Generator Gas Analyzer (GGA)

UTILITY SYSTEMS Generator Gas Analyzer (GGA) Instruction Manual HA0112P01 Rev. B

Contents Specifications... 4 Application... 5 System Description... 6 System Electronics... 6 Display Panel... 6 Sensor Cell Assembly... 7 Installation... 8 Generator Gas Analyzer Mounting... 8 Piping... 8 Electrical Connections... 8 Contacts... 8 Circuit Protection... 9 System Operation... 10 GGA Initialization... 10 Fn (Function) Menu... 11 Cell Output Voltages... 13 Generator Gas Analyzer Calibration... 13 Normal Operation... 14 Purge Operation... 14 Maintenance... 15 Periodic Maintenance... 15 Weekly... 15 Every Six Months... 15 Spare Parts... 16 1 HA0112P01 Rev. B

Figures Figure 1 - System Overview... 17 Figure 2 - Piping Schematic... 18 Figure 3 - System Electronics... 19 Figure 4 - Display Panel Assembly... 20 Figure 5 - Sensor Cell... 21 Figure 6 - Wiring Diagram... 22 HA0112P01 Rev. B 2

GENERATOR GAS ANALYZER IMPORTANT INFORMATION! THIS EQUIPMENT OPERATES AT VOLTAGE LEVELS THAT CAN BE HAZARDOUS TO PERSON- NEL. THE SECTION ABOUT SAFETY CONSIDERATIONS SHOULD BE READ BEFORE INSTAL- LATION OR SERVICE. THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT OR TO PROVIDE FOR EVERY POSSIBLE CONTINGENCY TO BE MET IN CON- NECTION 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. GENERATOR GAS ANALYZER SAFETY CONSIDERATIONS THE SYSTEM ELECTRONICS ENCLOSURE AND SENSOR CELL ENCLOSURE CONTAIN 120 VOLTS AC. THIS VOLTAGE APPEARS AT THE AC POWER STRIP AND VARIOUS OTHER POINTS. EQUIPMENT OPERATION INVOLVES A FLAMMABLE GAS (HYDROGEN) UNDER PRESSURE. APPROPRIATE MEASURES MUST BE TAKEN TO PREVENT LEAKS AND TO AVOID SOURCES OF IGNITION. WHEN ALL ELECTRICAL CONNECTIONS TO THE SYSTEM ELECTRONICS, SENSOR AND DISPLAY PANEL ARE COMPLETE AND TESTED, ENSURING THAT ALL SEALING FITTINGS ARE FILLED WITH AN APPROVED COMPOUND IS NECESSARY. THIS IS A NATIONAL ELECTRICAL CODE REQUIREMENT FOR CLASS 1, DIVISION 1, GROUP B ENVIRONMENTS (NEC 501-5). ALL GAS CONNECTIONS TO THE SENSOR CELL MUST BE LEAK CHECKED PRIOR TO AP- PLYING AC POWER. CHECK FOR LEAKS AT ALL TUBING AND MECHANICAL CONNECTIONS INSIDE THE SENSOR CELL ENCLOSURE. IF LEAKS ARE FOUND, DETERMINE THE CAUSE AND REPAIR. REPEAT- ING THE LEAK CHECK UNTIL THE SENSOR CELL ENCLOSURE IS DETERMINED TO BE LEAK TIGHT IS NECESSARY. 3 HA0112P01 Rev. B

Specifications Measurement Characteristics Case Purity 70 to 100% H 2 in Air Purge 0 to 100% H 2 in CO 2 0 to 100% Air in CO 2 Hydrogen Flow Rate 100 to 700 cc/min Electrical Characteristics Power Outputs, Relays Alarm, NO and NC Warning, NO and NC Trouble, NO and NC Normal, NO and NC Output, Signal 120 VAC, 50160 Hz 30 V/1.0 A DC, 120 V/0.5 A AC 125 V/0.005 A resistive DC (Alarm and warning levels are adjustable) 4-20 ma current output Mechanical Characteristics Dimensions: System Electronics Enclosure 11.00" x 12.00" x 9.25" Sensor Cell Enclosure 8.00" x 10.00" x 6.25" Display Enclosure 10.50" x 8.50" x 6.25" Valve Panel (optional) 24.00" x 24.00" x 8.00 Temperature Area Classification Hydrogen Pressure Gas Connections 30 to 125 F Class 1, Division 1, Group B 100 psi maximum 1/4" female NPT HA0112P01 Rev. B 4

Application Modern high capacity turbine generators use hydrogen gas as a cooling medium. Two reasons for the use of hydrogen are 1) it has the best heat transfer characteristics of any gas; and 2) the low atomic weight of hydrogen makes it the lightest and, therefore, the least dense of any stable gas (10 percent that of air at a purity of 98 percent), resulting in the lowest windage losses. Lower windage losses represent greater operating efficiency and lower cost per megawatt. The hydrogen auxiliary system exists to maintain the quality and quantity of cooling gas required to ventilate the conducting and rotating parts of hydrogen cooled generators. To optimize generator efficiency and safety, monitoring and maintaining hydrogen purity is important. Environment One s microprocessor controlled Generator Gas Analyzer (GGA) with its triple range sensor cell is capable of measuring 70 to 100 percent H 2 in Air, 0 to 100 percent H 2 in CO 2 and 0 to 100 percent Air in CO 2. The GGA continuously analyzes the generator cooling gas, displays gas purity in real time and has a corresponding 4-20 ma output. In the event that the gas purity falls to a warning or alarm level, a visual indication is given and alarm contacts are switched. The triple range sensor cell also monitors purge gases used during generator shutdown and maintenance. Purge gas purity is displayed and a corresponding 4-20 ma output is provided for H 2 in CO 2 or Air in CO 2. 5 HA0112P01 Rev. B

System Description The Generator Gas GGA is designed for use on hydrogen-cooled generators. It is designed to operate in Class 1, Division 1, Group B hazardous areas. Its main purpose is to analyze and, in real time, display the hydrogen gas purity on built-in numeric displays. The major components of the Generator Gas Analyzer include the System Electronics, Display Panel and Sensor Cell Assembly (Figure 1). System Electronics The System Electronics consist of one Controller board, one Input/Output Board and four Isolation Barriers. All are mounted in an explosion proof enclosure. Electrical connections are made through four ¾ female conduit openings (Figure 3). The System Electronics provide purity monitoring, calibration, mode selection, sensor unit control, alarm contacts, data logging, system inputs/outputs, sensing unit linearization, and diagnostics. Fail-safe operation of the GGA is assured by the following: 1. On power-up the GGA must execute and pass qualifying self tests. Failure in any test results in the termination of operation and the annunciation of the condition causing the failure. 2. Following power-up and/or system reset, the GGA is continuously supervised by an independent 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 processor functioning, internal voltages, analog-to-digital conversion accuracy, integrity of cabling, and relay operation. Any faults are immediately annunciated. For further information see the section ANALYZER FAILURE. Display Panel The Display Panel provides control of all functions of the GGA as well as complete annunciation of the status of the GGA. Functions are accessed by means of a four-button membraneswitch keypad and 16 (Function) key causes the LCD to continuously scroll the names of the available functions of the GGA. A function may then be accessed by pressing the Enter key when the function name appears. Subsequently, to signal confirmation, the function name will flash briefly. The Display Panel provides Light Emitting Diodes (LED s) to annunciate the Normal (H 2 in Air), Purge (H 2 in CO 2 and Air in CO 2 ), and Calibrate (H 2, CO 2 and N 2 ) GGA states. In addition, they indicate Warning, Alarm, and Trouble conditions. A green LED indicates AC Power. It is important to understand that, should the GGA go into either Warning and/or Alarm, it will lock into continuous monitoring of the gas stream. No other function can be accessed unless the Alarm/Warning Reset key is pressed first. To permit a system level initialization ( cold start ), a momentary push-button located behind HA0112P01 Rev. B 6

(Display Panel cont d) the Display Panel (Figure 4) in the upper right hand corner may be pressed. Since all calibration constants are stored in non-volatile memory, these values will not be lost should 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 gas mixture to the heat output of the thermistors under known constraints. See CELL OUTPUT VOLTAGES for a detailed description of the Sensor Cell. 7 HA0112P01 Rev. B

Installation The following instructions provide details to facilitate the equipment installation. The exact location of the Generator Gas Analyzer (GGA) should be in accordance with recommendations made by the generator manufacturer or its authorized representative. Prior to applying power to the GGA System, ensure that the local power source used matches the power rating on the GGA nameplate. All gas lines must be connected to the GGA Sensor Cell and leak tested before continuing. CAUTION! Care must be taken when removing the cover to avoid damage (scratches, etc.) to the sealing surfaces of the cover and enclosure. Do not remove the cover from the enclosure unless power is removed from the System Electronics and the system is free of hydrogen. Generator Gas Analyzer Mounting The location chosen should be such that the equipment will not be subjected to extremes of dust, temperature, vibration or shock. It should be accessible for service, with adequate clearance. Fasteners used should be compatible with the mounting surface to support the weight of the enclosures. Refer to figures 3, 4 and 5 for mounting dimensions. Piping Piping should be in accordance with Figure 2. All three calibration gases (hydrogen, carbon dioxide and nitrogen) should be at the same pressure as the generator case pressure. Gas connections are made through two 1/4" NPT fittings provided at the bottom of the Sensor Cell enclosure. All piping should be pressurized and leak tested prior to operation. Electrical Connections Electrical connections are made through four 3/4" male conduit unions provided at the bottom of the System Electronics enclosure (Figure 3). System power requirement is 120 VAC, 50/60 Hz. The source of AC power should be reliable and not subject to severe transients. To gain access to the inside of the System Electronics enclosure for electrical connections, the threaded cover needs to be removed. Wiring and wire routing should be in accordance with Figure 3 so that noise generated from the AC power and contacts does not interfere with the signals. Contacts As shown in Figure 6, the GGA provides the following 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. HA0112P01 Rev. B 8

(Contacts cont d) 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. Normal Relay Both a normally open and a normally closed contact (single pole, double throw configuration) is provided and Normal is signaled by an energized relay. Circuit Protection A 1/2-amp slo-blow fuse is used to provide circuit protection and is located on the Input/ Output PCB (Figure 6). 9 HA0112P01 Rev. B

System Operation GGA Initialization With system power on, press the RESET pushbutton on the backside of the DISPLAY PANEL (Figure 4). The GGA will perform several self tests and, if successful, the DISPLAY PANEL will respond with (a) all discrete LED s lit; (b) all segments and the tenths place decimal point of the GAS PURITY display lit; and (c) all pixels of the LCD display on. Within several seconds (a) all discrete LED s, except the AC POWER and TROUBLE LED s, will turn off; (b) all segments, except the tenths place decimal point of the GAS PURITY display will turn off; and (c) the display will indicate LINKING as the DISPLAY PANEL initiates communication with the rest of the system. Communication should be established within several seconds and the LCD display will then echo the results of cold start initialization: GGA ANALYZER READY INITIALIZING 12 BIT ADC CALIBRATED Note: If calibration is unsuccessful then the LCD will display 12 BIT ADC ERROR. After annunciating TROUBLE, the processor will be stopped because, at this point in the start-up sequence, this condition is a fatal error. 8 BIT ADC CALIBRATED Note: If calibration is unsuccessful then the LCD will display 8 BIT ADC ERROR. After annunciating TROUBLE, the processor will be stopped because, at this point in the start-up sequence, this condition is a fatal error. lout SET TO 4 ma where Iout is the 4-20 ma GGA output. See below. Tcell = XX.X OC (where XX.X is the instantaneous cell block temperature). For an indeterminate period (normally not exceeding 15 minutes for a cold start) the LCD will display the real-time temperature of the sensor cell block. When the temperature rises to 55.0 C +/- 0.5 C, the system will advance and the display will then indicate: ANALYZER READY After this last message, all discrete LED s will go out except AC POWER and TROUBLE. In response to the prompts NORMAL (H 2 /AIR), CONFIGURE VALVES, allow the sample gas to flow through the sensor then press the ENTER key. This is the NORMAL mode of operation. See NORMAL for more information. For a first time installation, it is essential that a gas sensor calibration be performed on the GGA system. Also, the faults log should be cleared. See SYSTEM, below. HA0112P01 Rev. B 10

Fn (Function) Menu The following items are available by pressing the Fn key: NORMAL (H 2 /AIR) This item, when displayed, can be selected by pressing the ENTER key. See NORMAL OPERATION for more information. PURGE This item, when displayed, can be selected by pressing the ENTER key. See the description PURGE OPERATION for more information. GAS CALIBRATION This item, when displayed, can be selected by pressing the ENTER key. See GENERATOR GAS ANALYZER CALIBRATION for more information. SETTINGS This item, when displayed, can be selected by pressing the ENTER key. If selected, ALARM LEVEL and WARNING LEVEL will be displayed. These sub-items permit adjustment of the levels at which system alarm and warning are annunciated. To adjust the alarm level press the ENTER key when this sub-item appears. The LCD will display the current purity level (in percent purity) at, or above which, the system will annunciate an alarm condition. This value can be adjusted by using the UP arrow and DOWN arrow keys, between 80 percent and 1 percent less than the setting for the warning level. The new level ran be selected by pressing the ENTER key. The new level will not be selected if the Fn key is pressed instead. To adjust the warning level press the ENTER key when this sub-item appears. The LCD will display the current purity level (in percent purity) at, or above which, the system will annunciate a warning condition. This value can be adjusted by using the UP arrow and DOWN arrow keys between 1 percent more than the setting for the alarm level and 99.9 percent. The new level can be selected by pressing the ENTER key. The new level can be selected by pressing the ENTER key. The new level will not be selected if the Fn key is pressed instead. The system will not permit the alarm and warning levels to have the same value; it will also not permit the alarm level to be higher than the warning level. SYSTEM. This item, when displayed, can be selected by pressing the ENTER key. If selected, five sub-items will be displayed: MONITOR Tcell, SHOW FAULTS LOG, CLEAR FAULTS LOG, RUN DIAGNOSTICS and SHOW PROGRAM ID. Pressing the ENTER key when a sub-item appears selects that sub-item. Selecting the sub-item MONITOR Tcell permits a real-time readout of the temperature of the gas sensor cell. Press the Fn key to terminate. The GGA is a self-supervised system and can identify and trap detected faults in its operation. Whenever a fault is detected the TROUBLE LED is illuminated, the TROUBLE RELAY is de-energized, and a description of the fault is logged (stored and latched). Faults can be displayed by pressing the ENTER key when the sub-item SHOW FAULTS LOG is displayed. Fault conditions that can be detected include errors in the system s 8- and 12-bit analog-todigital converters, power supply voltages, supervisory loop errors and gas sensor cell block temperature. Press the Fn key to terminate. The faults log can be erased by pressing the ENTER key when the sub-item CLEAR FAULTS LOG is displayed. If selected, the LCD will prompt CLEAR LOG? Press the ENTER key to clear all logged faults. Once executed the display will indicate LOG CLEARED for approximately two seconds and then go blank, leaving the system in the NORMAL mode. 11 HA0112P01 Rev. B

Pressing the Fn key instead will blank the display and place the system in the NORMAL mode without clearing the faults. Pressing the ENTER key when the sub-item RUN DIAGNOSTICS is displayed permits a readout of the GGA s initial cell reference voltage, the output voltages of all power supplies, tests the systems NORMAL, TROUBLE, ALARM and WARNING relays, and the Membrane Keypad on the DISPLAY PANEL. At any point press Fn to terminate testing. The test sequence is: 1. The LCD will display Vref=X.XXXVDC. This parameter is the voltage of the cell reference thermistor and was stored at the time of the last calibration of the cell (whether H 2, CO 2 or N 2 ). 2. The LCD will display Vh2=X.XXXVDC. This parameter is the voltage of the hydrogen calibration constant and was stored at the time of the last calibration of the cell. 3. The LCD will display Vco2=X.XXXVDC. This parameter is the voltage of the carbon dioxide calibration constant and was stored at the time of the last calibration of the cell. 4. LCD will display Vn2=X.XXXVDC. This parameter is the voltage of the nitrogen calibration constant and was stored at the time of the last calibration of the cell. 5. The LCD will display Vadc> X.XXVDC. This parameter is the reference voltage of the 12 bit analog-to-digital converter and will range between 3.97 and 4.22 VDC. 6. The LCD will display +5V> X.XXVDC. This parameter is the output of the +5 volt digital supply and will range between 4.50 and 5.50 VDC. 7. The LCD will display +12V> XX.XVDC. This parameter is the output of the +12 volt digital supply and will range between 10.8 and 13.2 VDC. 8. The LCD will display +15V> XX.XVDC. This parameter is the output of the +15 volt analog supply and will range between 13.5 and 16.5 VDC. 9. The LCD will display -15V> XX.XVDC. This parameter is the output of the -15 volt analog supply and will range between -13.5 and -16.5 VDC. For the above voltages, the LCD will flash the message ERROR alternately with the voltage if the measured voltage is out of limit. 10. The LCD will display RELAY TEST The system will cause each relay to be energized. If no errors are detected, the LCD will display RELAYS PASS. If an error is detected, the LCD will display RELAYS FAIL, FAILURE IN, and then either NORMAL RELAY, TROUBLE RELAY, ALARM RELAY or WARNING RELAY. 11. The LCD will display KEYPAD TEST Press each key on the Membrane Keypad on the DISPLAY PANEL, reserving the ENTER key for last (this key terminates the test). As each key is pressed, the LCD echoes the name of the key. Program instructions for the microcontroller within the GGA system are stored in Read-Only Memory (ROM) chips located within the system. The program identification and revision level, in the format P_GGA Rev. X.X, can be displayed by pressing the ENTER key when the HA0112P01 Rev. B 12

(Function Menu cont d) sub-item SHOW PROGRAM ID is displayed. Pressing the Fn key terminates this item. REMINDER! Should the system go into TROUBLE, access the menu items SHOW FAULTS LOG and RUN DIAGNOSTICS for more information. Cell Output Voltages The sensor cell is principally comprised of a sampling thermistor and a reference thermistor embedded in a temperature regulated cell block. The voltage derived from the reference thermistor (this voltage is displayed as cr) is used to compensate for any non-purity related variations in the voltage output of the sample thermistor (this voltage is displayed as s). When a cell is calibrated the value of cr is stored in non-volatile memory as the parameter Vref. Subsequently, during normal operation, the real time value of cr is mathematically combined with Vref to form a term compensating s. This operation assures long term measurement accuracy of the sensor cell. The output voltages of these thermistors can be viewed directly (i.e., prior to any computation) in real time by pressing the UP arrow. This information is updated every half second and is displayed in the format S=X.XXX cr=x.xxx, where, again, s stands for the sample thermistor voltage and cr stands for the current value of the reference thermistor voltage. The display of these voltages may be cancelled at any time by pressing the DOWN arrow. The parameter Vref is displayed during calibration and diagnostics. Generator Gas Analyzer Calibration Press the Fn (Function) key on the GGA. Wait until the display scrolls to the prompt GAS CALIBRATION then press the ENTER key. The display will scroll the prompts CALIBRATE H 2, CALIBRATE CO 2 and CALIBRATE N 2. When the display scrolls to the prompt CALI- BRATE H 2, press the ENTER key. In response to the prompts CALIBRATE H 2, CONFIGURE VALVES, permit the hydrogen calibration gas to flow through the sensor. With the calibration gas flowing the LCD will display the voltage output of the reference cell sensor in the format Vref=X.XXX VDC. If it is desired to cancel the calibration at this point, press the Fn key; this will permit a return to the main menu. If it is desired to continue the calibration, observe the reference voltage and, if it appears stable (i.e., a final change of not greater than 1 mv per minute) press the ENTER key. 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 is continued, observe the sample cell voltage as it adjusts to the flowing H2 calibration span gas. 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 will display H 2 CALIBRATED. This concludes the H 2 calibration. The display will scroll the prompts CALIBRATE H 2, CALIBRATE CO 2 and CALIBRATE N 2. Press the Fn (Function) key on the GGA to return to the main menu or, else, to continue gas calibration, wait until the display scrolls to the prompt CALIBRATE CO 2 and press the EN- TER key. In response to the prompts CALIBRATE CO 2, CONFIGURE VALVES, permit the carbon dioxide calibration gas to flow through the sensor. With the calibration gas flowing, the LCD will display the voltage output of the reference cell sensor in the format Vref=X.X-XX VDC. If it is desired to cancel the calibration at this point, press the Fn key; this will permit a return to the main menu. If it is desired to continue the calibration, observe the reference voltage and, if it appears stable (i.e., a final change of not greater than 1 mv per minute), press the ENTER key. 13 HA0112P01 Rev. B

(GGA Calibration cont d) The LCD will display the voltage output of the sample cell sensor in the format Vcell=X.XXX VDC. Again, the calibration may be terminated by pressing Fn. If it is continued, observe the sample voltage as it adjusts to the flowing CO 2 calibration zero gas. 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 will display CO 2 CALIBRATED. This concludes CO 2 calibration. The display will scroll the prompts CALIBRATE H 2, CALIBRATE CO 2 and CALIBRATE N 2. Press the Fn key on the GGA to return to the main menu or, else, to continue gas calibration, wait until the display scrolls to the prompt CALIBRATE N 2 and press the ENTER key. In response to the prompts CALIBRATE N 2, CONFIGURE VALVES, permit the nitrogen calibration gas to flow through the sensor. With the calibration gas flowing the LCD will display the voltage output of the reference cell sensor in the format Vref=X.XXX VDC. If it is desired to cancel the calibration at this point press the Fn key; this will permit a return to the main menu. If it is desired to continue the calibration, observe the reference voltage and, if it appears stable (i.e., a final change of not greater than 1 mv per minute), press the ENTER key. The LCD will display the voltage output of the sample cell sensor in the format Vcell=X.XX,X VDC. Again, the calibration may be terminated by pressing Fn. If it is continued, observe the sample voltage as it adjusts to the flowing N 2 calibration zero/span gas. 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 will display N 2 CALIBRATED. This concludes N 2 calibration. Press the Fn (Function) key to return to the main menu. This concludes the gas sensor calibration of the GGA system. Normal Operation Normal operation of the GGA system can be accessed by first pressing the Fn key to access the main menu and, then, pressing the ENTER key when the display scrolls to the prompt NORMAL (H 2 in AIR). In response to the prompts NORMAL (H 2 /AIR), CONFIGURE VALVES, permit the sample gas to flow through the sensor then press the ENTER key. In the NOR- MAL mode of operation the GGA can respond to both WARNING and ALARM levels. Both levels are programmable (see SETTINGS for detailed information). The 4-20 ma current output of the GGA corresponds to 70 percent to 100 percent gas purity and the GGA must remain below the WARNING or ALARM level for a minimum of one minute to generate an alarm. Should the GGA go into WARNING it will energize the WARNING RELAY (Figure 6), and illuminate the WARNING LED. Further system operation is locked out until the WARNING RESET key is pressed, at which point the GGA will revert to NORMAL operation. Purge Operation To monitor a purge operation, first press the Fn key to access the main menu, then press ENTER when the display scrolls to the prompt PURGE (H 2 in AIR) or PURGE (AIR in CO 2 ) key. In response to either the prompt PURGE (H 2 /AIR) or PURGE AIR/CO 2, CONFIGURE VALVES, permit the sample gas to flow through the sensor then press the ENTER key. The display panel will respond with the corresponding PURGE (H 2 in CO 2 ) or PURGE (Air in CO 2 ) LED illuminated. In this mode the 4-20 ma current output of each GGA corresponds to 0 to 100 percent gas purity. There is no alarm level for either of the PURGE operations. HA0112P01 Rev. B 14

Maintenance Periodic Maintenance The Generator Gas Analyzer is designed for reliable, trouble-free operation and ease of periodic checks and maintenance. Weekly 1. Check and adjust, if necessary, the GGA flow rates. 2. Visually inspect the moisture indicators. Blue media indicate dry hydrogen, while pink media indicate excessive moisture in the hydrogen gas sample that may affect the stability of the Generator Gas Analyzer. Replace or regenerate the Moisture Indicator and replace the Gas Purifier if the media are pink. 3. Blow down drip leg. Every Six Months 1. Calibrate GGA. See Generator Gas Analyzer Calibration. 15 HA0112P01 Rev. B

Spare Parts Part Number Description Quantity HC0021G02 Sensor Cell Assembly 1 HD0039G01 Controller Board 1 HD0043G01 I/O Board 1 HD0035G01 Display Board 1 HB0026G01 Display Panel 1 GA0109P03 Power Supply, +/- 15 VDC 1 HA0027P01 Power Supply, 12 VDC 1 HA0045P02 Isolation Barrier, Dual 2 HA0045P01 Isolation Barrier, Single 2 HA0038P01 Fuse, 1/2 Amp, Slo-Blow 1 HA0112P01 Rev. B 16

Figure 1 - System Overview 17 HA0112P01 Rev. B

Figure 2 - Piping Schematic HA0112P01 Rev. B 18

Figure 3 - System Electronics 19 HA0112P01 Rev. B

Figure 4 - Display Panel Assembly HA0112P01 Rev. B 20

Figure 5 - Sensor Cell 21 HA0112P01 Rev. B

Figure 6 - Wiring Diagram HA0112P01 Rev. B 22

A PCC Flow Technologies, Inc. Company Environment One Corporation 2773 Balltown Road Niskayuna, New York USA 12309 1090 Tel: (01) 518.346.6161 FAX: 518.346.6188 www.eone.com