Dual Hydrogen Control Panel (DHCP) : Installation and Operation Manual

DETECTION SYSTEMS
Dual Hydrogen Control Panel (DHCP)
Installation and Operation Manual
HA0156P01 Rev. D
120V & 220V Bottom Entry
Contents
Introduction ..................................................................................................................................... 6
Specifications .................................................................................................................................. 7
System Description ......................................................................................................................... 8

Gas Analyzers (Sensor Cells QT-290A, QT-290B, Controller PCB HD0039G01, I/O PCB
HD0043G01, Display PCB HD0138G03) ................................................................................... 8
Control/Display Panel ................................................................................................................ 9
Sensor Cell Assembly ................................................................................................................. 9
Flow Indicators with Metering Valves (FI-2971, FI-2972) .......................................................... 9
Total Gas Flowmeter (FI-2973) .................................................................................................. 9
Differential Pressure Gage (PDI-292) ....................................................................................... 10
Differential Pressure Transmitter (PDT-292) ............................................................................ 10
Purifiers ................................................................................................................................... 10
Moisture Indicators (MI-2971, MI-2972, MI-2973) ................................................................... 10
Metering Valves (HO-2971, HO-2972, HO-2973, HO-2974) ...................................................... 10
Installation .................................................................................................................................... 11
Cabinet Mounting .................................................................................................................... 11
Lifting ...................................................................................................................................... 11
Electrical Connections ............................................................................................................. 11
Contacts/Signals ...................................................................................................................... 12
Circuit Protection ..................................................................................................................... 12
System Operation ......................................................................................................................... 13

DHCP Initialization .................................................................................................................. 13
Flow Calibration ...................................................................................................................... 14
Gas Calibration ....................................................................................................................... 14
Normal Operation .................................................................................................................... 15
Purge Operation ....................................................................................................................... 16
Mode Menu .............................................................................................................................. 16
Cell Output Voltages ................................................................................................................ 18
Maintenance ................................................................................................................................. 19
Daily ........................................................................................................................................ 19
Weekly...................................................................................................................................... 19
Every Six Months ..................................................................................................................... 19
When the Generator is Down ................................................................................................... 19
Component Replacement Instructions .......................................................................................... 20

Removing a Gas Analyzer Sensor ............................................................................................. 20
Removing a Processor Circuit Board ........................................................................................ 20
Removing the Input/Output (I/O) Circuit Board ......................................................................... 21
Removing Solenoid Valves Coils ............................................................................................... 21
1 HA0156P01 Rev. D
Removing Moisture Indicators .................................................................................................. 21
Removing Gas Purifiers ........................................................................................................... 22
Removing Flow Meters............................................................................................................. 22
HA0156P01 Rev. D 2
Figures
Figure 1 - DHCP Outline ............................................................................................................................. 25
Figure 2 - DHCP Main Junction Box, Internal Component ........................................................................... 27
Figure 3 - Customer Interface Connections ................................................................................................. 28
Figure 4 - DHCP Wiring Diagram ............................................................................................................... 29
Figure 4a - DHCP Wiring Diagram ............................................................................................................. 31
Figure 5 - DHCP Piping Schematic ............................................................................................................. 33
Figure 6 - Analyzer Status ........................................................................................................................... 35
Figure 7 - DHCP Display ............................................................................................................................ 36
Figure 8 - DHCP Display Descriptions ........................................................................................................ 37
Figure 9 - DHCP Status .............................................................................................................................. 38
Figure 10 - DHCP Customer Contacts ........................................................................................................ 39
Figure 11 - Valve/Switch Configuration, Normal % H2 in Air ....................................................................... 40
Figure 12 - Valve/Switch Configuration, Purge % H2 in CO2 ....................................................................... 40
Figure 13 - Valve/Switch Configuration, Purge % Air in CO2 ...................................................................... 41
Figure 14 - Valve/Switch Configuration, Case .............................................................................................. 41
Figure 15 - Valve/Switch Configuration, Confirmation Mode, Turbine End .................................................... 42
Figure 16 - Valve/Switch Configuration, Confirmation Mode, Collector End.................................................. 42
Figure 17 - Valve/Switch Configuration, Calibrate N2 (Both Analyzers) ....................................................... 43
Figure 18 - Valve/Switch Configuration, Calibrate CO2 (Both Analyzers) .................................................... 43
Figure 19 - Valve/Switch Configuration, Calibrate H2 (Both Analyzers) ....................................................... 44
Figure 20 - Valve/Switch Configuration, Calibrate N2 (Turbine End) ............................................................ 44
Figure 21 - Valve/Switch Configuration, Calibrate N2 (Collector End) .......................................................... 45
Figure 22 - Valve/Switch Configuration, Calibrate CO2 (Turbine End) .......................................................... 45
Figure 23 - Valve/Switch Configuration, Calibrate CO2 (Collector End) ....................................................... 46
Figure 24 - Valve/Switch Configuration, Calibrate H2 (Turbine End) ............................................................ 46
Figure 25 - Valve/Switch Configuration, Calibrate H2 (Collector End) .......................................................... 47
Figure 26 - Parts List ................................................................................................................................... 48
3 HA0156P01 Rev. D
HA0156P01 Rev. D 4
Dual Hydrogen Control Panel (DHCP) System
Important Information
THIS EQUIPMENT OPERATES AT VOLTAGE LEVELS THAT CAN BE HAZARDOUS TO

PERSONNEL. READ THE SECTION ABOUT SAFETY CONSIDERATIONS BEFORE
INSTALLING OR SERVICING.
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 PROB-

LEMS ARISE THAT ARE NOT COVERED SUFFICIENTLY FOR THE PURCHASER’S
PURPOSES, 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.
Dual Hydrogen Control Panel (DHCP) System

Safety Considerations
THE SYSTEM ELECTRONICS ENCLOSURE AND CUSTOMER INTERFACE

ENCLOSURE CONTAIN 115 AND OR 230 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 AVOID SOURCES OF
IGNITION.
ALL ELECTRICAL CONNECTIONS BETWEEN THE SYSTEM ELECTRONICS,

CUSTOMER INTERFACE AND DISPLAY/CONTROL PANEL SHOULD BE TESTED AND
VERIFIED TO BE CORRECT.
ALL WIRING MUST BE IN ACCORDANCE WITH LOCAL CODE AND/OR CENELEC

STANDARD EN50014.
ALL GAS CONNECTIONS TO THE PANEL MUST BE LEAK CHECKED PRIOR TO

APPLYING AC POWER.
CHECK FOR LEAKS AT ALL TUBING AND MECHANICAL CONNECTIONS. IF LEAKS

ARE FOUND, DETERMINE THE CAUSE AND REPAIR. REPEAT THE LEAK CHECK
UNTIL THE PANEL IS DETERMINED TO BE LEAK TIGHT.
5 HA0156P01 Rev. D
Introduction
Modern high capacity turbine generators use hydrogen gas as a cooling medium. Two
reasons for using hydrogen are 1) hydrogen has the best heat transfer characteristics of any
gas; and 2) the low atomic weight of hydrogen makes it the lightest and, therefore, has the
lowest density of any stable gas (10 percent that of air at a purity of 98 percent), resulting in
the lowest windage losses.
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. Gland
seals are used to prevent hydrogen leakage through the clearance between the shaft and
the frame.
In order to maintain hydrogen gas purity of approximately 98 percent, some generators use
a seal gland system, where a small quantity of hydrogen gas is continuously scavenged
from two (collector end and turbine end) seal drain enlargements and discharged into the
atmosphere.
The Dual Hydrogen Control Panel (DHCP) contains two independent Generator Gas Analyz-
ers (GGA’s) and circuitry to control the rate of scavenging in order to maintain high gas
purity. Environment One’s microprocessor-controlled Generator Gas Analyzer (GGA), with
its triple-range sensor cell, is capable of measuring 70 to 100 percent H2 in Air, 0 to 100
percent H2 in CO2 and 0 to 100 percent Air in CO2.
Each GGA continuously analyzes the generator cooling gas, displays gas purity in real time
and has a corresponding 4 to 20 mA output. In the event that the gas purity falls to a warn-
ing or alarm 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 shut-
down and maintenance. Purge gas purity is displayed and a corresponding 4 to 20 mA
output is provided for H2 in CO2 or Air in CO2.
HA0156P01 Rev. D 6
Specifications
Input Voltage 120 Vac 50/60 Hz
220 Vac 50/60 Hz
Ambient Temperature 32 F to 125 F (0 C to 52 C)
Maximum Pressure 100 psi
Ambient Location Class 1, Division 1, Group B
Gas Analyzer Switchable — Triple Range

Sensing Unit (70-100% H 2 in Air)
(0-100% H2 in CO2)
(0-100% Air in CO2)
Accuracy +/- 1% of full scale @ 80-100% H 2 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 RAM

10 years minimum
Indicators AC power, Trouble, Normal (H2 in Air),

Purge (H2 in CO2), Purge (Air in CO2),
Calibrate H 2, Calibrate CO2, Calibrate N 2,
One 3-character LED numeric displays,
One 16-character LCD display
Weight 475 lbs (standard)

1,100 lbs (NEMA 3R)
Dimensions 17” d x 64 3/4” h x 36” w (standard)

27.5” d x 72” h x 42” w (NEMA 3R)
7 HA0156P01 Rev. D
System Description
The Dual Hydrogen Control Panel (DHCP) is designed for use on hydrogen-cooled genera-
tors. It is designed to operate in Class 1, Division 1, Group B hazardous areas. The DHCP
analyzes and, in real time, displays the hydrogen gas purity on built-in numeric displays.
Environment One’s GGA can be supplied as an Ex, CE labeled system for Zone 1 environ-
ments. Contact Environment One for details.
The major components of the DHCP include:
• 2 completely independent, generator gas analyzers (GGA)
• 2 hydrogen gas flow indicators with metering valves
• 1 total hydrogen gas flow indicator
• 1 fan differential pressure transmitter and gage
• 3 hydrogen gas purifiers
• 3 moisture indicators
• 4 metering valves
• Numerous isolation valves
• 2 local display panels that indicate gas purity and specific operating conditions
Gas Analyzers (Sensor Cells QT-290A, QT-290B, Controller PCB

HD0039G01, I/O PCB HD0043G01, Display PCB HD0138G03)
Analyzers and their printed circuit boards (PCBs) are interchangeable. Each analyzer is
comprised of a sensing unit, controller PCB, sensor cells and input/output (I/O) PCB. All
PCB’s are housed in the main junction box (Figure 1); local display panels are mounted on
the front of the panel (Figure 1).
Each analyzer independently provides purity monitoring, calibration, mode selection, sensor
unit control, alarm electronics, data logging, system inputs/outputs and sensing unit
linearization. See Figure 8 for display panel features and functions.
Fail-safe operation of the Gas Analyzers is ensured by:
1. On power-up the GGA must execute and pass qualifying self tests. Failure in any test
results 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 an

independent watchdog monitor that serves to reset it should its operation become
erratic.
HA0156P01 Rev. D 8
(Gas Analyzers cont’d)
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 as “trouble” on the display
and accompanied by a change in the corresponding relay state.
See Analyzer Failure for more information.
Control/Display Panel
The Control/Display Panel provides control of all functions of the GGA as well as complete
annunciation of the status of the GGA (Figure 7). Functions are accessed by means of a
four-button membrane-switch keypad and 16-character Liquid Crystal Display (LCD). Gener-
ally, pressing the Fn (Function) key causes the LCD to continuously scroll the names of the
GGA’s available functions. A function may then be accessed by pressing the ENTER key
when the function name appears. To signal confirmation, the function name flashes briefly.
The Display Panel provides Light Emitting Diodes (LEDs) to annunciate the Normal (H2 in
air), Purge (H2 in CO2 and air in CO2), and Calibrate (H2, CO2 and N2) GGA states. In addi-
tion, 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 first pressed.
To permit a system level initialization (“cold start”), a momentary push-button, located behind
the Display Panel (Figure 7) 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 for the sensor cell.
Flow Indicators with Metering Valves (FI-2971, FI-2972)

Two low-flow gas indicators with needle metering valves are used to adjust the hydrogen gas
flow through each sensing unit (Analyzer 1 and Analyzer 2, Figure 1). Both have a direct read
scale with a range of 90 to 900 cc/min, calibrated with hydrogen.
Note: Flow indication changes with different gases. For hydrogen, the flow should be set for
500 cc/min.
Total Gas Flowmeter (FI-2973)

A high flow gas indicator is used to indicate the scavenging flows (Total Flow, Figure 1). The
high flow gas indicator has a direct read scale with a range of 540 to 5,400 cc/min when
calibrated with hydrogen.
Note: Flow indication changes with different gases. Metering valves adjust the flow of the
collector end low flow, collector end high flow, turbine end low flow and turbine end high
flow. See Flow Calibration for flow settings.
9 HA0156P01 Rev. D
Differential Pressure Gage (PDI-292)
A differential pressure gage measures the generator fan differential pressure (Fan
Differential, Figure 1). The standard differential pressure gage has dual scales with ranges of
0 to 30 inches H 2O and 0 to 76.2 gm/cm2. Some units may be equipped with special gage
scales.
Differential Pressure Transmitter (PDT-292)

A differential pressure transmitter provides an output signal corresponding to the generator
fan differential pressure (Figure 1). This 4 to 20 mA output is externally provided by the
Mark V and corresponds to 0 to 30 inches H2O. Some units may be equipped with a special
range.
Purifiers
Three gas purifiers remove foreign matter from the hydrogen stream (Turbine End Purifier,
Case Purifier, Collector End Purifier; Figure 1). Removal of oil, water and particles above 12
microns is accomplished through the use of molecular sieve materials and special filters.
The filters are available in replaceable cartridges, HA0139P02.
Moisture Indicators (MI-2971, MI-2972, MI-2973)

Three moisture indicators indicate the downstream presence of moisture in the hydrogen
stream (Turbine End Moisture, Collector End Moisture, Case Moisture; Figure 1). The units
are supplied with a dyed silica gel, which gradually changes from blue (at relative humidity
less than 4 percent) to pink (at relative humidity higher than 40 percent). These devices are
replaceable.
Metering Valves (HO-2971, HO-2972, HO-2973, HO-2974)

Four needle metering valves provide adjustment for the scavenging flow rates (Collector
End Low Flow, Turbine End Low Flow, Collector End High Flow, Turbine End High Flow;
Figure 1). See Flow Calibration for flow settings.
HA0156P01 Rev. D 10
Installation
Follow the installation instructions to ensure proper installation of the equipment. The exact
location of the DHCP should be in accordance with the recommendations made by General
Electric or its authorized representative.
Cabinet Mounting
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 enclosure
and display panel doors (Figure 1). The DHCP has four foundation bolt openings (Figure 1).
The openings allow you to insert four 5/8-inch bolts for securing the panel to the floor. The
bolts are isolated from the panel through the use of compression vibration insulators. Use
fasteners that are compatible with the mounting surface and able to support the weight of
the panel. Lifting bolts at the top of the panel allow for easy connection to overhead cranes.
Lifting
The DHCP should be lifted by the pair of eye bolts provided at the top of the frame.
Electrical Connections
Prior to applying power to the DHCP unit, ensure that the local power source matches the
power rating on the DHCP nameplate.
The DHCP unit is shipped with all isolation and metering valves closed. All gas lines must be
connected to the DHCP and leak-tested before continuing.
Electrical connections are made through four 3/4-inch male conduit unions at the bottom or
top of the panel (Figure 1). System power requirements are 120 or 220 Volts AC (systems
are supplied for specifically 120 V or 220 V). The AC power source should be reliable and
not subject to severe transients. Total load max.: 400 watts.
Electrical connections, located inside of the main junction box, are accessed by removing 32
3/4” 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
junction box lid weighs 50 lbs (22.7 kg). Take precautions during removal. Prior to
opening the main junction box, remove power from the DHCP and ensure the system
is free of hydrogen.
Wire routing should be in accordance with Figure 3 or 4. This ensures that noise generated
from the AC power and contacts does not interfere with the signals. Connections are made
to barrier type terminal strips (Figure 3).
11 HA0156P01 Rev. D
Contacts/Signals
The DHCP includes alarm and status relays (Figures 3, 9, 10). They are:
• 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 an energized relay.
• 4-20 mA output signals are provided for Analyzer #1, Analyzer #2 and the DP Transmit-
ter (Figure 3).
• The 4-20 mA signals for Analyzer #1 and Analyzer #2 correspond to 70 to 100 percent in
Normal mode (H2 in air) and 0 to 100 percent in Purge modes (H2 and CO2 & Air in CO2).
• Analyzer #1 and Analyzer #2’s output signals are internally powered. These signals
are not to be powered by the Mark V, Mark VI.
• The 4-20 mA signal for the DP Transmitter is powered by the Mark V, Mark VI.
See Figure 3 for locations of signals on terminal block. See Figures 9 and 10 for description
of conditions where relays are activated.
Circuit Protection
Each GGA is individually fused. A half-amp slo-blo fuse, located on the Input/Output PCB,
provides circuit protection.
HA0156P01 Rev. D 12
System Operation
The DHCP’s main purpose is to analyze and display the hydrogen gas purity of hydrogen
cooled generators. This section describes system operation.
DHCP Initialization
With system power on, press the RESET push-button on the backside of the DISPLAY
PANEL (Figure 7). Reset each of the two gas analyzer units separately.
The GGA will perform several self tests and, if they are successful, the DISPLAY PANEL will
respond with (a) all discrete LEDs 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 LEDs, except the AC POWER and TROUBLE LEDS, 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. Contact Environment
One at (518) 346-6161.
• 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. Contact Environment
One at (518) 346-6161.
• Iout SET TO 4 mA where Iout is the 4-20 mA GGA output. See below.
• Tcell = XX.X 0C (where XX.X is the instantaneous cell block temperature). For an inde-
terminate 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 indicate:
• ANALYZER READY After this last message, all discrete LEDs will go out except AC
POWER and TROUBLE. In response to the prompts NORMAL (H2/AIR), CONFIGURE
VALVES, permit 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
system. Also, the faults log should be cleared. See System for more information.
13 HA0156P01 Rev. D
Flow Calibration
Refer to Figure 5 for piping component location and Figures 11 through 25 for valve configu-
rations.
With the DHCP system in normal operation, manually close all isolation valves and metering
valves.
Set CE low flow. Open isolation valve HV-2973. Adjust the collector end low flow metering
valve HO-2974 for a flow setting of approximately 1000 SCCM at total flow meter FI-2973.
Set CE high flow. While Mark V is energizing FY-2973, adjust the collector end high flow
metering valve HO-2973 for a total flow of approximately 2000 SCCM at total flow meter FI-
2973. After adjustment is made, ensure that FY-2973 is de-energized by the generator
control system (Mark V).
Set Cell #2 flow. Open isolation valves HV-2974, HV-2982 and HV-2981; adjust the flow
meter/metering valve FI-2972 for a flow of approximately 500 SCCM. Total flow meter FI-
2973 should indicate approximately 1500 SCCM. Close HV-2973, HV-2974, HV-2982 and
HV-2981.
Set TE low flow. Open isolation valve HV-2971. Adjust the turbine end low flow metering
valve HO-2972 for a flow setting of approximately 1000 SCCM at total flow meter FI-2973.
Set TE high flow. While Mark V is energizing FY-2971, adjust the turbine end high flow
metering valve HO-2971 for a total flow of approximately 2000 SCCM at total flow meter FI-
2973. After adjustment is made, ensure that FY-2971 is de-energized by the generator
control system (Mark V).
Set Cell #1 flow. Open isolation valves HV-2972, HV-2979 and HV-2980. Adjust the indica-
tor/metering valve FI-2971 for a flow of approximately 500 SCCM. Total flow meter FI-2973
should indicate approximately 1500 SCCM.
Open HV-2973, HV-2974, HV-2982 and HV-2981. Total flow meter FI-2973 should indicate
approximately 3000 SCCM.
Gas Calibration
Calibrate each of the two gas analyzer units separately.
Press the Fn 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
H2, CALIBRATE CO2 and CALIBRATE N2. Wait until the display scrolls to the prompt
CALIBRATE H2 then press the ENTER key. In response to the prompts CALIBRATE H2,
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. Press the Fn key to cancel the calibration at this
point, if desired; this will permit a return to the main menu. If desired to continue the
calibration, observe the reference voltage and, if it appears stable (i.e., a final change of not
greater than 1 to 2 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
HA0156P01 Rev. D 14
(Gas Calibration Cont’d)
continued, observe the sample cell voltage as it adjusts to the flowing H 2 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 H2
CALIBRATED. This concludes H 2 calibration.
The display will scroll the prompts CALIBRATE H 2, CALIBRATE CO2 and CALIBRATE N 2.
Press the Fn key on the GGA to return to the main menu or to continue gas calibration, wait
until the display scrolls to the prompt CALIBRATE CO2 and press the ENTER key. In
response to the prompts CALIBRATE CO2, CONFIGURE VALVES, permit the CO2
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
desired to cancel the calibration at this point, press the Fn key; this will permit a return to the
main menu. If desired to continue the calibration, observe the reference voltage and, if it
appears stable (i.e., a final change of not greater than 1 to 2 mV per minute), press the
ENTER key.
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 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 will display CO2 CALIBRATED.
This concludes CO2 calibration.
The display will scroll the prompts CALIBRATE H2, CALIBRATE CO2 and CALIBRATE N2.
Press the Fn key on the GGA to return to the main menu, or to continue gas calibration, wait
until the display scrolls to the prompt CALIBRATE N2, press the ENTER key. In response to
the prompts CALIBRATE N2, 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 desired to cancel the
calibration at this point, press the Fn key; this will permit a return to the main menu. If
desired to continue the calibration, observe the reference voltage and, if it appears stable
(i.e., a final change of not greater than 1 to 2 mV per minute) press the ENTER key.
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 N 2 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 will display N 2 CALIBRATED.
This concludes N 2 calibration.
Press the Fn key to return to the main menu. This concludes the gas sensor calibration of
the GGA system.
Normal Operation
Note: It is important to verify the lines connecting LE025 to the turbine-end seal drain
enlargement, LE026 to the collector-end seal oil enlargement and LE028 to the case fan
pressure are filled with hydrogen before placing the system in 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 (H2 in Air). In response to the prompts NORMAL (H2 in Air), CONFIGURE
VALVES, permit the sample gas to flow through the sensor then press the ENTER key. In
15 HA0156P01 Rev. D
(Normal Operation Cont’d)
the NORMAL mode of operation the GGA can respond to both WARNING and ALARM levels.
Both levels are programmable (see SETTINGS, above, for detailed information). The 4-20
mA current output of the GGA corresponds to 70 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 3)
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, and then
press ENTER when the display scrolls to the prompt PURGE (H2 in CO2) or PURGE (Air in
CO2) key. In response to either the prompt PURGE (H2 in CO2) or PURGE (Air in CO2),
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 (H2 in CO2) or
PURGE (Air in CO2) LED illuminated. In this mode the 4 to 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.
Mode Menu
The following items are available by pressing the Fn key:
• NORMAL (H2/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
Purge Operation for more information.
• GAS CALIBRATION This item, when displayed, can be selected by pressing the
ENTER key. See Gas Calibration for more information.
• SETTINGS This item, when displayed, can be selected by pressing the ENTER key. If
selected, two sub-items will be displayed: ALARM LEVEL and WARNING LEVEL. 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 can 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 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,”
HA0156P01 Rev. D 16
(Mode Menu Cont’d)
“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 opera-
tion. 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-to-
digital 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.
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 system’s 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
H2, CO2 or N2).
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. The 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.
17 HA0156P01 Rev. D
(Mode Menu Cont’d)
For the above voltages, the LCD will flash an ERROR message 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,” then “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 will terminate the test).
As each key is pressed the LCD will echo 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
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 ensures long-term mea-
surement accuracy of the sensor cell.
The output voltages of these thermistors can be viewed directly (i.e., prior to any computa-
tion) 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 canceled at any time by pressing the DOWN arrow.
The parameter Vref is displayed during calibration and diagnostics.
HA0156P01 Rev. D 18
Maintenance
The Dual Hydrogen Control Panel (DHCP) is designed for reliable, trouble-free operation.
Periodic checks and maintenance are easy. Following the required maintenance checks will
ensure safe trouble free operation of this equipment.
Daily
Check and adjust DHCP analyzer and scavenging flow rates. See Flow Calibration. Check
hydrogen purity.
Weekly
1. Visually inspect the moisture indicators. A blue medium indicates dry hydrogen, while a
pink medium indicates excessive moisture in the hydrogen gas sample that may affect
the stability of the Generator Gas Analyzers. Replace or regenerate the Moisture
Indicator and replace the Gas Purifier if the medium is pink. Refer to Removal of
Moisture Indicators and Gas Purifiers.
2. Blow down purifiers by first removing cap at the base of the isolation valve and then
open the valve itself. 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 Analyzers, 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 be
maintained to the DHCP, or b) the DHCP be isolated by placing all isolation valves in “off”
position.
19 HA0156P01 Rev. D
Component Replacement Instructions
The hydrogen analyzer sensing units, input/output circuit board, processor circuit boards,
power supplies and intrinsically safe barriers are located inside the main junction box. To gain
access to the inside of the main junction box for service, remove the 32, 3/4-inch captive
bolts. Two guide studs assist with removal/replacement.
CAUTION! Do not scratch sealing surfaces on the main junction box. The main junc-
tion box lid weighs 50 lbs (22.7 kg). Take precautions during removal. Prior to open-
ing the main junction box, remove power from the HCP and ensure the system is free
of hydrogen.
Removing a Gas Analyzer Sensor

To remove a hydrogen analyzer from a flameproof enclosure:
1. Disconnect AC input power.
2. Manually close isolation valves HV-2979, HV-2980, HV-2982 and HV-2981.
3. Remove the cover of the main junction box.
4. Remove 4 screws used to secure processor and I/O boards (see Figure 2).
5. Remove the 12-pin cable connector from the sensor circuit board.
6. Remove inlet and outlet tubing connections from the analyzer with a 7/16-inch wrench.
7. Remove mounting hardware (4 slotted screws).
8. 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 HV-2985, HV-2986, HV-2983 and HV-2973A.
3. Remove the main junction box cover.
4. To remove the upper processor board, disconnect the 40-pin ribbon cable and remove
the 4 nuts (11/32).
5. Install the new processor board in reverse order.
6. Check that pin #1 on the ribbon connector is properly aligned.
HA0156P01 Rev. D 20
Removing the Input/Output (I/O) Circuit Board
2. Close Isolation valves HV-2985, HV-2986, HV-2983 and HV-2973A.
3. Remove the main junction box cover.
4. Remove the processor board. Disconnect the 60-pin ribbon cable and 4 nuts (11/32).
5. Remove the 8 slotted screws, which hold the board in place and spacers in place (4 on
top, 4 on bottom of board).
6. Remove all wiring connections to the terminal blocks on the Input/Output board.
7. Disconnect power supply connections to the Input/Output board.
8. Disconnect the analyzer cell, 12-pin headers.
9. The Input/Output board can now be removed. Install the new input/Output board in
reverse order.
Removing Solenoid Valves Coils

All solenoid valves are connected in the main junction box. Once the inoperable solenoid
valve is located, remove AC power and manually close all isolation valves.
1. Reach under the solenoid and remove the top cap by prying it off.
2. Push the solenoid valve body down and slide the nameplate/retainer off.
3. Open the closest (small, adjacent) junction box to the solenoid valve and locate the 3
solenoid valve wires.
4. Cut and strip the wires.
5. Install the new solenoid valve.
6. Splice the wires together using a butt splice.
7. Replace the (small, adjacent) junction box cover.
8. Restore AC power and manually reopen the isolation valves.
Removing Moisture Indicators

Three moisture indicators and three gas purifiers are located on the front of the panel
(Figure 1).
To remove moisture indicators:
2. Manually close all isolation valves.

21 HA0156P01 Rev. D
(Removing Moisture Indicators cont’d)
3. Unscrew moisture indicator by hand.
4. Replace moisture indicator by screwing in the replacement by hand.
5. Open isolation valves HV-2971, HV-2972, HV-2979, HV-2980, HV-2973, HV-2974, HV-
2981, HV-2982 and HV-2978.
6. Perform leak check.
7. Reconnect AC input power.
Removing Gas Purifiers

3. Release pressure within purifier housing by opening drain at HV-2971A, HV-2972A or HV-
2973A, as appropriate.
4. Remove 8 bolts (1/2” hex) at bottom flange of purifier housing.
5. Remove purifier cartridge and two associated gaskets.
6. Replace cartridge and gaskets.
7. Resecure bolts (to 120” lbs torque).
8. Close drain.
9. Open isolation valves HV-2971, HV-2972, HV-2979, HV-2980, HV-2973, HV-2974, HV-
2981, HV-2982 and HV-2978.
Removing Flow Meters

3. Remove tubing fittings and locking nuts from the back of the flowmeter.
4. Withdraw flowmeter from the front side of the DHCP.
5. To install replacement, reverse above process.
HA0156P01 Rev. D 22
Figures
The figures that follow depict the DHCP and its components. All references in this document
refer to the following figures.
Please note that figures 11-25 depict portions of the DHCP. These figures are provided for
easy reference in configuring isolation valves and switches. Please note that isolation valve
handles and actual switches are not shown. Instead, “on,” “off” and arrow graphics are
provided. Contact Environment One with questions relating to any of the figures relating to
this manual.
23 HA0156P01 Rev. D
HA0156P01 Rev. D 24
LOOKING DOWN AT BASE PLATE FRONT VIEW Figure 1 - DHCP Outline
TURBINE END TOTAL COLLECTOR END

FLOW FLOW FLOW
TURBINE END ANALYAER #1 COLLECTOR END ANALYAER #2
NORMAL AC POWER TROUBLE

H2 H2
IN IN
AIR AIR
GAS PURITY GAS PURITY

RESET RESET
ALARM ALARM
WARNING WARNING
CALIBRATE PURGE CALIBRATE PURGE

H2 H 2 IN C0 2 H2 H 2 IN C02
C0 2 C0 2
N2 AIR IN C0 2 N2 AIR IN C02
Fn Fn
ENTER ENTER
Generator Gas Analyzer Generator Gas Analyzer
TURBINE END
LINE
TURBINE
END
LOW FLOW
TURBINE
END
HIGH FLOW
CONFIRMATION
TURBINE END
CONFIRMATION
CONFIRMATION
COLLECTOR END
COLLECTOR
END
HIGH FLOW
COLLECTOR
END
LOW FLOW
COLLECTOR END
LINE
SIDE VIEW
OFF OFF OFF OFF OFF
CALIBRATION GASES
CARBON
NITROGEN HYDROGEN PURGE CASE
DIOXIDE
FAN
DIFFERENTIAL OFF OFF OFF OFF OFF
PRESSURE
GAGE
TURBINE END CASE COLLECTOR END

MOISTURE MOISTURE MOISTURE
INDICATOR INDICATOR INDICATOR
TURBINE END CASE COLLECTOR END

FAN PURIFIER PURIFIER PURIFIER
DIFFERENTIAL
TRANSMITTER
TURBINE END-CASE/CAL/PURGE COLLECTOR END-CASE/CAL/PURGE CASE - CAL / PURGE
HA0156P01 Rev D Page 25

Figure 4 - DHCP Wiring Diagram
HD0156P01 Rev D Page 29

Figure 4a - DHCP Wiring Diagram

Figure 5 - DHCP Piping Schematic

H2
IN
AIR
RESET
GAS PURITY
ALARM
WARNING
CALIBRATE PURGE
H2 H 2 IN C0 2
C0 2
N2 AIR IN C0 2
Fn
ENTER
Generator Gas Analyzer

Figure 8 - DHCP Display Descriptions
Figure 8A - Display Indicators
Indicator Status Ref. 1
AC Power Lit when the display is powered and functioning properly
Normal Lit when the GGA is measuring the concentration of

hydrogen in air
Alarm Lit when the GGA is measuring hydrogen in air and the 1
concentration is below the warning level
Warning Lit when the GGA is in measuring hydrogen in air and the 2
concentration is below the warning level
Trouble Lit when the GGA detects an abnormal condition 3, 4, 5
Calibrate H 2 Lit when the GGA is calibrating against a 100% hydrogen

standard
Calibrate CO2 Lit when the GGA is calibrating against a 100% carbon
dioxide standard
Calibrate N 2 Lit when the GGA is calibrating against a 100% nitrogen
standard
Purge H 2 in Lit when the GGA is measuring the concentration of
CO 2 hydrogen in carbon dioxide
Purge Air in CO2 Lit when the GGA is measuring the concentration of nitrogen
in carbon dioxide
Gas Purity Three-digit gas purity indicator (0 to 99.9%)
LCD Display Displays the current menu selection when the menu is
active
Figure 8B - Display Keys
Key Function
Reset Clear the Alarm and Warning conditions in Normal mode
Fn Activate the menu
Enter Select a menu item
UP Arrow Used with some menu options to increase the value of a

constant
DOWN Arrow Used with some menu options to decrease the value of a
constant
37 HA0156P01 Rev. D
Figure 9 - DHCP Status
Condition Typical Cause Indicators Affected
1 Alarm The GGA is measuring hydrogen in air and the Alarm LED + Alarm
concentration is below the alarm level Relay
2 Warning The GGA is measuring hydrogen in air and the Warning LED +
concentration is below the warning level Warning Relay
3 Tcell ERROR The sensor cell is not at a temperature of 55 ±0.5 Trouble LED +
degrees centigrade Trouble Relay
4 Power Supply One or more power supplies are not within tolerance Trouble LED +
Problem2 Trouble Relay
5 Lower Error3 The GGA is detecting a communication error while Trouble LED +
trying to talk to the I/O board or the display. One or Trouble Relay
more relays are defective.
2
Run diagnostics to identify power supply problems.
3
Run diagnostics to identify which loop error is present.
HA0156P01 Rev. D 38
Figure 10 - DHCP Customer Contacts
Contact Status Ref. 4
Alarm Energized when the GGA is measuring hydrogen in air and 1

General Purpose the concentration is below the alarm level
Warning Energized when the GGA is measuring hydrogen in air and 2
General Purpose the concentration is below the warning level
Trouble De-energized when the GGA detects an abnormal 3, 4, 5

General Purpose condition
4
See Figure 9
39 HA0156P01 Rev. D
TURBINE END CONFIRMATION CONFIRMATION COLLECTOR END
TURBINE TURBINE CONFIRMATION COLLECTOR COLLECTOR
LINE TURBINE END COLLECTOR END LINE
END END END END
LOW FLOW HIGH FLOW HIGH FLOW LOW FLOW
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292 HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292
HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292 HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292
HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292 HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292
HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292 HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292
HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292
HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292
HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292
HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292
HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292
HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292
HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

END END END END
OFF OFF OFF OFF OFF

HO-2972 HO-2971 HO-2973 HO-2974
HV-2972 HV-2987 HV-2974
HV-2971 HV-2973
CALIBRATION GASES
CARBON
DIOXIDE
FAN
PRESSURE
GAGE
PDI-292
HV-2985 HV-2986 HV-2984 HV-2983 HV-2978

Item Description Tag Supplier Manufacturer Manufacturer Description
Number Drawing No. Number
Flowmeter FM1 FI-2973 HA0040P02 Brooks Instruments1355FA30CNA1A 540 to 5400 cc/min H2 flowmeter
Indicator/Metering Valve FM2 FI-2971 HA0040P01 Brooks Instruments1355FFG4CNE1A 90 to 900 cc/min H2 flowmeter/metering valve
Indicator/Metering Valve FM3 FI-2972 HA0040P01 Brooks Instruments1355FFG4CNE1A 90 to 900 cc/min H2 flowmeter/metering valve
HA0156P01 Rev. D
Isolation Valve IV1 HV-2971 HA0011P01 Parker 4F-B6LJ-V-SSP 1/4" female isolation ball valve, SS
Isolation Valve IV2 HV-2971A HA0011P01 Parker 4F-B6LJ-V-SSP 1/4" female isolation ball valve, SS
Figure 26 - Parts List
Isolation Valve IV14 HV-2979 HA0011P01 Parker 4F-B6LJ-V-SSP 1/4” female isolation ball valve, SS
Isolation Valve IV15 HV-2980 HA0011P01 Parker 4F-B6LJ-V-SSP 1/4” female isolation ball valve, SS
48
Analyzer Cell #1 QT-290A HC0021G01 Environment One HC0021G01 Analyzer Cell Assembly
Analyzer Cell #2 QT-290B HC0021G01 Environment One HC0021G01 Analyzer Cell Assembly
Metering Valve MV1 HO-2971 HA0010P01 Parker 4M-V4AN-V-SS 1/4" male-NPT ports metering valve, SS
Solenoid Valve SV1 FY-2971 HA0014P01 Automatic Switch EFHTL-8262G7 12060 2 way, NC, 120V, 60 Hz solenoid valve
Solenoid Valve SV2 FY-2973 HA0014P01 Automatic Switch EFHTL-8262G7 12060 2 way, NC, 120V, 60 Hz solenoid valve
Solenoid Valve SV3 FY-2972 HA0016P01 Automatic Switch EFHTL-8320G200 12060 3 way, 120V, 60Hz solenoid valve
Differential Trans. FT1 PDT-292 HA0058P08 Yokogawa 0 to 30" H2O, 9.5" normal differential transmitter
Differential Gage FG1 PDI-292 HA0041P01 Midwest 130-SC-10-00 0 to 30" H2, dual scale differential pressure gage
Moisture Indicator MI1 MI-2971 HA0013P01 Matheson 465 1/4" NPT, male/female moisture indicator
Item Description Tag Supplier Manufacturer Manufacturer Description
Number Drawing No. Number
Replacement Plug HA0013P02 Matheson PLU-0070-XX Replacement indicator plug

Turbine End Purifier FU1 HA0139P01 Matheson 460 1/4" female NPTfilter/purifier
Case Purifier FU2 HA0139P01 Matheson 460 1/4" female NPT filter/puifier
Collector End Purifier FU3 HA0139P01 Matheson 460 1/4" female NPT filter/puifier
Cartridge HA0139P02 Matheson 462 Replacement cartridge
Heater HA-17P1-1 HA0017P01 Chromalox AEPS-024-220-917 120V, 220 watt explosion proof heater
Heater HA-17P1-2 HA0017P02 Chromalox AEPS-024-220-917 220V, 220 watt explosion proof heater
I/O PC Board HD0043G01 Environment One HD0043G01 input/output printed circuit board
Controller Board HD0039G01 Environment One HD0039G01 analyzer processor printed circuit board
Display Panel HB0026G01 Environment One HB0026G01 analyzer display panel
Display Board Assembly HD0138G03 Environment One HD0138G03 analyzer display board
Power Supply HA0027P01 Tri-Mag Inc. UV420-7 12 VDC power supply
Power Supply GA0109P03 Polytronics P33 1098 15 VDC power supply
IS Barrier, Single HA-45P1-1 HA0045P01 Crouse Hinds SB19140M1250 single channel, isolation barrier
IS Barrier, Dual HA-45P2-1 HA0045P02 Crouse Hinds SB59240M0766 dual channel, isolation barrier
49
Flame Arrestor Housing HB-18P1-1 HB0018P01 Environment One HB0018P01 flame Arrestor housing
Flame Arrestor Housing HB-18P1-2 HB0018P02 Environment One HB0018P01 flame Arrestor housing
Flame Arrestor Filters HA-65P1 HA0065P01 Leeds & Northrup 85104 flame Arrestor filters
Thermal Protector HA-46P1 HA0046P01 Canadian Therm. E21-65-2-5 65 c thermostat
220 VAC Transformer HA-106P1 HA0106P01 Signal M4L-2-3 220 VAC Transformer
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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

Dual Hydrogen Control Panel (DHCP) : Installation and Operation Manual

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Dual Hydrogen Control Panel (DHCP) : Installation and Operation Manual

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DETECTION SYSTEMS

Dual Hydrogen Control Panel (DHCP)

Installation and Operation Manual

System Description ......................................................................................................................... 8

System Operation ......................................................................................................................... 13

Component Replacement Instructions .......................................................................................... 20

THIS EQUIPMENT OPERATES AT VOLTAGE LEVELS THAT CAN BE HAZARDOUS TO

THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS

SHOULD FURTHER INFORMATION BE DESIRED, OR SHOULD PARTICULAR PROB-

IT IS THE RESPONSIBILITY OF SITE MANAGEMENT TO ASSURE THAT ONLY

Dual Hydrogen Control Panel (DHCP) System

THE SYSTEM ELECTRONICS ENCLOSURE AND CUSTOMER INTERFACE

ALL ELECTRICAL CONNECTIONS BETWEEN THE SYSTEM ELECTRONICS,

ALL WIRING MUST BE IN ACCORDANCE WITH LOCAL CODE AND/OR CENELEC

ALL GAS CONNECTIONS TO THE PANEL MUST BE LEAK CHECKED PRIOR TO

CHECK FOR LEAKS AT ALL TUBING AND MECHANICAL CONNECTIONS. IF LEAKS

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

Maximum Pressure 100 psi

Ambient Location Class 1, Division 1, Group B

Gas Analyzer Switchable — Triple Range

Accuracy +/- 1% of full scale @ 80-100% H 2 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

Data Retention Lithium battery-supported RAM

Indicators AC power, Trouble, Normal (H2 in Air),

Weight 475 lbs (standard)

Dimensions 17” d x 64 3/4” h x 36” w (standard)

The major components of the DHCP include:

• 2 completely independent, generator gas analyzers (GGA)

• 2 hydrogen gas flow indicators with metering valves

• 1 total hydrogen gas flow indicator

• 1 fan differential pressure transmitter and gage

• 3 hydrogen gas purifiers

• Numerous isolation valves

Gas Analyzers (Sensor Cells QT-290A, QT-290B, Controller PCB

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

2. Following power-up and/or system reset, the GGA is continuously supervised by an

See Analyzer Failure for more information.

Sensor Cell Assembly

Flow Indicators with Metering Valves (FI-2971, FI-2972)

Total Gas Flowmeter (FI-2973)

Differential Pressure Transmitter (PDT-292)

Moisture Indicators (MI-2971, MI-2972, MI-2973)

Metering Valves (HO-2971, HO-2972, HO-2973, HO-2974)

• GGA ANALYZER READY

Cell Output Voltages

Every Six Months

2. Calibrate Generator Gas Analyzers, as necessary.

When the Generator is Down

Removing a Gas Analyzer Sensor

1. Disconnect AC input power.

2. Manually close isolation valves HV-2979, HV-2980, HV-2982 and HV-2981.

3. Remove the cover of the main junction box.

7. Remove mounting hardware (4 slotted screws).

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

Removing a Processor Circuit Board

1. Disconnect AC input power.

2. Close isolation valves HV-2985, HV-2986, HV-2983 and HV-2973A.

3. Remove the main junction box cover.

5. Install the new processor board in reverse order.

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

2. Close Isolation valves HV-2985, HV-2986, HV-2983 and HV-2973A.

3. Remove the main junction box cover.

7. Disconnect power supply connections to the Input/Output board.

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

Removing Solenoid Valves Coils

4. Cut and strip the wires.

5. Install the new solenoid valve.

6. Splice the wires together using a butt splice.

7. Replace the (small, adjacent) junction box cover.

8. Restore AC power and manually reopen the isolation valves.

Removing Moisture Indicators

To remove moisture indicators:

1. Disconnect AC input power.

2. Manually close all isolation valves.