DETECTION SYSTEMS. GCM Auto Alarm. Instruction Manual. GA0203P01 Rev. D

Transcription

1 DETECTION SYSTEMS GCM Auto Alarm Instruction Manual GA0203P01 Rev. D

2 Contents Limited Warranty... 3 Warning... 4 Safety Consideration... 4 General Description... 5 Installation... 6 Initial Adjustments... 7 System Tests... 8 No Flow Through the GCM... 8 Normal Hydrogen Flow through the GCM Operation GCM Controls Auto Alarm Controls Periodic Checks and Maintenance Daily Weekly Monthly Background Sample Servo Recorder Lamp Replacement System Tests Detailed Description Flow Alarm Computer Interface System Power Consumption Troubleshooting Replacement Parts GA0203P01 Rev. D

3 Figures Figure 1 - GCM Auto Alarm Outline Figure 2 - Auto Alarm Wiring to GCM Figure 3 - GCM Auto Alarm Schematic Figure A1 - Auto Alarm Computer Interface Figure A2 - Wiring Diagram Figure A3 - Circuit Board B GA0203P01 Rev. D 2

4 Limited Warranty ENVIRONMENT ONE CORPORATION WARRANTS THE INSTRUMENT DESCRIBED HEREIN TO BE FREE FROM DEFECTS IN MATERIAL AND FACTORY WORKMANSHIP, AND AGREES TO REPAIR SUCH INSTRUMENTS WHERE UNDER NORMAL USE AND SERVICE DISCLOSE THE DEFECT TO BE THE FAULT OF THE ENVIRONMENT ONE CORPORATION S MANUFACTURING. ENVIRONMENT ONE CORPORATION S OBLIGATION UNDER THIS WARRANTY RE- LATES TO THE ORIGINAL PURCHASER AND IS LIMITED TO A RETURN OF THE PUR- CHASE PRICE, OR, AT THE ENVIRONMENT ONE CORPORATION S SOLE DISCRE- TION, TO THE REPAIR OR REPLACEMENT OF THE INSTRUMENT OR ANY OF ITS PARTS, WHICH, IN ENVIRONMENT ONE S OPINION AND UPON EXAMINATION PROVES TO BE DEFECTIVE. FOR THIS WARRANTY TO BE IN EFFECT, ANY MATE- RIAL OR PART ALLEGED TO BE DEFECTIVE IS TO BE RETURNED TO ENVIRONMENT ONE WITH PRIOR WRITTEN APPROVAL, FULLY INSURED AND TRANSPORTATION PREPAID BE THE PURCHASER, WITHIN 12 MONTHS FROM DATE OF DELIVERY. THIS WARRANTY SHALL NOT APPLY TO AN INSTRUMENT THAT HAS BEEN 1) SUBJECTED TO MISUSE, NEGLIGENCE OR ACCIDENT; 2) CONNECTED, INSTALLED, OPERATED OR ADJUSTED OTHER THAN IN ACCORDANCE WITH INSTRUCTIONS FURNISHED BY ENVIRONMENT ONE; OR 3) REPAIRED, MODIFIED OR WORKED ON BY SOMEONE NOT AUTHORIZED BY ENVIRONMENT ONE, SO THAT IN THE COMPANY S JUDGE- MENT, THE PERFORMANCE OR RELIABILITY OF THE INSTRUMENT HAS BEEN IM- PAIRED. ENVIRONMENT ONE RESERVES THE RIGHT TO MAKE REPLACEMENT WITH EQUIVALENT MERCHANDISE AND TO MAKE CHANGES AT ANY TIME IN THE SPECIFI- CATION, DESIGN OR CONSTRUCTION OF THE INSTRUMENT WITHOUT INCURRING OBLIGATION TO MAKE ANY COMMENSURATE CHANGES IN UNITS PREVIOUSLY DELIVERED. ENVIRONMENT ONE CORPORATION ASSUMES NO LIABILITY FOR CONSEQUENTIAL OR CONTINGENT DAMAGES FOR A DEFECTIVE INSTRUMENT COVERED BY THIS WARRANTY, FAILURE OF DELIVERY IN WHOLE OR PART, OR FOR ANY OTHER CAUSE. THIS WARRANTY AND THE WRITING TO WHICH IT IS ATTACHED CONSTI- TUTE THE UNDERSTANDING OF THE BUYER AND SELLER SO THAT NO TERMS, CONDITIONS OR AGREEMENT PURPORTING TO MODIFY THE TERMS HEREOF SHALL BE BINDING UNLESS MADE IN WRITING AND SIGNED BY AN AUTHORIZES AGENT OF THE HOME OFFICE OF ENVIRONMENT ONE CORPORATION. 3 GA0203P01 Rev. D

5 Warning This equipment operates at voltage levels that can be hazardous to maintenance personnel. The section about safety considerations should be read before installation or service. These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise that are not covered sufficiently for the purchaser s purposes, the matter should be referred to Environment One Corporation. Safety Consideration This equipment operates on 117 volts AC, which appears at terminal strips and various other points. The equipment contains power supplies that have outputs of plus and minus 15 volts DC (30 volts maximum). Access behind the panel and inside the chassis should be avoided unless the input power is disconnected at the source. Should such access with power circuits be deemed necessary, it should be made only by qualified personnel who are familiar with the location of these voltages and the hazards involved. The equipment should be installed in a non-hazardous area where an explosive atmosphere is unlikely to be present. GA0203P01 Rev. D 4

6 General Description The GCM Auto Alarm is designed for use with any standard G5 or G6 Generator Condition Monitor. It permits monitoring and control of the GCM and Auto Sampler, and provides automatic alarm verification and Auto Sampler activation only after the alarm has been verified as being due to a generator fault. Electrical outputs of 0 to 10 volts and 4 to 20 milliamps DC are standard, as well as SPDT contacts to indicate warning, verified alarm and power loss. Output indication in the form of a panel meter, servo recorder or Rustrak recorder, and a computer interface output are available as options. A test switch can be used to initiate simulated fault or verified alarm sequences to confirm proper operation. Auto Sampler activation and switching of the verified alarm contacts are automatically inhibited in the test mode. A reset mode switch allows selection of automatic or manual alarm reset. 5 GA0203P01 Rev. D

7 Installation Outline dimensions of the GCM Auto Alarm are shown in Figure 1, and wiring connections to the GCM are shown in Figure 2. CAUTION! The Auto Alarm uses some unsealed electrical contacts and should not be installed where an explosive atmosphere can be present. Check wiring carefully before applying power to prevent damage to the GCM or alarm components. The Auto Alarm can be installed as part of a control panel of in a standard 19-inch relay rack cabinet, either by itself or with other panels. Ambient temperature must not exceed 122F/50C. If a step-down transformer is used for 230-volt operation, it should have a rating of 150 volt-amps, which will handle the electrical load of the Auto Alarm with servo recorder, and GCM with an ion chamber band heater. The recommended wiring arrangement as shown in Figure 2 has the source of AC power at the alarm panel, which in turn supplied power to the GCM. With this arrangement, the Auto Alarm circuit breaker protects both the panel and GCM. If the source of AC power is at the GCM instead of the Auto Alarm (for example, if the GCM has an integral step-down transformer), connect the wire from GCM terminal A8, and the wire from GCM terminal 9 to Auto Alarm terminal A9. The Auto Alarm circuit breaker will now protect only the alarm panel, and the GCM will be protected by its own fuse or circuit breaker. Relay K3 in the GCM Auto Sampler Control (nearest the Start/Stop buttons) should be replaced with the K3 adapter supplied, and TB2 terminals 7 and 8 connected together, as shown in Figure 2. If a servo recorder has been ordered, it will be packed separately. The servo recorder panel cutout is the DIN standard 138x138 mm. Follow the recorder manufacturer s instructions for mounting. Depending upon the installation, it may be easier to install the recorder after the panel is installed. Remove any shipping screws before installing the recorder. GA0203P01 Rev. D 6

8 Initial Adjustments The GCM should be in good working order and adjusted in accordance with the GCM Instruction Manual, with the Alarm Set at 50 percent output. If the GCM is an older model with a floating ball-type flowmeter, contact Environment One about updating it with a differential pressure flow gauge that incorporates a low flow alarm. Most servo recorders have some form of damping adjustment that controls response time. For G3 and G4 auto alarms with a servo recorder, this adjustment can be used to increase damping and response time. This will reduce recorder pen excursions due to ion chamber current fluctuations and produce a narrower recorded trace. Refer to the recorder instruction manual for more information. 7 GA0203P01 Rev. D

9 System Tests The amount of testing that can be performed on the system depends upon whether the generator to which the GCM is connected is operating so that hydrogen flow through the GCM can be established. No Flow Through the GCM The Low Flow indicator will be on, except where the GCM has a floating ball-type flowmeter. For all systems, the Warning indicator will remain on, except where noted and Safe will remain off. Warning contacts should be in the alarm position. Place the Run-Test switch in the Hi. Warn. position and apply AC power. Reset Mode should be in Auto. Power and Warning indicators should be on and the GCM in safe mode. Manual Start Only may also be on. If the Auto Alarm has a panel meter or Rustrak recorder, the reading should be at or about 100 percent. If the servo recorder is installed, it should read near zero. Power Loss and Verified Alarm contacts should be in the Safe position and Warning contacts should be in the Alarm position. With the GCM cover open, Alarm Inhibit and Warning should be on. After a time delay, the Alarm light should be on at the GCM. With the GCM cover closed, the Alarm light at the GCM should go out, as should the Alarm Inhibit at the Auto Panel. If Alarm Inhibit remains on, the link between terminals 7 and 8 of TB2 may be missing. Pressing the Manual Start Only button should alternately turn the indicator on and off. Pressing the Start button at the Auto Alarm should activate the Auto Sampler solenoid in the GCM and turn on the Start indicator. With the GCM cover open, press the Sampler Stop button at the GCM and the Start indicator should go out. Press and hold the Filter button at the Auto Panel; the light in the button should illuminate, the filter solenoid valve in the GCM should be activated, and the Filter light at the GCM should be on. Release the buttons; the lights should go out. Open the GCM cover and hold down the cover interlock switch behind the Auto Sampler control chassis. Momentarily press Particle Test at the Auto Alarm. The red Test light at the GCM should come on, but the Particle Test button light will not illuminate. Do not hold the button down for more than 2 to 3 seconds. Close the GCM cover and set the Run-Test switch to GCM Fault. The panel meter or Rustrak will read about 45 percent; the servo recorder will read near zero percent. The Filter and Alarm Sequence Reset indicators should come on. GA0203P01 Rev. D 8

10 The Filter light should go out after approximately 25 seconds. The GCM Fault light should come on approximately 15 seconds after the Filter light goes out. The GCM will be in alarm. The Alarm Inhibit light should not illuminate. It if does, relay K3 in the GCM Auto Sampler control has not been replaced by the K3 adapter. With the Reset Mode switch in Auto, set the Run-Test switch to Lo. Warn (Reset). The Alarm Sequence Reset and GCM Fault lights should go out. The GCM will be in safe mode. The panel meter or Rustrak will read about 65 percent; the servo recorder will read near zero percent. With the GCM cover closed, set the Run-Test to Verified Alarm, Manual Start Only off. The Filter and Alarm Sequence Reset lights should illuminate. While the Filter light is on, the panel meter or Rustrak recorder will read approximately 80 percent; the servo recorder will read near zero percent. The Filter light should darken after approximately 25 seconds. The panel meter or Rustrak will then read near 45 percent; the servo recorder will read near zero percent. Safe should be out and Warning should be on. Verified Alarm should come on after approximately 15 seconds after the Filter light darkens. Verified Alarm contacts should be in Safe position, and the Start indicator should remain off. The GCM will be in Alarm mode. Move the Reset Mode switch to Man. If the generator casing is pressurized, disconnect the hose from the collector to prevent hydrogen loss. Close the cabinet cover and switch Run-Test to Run. The Start indicator should illuminate and the Auto Sampler solenoid in the GCM should be on. The Filter light at the GCM Auto Alarm should be dark. Verified Alarm contacts should be in Alarm position. The panel meter, Rustrak or servo recorder indications should be near zero. Set Run-Test to Hi. Warn. and push Alarm Sequence Reset. Alarm Sequence Reset and Verified Alarm indicators should darken. Start remains on if less than 10 minutes have elapsed. The GCM will be in Safe mode. Open the cover and push Sampler Stop at the GCM. Start should darken and the Auto Sampler solenoid should be off. Replace the hose on the collector and close the cabinet cover. Turn off AC power. 9 GA0203P01 Rev. D

11 Power Loss and Warning contacts should be in Alarm positions Verified Alarm contacts should be in Safe position. Normal Hydrogen Flow through the GCM If the GCM has a floating ball-type flowmeter, adjust the flow to 15. If the flowmeter is a round gauge, adjust the flow to 20. For a rectangular gauge, adjust the flow to 1.5. Place Reset Mode in Auto and Run-Test in Run. Turn on AC power, open the GCM cover and with gain, adjust GCM output to 80 percent. If the GCM has a band heater, flow and output adjustments should be checked periodically for the first two hours of operation. Close the GCM cover. The panel meter, Rustrak or servo recorder should indicate the same as the panel meter or recorder on the GCM, +/- 5 percent. Power and Safe should be on. Pressing Manual Start Only should turn it on and off. All other indicators, including Low Flow, should be off. If the Alarm Inhibit light is on, the link between terminals 7 and 8 of TBS (Auto Sampler Control) may be missing. The GCM should be in Safe more and the Filter light should be off. Power Loss, Warning and Verified Alarm contacts should be in Safe position. Press Filter at the Auto Alarm; Filter lights at the Auto Alarm and the GCM should go on. Press Particle Test until the output starts to drop. If the output drops below 50 percent, Warning, Filter and Alarm Sequence lights will illuminate, followed by GCM Fault approximately 40 seconds later if the output is still below 60 percent. The GCM Fault and Alarm Sequence Reset lights should darken when output is great than 60 percent; the Warning light should darken when output is great than 70 percent. Press and hold the Filter button; simultaneously press and hold the Particle Test button for 20 seconds or less. There should be little or no change in output, and Safe should remain on. Hold the Filter button down for at least 5 seconds after releasing the Particle Test button. Open the cover and reduce flow indication at the GCM by at least 50 percent. The Low Flow and Warning indicators should come on, and Safe should darken. There will be no Low Flow indication on GCM s that are equipped with a floating ball-type flowmeter. Restore flow at the GCM and close the cover; Safe should be on and Low Flow and Warning should be off. Open the GCM cover. Alarm Inhibit and Warning should illuminate. With gain adjust the GCM output below 50 percent. Within a minute the Alarm light at the GCM should illuminate. Filter and Alarm Sequence Reset at the Auto Alarm should remain off. Restore GCM output to 80 percent and close the cover. The GCM will be in Safe mode. Alarm Inhibit and Warning should be off at the Auto Alarm and Safe should be on. GA0203P01 Rev. D 10

12 Place Run-Test in Hi. Warn.; Safe should go out and Warning should come on. Warning contacts should be in Alarm position. The panel meter or Rustrak will indicate approximately 100 percent and the servo recorder will read the GCM output. With the GCM cover closed, place Run-Test in GCM Fault. The panel meter or Rustrak will read approximately 45 percent; the servo recorder will indicate GCM output. The Filter and Alarm Sequence indicators should come on; the Filter light should darken after approximately 25 seconds. The GCM Fault light should illuminate approximately 15 seconds after the Filter light darkens. Open the cover, and using gain, place the GCM into alarm by reducing the output to less than 50 percent, then close the cover. Alarm Inhibit on the Auto Alarm should not remain on. If it does, relay K3 in the GCM Auto Sampler has not been replaced by the K3 adapter. Restore GCM output to 80 percent and close the cover. The GCM will remain in alarm. With the Reset Mode switch in Auto, set Run-Test to Lo. Warn. (Reset). The Alarm Sequence Reset and GCM Fault indicators should darken. The GCM should reset to Safe. The panel meter or Rustrak will indicate approximately 65 percent; the servo recorder will read the GCM output. With the GCM cover closed, set the Run-Test to Verified Alarm; the Filter and Alarm Sequence Reset lights should illuminate. While the Filter light is on, the panel meter or Rustrak will indicate approximately 80 percent, and the servo recorder will read the GCM output. Safe will be on. The Filter light should darken after approximately 25 seconds. When it darkens, the panel meter or Rustrak should read approximately 45 percent, and the servo recorder should indicate the same as the GCM output. Safe should be out and Warning should be on. Verified Alarm should illuminate after approximately 15 seconds after the Filter light darkens. Verified Alarm contacts should be in Safe position; the GCM is now in Safe mode. Place the Reset Mode switch in Man. Switch Run-Test to Run. The Start indicator should illuminate and the Auto Sampler in the GCM should be activated. Check for correct sampler flow. Warning will be off and Safe will be on, unless the ICD flow drops enough to produce a Low Flow indication, in which case Warning will be on and Safe will be off. Push Manual Start Only to turn on the indicator and open the GCM cover; push the Sampler Stop button to stop the sampler flow. Start should darken and ICD flow should return to normal. Close the GCM cover. Verified Alarm contacts should be in Alarm position. The panel meter, Rustrak or servo recorder should indicate GCM output of approximately 80 percent. Push Alarm Sequence Reset; Alarm Sequence Reset and the Verified Alarm indicator should darken. Turn off AC power. Power Loss and Warning contacts should be in Alarm position. Verified Alarm contacts should be in the Safe position. 11 GA0203P01 Rev. D

13 Operation GCM Controls Operation of the GCM controls is essentially the same as described in the GCM Instruction Manual, to which reference should be made while performing adjustments and maintenance. The GCM alarm is automatically reset when the Auto Alarm is reset. This automatic reset function is inhibited when the GCM cover is open in order to facilitate adjustments. When the Auto Alarm panel is in Safe mode, the Auto Sampler s Start and Stop controls at the GCM can be used to check sampler flow. However, when the Run-Test switch on the Auto Alarm is in Run, the Manual Start Only indicator is off and a Verified Alarm condition exists, the Auto Sampler will be activated and sampler flow will continue for the full timed interval as determined by the Auto Sampler control, even if the Stop button is depressed. If stopping the sampler flow earlier is necessary, either of the following must be done at the Auto Alarm before the Stop control is effective: Place in Manual Start Only mode Place Run-Test in a Test position Reset the Auto Alarm While the GCM cover is open, the Auto Alarm is inhibited so that maintenance operations such as checking electrometer zero will not initiate the alarm sequence. For this reason, the GCM cover must be kept closed during normal operation. Auto Alarm Controls Power Will be on when the system is energized. Safe Will be on when the GCM output is in normal range, between 70 percent and 95 percent and the alarm is not inhibited. Normal flow will also be indicated. Manual Start Only When on, the Auto Sampler will not start automatically when a Verified Alarm is produced. Pushing the button turns the indicator on and off. Start Will be on while the Auto Sampler is sampling. Pushing the button starts the Auto Sampler manually. Particle Test This button activates the Test Particle Source in the GCM and the indicator illuminates. The source should only be activated when the Auto Alarm is in Safe mode and for no longer than 20 seconds at a time. Filter Pushing the button inserts the test filter manuals; the indicator will be illuminated while the test filter is inserted. Alarm Inhibit The indicator will be on while the GCM is on or when power is lost. Alarm sequence will not be initiated when the alarm is inhibited and Warning will be on. Warning This indicator will be on whenever GCM output is less than 70 percent or greater than 95 percent, or when Alarm Inhibit is on. This indicator will also be on when GA0203P01 Rev. D 12

14 flow is low; Warning contacts will be in Alarm position. Alarm Sequence Reset The indicator will come on when the GCM s output drops below 50 percent; the filter will be inserted. After approximately 25 seconds the output level will be stored and the filter deactivated. Fifteen seconds later, the new output level will be compared with the level produced while the filter was inserted. GCM Fault The indicator will illuminate if the ratio of the output levels resulting from the alarm sequence is less than 1.2. This means that insertion of the filter has little effect on GCM output and, therefore, the hydrogen particle level is low. This may not mean a problem with the GCM because this indication will be produced by loss of hydrogen flow, as when a generator is shut down. Verified Alarm The indicator will illuminate if the ratio of the output levels resulting from the alarm sequence is greater than 1.2. This means that insertion of the filter has significant effect on GCM output and particles are present in the hydrogen. The Auto Sampler will be activated (if Manual Start Only is out) and the Verified Alarm contacts will switch (unless Run-Test is in Test Mode). Reset Mode With this switch in the Auto mode, the alarm will automatically reset when the GCM output is greater than 60 percent. With the switch in the Man. mode, the alarm can be reset by pushing the Alarm Sequence Reset button. Reset can take place only if the GCM s output is above 60 percent and the Alarm Sequence has been completed, when wither GCM Fault or Verified Alarm comes on. Low Flow This indicator will illuminate if the hydrogen flow drops below the alarm setting of the GCM Flow gauge. Run-Test This switch allows testing of the Alarm and Warning modes. In the Test mode the appropriate indicators will come one, but the Verified Alarm contacts will not switch and the Auto Sampler will not be activated. The panel meter or Rustrak recorder will indicate the simulated test voltages, which the servo recorder will indicate the GCM output. Note: If the Reset Mode switch is in Man., the Verified Alarm should be reset manually before the switch is placed in the Run position. If this is not done, the Verified Alarm contacts will switch and the Auto Sampler may be activated. The alarm can be reset with the switch in the Lo. Warn. (Reset) position; if the switch is moved quickly through the GCM Fault position, the Alarm Sequence will not be initiated. Power Loss In the event of power loss to the system, the Power Loss and Warning contacts will switch to the Alarm position. If power to the GCM only is lost, the Alarm Inhibit and Warning lights will illuminated and the Warning contacts will switch to Alarm. Normal Operation Only the Power and Safe indicators should be illuminated during Normal Operation. The Manual Start Only indicator will be illuminated if automatic activation of the Auto Sampler is not desired. All contacts will be in the Safe position. 13 GA0203P01 Rev. D

15 Periodic Checks and Maintenance Daily Check the GCM s hydrogen flow and adjust if necessary; the output should be 80 percent. Power and Safe indicators on the Auto Alarm should be on. Manual Start Only is the only other indicator that should be on if automatic actuation of the Auto Sampler is not desired. Note: If the Filter indicators at the GCM or Auto Alarm remain on or do not illuminate when they should, investigate and correct immediately because a generator fault will not be detected if the filter is continuously inserted or is not inserted during the alarm sequence. Weekly Check GCM electrometer zero. Monthly Move the Run-Test switch through the Test positions and check for correct operation. Ensure that Verified Alarm is reset before switching back to Run. Perform the particle test as described in Normal Hydrogen Flow through GCM. Refer to Source Replacement in the GCM Instruction Manual if there is insufficient response to the Particle Test. Background Sample Activate the Auto Sampler manually to obtain a background sample at intervals recommended by the generator manufacturer. Servo Recorder Refer to the recorder s instruction manual for maintenance and service. Chart paper, ink cartridges, service, etc. should be obtained through the recorder manufacturer. Lamp Replacement The illuminated indicators use lamp #387, 28 volts,.040 amp. The lamp can be ordered from Environment One, Part No GA0085P01. To replace, pull out the legend button and pull the lamp from its socket in the button. System Tests Perform system tests as described in System Tests whenever repairs have been performed on the GCM or Auto Alarm, or if the wiring between them has been disturbed, The tests outlined in No Flow through GCM should be performed whenever the generator is shut down. GA0203P01 Rev. D 14

16 Detailed Description A schematic diagram of the GCM Auto Alarm is shown in Figure 3. The GCM output signal is filtered, buffered by unity gain amplifier A1-A and then applied to the zero- to 10-volt output terminals and servo recorder (if installed). The signal also goes to S2, the Run-Test Selector switch that selects either the GCM signal or a test voltage. The selected voltage is also distributed to the panel meter or Rustrak recorder (if installed) and the various control circuits. The control signal from S2 is compared to a 7-volt reference voltage by comparator VC1-A. If the signal is above the reference voltage, relay K1 is off and the normally closed contact of K1 will energize relay K15, turning on the Safe indicator. When the signal drops, relay K1 will be energized and relay K15 will turn on the Warning indicator and switch the Warning contacts. If the signal becomes greater than the 9.5-volt reference at VC1-D, K1 will again be energized and a Warning indication produced. When the GCM cover is closed, AC voltage is applied to relay coil K17. This energizes relay K7 through a short time delay produced by resistor R79 and capacitor C13. The control signal is compared to a 5-volt reference by VC1-B. In Normal operation with contact K7 closed, relay K2 will be energized when the control signal drops below 5 volts. Contact K2 will close and the output of VC2-C will go negative. Positive feedback through R42 will make the positive input terminal of VC2-C negative and relay K4 will be latched closed. Contact K4-A will close, turning on the Alarm Sequence Reset indicator through relay K12. Contact K4-B will also close, energizing relays K8 and K11 and timer T1. K11 is a solid state relay that controls the filter solenoid in the GCM. Contact closure of K8-A increases the 4.5-volt test voltage at S2 in the Verified Alarm position to simulate the increase in GCM output that results from inserting the test filter. The closing of contact K8-B applied the control signal to capacitor C5 and to the input of unity gain amplifier A2-A. The control signal also goes to inverting amplifier A2-B, which also has unity gain. Therefore, while K8- B is closed, the voltage at the output of A2-B is equal in magnitude but opposite of polarity, to that at the output of A2-A. If the GCM cover is open, K17 will be de-energized and the K7 contact will be open so that the alarm sequence is not initiated. The Alarm Inhibit indicator will be turned on by the normally closed contact of K17. The purpose of the time delay is to prevent the alarm sequence from being initiated when power is turned on or interrupted. Timer T1 will initially present a high impedance across its terminals 1 and 3 and relay K9 will not be energized. After the timed interval of 25 seconds, as determined by the value of R70, relay K9 will be energized. Contact K9-B will open, as will K8-A and K8-B, and the filter solenoid valve will be deactivated. C5 is a low leakage ceramic capacitor, and because of the low input current of A2, the voltage that was on C5 when K8-B opened will be retained for several minutes. This voltage corresponds to the GCM output current for clean hydrogen with no particulate. The magnitude of the negative voltage at the output of A2-B now represents the GCM output for unfiltered hydrogen. These voltages are combined by a resistor network. 15 GA0203P01 Rev. D

17 When contact K9-A closed, timer T2 was activated. After completion of a 15-second time interval set by R71, relay K10 will be energized, closing contacts K10-A and K10-B. At this time, the voltage at the negative input terminal of VC3-C will be positive with respect to the other terminal if the GCM output for filtered hydrogen was 1.2 times higher than the output for unfiltered hydrogen. The level at VC3-C output will be negative and relay K6 will be energized. Closure of contact K6 will latch VC3-A, energizing relay K5. With contacts K10-B and K5-A closed, relay K13 will be energized, the Verified Alarm indicator will be on, the contacts will switch to the Alarm position, and the Auto Sampler will be active. If, at the end of the 15- second interval, the GCM output for filtered hydrogen is not 1.2 times greater than the output for unfiltered hydrogen, the voltage at the negative input terminal of VC3-C will be negative with respect to the other input terminal. The output of VC3-C will be positive (with K10-A closed), and relay K6 will remain off, clamped by the positive voltage on the negative input terminal of VC3-D. With contact K6 open, relay K5 will be off so that, with contacts K10-B and K5-B closed, the GCM Fault indicator will illuminate. With S1, the Reset Mode switch, in the Auto. mode, a 6-volt reference voltage is applied to VC2-A so that when the control signal goes above 6 volts, the output of VC2-A will switch from a negative to a positive voltage. This will cause VC2-C and VC3-A to be reset to their normal states and the alarm will be cleared. K10-A will open, resetting VC3-D. It would not be desirable for this reset sequence to be initiated during the GCM output current increase resulting from insertion of the filter. To prevent this, a positive voltage at the output of VC2- B is applied to the negative input terminal of VC2-A through isolating diode D11. At the end of the 15-second interval when K10-A closes, the output of VC2-B will go negative, allowing reset to take place. The reset will open K10-A so capacitor C4 provides a delay to ensure that the reset voltage pulse will be of sufficient duration. Actual reset pulse duration is approximately 5 to 10 milliseconds. With S1 in the Man. mode, the reference voltage at VC2-A is 15 volts; since the control signal cannot exceed this, reset will not take place unless the Alarm Sequence Reset button is pushed, making VC2-A reference 6 volts. Whenever the Run-Test switch is in any of the Test positions, relay K14 is energized. This prevents switching of the Verified Alarm contacts and activation of the Auto Sampler. Auto Sampler activation is also prevented when the Manual Start Only contact is open. The test voltages at the various positions of the Run-Test switch are: Hi. Warn. 10 volts GCM Fault 4.5 volts Lo. Warn. (Reset) 6.5 volts Verified Alarm 4.5 volts; 8 volts while filter is activated As long as the Alarm Sequence Reset indicator is off (GCM output greater than 50 percent), a 15-volt reset signal is sent to the GCM through relay contacts K17 and K12. With the GCM cover open, contact K17 is open; with the alarm sequence initiated, contact K12 is open so that in either case the reset signal is removed and the GCM will remain in alarm. GA0203P01 Rev. D 16

18 An adapter (Figure 3) is used in place of relay K3 on the GCM Auto Sampler Control to prevent the Alarm Inhibit indicator from coming on when the GCM is in alarm and to avoid Auto Sampler start in the GCM Fault mode. Flow Alarm The ICD flow gauge in the GCM contains a switch that will open when the hydrogen flow drops below a set point. When the switch opens, an AC voltage is applied to relay K18 in the Auto Alarm. When relay K18 is energized, its contact turns on the Low Flow indicator and also causes the reference voltage on VC1-A to go from 7 volts to 15 volts, producing a Warning response regardless of the signal level. Computer Interface An optional feature allows Auto Alarm status to be monitored by a computer through a 25- pin connector. Computer Interface details are shown in Appendix A. System Power Consumption Total power consumption of the Auto Alarm with servo recorder plus the GCM with band heater for normal operations is 62W (68VA). Maximum power with Auto Sampler and Filter activated is 90W (112VA). 17 GA0203P01 Rev. D

19 Troubleshooting Typically, troubleshooting should follow a logical pattern once and understanding of system operating characteristics has been obtained. Connections should be checked and power supply voltages should be measured. The main circuit board receptacle is hinged so that measurements can be made on both sides of the board. If a problem is suspected with the circuit board, a temporary substitution of a good board can be made as confirmation. Always turn off power when removing or inserting a board. Some of the components are in sockets and can be replaced easily. CAUTION! Observe correct polarity. An insertion tool is very useful and should be used to avoid bending component pins. Always unplug the board to remove of replace components. When testing the Auto Alarm by itself and not connected to the GCM, connect a jumper between rear terminals B3 and B9 to prevent the alarm from being inhibited. A variable 0- to 10-volt DC input to simulate GCM output can be connected to terminals B1 (+) and B2 (-). CAUTION! Relays K12-K16 are rated for 24-volt AC operation. Do not interchange with GCM relays, which operate on 117 volts. The system is protected by a 5-amp circuit breaker on the Auto Alarm panel. When tripped, the button will be extended and a red band will be visible. To reset, push the button after determining and correcting the cause of the trip. GA0203P01 Rev. D 18

20 Replacement Parts Instruction Manual GA0203P01 Front Panel Panel Meter (G1, G2) Rustrak Recorder, 60 Hz (G5, G6) Rustrak Recorder, 50 Hz (G5, G6) Rustrak Recorder Chart Paper Servo Recorder (G3, G4) Run-Test Switch (S2) Reset Mode Switch (S1) Circuit Breaker, 5A (CB1) Indicator Socket (L1-L6) Alternate Action Switch (LS1) Momentary Switch (LS2-LS5) Low Flow Indicator (L7) (G1, G3, G5) GB0023P02 GB0113G01 GB0113G02 GA0067P01 as ordered GA0209P01 GA0208P01 GA0191P05 GA0084P04 GA0084P03 GA0084P01 GA0207P01 Buttons Green, Power (L1) White, Manual Start Only (LS1) Amber, Particle Test (LS2) Amber, Alarm Inhibit (L2) White, Alarm Sequence Reset (LS3) Red, GCM Fault (L3) Green, Safe (L4) White, Start (LS4) Amber, Filter (LS5) Amber, Warning (L5) Red, Verified Alarm (L6) GA0055P07 GA0055P12 GA0055P09 GA0055P10 GA0055P14 GA0055P15 GA0055P17 GA0055P13 GA0055P02 GA0055P11 GA0055P16 19 GA0203P01 Rev. D

21 Lamp, #387 (L1-L6) (LS1-LS5) GA0095P01 Chassis Power Supply +/- 15 volts, 200 MA (PS1) Voltage to Current Converter (VI1) GA0109P03 GA0183P01 Relay, 24V AC (K12-K16) Relay, 120V AC (K17) (K18, G1, G3, G5) Timer, 24V DC (T1, T2) Transformer, 24V (TR1) Resistor, 2.5K 10W (R67-R69) Capacitor, 600 uf, 25V (C13) Capacitor.1 uf, 600V (C1) Varistor (V1) Varistor (V2-V4) Circuit Board B1 GA0129P02 GA0062P03 GA0058P01 GA0073P06 GA0073P01 GA0088P03 GA0088P01 GD0015G02 Voltage Comparator (VC1-VC3) Dual Op-amp (A1, A2) Circuit Board B2 Computer Interface Circuit Board B3 (optional) GB0071G01 GA0257G01 GA0203P01 Rev. D 20

22 Figures 21 GA0203P01 Rev. D

23 Figure 1 - GCM Auto Alarm Outline GA0203P01 Rev. D 22

24 Figure 2 - Auto Alarm Wiring to GCM 23 GA0203P01 Rev. D

25 GA0203P01 Rev. D 24

26 11 10 NOTES: 1.CAPACITANCE IN UF 2.RESISTORS 1/4W 5% ULESS SPECIFIED 3.D1-11,16 1N457 OR EQUIV 4.D15 HP (#) RELAY ENERGIZED DURING NORMAL OPERATION

27 Figure A1 - Auto Alarm Computer Interface 27 GA0203P01 Rev. D

28 Figure A2 - Wiring Diagram GA0203P01 Rev. D 28

29 Figure A3 - Circuit Board B3 29 GA0203P01 Rev. D

30 GA0203P01 Rev. D 30

31 A PCC Flow Technologies, Inc. Company Environment One Corporation 2773 Balltown Road Niskayuna, New York USA Tel: (01) FAX: