HA0298P01 Rev. A

GGM Figure 2 - Generator Gas Manifold Display/Valve Panel

LOW-LOW

LOW

CASE PRESSURE

FAN DIFFERENTIAL

PRESSURE

CARBON DIOXIDE

PRESSURE

HIGH

LOW

HIGH

LOW

HYDROGEN SUPPLY

PRESSURE

WATER DECTECTOR

HIGH

POWERHYDROGEN BOTTLE

LOW PRESSURE

HYDROGEN

HIGH TEMPERATURE

SEAL OIL PUMP

PRESSURE LOW

SEAL OIL PUMP

OFF

DEFOAMING TANK

LEVEL HIGH

VACUUM PUMP

OFF

HYDROGEN SIDE

LEVEL LOW

ENTER

FN

TROUBLE

GAS

SIL

RESET

27 HA0298P01 Rev. A

GGM Figure 3 - Menu Tree

SETUP MENU

VIEW MENU

LOG MENUFUNCTION MENU SHOW FAULTS LOG

CLEAR FAULTS LOG

SHOW POWER LOG

CLEAR POWER LOG

SHOW PROGRAM ID

SETUP SENSORS

SET SCROLL ON

SET SCROLL OFF

START MONITORING

STOP MONITORING

CONTACT TEST

RELAY TEST

POWER TEST

OUTPUT TEST

KEYPAD TEST

VIEW 12BIT ADC

TEST MENU

VIEW STATUS

VIEW VALVES

VIEW COLUMN

HIGH ALARM

LOW ALARM

H2 SUPPLY PRES.

CASE PRESSURE

FAN DIF. PRES.

CO2 SUPPLY PRES.

SET GAIN

SET ZERO

RESET

SET GAIN

SET ZERO

RESET

SET GAIN

SET ZERO

RESET

SET GAIN

SET ZERO

RESET

HIGH ALARM

LOW ALARM

HIGH ALARM

LOW ALARM

28HA0298P01 Rev. A

KAHN

THE KAHN COMPANIES885 Wells Road, Wethersfield, CT 06109 Phone (860) 529-8643 Fax (860) 529-1895 E-mail [email protected]

TRANSMET I.S.

INTRINSICALLY SAFEDEWPOINT TRANSMITTER

INSTALLATION, OPERATION ANDMAINTENANCE MANUAL

Instruction Manual

KAHN INSTRUMENTS, INC. 885 Wells Road, Wethersfield, CT 06109Tel: 860-529-8643; Fax: 860-529-1895

E-mail: [email protected]

PAGE 1

Issue October 2000

TRANSMET I.S.

INTRINSICALLY SAFEDEWPOINT TRANSMITTER

INSTALLATION, OPERATION ANDMAINTENANCE MANUAL



PAGE 2

TABLE OF CONTENTS

SECTION PAGE1. INTRODUCTION .................................................................................................................... 4

1.1 General ............................................................................................................................. 41.2 Ceramic Sensing Element ................................................................................................ 41.3 Calibration ........................................................................................................................ 41.4 Manufacturing Quality ...................................................................................................... 51.5 TRANSMET I.S. Identification .......................................................................................... 5

2. MECHANICAL INSTALLATION .............................................................................................. 63. OPERATING PRECAUTIONS ................................................................................................ 8

3.1 Sampling Hints ................................................................................................................. 83.2 Response Characteristics ................................................................................................ 93.3 Which Gases to Measure ................................................................................................. 9

4. MAINTAINING THE TRANSMET I.S. ..................................................................................... 105. TRANSMET I.S. SPECIFICATION ......................................................................................... 116. TRANSMET I.S. TERMINAL BLOCK CONNECTIONS .......................................................... 127. TRANSMET I.S. OUTPUT ...................................................................................................... 13

7.1 Selecting the Current Output Range ................................................................................ 137.2 TRANSMET I.S. Installation in Hazardous Areas ............................................................. 147.3 Measuring the Current Output from TRANSMET I.S. for a SYSTEM 1 Installation .......... 147.4 Cable Requirements / Limits for SYSTEM 1 Installation .................................................. 147.5 Measuring the Current Output from TRANSMET I.S. for a SYSTEM 2 Installation .......... 15

8. TRANSMET I.S. CABLE SHIELD TERMINATION .................................................................. 168.1 Cable connection.............................................................................................................. 16

9. USING TRANSMET I.S. INTERFACE UNIT ........................................................................... 1710. INTRINSICALLY SAFE SYSTEM 1 DRAWING ...................................................................... 1811. INTRINSICALLY SAFE SYSTEM 2 DRAWING ...................................................................... 19



PAGE 3

FIGURES PAGE

Figure 1 Terminal block connections............................................................................................. 12Figure 2 Current output switch settings ........................................................................................ 13Figure 3 Current measurement for SYSTEM 1 ............................................................................. 15Figure 4 Cable shield connection ................................................................................................. 16Figure 5 Interface Unit Wiring Diagram ........................................................................................ 17



PAGE 4

1. INTRODUCTION

1.1 General

The Intrinsically Safe TRANSMET I.S. Ceramic Dewpoint Transmitter measures dewpoint overthe range -100/+20°C. It is designed for use within the following hazardous areas: Class I, Divi-sion 1, Groups A, B, C & D T4 when used with an appropriate safety barrier(s).

The TRANSMET I S is connected as a 3-wire transmitter with a current sink output, which can beswitch selected for either 4-20mA or 0-20mA. This output is linear over the entire dewpointmeasurement range, from -100/+20°C DP.

TRANSMET I.S. is approved as an intrinsically safe device for use in hazardous locations.

Factory Mutual Research Corporation (FM)

TRANSMET I.S. confirms to the Approval Standard FM3610 (October 1988) and carries thefollowing marking code: Intrinsically Safe CL I, Div 1, Gp A, B, C & D T4.

C.E.N.E.L.E.C

Transmet I.S. conforms to the C.E.N.E.L.E.C. standards specified in BS EN 50014 and BS EN50020, with certification code EEx ia IIC T4.Before using TRANSMET I.S. in any hazardous environment, be sure you are fully familiar withthe above Factory Mutual or C.E.N.E.L.E.C. standards relating to the certification of this instru-ment and also with the further information relating to intrinsically safe apparatus to be foundin Article 504 in the National Electrical Code, ANSI/NFPA 70 or equivalent codes of practice inthe country of installation.

WARNING: SUBSTITUTION OF COMPONENTS MAY IMPAIR INTRINSIC SAFETY.

1.2 Ceramic Sensing ElementTRANSMET I.S. utilizes a Ceramic Moisture Sensor manufactured from metalized ceramics usingthin and thick film technologies. The Kahn ceramic moisture sensor is virtually chemicallyinert with inherently fast response, high calibration stability and high resilience to corrosiveenvironments TRANSMET I.S. measures humidity by monitoring the electrical responseexhibited by the sensor to variations in partial pressure of water vapor of the gas composition towhich it is exposed.

1.3 Calibration



PAGE 5

Calibrations are performed using precision dewpoint generators and transfer standard opticalhygrometers which have been calibrated directly at the National Institute of Standards & Technol-ogy (NIST) Gaithersburg, MD, USA.

1.4 Manufacturing Quality

Your TRANSMET I.S. should reach you imperfect working condition. We have rigorous proce-dures at every stage of production to ensure that the materials of construction, manufacturing,calibration and final test procedures meet the requirements laid down by our Quality System.

1.5 TRANSMET I.S. Identification

The TRANSMET I.S. can be identified by a serial number label located on the outside of theTRANSMET I.S. housing. The label also describes the I.S. certification for TRANSMET I.S.



PAGE 6

2. MECHANICAL INSTALLATION

TRANSMET I S is provided with a 5/8"UNF parallel mounting thread which is suitable for housingin an optional flow-through sampling block. The body of the TRANSMET I.S. is designed to matewith the bonded seal provided (optional stainless steel bonded viton seal available). WithTRANSMET I S the bonded seal provided should be placed over the sensing part of the transmit-ter before it is screwed into the sampling block. TRANSMET I.S. can also be mounted by directinsertion.

If TRANSMET IS is to be mounted in the optional sampling block, appropriate gas couplingsshould be selected and fitted (using PTFE tape) into the female 1/8"NPT (taper) threads provided.Sample gas flow can be in either direction through the block. If the TRANSMET I.S. is to bemounted by direct insertion, appropriate care should be taken to insure a proper seal.

Although the operation of TRANSMET I.S. is not sample flow-rate dependent, it is important toinsure that the flow velocity through the sample line connecting the sample source to the sampleblock is high enough to avoid long time lags in response to changes in humidity at the samplesource. We therefore recommend a flow rate of 1 to 5 liters/minute at sample point (or equivalentat pressure) be set when TRANSMET I.S. is mounted in the standard sampling block and thatthe instrument is mounted as close as possible to the sample point. The gas sample may then bereturned to the process gas stream via the 2nd port in the sample block, or alternatively, ifoperating conditions allow, the gas sample can be vented - a vent pipe of at least 1 meter inlength should be fitted to the outlet port of the sample block. In direct insertion applications awide range of gas flow velocities are acceptable. Flow velocities up to 20 meters/second areacceptable with the protection given by the standard sintered guard.

Note: The correct selection of the cable gland for TRANSMET I.S. is essential with regards to I.S.installations. The specified IP65 rating of the instrument will only be maintained if an equivalent orhigher IP rated cable gland is fitted. See TRANSMET I.S. specification for dimensions.

After installation into the gas stream, the TRANSMET I.S. housing may be positioned at anyangle through approximately 330° of rotation, to allow for the cable gland positioning. To positionthe Sensor housing first loosen the large clamping nut sufficient to allow free rotation of thehousing around the Sensor body.

WARNING: TRANSMET I.S. is fitted internally with a stop device to prevent full 360° rotation ofthe housing around the Sensor body. Rotation beyond 330° may internally damage theSensor. The stop device is only to provide indication to the installer when maximum travel ineither direction has been reached.

Rotate the Sensor housing until the cable gland is in the desired position. While firmly holding thehousing in position, retighten the large clamp nut up against the housing seal using a wrench ofthe correct size. Do not apply excessive force.



PAGE 7

High pressure samples may be measured up to a maximum of 5000 PSIG. Make sure that thecorrect pipe fittings are used and that the bonded seal provided is used to seal the radial face ofTRANSMET I.S./sensor block seal.

Similarly, TRANSMET I.S. is suitable for measuring samples below atmospheric pressure. Careshould be taken at joints and pipe fittings that no lea exists which could allow ambient air to con-taminate the sample gas. If there is doubt, a standard leak test procedure should be employed(helium or vacuum seal).



PAGE 8

3. OPERATING PRECAUTIONS

Precautions should be taken to protect the Kahn Ceramic Moisture Sensor from damage.Statistical information indicates that the vast majority of failures are caused either by incorrectsampling methods, sampling positions or inadequate protection against dangerous substances.

3.1 Sampling Hints

As mentioned in section 2, TRANSMET I.S. may be provided with a sampling block that willenable a small sample of process gas to be diverted past the ceramic sensing element beforereturning to the main gas stream or being bled off to atmosphere. Alternatively, TRANSMET I.S.can be mounted directly into a flowing gas stream in a duct or pipe, provided there is no form ofcontamination within the duct/pipe that will damage the ceramic sensing element. (See Section3.3).

Sample system guidelines:

a) Be sure that the sample is representative of the gas under test.

The sample point should be as close to the critical measurement point as possible. For examplein a glove box application, mount the TRANSMET I.S. at the exit of the glove box, not at the gasentry point. Always use the shortest run of tubing possible between two points.

b) Minimize dead space in sample lines.

Minimize couplings and tubing. Where possible build up sampling tubing specifically for the joband do not use tubing previously installed for another application. Dead space in sample linesincreases response time by holding water molecules that are released to the passing gassample.

c) Remove any particulate matter or oil from the gas sample.

The Ceramic Moisture Sensor element of TRANSMET I.S. is protected against particulatecontamination by a 80)mn stainless steel sintered guard. This protects against physical damagecaused by large particles at high velocity such as rust in a compressed air line. However, fineparticles will not be prevented from contact with the Ceramic Sensing Element. If highconcentrations of fine particles are present in the sample flow they may “blind” the CeramicMoisture Sensor element and reduce its response speed. If TRANSMET I.S. is installed in asystem where particulate such as degraded desiccant or pipe swarf and rust are present, use aparticulate in-line filter. Contact Kahn Technical Sales staff for further advice on filteringtechniques.



PAGE 9

d) Use high quality sample tubing and fittings.

We would recommend that, wherever possible, stainless steel tubing, fittings and components(e.g. filters) be used. This is particularly important when measuring low dewpoints since materialsother than stainless steel may have undesirable characteristics such as the adsorbing of moistureon the walls, which slows down response and in extreme circumstances gives false readings. Fortemporary applications, or where stainless steel tubing is not feasible, use high quality, thick-walled PTFE tubing as this exhibits similar characteristics to stainless steel.

Use the lowest internal diameter tubing possible to reduce response time, but take care not toinduce pressure differentials by aiming for too high a flow rate through small bore tubing. Asampling flow up to 1 to 5 L/min (or equivalent at pressure) will be satisfactory for TRANSMETI.S. to operate correctly.

3.2 Response CharacteristicsResponse characteristics from dry to wet are orders of magnitude faster than from wet to dry.Time taken to dry down TRANSMET I.S. from ambient conditions to the operational dewpointlevel of the process will normally be shorter than the time taken to dry down the process itself.Therefore, when TRANSMET I.S. is installed into the system prior to system start-up, there isnormally no time lag before representative test results are obtained.

When a TRANSMET I.S. is installed into an operational system, then typically fifteen to thirtyminutes should be allowed for any tubing, filter and TRANSMET I.S. to reach equilibrium with thesample gas passing through.

3.3 Which Gases to Measure

TRANSMET I.S., by nature of its design, is suitable for measurement of the moisture content of awide variety of gases. In general, if the gas (in conjunction with water vapor) is not corrosive tobase metals then it will be suitable for measurement by the Transmitter. However gases contain-ing entrained solids or hydrocarbon mists should be filtered before presentation to the sensorusing a coalescing filter. If only particulate matter is present in the sample line then a particulatein-line filter is all that is required. Suitable filters are available from Kahn Instruments.

If a very dry gas, which would become corrosive when coming into contact with higher concentra-tions of moisture, is to be measured, then the instrument must be purged with an inert gas imme-diately after the measurement has been made. This will prevent any potentially corrosive gasesremaining in the sensor block from contaminating the sensor.



PAGE 10

4. MAINTAINING THE TRANSMET I.S.

Routine maintenance of TRANSMET I.S. should only require regular re-calibrations. The normalcalibration period is one year. This re-calibration work can only be performed by exposure of theMoisture Sensor to sample gases of known moisture content. Calibration services traceable toNIST are provided by Kahn Instruments.

The frequency of re-calibrations required in order to maintain the performance of TRANSMETI.S. transmitter is primarily dependent on the composition of the gas to which the Moisture Sensoris exposed i.e. content of liquid and particulate contaminates, corrosive elements etc (refer tosection 3 of this manual for guidance). In most applications annual re-calibration ensures that thestated accuracy of TRANSMET I.S. is maintained.



PAGE 11

5. TRANSMET I.S. SPECIFICATION

I.S. Certification codeFM approval Intrinsically Safe Class I, Division 1, Groups A, B, C & D T4C.E.N.E.L.E.C. EEx ia IIC T4. To B.S. EN 500 14 and B.S. EN 500 20

Sensor type Kahn Ceramic Moisture SensorGas wetted components 316 Stainless steelSensor mounting thread 5/8" UNFHousing 316 Stainless steel natural finishIngress protection IP65, NEMA 4Electrical connection Internal screw terminals.

Connection capacity:Solid / Stranded / Conductor sizes:mm2/mm2/AWG = 0.14 – 0.5 / 0.14 – 0.5 /26-20

Dimensions Outline: 172mm long x 106mm high x 86mm diameter (lid)Weight 1.1KgCable gland port ½” BSPPower Max. 30V regulated DC supply

Min. 6V regulated DC supplyCurrent consumption 15mA +/- 30% (not including dewpointsignal current)

Operating modes Selectable 0-20mA or 4-20mA linear current sink output corre-sponding to C dewpoint

Range -100 / +20 C (-148 / +68 F) dewpointAccuracy +/- 1 C between +20 C DP & -60 C DP

+/- 2 C between -60 C DP & -100 C DPResolution 0.1 C between +20 C DP & -80 C DP

1 C between -80 C DP & -100 C DPOperating temperature -20 / +40 C (-4 / +104 F)Storage temperature -40 / +70 C (-40 / 158 F)Operating pressure Max. 5000 psigFlow rate 0 to 10 Normal Liters per minuteGas Velocity Max. 20 meters per secondAssociated I.S. system SYSTEM 1: (Zener diode barrier system)apparatus - See SYSTEM 1 drawing

SYSTEM 2: (Isolation barrier(s) system)- See SYSTEM 2 drawing



PAGE 12

6. TRANSMET I.S. TERMINAL BLOCK CONNECTIONS

Connections to the TRANSMET I.S. are made via 3 terminals of an 8-way screw terminal blocklocated on the TRANSMET I.S. PCB (annotated TB1). The terminal block has its terminals la-beled 1 to 8, however, only terminals 5, 6 and 8 are required to connect the TRANSMET I.S. Togain access to the terminal block, unscrew the li of the TRANSMET I.S. housing.

Figure 1 Terminal block connections



PAGE 13

7. TRANSMET I.S. OUTPUT

7.1 Selecting the Current Output Range

There are two current ranges available from the TRANSMET I.S. which are selectable as either 4to 20 mA or 0 to 20 mA, both corresponding to a dewpoint of -100 to +20 C dp. An 8-way DIPswitch is located on the TRANSMET I.S. PCB and is accessed by removing the TRANSMET I.S.housing lid. The 8-way DIP switch must be off. Switch 6 is used to select the current range (seeFig. 2 below). Note: Current range can be changed while the TRANSMET I.S. is in operation.

Figure 2 Current output switch settings



PAGE 14

7.2 TRANSMET I.S. Installation in Hazardous Areas

TRANSMET I.S. is approved as an intrinsically safe device for use in hazardous locations.

TRANSMET I.S. confirms to FM Approval Standard FM3610 (October 1988) and carries thefollowing marking code: Intrinsically Safe CL I, Div 1, Gp A, B, C & D T4.

The instrument conforms to the C.E.N.E.L.E.C. standards specified in BS EN 50 014 and BS EN50 020, with certification code EEx ia IIC T4.

Before using TRANSMET I.S. in any hazardous environment, ensure you are fully familiar withthe above FM or C.E.N.E.L.E.C. standards relating to the certification of this instrument and alsowith the further information relating to intrinsically safe apparatus to be found in Article 504 in theNational Electrical Code, ANSI/NFPA 70 or equivalent codes of practice in the country ofinstallation.

TRANSMET I.S. can be installed using either a SHUNT DIODE BARRIER unit as shown inSYSTEM 1 drawing on page 18, or alternatively, if a factory I.S. ground is not available, using twoGALVANICALLY ISOLATED BARRIER units as shown in SYSTEM 2 drawing on page 19.

NOTE: Installation of TRANSMET I.S. MUST be as per either system drawing in order to complywith the intrinsic safety certification for TRANSMET I.S.

7.3 Measuring the Current Output from TRANSMET I.S. for a SYSTEM 1 Installation

This method uses a shunt resistor in-line with the current signal line on the safe side of anintrinsically safe application. The current flowing through the shunt resistor produces a differentialvoltage (Vdiff) across it, which can be directly measured or interfaced to a control or meteringsystem. The method is illustrated below in Fig 3.

Power Voltage and Shunt Resistance limits

Refer to Figure 3 for the information regarding the voltage required to power the Transmet I.S.while using specific shunt resistance value.

7.4 Cable Requirements / Limits for SYSTEM 1 Installation

Refer to section 8 and the SYSTEM 1 drawing for details.



PAGE 15

7.5 Measuring the Current Output from TRANSMET I.S. for a SYSTEM 2Installation.

Contact Kahn Instruments for technical details regarding System 2 installation.

Figure 3 Current measurement for SYSTEM 1



PAGE 16

8. TRANSMET I.S. CABLE SHIELD TERMINATION

Any cable used on the installation must be shielded. This shield must always be connected toGround of the TRANSMET I.S. To ease the shield connection, a lead assembly is provided andis attached to the TRANSMET I.S. PCB. This lead assembly is connected to TRANSMET I.S.ground. The lead is green in color and is terminated with a Butt-crimp as shown below in Fig 4.Refer to the appropriate SYSTEM drawing before choosing a cable type.

8.1 Cable connection

The cable used for installation can be of any type as long as it meets the intrinsically saferequirements set out by the appropriate standards and TRANSMET I.S. SYSTEM drawing.For the standards, refer to section 7.2. For the system drawings, refer to the SYSTEM 1 (Zenerbarrier system) and SYSTEM 2 (Isolation barrier(s) system) at the end of this manual.

Figure 4 Cable shield connection



PAGE 17

9. USING TRANSMET I.S. INTERFACE UNIT

The optional Transmet I.S. interface unit can be supplied to simplify the installation of theTransmet I.S. hygrometer. The interface unit includes the following components mounted on themetal plate:

• Intrinsically Safe Barrier Unit (ISBU);• Signal isolator/converter;• Power supply with 96-260 VAC input;• Terminal block for safe area connections.

The interface unit allows conversion of the current sink output of the Transmet I.S. into anisolated current or voltage signal. This signal is convenient to interface with customer suppliedPLC, computer-based data acquisition systems or other equipment. The user can select one ofthe following isolated output signals from the interface unit:

• 0-5 VDC• 0-10VDC• 0-1 mADC• 4-20 mADC (default)• 0-20 mADC

Figure 5 Interface Unit Wiring Diagram



PAGE 18

10. Intrinsically Safe System 1 Drawing

Zener barrier installation method



PAGE 19

11. Intrinsically Safe System 2 Drawing

Isolation barrier installation method

KAHN

THE KAHN COMPANIES885 Wells Road, Wethersfield, CT 06109 Phone (860) 529-8643 Fax (860) 529-1895 E-mail [email protected]

Brooks Instrument

Installation and Operation ManualX-1350E

February, 2001Issue 13

(Supersedes Issue 12, dated March, 1987)

Sho-RateTM “50”Model 1350E

andSho-RateTM “150”

Model 1355ESizes 1-6

Brooks Instrument Sho-Rate™ “50” and “150” Sizes 1-6

Essential InstructionsRead this page before proceeding!

Brooks Instrument designs, manufactures and tests its products to meet many national andinternational standards. Because these instruments are sophisticated technical products, you mustproperly install, use and maintain them to ensure they continue to operate within their normalspecifications. The following instructions must be adhered to and integrated into your safety programwhen installing, using and maintaining Brooks Products.

• Read all instructions prior to installing, operating and servicing the product. If this instructionmanual is not the correct manual, telephone 1-215-362-3700 and the requested manual will beprovided. Save this instructions manual for future reference.

• If you do not understand any of the instructions, contact your Brooks Instrument representativefor clarification.

• Follow all warnings, cautions and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation and maintenance of theproduct.

• Install your equipment as specified in the installation instructions of the appropriate instructionmanual and per applicable local and national codes. Connect all products to the proper electricaland pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program andmaintain the product.

• When replacement parts are required, ensure that qualified people use replacement partsspecified by Brooks Instrument. Unauthorized parts and procedures can affect the product’sperformance and place the safe operation of your process at risk. Look-alike substitutions mayresult in fire, electrical hazards or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except whenmaintenance is being performed by qualified persons, to prevent electrical shock and personalinjury.

WARNING!

It is recommended that this publication be read in its entirety beforeperforming any operation. Failure to understand and follow theseinstructions could result in serious personal injury and/or damage tothe equipment.Should this equipment require repair or adjustment, contact the nearestBrooks Instrument Sales Office. It is important that servicing beperformed only by trained and qualified service personnel. If thisequipment is not properly serviced, serious personal injury and/ordamage to the equipment could result.

Paragraph PageNumber Number1-1 Description .......................................................................... 1-11-2 Specifications ...................................................................... 1-1

2-1 Receipt of Equipment ......................................................... 2-12-2 Unpacking ........................................................................... 2-12-3 Return Shipment ................................................................. 2-22-4 Recommended Storage Practice ........................................ 2-22-5 Installation ........................................................................... 2-3

3-1 Operation ............................................................................ 3-1

4-1 Disassembly & Cleaning ..................................................... 4-14-2 Reassembly procedure ....................................................... 4-1

5-1 General ............................................................................... 5-1

Contents

Section 1Introduction

Section 2Installation

Section 3Operation

Section 4Maintenance

Section 5Parts List

CONTENTS

i


Figure PageNumber Number2-1 Typical Flowmeter Installation ............................................. 2-32-2 Dimensions – Sho-Rate 1350E (Sizes 1-6) ......................... 2-42-3 Dimensions – Sho-Rate 1350E (Sizes 1-6)with Integral Controller .............................................................. 2-52-4 Dimensions – Sho-Rate 1355E (Sizes 2-6) ......................... 2-62-5 Dimensions – Sho-Rate 1355E (Sizes 2-6)with Integral Controller .............................................................. 2-75-1 Parts Drawing Sho-Rate Models 1350E and 1355E (Sizes 1-6).................................................................................................. 5-2

Table PageNumber Number5-1 Parts List – Sho-Rate Models 1350E and 1355E(Sizes 1-6) ................................................................................ 5-3

Figures

Tables

ii

The Sho-Rate Flowmeters are variable area, glass tube, flow rateindicating meters. The basic elements are a tapered glass meteringtube and a metering float. Features include quick and simple removalor installation of the tube and float while the meter remains in theprocess piping.

Pressure Rating200 psig at fluid temperatures up to 250°F (121°C) and ambienttemperatures of 122°F (50°C)

Standard accuracy65mm - meter specified to have an accuracy ± 10% of maximumscale from 100% to 10% of scale reading.150mm - meter specified to have an accuracy ± 5% of maximumscale from 100% to 10% of scale reading.

Repeatability1/2% full scale

Rangeability10:1

ConnectionsStandard -1/8" female NPT with locknuts(Other connections available)

Introduction

1-1 Description

1-2 Specifications

Do not operate this instrument in excess of the specificationslisted below. Failure to heed this warning can result in seriouspersonal injury and/or damage to the equipment.

WARNING!

Glass metering tubes are designed for operation up to themaximum operating pressures and temperatures as specifiedherein. Due to the inherent brittle characteristics of glass andconditions beyond our control, tube breakage could result evenwithin specified operating conditions. Do not use glass tubemeters with fluids that are toxic, or chemically react with glasssuch as water above 140°F, steam, alkalis, fluorine, hydrofluo-ric acid, or molten metal. Failure to heed warning can result inserious personal injury and/or damage to the equipment.

WARNING!

Section

1

1-1


1-2

When the equipment is received, the outside of the packing caseshould be checked for any damage incurred during shipment. If thepacking case is damaged, the local carrier should be notified at onceregarding his liability. Remove the envelope containing the shippinglist. Carefully remove the equipment from the packing case andinspect for any damaged or missing parts.

In the event that the meter is damaged during shipment, the ProductService Department, Brooks Instrument Division, Emerson ElectricCo., Hatfield, PA 19440 should be contacted to obtain a return ship-ment form.

Brooks Instrument407 W. Vine StreetP.O. Box 903Hatfield, PA 19440 USAToll Free (888) 554-FLOW (3569)Tel (215) 362-3700Fax (215) 362-3745Email [email protected]://www.brooksinstrument.com

Brooks Instrument B.V.Groeneveldselaan 6P.O. Box 563900 AB Veenendaal, NetherlandsTel 31-318-549-549Fax 31-318-549-559Email [email protected]

Carefully unpack the meter and inspect it for any damage that mayhave occurred during shipment. The flowmeters are shipped com-pletely assembled and tested. It should not be necessary to tighten oradjust any of the parts when it is received.

2-1 Receipt of Equipment

2-2 Unpacking

Fisher-Rosemount Japan Co.,Ltd. Brooks Division1-4-4, Kitasuna Koto-KuTokyo 1136-0073 JapanTel 011 81-3-5633-7105Fax 011 [email protected]

Installation Section

2

2-1


Do not return any assembly or part without a Return MaterialsReport. The Return Materials Report is available from all DistrictSales Offices and the Product Service Department, Hatfield, PA19440. Information describing the problem, corrective action, ifany, and the work to be accomplished at the factory must beincluded.

Brooks Instrument407 W. Vine StreetP.O. Box 903Hatfield, PA 19440 USAToll Free (888) 554-FLOW (3569)Tel (215) 362-3700Fax (215) 362-3745Email [email protected]://www.broooksinstrument.com

Brooks Instrument B.V. Fisher-Rosemount Japan Co.,Groeneveldselaan 6 Ltd. Brooks DivisionP.O. Box 56 1-4-4, Kitasuna Koto-Ku3900 AB Veenendaal, Netherlands Tokyo 1136-0073 JapanTel 31-318-549-549 Tel 011 81 -3-5633-7105Fax 31-318-549-559 Fax 011 81 -3-5633-7124Email [email protected] Email [email protected]

If intermediate or long term storage is required for equipment, assupplied by Brooks Instrument Division, it is recommended thatsaid equipment be stored in accordance with the following:

a. Within the original shipping container.b. Stored in a sheltered area, preferably a warm, dry heated

warehouse.c. Ambient temperature 70°F (21.0°C) nominal 110°F maximum/

45°F minimum (43°C maximum/7.1°C minimum).d. Relative humidity 45% nominal 60% maximum/25% minimum.

Upon removal from storage, a visual inspection should be con-ducted to verify the condition of equipment is “as received”. If theequipment has been in storage for an excess of two (2) years orin conditions in excess of those recommended, all pressureboundary seals should be replaced and the device subject to ahydrostatic/pneumatic pressure test to 150% of rated pressure.

2-2 Return Shipment

2-4 Recommended Storage Practice

2-2

The flowmeter should be mounted within 6° of true vertical. The inletconnection to the flowmeter is in the bottom end fitting. The connec-tions are normally horizontal, female NPT. Be sure the piping isadequately supported to prevent undue strain on the meter.

It is recommended that a final leak test of the system plumbing andmeter be performed before subjecting it to process fluid.(See Section 4, Paragraph 4-2, e.)

Installation

2-5 Installation (See Figures 2-1, 2-2, 2-3, 2-4 and 2-5)

Figure 2-1 TypicalFlowmeter Installation.

If the inlet and outlet valves adjacent to the flowmeter are to beclosed for any reason, the flowmeter must be completelydrained. Failure to do so may result in thermal expansion ofthe liquid which can cause rupture of the meter and possiblepersonal injury.

WARNING!

Care must be taken in the system piping to this instrument toprevent sudden excessive pressure or flow surges. Protectivedevices should be installed upstream from this instrument,such as flow controllers, pressure regulators, pressure snub-bers and rupture discs.

WARNING!

2-3


Figure 2-2 Dimensions - Sho-Rate 1350E (Sizes 1-6)

2-4

Installation

Figure 2-3 Dimensions - Sho-Rate 1350E (Sizes 1-6) with Integral Controller

2-5


Figure 2-4 Dimensions - Sho-Rate 1355E (Sizes 1-6)

2-6

Installation

Figure 2-5 Dimensions - Sho-Rate 1355E (Sizes 2-6) with Integral Controller

2-7


2-8

After the flowmeter has been installed in the flow system, it is readyfor operation. An optional built-in needle control valve may be pro-vided to control the flow through the flowmeter. These control valvesare designed for fine control. Excessive tightening may damage thevalve seat and limit its effectiveness as a control valve. If tight shut-off is required, it is recommended that a separate shut-off valveshould be installed in the line immediately before the flowmeter.

Flow indication is measured using the center of the spherical float asthe reference point.

Operation Section

3-1 Operation

3

3-1


3-2

It is recommended the user periodically inspect the tube and float,and clean if necessary. Dirt or foreign materials adhering to the tubeand float may cause inaccuracy and sticking of the float. The meter-ing tube (Borosilicate glass) and related parts may be cleaned withany solvent which does not attack glass. To disassemble use thefollowing procedures:a. Remove the plastic window and back plate.b. Loosen the seal spindle or jack screw by turning it counterclock-

wise with a 5/32" hex wrench. The tube may now be canted out ofthe meter housing.

c. On meter sizes 1 through 6, the tube, float and float stops may becleaned as an assembly or may be dissembled for cleaning. Usinga small hook, remove either Teflon® float stop from the meteringtube and remove the float. Be careful not to chip the tube.

d. Packing seats and packing inserts may now be removed.e. With the metering tube out, the seal spindle or jack screw may be

rotated clockwise for removal. It should not be necessary toremove the seal spindle unless the O-ring which seals the spindlerequires replacement. The O-ring may be used as long as it is nottorn or distorted.

f. The needle control valve assembly may be removed by turning thevalve body counterclockwise. The valve seat, stem and packingthen may be removed easily from the valve body for cleaning orreplacement.

a. Use the reverse of Steps a through f of the disassembly procedureto reassemble the meter.

b. Prior to installing the needle control valve assembly make certainthat the valve stem is turned completely counterclockwise (fullopen position) to prevent damage to the valve seat. Packing seatsshould be examined for damage or deterioration and replaced ifnecessary.

c. When replacing the packing seats in the flowmeter body be surethe packing inserts are approximately 1/16" above the top of thepacking seat. Also be certain the tube seats firmly on the packingseats and does not overlap onto the end block.

d. The seal spindle serves to axially compress the tube seat gasketand exert a uniform pressure on the metering tube to prevent anypossibility of leakage. Do not overtighten the seal spindle.

e. After the flowmeter has been reassembled, it is important that it beleak tested with air at a minimum pressure of 15 psig at roomtemperature. To detect leaks, brush soapy water around all pos-sible leak points (tube packing, connections, and seal spindle) andcheck if bubbles are being formed. Should a leak be detected,tighten that particular joint to see if the leak can be stopped. If theleak persists, disassemble the area involved and check for dirt ordamaged elastomer. Clean and replace elastomer.

Maintenance

4-1 Disassembly and Cleaning

4-2 Reassembly Procedure

Section

4

4-1


TRADEMARKSBrooks ............. Brooks Instrument Division, Emerson Electric Co.Kalrez ........................................................DuPont Dow ElastomerNeoprene...................................... E.I. DuPont de Nemours & Co.Sho-Rate ......... Brooks Instrument Division, Emerson Electric Co.Teflon ........................................... E.I. DuPont de Nemours & Co.Viton-A ...................................................... DuPont Dow Elastomer

4-2

Parts List

5-1 General

Section

When ordering parts please specify:Brooks Serial NumberModel NumberPart NumberDescription and Quantity(Refer to Figure 5-1 and Table 5-1)

5

5-1


Figure 5-1 Parts Drawing Sho-Rate Models 1350E and 1355E (Sizes 1-6)

5-2

Parts List

Table 5-1 Parts List - Sho-Rate Models 1350E and 1355E (Sizes 1-6)

5-3


LIMITED WARRANTY

Seller warrants that the Goods manufactured by Seller will be free from defects in materialsor workmanship under normal use and service and that the Software will execute theprogramming instructions provided by Seller until the expiration of the earlier of twelve (12)months from the date of initial installation or eighteen (18) months from the date of ship-ment by Seller.

Products purchased by Seller from a third party for resale to Buyer (“Resale Products”)shall carry only the warranty extended by the original manufacturer.

All replacements or repairs necessitated by inadequate preventive maintenance, or bynormal wear and usage, or by fault of Buyer, or by unsuitable power sources or by attackdeterioration under unsuitable environmental conditions, or abuse, accident, alteration,misuse, improper installation, modification, repair, storage or handling, or any other causenot the fault o Seller are not covered by this limited warranty, and shall be at Buyer’s ex-pense.

Goods repaired and parts replaced during the warranty period shall be in warranty for theremainder of the original warranty period or ninety (90) days, whichever is longer. Thislimited warranty is the only warranty made by Seller and can be amended only in a writingsigned by an authorized representative of Seller.

Fisher-Rosemount Japan Co.,Ltd. Brooks Division1-4-4 Kitasuna Koto-KuTokyo, 136-0073 JapanTel 011-81-3-5633-7105Fax 011-81-3-5633-7124E-mail [email protected]

Brooks Instrument B.V.Groeneveldselaan 6P.O. Box 563900 AB Veenendaal, NetherlandsTel 31-318-549-549Fax 31-318-549-559E-mail [email protected]

Brooks Instrument407 W. Vine StreetP.O. Box 903Hatfield, PA 19440-0903 USATel (215) 362-3700Fax (215) 362-3745E-mail [email protected]://www.brooksinstrument.com

Brooks Instrument© Copyright 2001 Brooks Instrument Division, Emerson Electric Co. All rights reserved. Printed in U.S.A.

1 Parker Hannifin CorporationFiltration and Separation DivsionTewksbury, MA • 1-800-343-4048www.parker.com/balston

Filtration

Bulletin TI-8000ATechnical Information

Installation, Operation and Maintenance ManualCompressed Air and Gas In-Line Filters

These instructions must be thoroughly read and understood before installing andoperating this product. If you have any questions or concerns, please call the TechnicalServices Department at 800-343-4048, 8AM to 5PM Eastern Time (North America only).For other locations, please contact your local representative.

When properly installed on a compressed air or gas line, Parker Filtration 8000 Series in-linefilters effectively remove oil, water, and particulate contamination from a gas supply. Thequantity of oil and water and the size of the particulate contamination removed from a gassupply is dependent upon the grade of the filter cartridge installed in the housing.Warning: Do not expose filter assemblies with plastic or nylon components to solvents,alcohols, or glycols. Exposure to these materials could cause failure of the housing. Useonly non-detergent mineral base oils with housings containing polycarbonate compo-nents. Use of any other types of oils could lead to dangerous failure of the product.

Filter housings are pressure vessels and all system connections and accessory outlets must beleak-tight. It is good practice to apply pipe sealant to the male threads before connecting thepipe to the filter ports. Any lubricant used must be compatible with the filtered media. The useof lubricant facilitates disassembly at a later time, if necessary.

For most applications, the flow direction through the filter cartridge should be from the inside-to-outside. Most Filtration 8000 Series filters have a flow arrow indicating the flow directionfrom inside-to-outside through the cartridge.

For coalescing applications, the flow of compressed gas through the filter cartridge should befrom inside-to-outside. Suspended liquids will be coalesced throughout the cartridge and willdrain from the outside of the cartridge into the bowl of the filter assembly. Accumulated liquidsmay be drained from the filter bowl by automatic or manual drains. For more details oncoalescing filtration and liquid drains, request Bulletin PK10-1.

For installations where the compressed gas is sourced from an overhead line, the gas shouldbe piped from the top of the header to the filter. In this way, excessive moisture and dirt are notgravity-fed to the in-line filter. For installations in which long runs of piping carry filtered gasfrom the filter to the point of use, filters should be located as close to the point of use aspossible to trap condensation and particulate which may have been picked up in the pipe.

Mounting bracket kits are available for most filters (see Figure 5 and Table 1). Some filterassemblies may be pipe mounted if the size and weight of the housing and piping permit it.

All fittings must be leak tight before applying gas pressure to the filter.

Do not install Parker Filtration 8000 Series filter housings in corrosive environments.

Installation, Operation, and Maintenance Manual

Parker Filtration 8000 SeriesCompressed Air and GasIn-Line Filters

General

Filter HousingInstallation

Bulletin TI-8000A

2Parker Hannifin CorporationFiltration and Separation DivsionTewksbury, MA • 1-800-343-4048www.parker.com/balston

Filtration



Operation and Maintenance

The schematic below shows typical installations for three commonly required coalescingapplications in compressed air systems.

All installation and maintenance activities should be performed by suitable personnelusing reasonable care. Turn off the compressed gas supply and depressurize the filterhousing prior to performing routine maintenance. The 8000 Series is equipped with avent valve at the base of the bowl which can be used to depressurize the housing.

Most filter housings are ordered separately from filter cartridges. Parker Filtration 8000Series coalescing filter assemblies, however, are shipped from the factory with the filtercartridge installed. 8000 Series adsorbent filter assemblies are shipped from the factory withthe adsorbent filter packaged separately from the filter housing. The adsorbent cartridgemust be installed into the housing prior to installing the housing on the compressed air line.This packaging procedure extends the life of the cartridge by preventing exposure to theatmosphere prior to initial use.

An adhesive-backed label indicating the grade of the filter cartridge is packed inside each boxof filter cartridges. This label should be affixed to the filter housing when the first filtercartridge is installed. Using the cartridge grade label will help ensure that the correct filtercartridge is used when maintenance is performed on the housing. The date that the replace-ment cartridge is installed may be recorded, with a marking pen or grease pencil, on the filterhousing label to provide a ready reference for scheduling routine maintenance.

Parker Filtration 8000 Series Microfibre® filter cartridges are sealed in place by compressionagainst a flat surface. Gaskets are not required between the filter cartridge and the filterhousing. The filter cartridge is centered by guides on the housing which fit the inside diam-eter of the cartridge at each end. In most 8000 Series housing designs, the filter cartridge issealed by tightening a threaded element retainer on a tie rod. Do not use excessive force ortools on the element retainer. The filter cartridge is securely sealed by tightening the elementretainer 1 -1/2 to 2 turns after it first contacts the filter cartridge. (Note: In high flow, multi-cartridge housings, it may be necessary to tighten the element retainer 3 to 4 turns aftercontact with the filter cartridge.)

Proper Replacement of the Filter Bowl requires the sightglass to be aligned perpen-dicular with the Differential Pressure Indicator or at a 90° position from inlet/outletpipe. Failure to replace the filter bowl in the locked position as described above couldresult in catastrophic failure and personal injury (see Figure 1 on Page 3).

Always replace the filter bowl guard, when applicable, after servicing the filter.

Filter CartridgeInstallation


Filtration



The efficiency of the Parker Filtration 8000 series Microfibre filter cartridge is relatively unaf-fected by liquids entrained in the compressed air or gas stream. The life of the filter cartridge isdetermined by the increase in flow resistance caused by solids trapped within the depth of thefilter cartridge. The change in pressure through the filter cartridge should be monitored whilethe filter is in use (many of the 8000 Series filter assemblies are equipped with DifferentialPressure Indicators). The filter cartridge should be changed when the flow through the housingfalls below an acceptable level, or when the pressure drop becomes too high for the applica-tion. In any case, the filter cartridge should be changed when the pressure drop reaches5-7 psid. (Note: The 8000 Series Microfibre filter cartridge cannot be cleaned by back-flushingbecause the solids are trapped within the depth of the cartridge, not on the surface.)

Failure of the filter cartridge resulting from a high pressure drop or excessive solidsloading may cause damage to the filter housing and/or any downstream equipment.

In many applications, the pressure drop through the filter assembly may be measured usingtwo pressure gauges, one directly upstream from the filter assembly, and one directly down-stream from the filter assembly. In compressed air filtration, however, the pressure dropthrough the filter assembly is difficult to measure in this way because of inaccuracies in thepressure gauges and rapid fluctuations in system pressure. For monitoring pressure dropthrough a compressed air filter assembly, use a Differential Pressure Indicator. Most 8000Series filter assemblies are available with factory installed Differential Pressure Indicators.

Some Parker Filtration 8000 Series filter assemblies have filter cartridges installed whenshipped from the factory. If filter cartridges are being ordered separately, either as replace-ments for an existing assembly or as an original for a new installation, specify both the sizeand grade of the filter cartridge. Filter cartridges for compressed air and gas filter assemblesare available in boxes of 4. The size of the filter is designated by a three-digit number followedby a two digit number (e.g., 4/100-12, 4/150-19, 4/200-80). The retention efficiency of the filteris designated by a series of letters or numbers following the size designation (e.g., 4/100-12-DX, 4/150-19-BX).

To ensure consistent product performance and reliability use only genuine Parker Filtration8000 Series replacement parts and filter cartridges.

The replacement parts for the 8000 Series filters (except Grade SA) are detailed in Figure 3(page 6) and table 1 (page 7). Inspect all seals when changing filter cartridges and replace asneeded. Lubricate all replacement seals prior to installation. Use a lubricant which is compat-ible with the gas being filtered.

Filter CartridgeLife

OrderingReplacementFilter Cartridges

Ordering FilterAssemblyReplacementParts

Figure 1 - Proper Bowl Replacement


Filtration



Accessories

If the filter housing is ordered with an automatic float drain, the drain is installed at thefactory.

Float drains are available on select assemblies with DX or BX cartridges. They are notavailable for assemblies with Grade Cl adsorbent cartridges or Grade SA sterile air car-tridges.

If the filter housing is not equipped with a drain, several different drain assemblies areavailable which may be integrated into the housing.

Most Parker Filtration 8000 Series Compressed Air Filter Assemblies are shipped withDifferential Pressure Indicators (DPIs) installed. The DPI monitors the pressure drop acrossthe filter, and may be used to measure pressure drop across other components in thecompressed air system. Differential Pressure Indicators may also be purchased as accesso-ries for other 8000 Series filter assemblies. Two different models of DPIs are available: 41-071 and 41-082.

Connect the indicator to the HIGH (upstream) and LOW (downstream) sides of the line asindicated by the marking on the indicator.

The Parker Filtration 8000 Series Differential Pressure Indicators give a quick visual indica-tion of the pressure drop in the line. It is not intended to be an accurate pressure gauge.

Automatic FloatDrains

DifferentialPressureIndicators (DPI)

OrderingInformation

1 If the 41-082 DPI is not mountedon the filter housing, a mountingblock (P/N 76256) must be ordered.

2 To ensure consistent productperformance and reliability use onlygenuine Parker Filtration 8000 Seriesreplacement parts and filter cartridges.

Model Ports Maximum Pressure Maximum Temperature

41-071 1/8" NPT 250 psig 130°F (54°C)

41-082 3/8"-24UNF(1) 300 psig 150°F (65°C)

Notes:


Filtration



Figure 2 - Mounting Bracket Installation


Filtration



Figure 3 - Exploded Parts View


Filtration



Figure 4 - Drain Details


Filtration



Installation, Operation and Maintenance - Parker Filtration 8000Series Sterile Air Filters

These instructions must be thoroughly read and understood before installing andoperating this product. If you have any questions or concerns, please call the Techni-cal Services Department at 800-343-4048, 8AM to 5PM Eastern Time (North Americaonly). For other locations, please contact your local representative.

All water, oil, and dirt must be removed from compressed air before it enters a sterile airfilter. Parker 8000 Series coalescing filters remove these contaminants from compressed airat very high efficiencies, up to 99.99% for 0.01 um for particles and droplets. Collected liquiddrips from the filter cartridge to an automatic drain as rapidly as it enters the filter. A Parkercoalescing filter will remove liquids for an unlimited time without loss of efficiency or flowcapacity.

Two stages of coalescing filters, a Parker Grade DX followed by a Parker Grade BX, arerecommended to satisfy all requirements for preparing compressed air for sterile filtration(see Figure 5, Recommended Installation diagram, on page 9).

NOTE: All housings with “SA” designations (3rd stage in diagram) must be installedso that flow direction of the compressed air is “outside to inside” through the filtercartridge.

The filter housing is a pressure vessel and the system connections and accessory outletsmust be leak-tight. Apply a pipe sealant to the male threads before connecting the pipe lineto the filter ports. The sealant also permits disassembly at a later time, if necessary. Anysealant such as Teflon®* tape, paste, or other compound may be used if it is compatible withthe filtered media. Special consideration must be taken when the application requires steamsterilization of the sterile air filter. The sterile air filter should be piped so that it may beisolated from the coalescing prefilters when it is being steam sterilized (see Figure 5 on page9). Any filter housing which is steam sterilized must be stainless steel.

Please note that an adhesive-backed grade label is packed in each box of filter cartridges.Affix the grade label to the filter housing when installing the first filter cartridge, so thatmaintenance personnel know which grade of filter to use for replacement. The date the filtercartridge is installed may be written on the housing label with marking pen or grease pencil,ensuring that the cartridges are changed on a regular schedule.

Microfibre filter cartridges are sealed in place by compression against a flat surface. Gasketsare not required between the filter cartridge and the filter housing. The filter cartridge iscentered by guides which fit the inside diameter of the cartridge at each end. In most ParkerFiltration housing designs, the filter cartridge is sealed by tightening a threaded elementretainer on a tie rod. It is not necessary to use excessive force or tools on the elementretainer. The filter cartridge is securely sealed by tightening the element retainer 1 -1/2 to 2turns after it first contacts the filter cartridge.

A Microfibre filter cartridge continues to filter at its original efficiency as long as it is kept inservice. The life of the filter cartridge is determined by the increase in flow resistance causedby solids trapped within the depth of the cartridge. The filter cartridge should be changedwhen the flow falls below an acceptable level, or the pressure drop becomes too high. Thepressure drop through the cartridge should not exceed 10 psid. The filter cartridge cannot becleaned by back-flushing, because the solids are trapped in the depth of the cartridge, not onthe surface.

Changing theFilter Cartridge

PreparingCompressed Air forSterilization

Installing a ParkerSterile Air FilterAssembly

The FilterCartridges

Installing FilterCartridges

* “Teflon” is a registered trade mark of the Dupont company


Filtration



Steam must flow through the sterile air filter in an outside-to-inside flow direction.

In installations where the sterile air filter requires steam sterilization, we recommend thefollowing:

When steam sterilizing, ensure the steam pressure does not exceed 60 psig. It is preferable toold the steam pressure to 40 psig or less. A typical sterilization cycle consists of using steamat30 psig for 20 minutes. Steam sterilization time can be increased as desired without harm tothe filter cartridges; however, the steam flow rate should not exceed the normal air flow rate forthe unit. A condensate drain valve must be installed on the sterile air filter to ensure no conden-sate buildup during the steam sterilization cycle. If condensate is allowed to build up within thehousing during steam sterilization, the sterility and integrity of the sterile air filter may becompromised Typically, the Parker Filtration Sterile Air filter cartridge will withstand approxi-mately 60 steam sterilization cycles.

Use only filtered steam to sterilize a sterile air filter. The use of unfiltered steam may contami-nate the filter housing, filter cartridge, and any downstream equipment or piping RequestLiterature Pack 9 for more information on Parker Steam Filters.

The Parker Filtration 8000 Series Grade SA sterile air filter cartridges will tolerate temperaturesto 300 F (149°C) in dry gas. Viton or other appropriate heat-resistant sealing should be used inthe housing during autoclaving. The housing must be rated for the temperature used duringautoclaving.

The replacement parts for the Grade SA 8000 Series filters are detailed in Figure 6 (page 10)and Table 3 (page 11). When replacing seals, lubricate prior to installation. Use a lubricantwhich is compatible with the gas being filtered.

Summary of FilterCartridgeRecommendations

SteamSterilizationProcedure

AutoclavingProcedure

Ordering andInstallingReplacementParts

1st Stage Grade DX 2nd Stage Grade BX 3rd Stage Grade SA

For removal of largequantities of oil, water,and dirt from compressedair. Prefilter to GradeBX.

For complete removal oftrace quantities of oil, water,and dirt.

For removal of bacteriawhen providing sterile air.

Parker does not recommend the use of Grade BX without a Grade DX prefilter.

Figure 5 - Recommended Installation


Filtration



Figure 6 - Exploded Parts View (Sterile Air)


Filtration



Table 3: Spare Parts Table (Sterile Air)


Filtration



©Parker Hannifin Corporation 2001, 2002Printed in U.S.A. Bulletin TI-8000AFiltration

Parker Hannifin CorporationFiltration and Separation Division100 Ames Pond Drive, P.O. Box 1262Tewksbury, MA 01876-0962Tel: 978-858-0505 Fax: 978-858-0625

Parker Hannifin UK LtdHermitage Court, Hermitage LaneMaidstone, Kent ME16 9NT, EnglandTel: +44 (01622) 723300Fax: +44 (01622) 728703

\\sbs_mw\sys\applic\services\s6904 E-One\Production\Manual 204-CS-YLX.doc

INSTALLATION, OPERATION &

MAINTENANCE INSTRUCTIONS

FOR

ROOTS BLOWER

MODEL: 204-CS-YLX

CUSTOMER: Environmental One Corporation

ORDER NO: 020472

ROOTS SYSTEMS REF: S6904/02


INDEX

SECTION 11.1 Foreward

1.2 Installation

1.3 Commissioning

1.4 Operation

1.5 Service

SECTION 21.1 Maintenance Instructions – Booster Disassembly

1.2 Maintenance Instructions – Booster Assembly

1.3 Rotor Clearance Data


1.1 - FOREWORD

U.K. HEALTH & SAFETY AT WORK ACT (HASAWA) : 1974

1.1.1 Compliance with Instructions in this Manual

The Purchaser should comply with the instructions and information in this manual and allpersonnel to be associated with the apparatus under this contract, should be made familiarwith the information contained herein.

1.1.2 Guidance Notes for Users on the Safety of Personnel using Electrical Apparatus

The above Act stipulates that electrical apparatus should be designed, tested and installedto be safe and without risk to health when properly used and that information is providedon the conditions necessary for safety and on any hazards which could arise during normaluse and how these are to be avoided (See Section 6 of HASAWA).

The above Act stipulates that, the user, on his part, shall ensure that his employees areinformed, trained and supervised and use proper working procedures to ensure theirsafety. He is advised to comply with the information provided in order to maintain the plantin a safe condition. (See Section 2 of HASAWA).

Compliance with these two basic requirements ensures that, under normal healthy plantconditions, the apparatus will be safe for use by electrically unskilled operators.

With certain categories of apparatus, safety hazards may arise when it is necessary to gainaccess by opening enclosures, removing covers, etc., in order to carry out maintenancework, testing, setting up, etc. This is especially the case when the apparatus cannot becompletely isolated before working on it, as for example, where circuits must be energisedfor the purpose of carrying out electrical tests.

As it is often impracticable or impossible to achieve hazard free conditions when workingwith energised circuits, the main burden of responsibility for the safe conduct of thosecarrying out the work, rests on those under whose authority they act (See Section 2 ofHASAWA).

1.1.3 Installation, Operation and Maintenance

The Purchaser is advised to ensure that the apparatus supplied by the Company to the Purchaser’s order is correctly installed, in a suitable location, by technically qualified and competent persons experienced in the class of work involved. The rules for ensuring the safety of personnel can be summarised under the following headings:-


1.1.3.1 During normal use ensure that the plant operators:-

• Are fully conversant with all controls, particularly those for emergency shutdown.

• Comply with safety warning notices and keep all enclosures shut.

• Are trained to recognise signs of mal-operation and know what action to take inthe event of trouble of difficulty.

1.1.3.2 During maintenance and testing of other work involving electrical competence• Ensure that only suitably skilled persons are permitted to carry out work and that

they:

• Isolate the apparatus completely, wherever possible, before openingenclosures and starting work

• Comply with safe working procedures

• Are conversant with the information provided particularly on measures relatingto their safety

• Recognise the hazards which can arise when working on energised apparatusand take all the necessary precautions.


1.2 – INSTALLATION

1 On receipt of gas booster, check for any visible signs of damage or deterioration.

2 The booster must always be mounted level with the gas flow in a vertical direction and withthe oil sight glass on the gear end, and the oil level plug on the drive end, below the centreline.

3 Mount booster in pipework between flanges (1" ANSI 150lb). The pipework must be suffi-ciently rigid to accommodate the weight of the booster (47kg).

4 Ensure booster is installed with all necessary client supplied ancillary equipment, i.e bypassloop, aftercooler, temperature switch.

5 Fill the gear end with the Shell Tellus R100 oil or an equivalent. Ensure the oil level iscorrect as indicated on the label on the gear end of the machine. Fill the drive end with oil,having first removed oil level plug - item 42. The correct oil level is achieved when oil flowsfrom this hole.

NOTE: Overfilling may cause malfunction.

Refer to Section 1.5 for details of oil filling.

6 Make all necessary electrical connection to the motor. Viewing the fan end of the motor, flipstart the machine to check direction of rotation - it may be necessary to remove the fancowl to enable viewing.

Fan rotating clockwise for top inlet.

Fan rotating anti-clockwise for bottom inlet.

7 Check flanges for leak tightness. (Use inert gas at 1.0 bar g).


1.3 – COMMISSIONING

1 Carry out commissioning checks over a 6 hour period.

2 During commissioning check the following at regular intervals:

Inlet Pressure 14.7PSIA

Booster Differential Pressure: Not to exceed 2.5 PSIG (Helium)/

10PSIG (Air)

Motor Line Current: Not to exceed 5.9 Amps

Gear case oil level and condition: Level not to be below sight gauge

Discharge Temperature: Not to exceed 190°C (Trip Point).

3 When satisfactory commissioning is complete, normal operation may proceed.


1.4 – OPERATION

1 Check motor line current, oil level and general running condition every day.

2 Check general running condition and vibration level every 2000 hours. Observe for anysudden change of readings.


1.5 – SERVICE

1 Oil change – the oil should be changed every 2000 hours.

2 Prior to changing the oil, the booster and adjoining pipework must be de-pressurised.

3 After de-pressurising/purging, remove the drain plugs from the underside of the boosterand fill plugs from the top of the booster. Drain oil for disposal.

4 Refit drain plug and remove oil level plug. Fill booster with oil to the correct level.

5 Refit oil level and oil fill plugs. Ensure plug seals (Item 30) are fitted.

6 Pressure test to ensure the booster is sealed, using inert gas.

7 Booster ready to resume service.


2.1 – MAINTENANCE INSTRUCTIONS – BOOSTER DISASSEMBLY

Blower Model 204-CS-YLX - refer to Sectional Drawing

1 Release screws Item 43 and remove motor Item 22, motor support Item 8 and outermagnet assembly Item 14 taking care not to damage the magnetic element of Item 14.

2 Release screws Item 37 and remove shroud assembly Item 12 and ‘O’ ring Item 36.

3 Release screw Item 35 and remove inner magnet assembly Item 13 from shaft usingextracting tool. Remove spacer Item 50 drain oil from adaptor plate, before removal.

4 Release nuts Item 29 and remove adaptor plate Item 7 complete.

5 Remove spacer Item 19.

6 Remove oil thrower Item 4 by releasing screw Item 35.

7 The bearing housings Item 9 can now be removed by using jacking holes providedcomplete with bearings Item 20.

8 Remove rotor sleeve Item 25 complete with ‘O’ rings Item 34.

9 Remove endplate drive end Item 5 using M8 jacking holes provided.

10 Drain oil from gear end via drain plug in cover Item 6.

11 Release nuts Item 28 and remove end cover Item 6.

12 Release screws Item 35 and remove clamp washer Item 51.

13 Remove timing gears Item 11 using a gear puller.

14 Remove bearing housings as steps 7 & 8.

15 Remove housing Item 3.

16 Hold endplate non drive end Item 5 on press and press rotor shafts out of endplate.

17 Remove screws Item 28 and washers Item 29.

18 After disassembly, wash all parts in an industrial solvent and inspect their condition.

19 Prior to re-assembly all bearings and ‘O’ rings should be replaced with new. The timinggears should be inspected and replaced if worn.


2.2 – MAINTENANCE INSTRUCTIONS – BOOSTER ASSEMBLY

1 Press lip seals Item 18 into endplates as shown on sectional drawing RSC , by usinga press tool.

2 Hold rotors Item 1 & 2 with gear end shafts upright and drop gear endplate Item 5 overshafts.

3 Slide rotor shaft sleeves Item 9 over shafts.

4 Fit ‘O’ rings Item 34.

5 Fit bearing housings Item 9 into endplates.

6 Press onto shafts, bearings Item 20 using hollow press tool.

7 Fit bearing retaining plate Item 15 and screw Item 33.

8 Fit gear spacer Item 49 over rotor shafts.

9 Press one gear onto shaft.

10 Turn rotors to position:

11 Press on second gear.

12 Check that rotors will turn.

13 Fit ‘O’ ring Item 27 into endplate.

14 Fit housing Item 2 to endplate, tap in dowels Item 31 and secure with slave nuts.

15 Place drive endplate Item 5 over drive end rotor shafts; ensuring ‘O’ ring Item 27 is in place.

16 Insert dowels Item 31 and secure with slave nuts.

17 Slide rotor shaft sleeves Item 25 over shafts.

18 Slide bearing housings Item 9 over rotor shafts.

19 Press in bearings Item 20 into bearing housings as shown.

20 Secure with screws Item 33.

21 Fit spacer Item 19 over drive rotor Item 1 as shown.

22 Fit oil thrower Item 4 to the driven rotor Item 2 and secure with screw Item 35.

23 Fit outer ‘O’ ring Item 27 to endplate and fit adaptor plate Item 7 secure with nuts Item 28.


24 Fit bearing Item 20 over drive rotor into adaptor plate.

25 Adapt rotor clearances (if necessary) by holding the gears fixed, and tapping the rotorlobes.

26 Manually rotate rotors to ensure freedom of rotation.

27 Secure gears Item 11 by using clamp washer Item 51 and screw Item 35.

28 Fit ‘O’ ring Item 27 to endplate and then fit gear end cover Item 6.

29 Fit spacer Item 19 to drive rotor shaft.

30 Press inner magnet assembly Item 13 onto drive shaft and secure with screw item 35 -check for drive shaft run out.

31 Fit shroud assembly Item 12 and secure with screws Item 37. Ensure ‘O’ ring Item 36 is inplace.

32 Carefully fit motor Item 22 motor support Item 8 and outer magnet assembly Item 14 andsecure using screws Item 39.

Care must be taken to ensure the magnets on the outer magnet assembly Item 14 are notdamaged.

See Section for re-commissioning.

2.3 – Rotor Clearance Data

INTERLOBE - 0.004” (0.1 mm)

END CLEARANCE – 0.005” (0.13 mm)

ROTOR TIPS TO HOUSING - 0.002” (0.051 mm)


DATA DOSSIER

Client: ENVIRONMENTAL ONE CORPORATION

Clients Order No: 020472

Project: N/A

Roots Systems Ref: S6904/02

Equipment: 1 Off HYDROGEN GAS CIRCULATOR

MODEL 204-CS-YLX

SERIAL No 2638


S6904/02

DATA DOSSIER INDEX

1. CERTIFICATE OF CONFORMITY

2. MOTOR DETAILS

3. TEST CERTIFICATE


DATA DOSSIER

Client: ENVIRONMENTAL ONE CORPORATION

Clients Order No: 020472

Project: N/A

Roots Systems Ref: S6904/02

Equipment: 1 Off HYDROGEN GAS CIRCULATOR

MODEL 204-CS-YLX

SERIAL No 2638


CERTIFICATE OF CONFORMITY

CUSTOMER: ENVIRONMENTAL ONE CORPORATION

CUSTOMERS ORDER NO: 020472

ROOTS SYSTEMS LTD NO: S6904/02

ITEM QTY DESCRIPTION

1 1 HYDROGEN GAS CIRCULATORMODEL – 204-CS-YLXSERIAL No 2638

We, ROOTS SYSTEMS LTDUPPER MILLS INDUSTRIAL ESTATEBRISTOL ROADSTONEHOUSEGLOS., GL10 2BJENGLAND

Certify that the equipment described above, which has been manufactured and/orsupplied by us has been inspected, tested and unless otherwise stated conformswith the requirements of the aforementioned Purchase Order and Requisitions.

SIGNATURE OF AUTHORISED PERSON ......................................................

D. ROLLINGSQUALITY CONTROL DEPARTMENT

DATED:


TEST CERTIFICATE

CUSTOMER: ENVIRONMENTAL ONE CORPORATION

CUSTOMERS ORDER NO: 020472

ROOTS SYSTEMS LTD NO: S6904/02

ITEM QTY DESCRIPTION

1 1 HYDROGEN GAS CIRCULATORMODEL – 204-CS-YLXSERIAL No 2638

We, ROOTS SYSTEMS LTDUPPER MILLS INDUSTRIAL ESTATEBRISTOL ROADSTONEHOUSEGLOS., GL10 2BJENGLAND

Certify that the equipment described above, which has been manufactured and/orsupplied by us has been inspected, tested and unless otherwise stated conformswith the requirements of the aforementioned Purchase Order and Requisitions.

SIGNATURE OF AUTHORISED PERSON ......................................................

D. ROLLINGSQUALITY CONTROL DEPARTMENT

DATED:

Environment One Corporation2773 Balltown RoadNiskayuna, New York USA 12309–1090

Tel: (01) 518.346.6161FAX: 518.346.6188

www.eone.com

A PCC Flow Technologies, Inc. Company

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