gas station instruction manual · sures to avoid damage (scratches, etc.) to the sealing surfaces....

Top Level Drawing No.: HD0196G01I/O Manual No.: HA0324G01 Rev. A

Gas Station Instruction Manual

Two-Module Configuration

UTILITY SYSTEMS

1 HA0324G01 Rev. A

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

Mechanical Installation & Considerations ......................................................................................... 7Mounting ......................................................................................................................................... 7Lifting ............................................................................................................................................. 7Arrangement ................................................................................................................................... 7Piping .............................................................................................................................................. 7

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

Getting Started ................................................................................................................................... 11Power Connections ....................................................................................................................... 11Signal Connections ....................................................................................................................... 14Contact Connections .................................................................................................................... 14Special Consideration ................................................................................................................... 14Pressure Test ................................................................................................................................. 14Apply Power – System Power-Up ................................................................................................ 14

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FiguresFigure 1 - Outline, Major Component Locations .................................................................................................. 6Figure 2 - Drip Leg/User Connection Panel ........................................................................................................ 8Figure 3 - Lifting Guide ........................................................................................................................................ 9Figure 4 - User Interface ................................................................................................................................... 12Figure 5 - Input Power (TB1) ............................................................................................................................ 13

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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.

4HA0324G01 Rev. A

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 HA0324G01 Rev. A

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 two-module Gas Station consists of:

· One Generator Gas Analyzer (GGA) module for monitoring gas purity

· One Generator Condition Monitor (GCM-X) to provide immediate indication of overheatingin hydrogen-cooled generators before extensive damage can occur.

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

See Figure 1, Outline, Major Component Locations.

6HA0324G01 Rev. A

Figure 1 - Outline, Major Component Locations

CONNECTIONS

DRIP LEG

CUSTOMER

GCM-X

GGA

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7 HA0324G01 Rev. A

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. See Figure 1.

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 600 lbs.). Never lift the GasStation from cable, plumbing or other exterior surfaces. See Figure 3, Lifting Guide.

Arrangement

The Gas Station is configured as a panel arrangement suitable for indoor locations.

Piping

Piping connections should be in accordance with Figure 2, Dripleg/User Connection Panel.Gas connections are made through 1/4-inch tube compression fittings on the panel. Electri-cal connections are made through three 1-inch conduit provisions at the side of the GasStation.

8HA0324G01 Rev. A

Figure 2 - Drip Leg/User Connection Panel

��

DRIP LEG

CONNECTIONS

CUSTOMER

9 HA0324G01 Rev. A

Figure 3 - Lifting Guide

GGA

GCM-X

10HA0324G01 Rev. A

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.

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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, User Interface.

2. Connect 120VAC Line (1), Neutral (2) and Ground (3) as indicated in Figure 5, InputPower (TB1).

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Figure 4 - User Interface

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Figure 5 - Input Power (TB1)

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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 4, TB-1.

3. Connect signals from TB-1 to the power plant control room or plant data acquisitionsystem.

Contact Connections


2. Observe contact ratings as indicated in Figure 4, 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.

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.

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 GGA subsystem, as itrelates to gas purity levels.

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When power is applied:

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

· Each module will perform its initial power-up check

· The GGA module, upon successfully completing their power-up check, will read “Config-ure Valves” at the function menu display (LCD). Upon configuring the valves to theirproper orientation, press Enter.

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

· The GCM-X module, upon successfully completing its power-up check, will flash “NormalOperation”

16HA0324G01 Rev. A

Generator Condition Monitor (GCM-X)Module

Installation and Operation Manual

HA0292P01 Rev. A

UTILITY SYSTEMS

1 HA0292P01 Rev. A

ContentsSpecifications ....................................................................................................................................... 6

Standard Application ............................................................................................................................ 7Principle of Operation .................................................................................................................... 7

System Description .............................................................................................................................. 9System Electronics .......................................................................................................................... 9Display Panel .................................................................................................................................. 9

Installation ......................................................................................................................................... 10Mounting ....................................................................................................................................... 10Piping ............................................................................................................................................ 10Electrical Connections .................................................................................................................. 11Contacts ........................................................................................................................................ 11Signals ........................................................................................................................................... 11Circuit Protection ......................................................................................................................... 12

System Operation .............................................................................................................................. 13GCM-X Initialization .................................................................................................................... 13GCM-X Menu Displays ................................................................................................................. 13Navigating the LCD Display ........................................................................................................ 13LCD Display Menu — Two Modes of Operation .......................................................................... 14Menu Profile ................................................................................................................................. 14

Menu Navigation Tutorial ................................................................................................................. 15Activating the Menu ..................................................................................................................... 15Navigating the Menu in Scrolling Mode (GCM-X default) ........................................................... 15Disabling Scrolling Mode .............................................................................................................. 15Navigating the Menu in Non-Scrolling Mode ............................................................................... 15Function (FN) Menu ..................................................................................................................... 16Setup Menu ................................................................................................................................... 16Test Menu ...................................................................................................................................... 17View Menu .................................................................................................................................... 17Log Menu ...................................................................................................................................... 17

Procedures ......................................................................................................................................... 19Calibrating the Ion Chamber ....................................................................................................... 19Setting the Sampler Interval ......................................................................................................... 19Setting the Warning Level ............................................................................................................. 19Setting the Low Flow Limit .......................................................................................................... 20Setting the High Flow Limit ......................................................................................................... 20About the Faults Log .................................................................................................................... 20About the Power Log .................................................................................................................... 21

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Modes of Operation .......................................................................................................................... 22Startup .......................................................................................................................................... 22Startup Problems .......................................................................................................................... 22Suspended Operation .................................................................................................................... 23Normal Operation ......................................................................................................................... 23

Maintenance ...................................................................................................................................... 24Daily .............................................................................................................................................. 24Weekly ........................................................................................................................................... 24Monthly ......................................................................................................................................... 24Annually ........................................................................................................................................ 24When the Generator is Down ....................................................................................................... 24Tubing and Fitting Replacement ................................................................................................... 24

Troubleshooting ................................................................................................................................. 25

Component Replacement Instructions ............................................................................................. 29ICD, Filter Solenoid and Sampling System Solenoid .................................................................... 29Controller Assembly ...................................................................................................................... 29I/O Assembly (Located in the System Electronics Enclosure) ....................................................... 30Display Assembly .......................................................................................................................... 30Fuses ............................................................................................................................................. 31

GCM-X Parts List ............................................................................................................................. 32

3 HA0292P01 Rev. A

FiguresTable 1 - Customer Contacts ............................................................................................................................. 25Table 2 - Display Indicators ............................................................................................................................... 26Table 3 - Display Keys ...................................................................................................................................... 27Table 4 - GCM-X Status .................................................................................................................................... 28Table 5 - Relay Problems .................................................................................................................................. 29GCM-X Figure 1 - System Overview ................................................................................................................ 33GCM-X Figure 2 - GCM-X Module, Front View .............................................................................................. 34GCM-X Figure 3 - Control/Display Panel ......................................................................................................... 35GCM-X Figure 4 - Major Components (Typical) .............................................................................................. 36GCM-X Figure 5 - ICD Current and Flow ........................................................................................................ 37

4HA0292P01 Rev. A

5 HA0292P01 Rev. A

GENERATOR CONDITION MONITOR (GCM-X)IMPORTANT INFORMATION!

THIS EQUIPMENT OPERATES AT VOLTAGE LEVELS THAT CAN BE HAZARDOUS TOPERSONNEL. THE SECTION ABOUT SAFETY CONSIDERATIONS SHOULD BE READBEFORE INSTALLING 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, THE MATTER SHOULD BE REFERRED TO ENVIRONMENT ONE CORPO-RATION.

GENERATOR CONDITION MONITOR (GCM-X)SAFETY CONSIDERATION

THE SYSTEM ELECTRONICS ENCLOSURE, CUSTOMER INTERFACE, AND HEATERCONTAIN 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 TO THE SYSTEM ELECTRONICS, CUSTOMER IN-TERFACE AND CONTROL/DISPLAY PANEL SHOULD BE TESTED AND VERIFIED TO BECORRECT.

ALL WIRING MUST BE IN ACCORDANCE WITH APPROPRIATE ATEX, NEC 500-503 ORCENELEC EN50014 STANDARDS.

USE OF THIS EQUIPMENT IN A MANNER NOT SPECIFIED BY ENVIRONMENT ONECORPORATION IS STRICTLY PROHIBITED.

IT IS NECESSARY TO ENSURE THAT ALL SEALING FITTINGS ARE FILLED WITH ANAPPROVED COMPOUND. THIS IS A REQUIREMENT FOR ZONE 1, GAS GROUPING IIC,(CLASS 1, DIVISION 1, GROUP B) ENVIRONMENTS.

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

CHECK FOR LEAKS AT ALL TUBING AND MECHANICAL CONNECTIONS ON THE GCM-XMODULE. IF LEAKS ARE FOUND, DETERMINE THE CAUSE AND REPAIR. REPEATINGTHE LEAK CHECK UNTIL THE GCM-X IS DETERMINED TO BE LEAK TIGHT IS NECES-SARY.

6HA0292P01 Rev. A

Specifications

Measurement Characteristics

Detection Principle Ionization chamber

Hydrogen Flow Rate Adjusted by internal valve

Differential Pressure 4" to 5" (102 mm to 127 mm) min.

Readout (bar graph)Normal Operation 80% of scale, typicalAlarm Condition 50% of scale, typicalFlow 1.5

Electrical Characteristics

PowerInput Voltage 85 VAC to 250 VACInput Frequency 47 Hz to 63 HzInput Power 100WInrush Current 2A

Outputs, RelaysContact Rating 5A @ 250 VAC resistiveAlarm, NO and NCWarning, NO and NC 5A @ 30 VDC resistiveTrouble, NO and NC 100 mA @ 125 VDC resistive

Outputs, Signal (Caution: Do not externally excite output signals)Output 4-20 mA current output (transmitter)

4-20 mA = 0-100%

Flow 4-20 mA current output (transmitter)4-20 mA = 0-3" H2O

Mechanical Characteristics

Dimensions Overall 25" x 23" module

Temperature 32 to 122 F (0 to 50 C)

Area Classification Zone 1, Ex IIC (Class 1, Div 1, Group B)(Hydrogen environment)

Hydrogen Pressure 100 psi maximum

Connections, gas inlet 1/4” tube bulkheads

7 HA0292P01 Rev. A

Standard Application

The Generator Condition Monitor (GCM-X) is a sensitive real-time instrument designed toprovide immediate indication of overheating in hydrogen-cooled generators before extensivedamage can occur. Tests conducted on operating hydrogen-cooled generators have shownthat the GCM can detect thermal decomposition of small amounts of insulating materials.

Thermal decomposition of organic materials such as epoxy paint, core lamination enamel orother insulating materials used in the generator results in the production of a large number ofsmall particles. The onset of particle production, as the material is heated, occurs at atemperature characteristic of the material and its surrounding atmosphere. Below thistemperature, no particles are created, yet once the critical temperature is reached, millionsof sub-micron particles are generated each second for every square centimeter of surface.

GCM-X represents the next generation in condition monitoring — incorporating microproces-sor-based electronics, flameproof, intrinsically safe design features (Ex, IIC, CE) and self-diagnostics. E/One has taken the field-proven system that has served the worldwide powergeneration community for decades and improved upon it in the form of increased safety,performance and reliability.

GCM-X features:

• Microprocessor-based electronics

• Flameproof, intrinsically safe design

• Self-diagnostics

• Flow indication

• Trouble indication

• Integral auto/manual sampling system (optional)

• Automatic alarm verification

• Simple installation

• Maintenance-free operation

Principle of Operation

A basic understanding of the GCM is necessary in order to properly utilize the information itprovides.

Particle detection occurs by means of an ionization chamber through which the hydrogencooling gas is continuously circulated by the pressure produced by the generator fan. The ionchamber detector (ICD) consists of an ionizing section and ion collecting chamber containedin a pressure housing. The hydrogen first passes through the ionizing section, which con-tains a low level alpha source (Thorium 232). The resulting ions then pass with the hydrogento the ion collecting chamber in which there is an electrode maintained at -10 VDC. Becausethe ions are extremely small, they have a high ratio of charge to mass, giving them a high

8HA0292P01 Rev. A

mobility when placed in an electric field. The -10 VDC potential is sufficient to cause most ofthe ions to be attracted to a collecting electrode, where they produce the output current.

High concentrations of sub-micron particles (pyrolysis products) are produced whenever anymaterial within the generator is heated sufficiently to produce thermal decomposition. These“hot spots” can lead to catastrophic failure if not caught in time.

When particles are present in the hydrogen, some of the ions will become attached to them.Therefore, the charge to mass ratio of the particle-ion combination is very much reduced (bya factor of one thousand or so), and the mobility is very low. This means that only a very feware now attracted to the collecting electrode, resulting in a reduced output current.

Upon detection, the microprocessor initiates and monitors an alarm verification sequence. Ifthe alarm is confirmed, a verified alarm indication is given, alarm contacts are switched anda portion of the hydrogen flow automatically passes through the sampling system wherethese particles are collected for laboratory analysis. The sampling system can be set to autoor manual.

Alarm confirmation is made quickly by the automatic alarm verification circuit that activatesthe solenoid valve in the filter/solenoid valve assembly. Normally bypassed, all the hydrogenthen passes through the filter, which removes the particles. If the alarm is valid and thermallyproduced particles are present, their removal in this manner will cause the collector currentto return to its normal level, confirming their presence and overheating.

GCM-X Figure 1 provides a typical system overview. In this arrangement, a different pressuretransmitter that monitors the pressure drop across the ion chamber indicates flow.

Ion chamber output current is amplified by an electrometer. The amplified current and floware displayed on bar graphs. The usual operating procedure is to adjust the flow to a givendifferential pressure indication and calibrate the electrometer gain to produce an output of 80percent.

9 HA0292P01 Rev. A

System Description

The GCM-X is designed for use on hydrogen-cooled generators. It is designed to operate inZone 1, IIC hazardous areas (Class 1, Division 1, Group 1B). GCM-X’s main purpose is todetect overheating in hydrogen cooled generators.

The major components of the GCM-X include the control/display panel, ion chamber detec-tor, transmitter, solenoid valves and sample collector (GCM-X Figures 2, 3 and 4). Systemelectronics and customer interface points are located in the Gas Station junction boxes.

System Electronics

The system electronics consist of one processor board, one input/output board, one powersupply, one RFI filter and isolation barriers. All are mounted in a flameproof enclosure. Electri-cal connections are made through conduit entries in the customer interface juction box(Appendix Figure 1).

The system electronics provide calibration, mode selection, alarm contacts, data logging,system inputs/outputs and diagnostics.

Fail-safe operation of the GCM-X is ensured by:

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

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

3. The GCM-X is completely self-supervised and continuously checks itself for legal proces-sor functioning, internal voltages, analog-to-digital conversion accuracy, integrity ofcabling and relay operation. Any faults are immediately annunciated.

Display Panel

The display panel provides control of all functions of the GCM-X, as well as complete annun-ciation of GCM-X’s status (GCM-X Figure 3). Functions are accessed by means of a four-button membrane-switch keypad and 16-character Liquid Crystal Display (LCD). See MenuNavigation Tutorial for more information.

The display panel provides Light Emitting Diodes (LED’s) to annunciate GCM-X status; theyindicate Warning, Alarm and Trouble conditions. In addition, they display Sampler and Resetmode, and the status of the sampler and verification filter. A green LED indicates AC power.

To permit a system level initialization (“cold start”) a momentary push-button — locatedbehind the display panel (at the upper edge of the board) — may be pressed. Since allcalibration constants are stored in non-volatile memory, these values will not be lost shouldthe system be initialized or should it lose, then regain, AC power.

The “cold start” button should be pressed via a nonconductive tool. Depending on the GCM-Xconfiguration, the “cold start” button may be accessed by reaching behind the display as-sembly from the front (GCM-X Figure 3).

10HA0292P01 Rev. A

Installation

These instructions provide details to facilitate the equipment installation. The exact location ofthe GCM-X should be in accordance with recommendations made by the generator manu-facturer or its authorized representative.

Prior to applying power to the GCM-X System, ensure that the local power source usedmatches the power rating on the GCM-X nameplate.

All gas lines must be connected to the GCM-X and leak tested before continuing.

CAUTION! Care must be taken when opening the covers on flameproof enclosures toavoid damage (scratches, etc.) to the sealing surfaces of the cover and enclosure.Do not open the cover on the enclosure unless power is removed from the SystemElectronics and the system is free of hydrogen. Individuals involved in opening theflameproof enclosure covers must be trained in the use of such equipment andshould adhere to ATEX, Cenelec or NEC standards, local codes and generally ac-cepted professional practices.

Mounting

The GCM-X should be installed indoors, or at least under a roof that extends far enough toprotect it from the elements. If outdoor installation is necessary, a protective enclosure mustbe used, located out of direct sunlight to prevent the interior ambient temperature fromexceeding 122 F/50 C. The protective enclosure should also be ventilated to prevent theaccumulation of hydrogen in the event of a leak.

Piping

Appendix Figure 1 shows the locations of gas connections. The GCM-X should be locatedclose to the generator so that the inlet gas line will be 100 feet (30 meters) or shorter in orderto minimize loss of signal. The ambient temperature should not exceed 122 F/50 C. Gasdryers, or other devices that would filter out particles, should not be installed in series in thesignal line ahead of the GCM-X.

The outlet and inlet connections at the generator must be located so as to produce adequatepressure differential in order to provide sufficient flow (DP of 4" to 5" min.). If a dryer isconnected in parallel with the GCM-X, its effect on the pressure drops in the piping should bechecked so that flow changes through the dryer (as when it is being reactivated) will notadversely affect the flow through the GCM-X. Care should also be taken in location of thegenerator outlet connection so that the hydrogen stream will not be contaminated by oil vaporfrom the bearings. The high and low pressure taps should be located preferably as high aspossible on the generator casing in order to prevent the entry of liquids into the lines. Genera-tors with two fans should have an outlet tap at each end connected to a manifold so a com-posite hydrogen sample is supplied to the GCM-X.

To prevent the accumulation of liquids in the lines, horizontal runs should slope down in thedirection of flow, with a drip leg installed at all low points. At each drip leg the succeedinglength of pipe should start with a vertical tap at the top of the preceding section. This appliesalso to the lines from the GCM-X back to the generator, to prevent liquids from draining backto the GCM-X, particularly after shutdown. It is recommended that an oil moisture trap, such

11 HA0292P01 Rev. A

as Environment One Part No. GA0174P02, with grounding kit GB0084G02, be installed at theinlet of the GCM-X.

CAUTION! Some oil-moisture traps can remove the overheating particulate sensedby the GCM-X. Consult Environment One before using any trap other than thatsupplied by Environment One.

A line must be connected to the Gas Station (Appendix Figure 1). This line should not containvalves, and must provide low restriction to the flow of hydrogen so that it can be safelyvented to atmospheric pressure.

Electrical Connections

Electrical connections are made through conduits provided at the Gas Station’s customerinterface junction box (Appendix Figure 1). The system power requirement is 115/optional230 VAC, 50/60 Hz. The source of AC power should be reliable and not subject to severetransients.

To gain access to the inside of the system electronics enclosure for electrical connections,open the enclosure cover. Take care that the surfaces of the enclosure are not damagedduring opening process.

CAUTION! Do not scratch sealing surfaced 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 GCM-X and ensurethe system is free of hydrogen.

Wiring and wire routing should be in accordance with Figure 4 so that noise generated fromthe AC power and contacts does not interfere with the signals. If a circuit breaker is used, itshould be 10 amps. The ground wire should be 12 AWG with 25-amp capacity. ALL WIRINGMUST BE IN ACCORDANCE WITH CENELEC STANDARD EN50014.

Contacts

As shown in Appendix Figure 3, the GCM-X provides these relay contacts:

• 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.

Signals

• Output Signal 4-20 mA signal (transmitter)

• Flow 4-20 mA signal (transmitter)

12HA0292P01 Rev. A

Circuit Protection

The 2-amp slo-blow fuse (F1) provides circuit protection for 115/230 VAC. The fuse is lo-cated on the I/O PCB.

13 HA0292P01 Rev. A

System Operation

GCM-X Initialization

With system power on, press the RESET push-button on the backside of the display panel(GCM-X Figure 3). The GCM-X display panel will respond with (a) all discrete LED’s lit; (b) allsegments of the FLOWSET and OUTPUT bar graphs lit; and (c) all pixels of the LCD displayon.

Once communication has been established with the rest of the system, (a) all discreteLED’s, except the AC POWER, LOCAL, GCM FAULT and FLOW LED’s, will turn off; (b) allsegments of the FLOWSET and OUTPUT displays will turn off; and (c) the display will echothe results of cold start initialization:

• GCM-X Ver 2.0E-20

• CHECKSUM OK

• POWER OK

• RELAY TEST …

• … PASSED

• ICD=N.NpA

• DP=N.N INCHES

NORMAL OPERATION will flash for two seconds; the GCM-X will begin normal operation andthe display will read GCM-X BY E/ONE.

For a first-time installation, it is essential that a calibration be performed on the GCM-Xsystem; also, the faults log should be cleared. See CALIBRATION under the SETUP MENUand CLEAR FAULTS LOG under LOG MENU for specific instructions.

GCM-X Menu Displays

The following sections provide definitions and user information regarding the various menusthat are accessible via the GCM-X’s LCD display. It is strongly recommended that usersfamiliarize themselves with this section. Additional questions can be forwarded to Environ-ment One.

Navigating the LCD Display

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

• 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.

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LCD Display Menu — 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 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, View and Test. The Function menu is thetop-level menu; all of the other menus are accessed through this menu.

15 HA0292P01 Rev. A

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 (GCM-X default)

1. Press FN to start the menu. The LCD should display the prompt FUNCTION MENU. Aftertwo seconds the prompt should change to GO REMOTE.

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 is SHOW ICD CURRENT, then press the ENTER key. The displayshould show ICD=N.NpA where N.N is the present value of the ICD current. Press the FNkey. The prompt will be restored to SHOW ICD CURRENT.

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

6. Press FN a third time. The LCD will display GCM-X BY E/ONE as the menu is deacti-vated.

Disabling Scrolling Mode

1. Press FN to start the menu.

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

3. Wait until the prompt is 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 is 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 is SHOW ICD CURRENT and press the ENTER key. The display shouldshow ICD=N.NpA where N.N is the present value of the ICD current.

3. Press the FN key. The prompt will be restored to SHOW ICD CURRENT.


5. Press FN a third time. The LCD will display GCM-X 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 SETUP MENU Select this item to enter the SETUP MENU. The setup menuincludes selections for calibration and configuration. Items that can be configured includethe sampler interval, the operating mode and the menu scroll rate. The setup menu alsoincludes a selection to calibrate the ion chamber detector.

• 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, the solenoids, the bargraphs and the 4-20 mA outputs.

• GO TO VIEW MENU Select this item to enter the VIEW MENU. The view menu containsselections to view the ion chamber electrical output, the differential pressure across theion chamber and the four software variables associated with the ion chamber amplifier.

Setup Menu

• CALIBRATION Select this item to calibrate the ion chamber output. When selected, theCALIBRATION prompt will flash for two seconds before entering the calibration proce-dure. If the FN key is pressed while it is still flashing, the procedure will be canceled. SeeCalibrating the Ion Chamber for more information.

• SAMPLER INTERVAL Select this item to change the sampler interval. This option ispresent when the GCM-X is equipped with the optional sampling system. See Setting theSampler Interval for more information.

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

• LOW FLOW LIMIT Select this item to change the low flow limit. See Setting the Low FlowLimit for more information.

• HIGH FLOW LIMIT Select this item to change the high flow limit. See Setting the HighFlow Limit for more information.

• STOP MONITORING This item is used for troubleshooting and is displayed when themonitoring is turned on; select it to turn off monitoring. When selected the STOP MONI-TORING prompt will flash STOPPING for two seconds before monitoring is suspended. Ifthe FN key is pressed while it is still flashing, the command will be canceled. See Sus-pended Operation for more information.

• START MONITORING This item is displayed when the monitoring is turned off; select itto turn on monitoring. 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 turned on; select it toturn off scrolling. When scrolling is inactive, the displayed menu items will not changeuntil a menu key (UP ARROW, DOWN ARROW, FN or ENTER) is pressed.

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• SET SCROLL ON This item is displayed when the scrolling is turned off; select it to turnon scrolling. When scrolling is active, the displayed menu items will change once everytwo seconds.

Test Menu

• CONTACT TEST Select this item to start an interactive test of the relay contacts. TheGCM-X will place all relays except one in a de-energized condition. The LCD will displaythe name of the single relay that is still energized; use the arrow keys to change whichrelay is energized. Press the FN or ENTER key 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 GCM-X will clear the bar graphs, set the 4-20 mA outputs to fourmilliamps and display CURRENT=4mA on the LCD display at the start of the test. Usethe arrow keys to increase or decrease the current in one milliamp steps. The bar graphswill track the current outputs with four milliamps equal to zero percent and 20 milliampsequal to 100 percent. Press FN or ENTER to terminate the test.

• POWER TEST Select this item to test the power supplies. When POWER TEST isselected, the GCM-X will display the voltage for each power supply in the format <nomi-nal value>=<present value>. An example for the 12-volt power supply would be +12VOLTS =12.1. The GCM-X will scroll through all five power supply voltages. The voltagesare displayed for two seconds apiece.

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

View Menu

• SHOW ICD CURRENT Select this item to display the ICD’s electrical output in picoamps.

• SHOW DP INCHES Select this item to display the differential pressure across the ionchamber in inches of water.

• SHOW AMPLIFIER Select this item to view the four software variables associated withthe ion chamber amplifier. The variables are displayed as four pairs of hexadecimaldigits. This is an advanced diagnostic intended for factory use only.

Log Menu

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

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• 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 GCM-X Rev X.X. This manual was written for software version 2.0C-7.Press FN to return to the log menu.

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Procedures

Calibrating the Ion Chamber

Alarms and warnings are detected by comparing the electrical output of the ICD against areference level. The calibration process sets this reference level.

The calibration procedure takes about 25 seconds to run. Once started, the calibrationprocedure can be canceled by pressing the FN key.

The GCM-X requires that the differential pressure across the ICD be between 1.4 and 1.6inches of water during the calibration procedure. The GCM-X will halt calibration and promptthe operator to adjust the FLOWSET valve if the pressure is outside of this range. Calibrationwill resume when the differential pressure enters the required range and remains there for atleast five seconds. If insufficient differential pressure is available to meet this requirement, itcan be bypassed by pressing the FN key. However, operating the GCM-X with insufficientdifferential pressure will reduce response time.

The GCM-X engages the verification filter to remove any particulate from the gas streamduring the calibration process. It waits at least 15 seconds for the filtered gas to flush anyparticulate out of the ion chamber. It considers the ion chamber flushed when its outputcurrent varies by less than 4 percent over a five-second period. If the output current is notstable at the end of the 15-second waiting period the GCM-X will wait until it becomes stable.

The GCM-X displays the output as a percentage of the initial reference level at the end of theinitial 15-second waiting period. Once the output stabilizes, the GCM-X calculates a newvalue for the reference level and displays the output as a percentage of this new referencelevel.

The new reference level will be 1.25 times the average electrical output level of the ICDduring the last five seconds of the calibration procedure.

Setting the Sampler Interval

The sampler interval is the length of time that the GCM-X routes hydrogen through the collec-tor in response to a verified alarm or the operator pressing the SAMPLER START/STOP key.The sampler interval can be changed by selecting SAMPLER INTERVAL from the SETUPMENU.

When SAMPLER INTERVAL is selected, the sampler interval will be displayed on the LCDdisplay. Press the UP ARROW key to increase it; press the DOWN ARROW key to de-crease it. It cannot be increased beyond 30 minutes or decreased below 10 minutes.

Press the ENTER key to save your changes and return to the SETUP MENU. Press the FNkey to discard the changes and return to the SETUP MENU.

Setting the Warning Level

The warning level determines what electrical output from the ion chamber detector will triggera WARNING indication. The warning level is expressed as a percentage of the referencelevel set by the calibration procedure. A WARNING indication is given when the ratio of theelectrical output to the reference level is less than the value of warning level. The factory

20HA0292P01 Rev. A

default value for the warning level is 70 percent. The warning level can be changed by select-ing WARNING LEVEL from the SETUP MENU.

When WARNING LEVEL is selected, the warning level will be displayed on the LCD display.Press the UP ARROW key to increase it; press the DOWN ARROW key to decrease it. Thewarning level cannot be increased beyond 80 percent or decreased below 50 percent. Pressthe ENTER key to save your changes and return to the SETUP MENU. Press the FN key todiscard the changes and return to the SETUP MENU.

Setting the Low Flow Limit

The low flow limit determines what differential pressure, across the ICD, will cause a FLOWTROUBLE indication. The low flow limit is expressed in inches of water. A FLOW TROUBLEindication is given when the differential pressure drops below the low flow limit. The factorydefault value for the low flow limit is 1.1 inches of water. The low flow limit can be changed byselecting LOW FLOW LIMIT from the SETUP MENU.

When LOW FLOW LIMIT is selected, the low flow limit will be displayed on the LCD display.Press the UP ARROW key to increase it; press the DOWN ARROW key to decrease it. Thelimit cannot be increased beyond 2.5 inches of water or decreased below 0.5 inches ofwater. Press the ENTER key to save your changes and return to the SETUP MENU. Pressthe FN key to discard the changes and return to the SETUP MENU.

Setting the High Flow Limit

The high flow limit determines what differential pressure, across the ICD, will cause a FLOWTROUBLE indication. The high flow limit is expressed in inches of water. A FLOW TROUBLEindication is given when the differential pressure rises above the high flow limit. The factorydefault value for the high flow limit is 1.9 inches of water.

The high flow limit can be changed by selecting HIGH FLOW LIMIT from the SETUP MENU.When HIGH FLOW LIMIT is selected, the high flow limit will be displayed on the LCD display.Press the UP ARROW key to increase it; press the DOWN ARROW key to decrease it. Itcannot be increased beyond 2.5 inches of water or decreased below 0.5 inches of water.Press the ENTER key to save your changes and return to the SETUP MENU. Press the FNkey to discard the changes and return to the SETUP MENU.

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.

• An Unverified Alarm is logged when the GCM-X starts an alarm verification sequence butcannot verify the alarm.

• A Flow Fault is logged when the differential pressure across the ion chamber detectorfalls below the low flow limit or climbs above the high flow limit.

21 HA0292P01 Rev. A

• 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 GCM-X 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.

22HA0292P01 Rev. A

Modes of Operation

Startup

The GCM-X initializes the display mode to local and all relays to the de-energized position.

The GCM-X executes a “power-on self-test” (POST) to verify its proper operation. It verifiesits software by checksum testing the contents of its read-only memory (ROM). It tests all ofits power supplies and all of its relays and solenoids. It checks the differential pressureacross the ICD and if it is out of spec prompts for its adjustment. It checks the output level ofthe ICD and prompts for calibration if required.

The POST will take about 20 seconds to complete if no errors are encountered. At theconclusion of the POST the GCM-X display panel will flash NORMAL OPERATION for twoseconds before beginning normal operation. If the FN key is pressed while it is still flashing,normal operation will be canceled and the GCM-X will enter suspended operation instead.

Startup Problems

Immediately after power-up, the GCM-X begins searching for displays. If the local display ispresent and functioning properly, the search will complete in less than one tenth of a second.If the GCM-X cannot communicate with the local display, LINKING … may appear on theLCD. The GCM-X stops trying to communicate with the local display after four seconds andstarts trying to communicate with a remote display. If it finds a remote display, the GCM-X willstart in remote mode rather than local mode. If the GCM-X cannot find a local or a remotedisplay within six seconds, it will assume local mode and proceed with the POST.

The GCM-X 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 GCM-X to continue the POST process.However, proper operation cannot be guaranteed if this error is present.

The GCM-X will annunciate any problems it finds with the power supplies, relays or sole-noids. The presence of one or more of these faults will not stop the POST process. How-ever, they should be corrected as soon as possible because they indicate a hardware prob-lem.

The GCM-X requires the differential pressure across the ion chamber detector to be between1.4 and 1.6 inches of water. The POST will be halted and the operator prompted to adjust theFLOWSET valve if the pressure is outside of this range. The POST will resume once thedifferential pressure enters the required range and remains there for at least five seconds.The test can be bypassed by pressing the FN key.

The GCM-X expects the electrical output of the ICD to fall between the warning level and 95percent of the reference level. The POST is halted and the operator prompted to calibrate theGCM-X if the output is outside of this range. The POST resumes once the FN key ispressed.

The GCM FAULT LED will remain illuminated after startup in normal mode if the output bargraph is not between the warning level and 95 percent. This problem can be caused by theGCM-X being out of calibration or by the presence of particulate in the hydrogen gas.

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Suspended Operation

When the GCM-X is in suspended operation, it will monitor the flow rate and particulate levelof the hydrogen, but it will not generate any alarms or warnings.

The GCM FAULT LED will be illuminated and the SAFE LED will be darkened whenever theGCM-X is in this mode of operation.

The GCM-X monitors the flow rate with a differential pressure gauge and a calibrated orifice.It monitors the particulate level with an ICD.

The GCM-X will display the differential pressure and the ICD output current on the LED bargraphs. The differential pressure and ICD output current are also available through two 4-20mA outputs.

The ICD output current is updated once every one to three seconds, and the differentialpressure is updated 10 times per second.

Normal Operation

When the GCM-X is in normal operation, it will monitor the flow rate and particulate level ofthe hydrogen. It will indicate a warning or alarm condition if it is out of specification.

The GCM-X monitors the flow rate with a differential pressure gauge and a calibrated orifice.It monitors the particulate level with an ICD.

The GCM-X will display the differential pressure and the ICD output current on the LED bargraphs. The differential pressure and ICD output current are also available through two 4-20mA outputs.

The ICD output current is updated once every one to three seconds and the differentialpressure is updated 10 times per second.

The GCM-X will display a flow warning if the differential pressure drops below the low flowlimit or climbs above the high flow limit.

The GCM-X will display a warning if the ICD output current drops below the warning level orclimbs above 95 percent and remains there for at least four seconds. It will also display awarning during the alarm verification sequence.

The GCM-X will initiate an alarm verification sequence if the output current of the ICD dropsbelow 50 percent and remains there for at least four seconds.

24HA0292P01 Rev. A

Maintenance

The Generator Condition Monitor is designed for reliable, trouble-free operation and ease ofperiodic checks and maintenance.

Daily

Check GCM-X hydrogen flow and adjust if necessary. The output should be at 80 percent.POWER and SAFE indicators should be on.

Weekly

Push the VERIFICATION FILTER button at the GCM-X display panel. The indicator lightshould illuminate. There should be little or no change in flow or output. If the flow indicationdrops more than 20 percent, the filter may be restricted. If the output increases significantly,particulate may be present in the hydrogen.

Monthly

Perform RELAY TEST check; see SYSTEM description for instructions.

Annually

Check tubing connections annually, or whenever they have been disturbed. Use leak checksolution on joints, fittings and valve packing. Activate MANUAL sampler to obtain a back-ground sample at intervals recommended by the generator manufacturer.

When the Generator is Down

During periods where the generator is shut down, it is recommended that power be main-tained to the GCM-X, particularly during periods of high humidity, in order to maintain anelevated temperature within the ion chamber. This will serve to eliminate the possibility ofcondensation buildup within the ion chamber. If power plant personnel wish to isolate theGCM-X while power is applied and relieve hydrogen pressure from the instrument, close thedrip leg isolation valves (Appendix Figure 2) and place the auto sampler in manual mode bypressing the sampler mode button (GCM-X Figure 3).

If power plant personnel wish to isolate the GCM-X and relieve hydrogen pressure from theinstrument when power has been removed, close the drip leg isolation valves (AppendixFigure 2) and open the drip leg drain isolation valves. Please note that approximately 1 liter ofhydrogen will be released through the drip leg drain isolation valves.

Tubing and Fitting Replacement

The differential pressure measured by the flow gauge includes the drop in some of theinternal tubing and fittings. If replacing tubing or fittings is necessary, replacements should bethe same size as the original in order to avoid changing the flow calibration. EnvironmentOne should be notified of instances where site personnel are performing such replacements.Plant management must ensure that individuals performing such work are acting in accor-dance with Cenelec guidelines, local codes and generally accepted professional practice.Perform a leak check whenever tubing connections are disturbed.

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Table 1 - Customer Contacts

Troubleshooting

Contact Status Ref.1

ALARMGeneral Purpose

Energized when a verified alarm occurs

WARNINGGeneral Purpose

TROUBLEGeneral Purpose

Energized when the output level is out of specification

De-energized when the GCM-X detects an abnormal condition

1

2

3, 4, 5, 6,7, 9

1 Applicable line in Table 4 - GCM-X Status4 Check the fault log to distinguish between items 4, 5, 6 and 75 Run a power test to identify power supply problems

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Table 2 - Display Indicators

Indicator Status Ref.2

LOCAL Lit when the local display has the focus

REMOTE

POWER

Lit when the remote display has the focus

Lit whenever the display panel is powered and functioning prop-erly

SAFE Lit when the GCM-X is not in trouble and not in warning or alarm

WARNING Lit when the output level is out of specification

Auto Alarm Reset Indicates that a verified alarm condition will be reset automaticallyupon return to normal

Reset ModeManual

Indicates a verified alarm condition can only be cleared by press-ing RESET

Verification Filter Lit when hydrogen gas passes through the verification filter

Trouble GCM Fault Lit when the GCM-X detects an abnormal condition

Trouble Flow Lit when the differential pressure is out of specification

2

8

8

8

4, 5, 6, 7

ALARM

9

Lit when a verified alarm occurs

Trouble SamplerOn

Sampler ModeAuto

Sampler ModeManual

Sampler Start/Stop

Lit when hydrogen gas passes through the collector

Indicates that the sampler will engage automatically with a verifiedalarm

Indicates that the sampler must be engaged manually

Same as Sampler On

9

9

9

3

2 Applicable line in Table 4 - GCM-X Status

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Table 3 - Display Keys

Key Function Ref.3

Reset Clear a verified alarm

Reset Mode

Verification Filter

Toggle “automatically reset alarm upon return to normal condi-tions” on and off

Manually activate the verification filter

Sampler Mode Toggle “automatically start collecting a sample for analysis” onand off

Sampler Start/Stop Manually start collecting a sample for analysis

1

1

8

9

9

3 Applicable line in Table 4 - GCM-X Status

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Table 4 - GCM-X Status

Condition Typical Cause Indicators Affected

1 Verified Alarm High concentration of submicron particles arepresent in the gas stream

2 Warning

3 Gas FlowProblem

ICD current is not between warning level and 90percent of the reference value (see page 21)

Differential pressure across the ICD is less than1.1 inch of water or greater than 2.0 inches of water(see page 21)

4 Unverified Alarm4 The GCM-X started an alarm verification sequencebut was unable to verify the alarm

6 Power SupplyProblem4,5

One or more power supplies are not withintolerance

7 I/O Error4 The GCM-X is detecting a communication errorwhile trying to talk to the I/O board or display

8 Verifying pres-ence of particles inthe gas stream

User activation or as part of the alarm verificationsequence

9 Collecting asample for analy-sis

User verification or in response to a verified alarmwith “Sampler Mode Auto” enabled

Alarm RelaysVerified Alarm LED

Trouble RelayGCM Fault RelayTrouble GCM Fault LED

Verification RelayVerification Filter LED

Trouble RelayTrouble Sampler On LEDSampler Start/Stop LED

5 Solenoid orRelayProblem4

A missing or defective relay or solenoid

Warning RelaysWarning LED

Trouble RelayFlow RelayTrouble Flow LED




Table 5 - Relay Problems

Item Stuck On Stuck Off

Solenoids Open coil, not installed prop-erly or an electronics failure

Electronics failure

General PurposeRelays (K2 to K4)

Electronics failure Electronics failure

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Component Replacement Instructions

The GCM-X was designed to facilitate component replacement, when and if it becomesnecessary in the field. Several GCM-X components/assemblies may be removed by sitepersonnel and forwarded to Environment One for evaluation repair/replacement, as notedbelow. In all other instances, the GCM-X will need to be returned to Environment One forservice, or an Environment One technician will be required on site.

Plant management must ensure that individuals performing work on the GCM-X are ad-equately trained to do so and that they work in accordance with ATEX, NEC or Cenelecrequirements, local codes and generally accepted professional practice.

If oil contamination is suspected, Environment One recommends that the GCM-X be re-turned for comprehensive evaluation, cleaning and repair.

After the GCM-X has been installed and commissioned, individuals performing service workon the electronics must wear an electrostatic wrist-strap.

ICD, Filter Solenoid and Sampling System Solenoid

The ICD (GD0013G04), Filter Solenoid Assembly, Sampling System Solenoid Assembly andGCM-X Heater (GA0363P01) are mounted on the GCM-X “mounting plate,” which is analuminum plate attached to the GCM-X frame by four 3/8-inch nuts. Removal of any of themounted components is best accomplished by removing the back plate first and then remov-ing the individual assembly.

To remove the mounting plate:

1. Disconnect power from the GCM-X.

2. Detach the heater from the mounting plate by removing the four screws on the heater’smounting bracket.

3. Detach grounding wire and other cables from the four wire ties.

4. Detach solenoid coils from the two solenoid valves.

5. Detach tubing connections from assemblies mounted to the mounting plate.

6. Remove the four 3/8-inch bolts that secure the mounting plate to the GCM-X frame.

Each of the respective components mounted on the GCM-X back plate can then be removedfor service, replacement or return to Environment One. To re-install the assemblies, install inreverse process.

Controller Assembly

The Controller Assembly (GA0449G01) (GD0082G02+GA0396P03) is located in the flame-proof enclosure, which is referred to as the System Electronics. To remove the ControllerAssembly:


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2. Open cover of the flameproof enclosure, taking care not to damage the surfaces.

3. Remove the molex connectors at J3 and J4.

4. Detach the ribbon cable at J2.

5. Detach the BNC connector at right-hand side of circuit board.

6. Remove the four nuts from the mounting studs.

7. Remove the assembly from the enclosure.

8. Install in reverse process.

I/O Assembly (Located in the System Electronics Enclosure)

The I/O Assembly (GD0094G04 Rev.-) is located in the flameproof enclosure, referred to asthe System Electronics. To remove the I/O Assembly:


2. Open the cover of the flameproof enclosure, taking care not to damage the surfaces.

3. Remove the Controller Assembly (see above).

4. Remove all wiring connections to TB1 and TB2 on the I/O board.

5. Remove the molex power supply connectors at J4 and J5.

6. Remove the RFI filter connection at J6.

7. Remove the four standoffs that connected the processor board to the I/O board.

8. Remove assembly from enclosure.


Display Assembly

The Display Assembly (GD0052G01 Rev. -) is located behind the GCM-X subdoor, which isintegral to the GCM-X module assembly. To remove the Display Assembly:


2. Open the GCM-X front door.

3. Open the GCM-X module, which will enable access to the GCM-X Display Panel.

4. Disconnect the 15-pin D-connector from the back of the display board.

5. Loosen the four display assembly mounting screws located on the back side of the GCM-X module (support the display assembly with your other hand).

6. Detach the grounding wire and remove the display assembly.

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Fuses

The GCM-X contains a 2A slo-blow fuse that may be replaced by plant personnel. The fuse islocated on the I/O board, adjacent to the power and heater connections. It is labeled F1.


2. Open the cover of the flameproof enclosure, taking care not to damage the surfaces.

3. Use a fuse puller to remove the fuse.

4. Replace the fuse with a Littlefuse #218 002 or equivalent.

5. Close the flameproof enclosure cover and secure.

32HA0292P01 Rev. A

GCM-X Parts List

Description Part Number

GCM-X Instruction Manual HA0292P01

Controller Assembly (Circuit Board) GA0449G01 (GD0082G02 PCB,GA0396P03 Software)

I/O Assembly (Circuit Board) GD0094G04

Display Panel (Keypad) GC0123G01

Display Assembly (Circuit Board) GD0052G03

Ion Chamber Detector GD0013G05

Filter Cartridge GA0150P01

2-Way Solenoid Valve GA0422P02

3-Way Solenoid Valve GA0422P01

Transmitter HA0058P07

Collector GA0349G01

Power Supply (+12V) HA0027P02

Alpha Source Assembly GA0281G02

Isolation Barrier (DC) HA0045P01

Isolation Barrier (AC) HA0045P02

Ion Chamber Heater GA0363P01

33 HA0292P01 Rev. A

GCM-X Figure 1 - System Overview

34HA0292P01 Rev. A

GCM-X Figure 2 - GCM-X Module, Front View

35 HA0292P01 Rev. A

GCM-X Figure 3 - Control/Display Panel

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GCM-X Figure 4 - Major Components (Typical)

37 HA0292P01 Rev. A

GCM-X Figure 5 - ICD Current and Flow

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38HA0292P01 Rev. A

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.

6HA0291P01 Rev. A

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.

7 HA0291P01 Rev. A

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

8HA0291P01 Rev. A

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 Panel

The 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.

9 HA0291P01 Rev. A

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.

10HA0291P01 Rev. A

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.

11 HA0291P01 Rev. A

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.

12HA0291P01 Rev. A

Circuit Protection

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

13 HA0291P01 Rev. A

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.

14HA0291P01 Rev. A

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.

15 HA0291P01 Rev. A

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.


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.

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


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

16HA0291P01 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 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.

17 HA0291P01 Rev. A

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

18HA0291P01 Rev. A

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.

19 HA0291P01 Rev. A

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.

20HA0291P01 Rev. A

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.

21 HA0291P01 Rev. A

• 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.

22HA0291P01 Rev. A

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.

3. Remove the main junction box cover.

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)

Item Description Part Number Description

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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na

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r

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Fn

H2

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ALA

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WA

RN

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LIB

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H2 2

N2

RE

SE

T

IN AIRNO

RM

AL

PU

RG

E

2 2

H2

INC

0

C0

INA

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S P

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ITY

AC

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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

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

gas station instruction manual · sures to avoid damage (scratches, etc.) to the sealing surfaces....

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