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EL3000

CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C

… 5 Electrical connections

… Model EL3040

Figure 40: Cable glands model EL3040

Type

Application (recommended)

Permissible cable diameter

M20

Power supply

5 to 13 mm

M25

Modbus / Profibus

8 to 17 mm (insert 5 × 4 mm)

M25

Network

8 to 17 mm

M25

3 × analog outputs

8 to 17 mm (insert 3 × 7 mm)

M32

Digital inputs/outputs

12 to 21 mm

M32

Digital inputs/outputs

12 to 21 mm

Summary of Contents for EasyLine EL3000

Page 1: ...Automatic calibration and the use of superior ABB calibration cell technology in the photometer avoids the use of expensive test gas cylinders in most applications Zero point calibration with ambient...

Page 2: ...combustion gas line 85 Fidas24 Connecting the sample gas line to the heated sample gas connection 86 Fidas24 Connecting the sample gas line to the unheated sample gas connection 88 5 Electrical connec...

Page 3: ...t be observed These may not be removed and must be fully legible at all times The operating company must strictly observe the applicable national regulations relating to the installation function test...

Page 4: ...that can be ignited by adding air Operation in hazardous areas DANGER Explosion hazard Explosion hazard when measuring flammable gases in hazardous areas The gas analyzer in the explosion proof desig...

Page 5: ...t and it left the factory in perfect condition To maintain this condition and to assure safe operation read and follow the safety instructions in this operating instruction Failure to do so can put pe...

Page 6: ...as mixture cannot escape to the outside Conditions to be complied with by the end user The end user must comply with the following prerequisites and conditions to ensure safe operation of the gas anal...

Page 7: ...be at least 4 mm If the gas analyzer is installed in a closed cabinet adequate ventilation of the cabinet must be provided at least 1 change of air per hour The distance to adjacent built in component...

Page 8: ...tool EasyLine Configuration Tool Password protection on page 111 This limits access to both the ECT software tool itself and to the calibration and configuration functions of the device Manufacturer...

Page 9: ...devices that may be opened as part of normal operation such as registration devices or for which it is expressly noted in the type examination certificate Maintenance work on the device where opening...

Page 10: ...or Caldos27 or oxygen sensor The gas analyzer may be used for measurement of non flammable gases and vapors The gas analyzer is marked in accordance with the European directive 2014 34 EU as II 3G Ex...

Page 11: ...designed and operated in such a way that mechanical damage to the viewing glass with an energy greater than 2 J can be excluded If the viewing glass becomes nevertheless damaged to the point that the...

Page 12: ...n configuration and maintenance of the gas analyzer or about the Modbus and PROFIBUS interface Analyzer data sheet The design of the gas analyzer that has been supplied is documented in detail in the...

Page 13: ...stranded or solid conductors is 1 mm2 17 AWG The stranded conductor may be tinned on the tip or twisted for simplified connection When using wire end ferrules the total section must not exceed 1 mm2...

Page 14: ...on from adverse ambient conditions Protect the gas analyzer from the following influences Cold Exposure to heat from e g the sun furnaces boilers Temperature variations Strong air currents Accumulatio...

Page 15: ...device The power supply built into the system housing is used to supply 24 V DC to the analyzer module and the associated electronics Input voltage 100 to 240 V AC 15 10 50 to 60 Hz 3 Hz Power Maximum...

Page 16: ...asurement in corrosive gases Associated gases such as chlorine Cl2 or hydrogen chlorides such as wet HCl as well as gases or aerosols containing chlorine must be cooled or pre absorbed Flammable gases...

Page 17: ...lls or span gas Uras26 Magnos27 manual calibration Zero point gas for Uras26 or Magnos27 or IR sample component free test gas with O2 concentration in an existing measuring range or ambient air Span g...

Page 18: ...at standard flow rate of 60 l h Permissible absolute pressure range 800 to 1250 hPa Operation under lower absolute pressure e g at altitudes above 2000 m on request Gauge pressure in the sample cell m...

Page 19: ...ibration cells automatic calibration i e Magnos206 Magnos28 with single point calibration N2 or oxygen and UV sample component free gas Either calibration cells and test gas for oxygen detector or tes...

Page 20: ...ssure sensor must be connected to the sample gas path The pressure compensation must be calculated externally The analyzer module is function tested for 5000 hPa internal pressure without damage Flow...

Page 21: ...alibration 100 Vol O2 or test gas with O2concentration in the measuring range Test gas with O2 concentration near the end point of the measuring range Magnos206 with single point calibration Test gas...

Page 22: ...ust be calculated externally The analyzer module is function tested for 5000 hPa internal pressure without damage Flow rate 30 to 90 l h Abrupt changes in the sample gas flow rate should be avoided wh...

Page 23: ...ith O2 concentration in an existing measuring range or ambient air Magnos28 with substitute gas calibration Oxygen free process gas or substitute gas O2 in N2 Substitute gas for example dried air Magn...

Page 24: ...pressure drop 5 hPa at standard flow rate of 60 l h Permissible absolute pressure range 800 to 1250 hPa Operation under lower absolute pressure e g at altitudes above 2000 m on request Gauge pressure...

Page 25: ...nalyzer module is suitable for measuring flammable gases in a non explosive environment The concentration of flammable gases in the sample gas must not exceed 100 ppm Associated gas effect Inert gases...

Page 26: ...ced by controlled valves suitable for the oxygen trace measurement as required A Reference air B Stainless steel pipe C FPM hose 1 Sampling point with primary shut off valve 2 Multi way ball valve 3 3...

Page 27: ...ir Bypass The gas analyzer is connected to a gas flow in the bypass at a constant flow rate approx 30 l h The needle valve is installed upstream of the branch to the gas analyzer and the bypass flowme...

Page 28: ...sure range 800 to 1250 hPa Operation under lower absolute pressure e g at altitudes above 2000 m on request Gauge pressure in the measuring chamber max 100 hPa Flow rate Typically 10 to 90 l h minimum...

Page 29: ...gnos28 automatic calibration Same as manual calibration with the following limitation Zero point and single point calibrations are performed for all sample components simultaneously since for thid pur...

Page 30: ...atmospheric pressure Flammable gases The gas analyzer may be used for the measurement of flammable gases provided that the flammable portion does not up scale 15 Vol CH4 or does not up scale C1 equiva...

Page 31: ...mum of 10 l h H2 or 25 l h H2 He mixture For this purpose the operator has to provide suited measures outside the gas analyzer ABB recommends using a bulkhead fitting with an integrated flow restricto...

Page 32: ...ctions and electrical connections Fidas24 model EL3020 on page 80 and Gas connections and electrical connections Fidas24 model EL3040 on page 81 Sample gas input and output conditions Analyzers Analyz...

Page 33: ...so that the flow effect is minimized If the pressure sensor is not connected to the sample gas output the pressure sensor and sample gas output must be at the same level of pressure Pressure sensor w...

Page 34: ...ow rate of 20 l h at the device inlet the purge gas flow rate at the device outlet is approx 5 to 10 l h Housing purge during operation when measuring flammable gases The housing must be purged using...

Page 35: ...EL3000 CONTINUOUS GAS ANALYZERS CI EL3000 EN REV C 35 Dimensions 19 housing model EL3020 Dimensions in mm in Figure 2 19 housing model EL3020...

Page 36: ...ing model EL3020 with Magnos27 Dimensions in mm in Figure 3 19 housing model EL3020 with Magnos27 Note Only the front view of the housing with its height differing from the standard dimension is depic...

Page 37: ...EL3000 CONTINUOUS GAS ANALYZERS CI EL3000 EN REV C 37 Wall mount housing model EL3040 Dimensions in mm in A Consider free space to swivel the door Figure 4 Wall mount housing model EL3040...

Page 38: ...rocesses since no automatic purging with an inert gas is possible Note The version for the measurement of flammable gases and the explosion proof design in degree of protection II 3G see Use in potent...

Page 39: ...eed path may not up scale the maximum value of 100 hPa in standard operation and a maximum value of 500 hPa in the event of a fault The gas analyzer with Magnos28 can be used up to an absolute pressur...

Page 40: ...as analyzer Note Keep the shipping carton and cushioning material for future transportation Name plate Contents of the name plate The name plate contains the following information Production Number P...

Page 41: ...necting the gas lines Gaskets Do not use sealing compound to seal the fittings Some components of the sealing paste could falsify the measurement results Requisite Material Screw in spud with hose noz...

Page 42: ...s26 see page 43 see page 45 Uras26 with Magnos206 see page 46 see page 48 Uras26 with Magnos28 see page 50 see page 52 Uras26 with Caldos27 see page 54 see page 56 Limas23 see page 58 see page 59 Lima...

Page 43: ...sensor connected to the outside by hose option 5 Sample gas inlet gas path 2 For second sample gas or flowing reference gas sample cell 1 depending on the design of the analyzer 6 Sample gas outlet ga...

Page 44: ...sensor Screwed connections with hose nozzles stainless steel 1 4305 for hoses with 4 mm inside diameter included in scope of supply 11 Sample gas inlet NPT female thread stainless steel 1 4305 for th...

Page 45: ...cell and for two measuring cells with separate gas paths 5 Purge gas inlet housing 6 Purge gas outlet housing 7 Sample gas inlet gas path 2 8 Sample gas outlet gas path 2 Sample gas outlet gas path 1...

Page 46: ...feed option with flow sensor only without solenoid valve Pressure sensor For Pressure sensor connected to the outside by hose option 5 Sample gas inlet gas path 2 For second sample gas or flowing ref...

Page 47: ...s outlet For two sample cells in series Note The oxygen sensor the integrated gas feed option and the version with separated gas paths are not possible Magnos206 Gas Connections Pos Connection Supplem...

Page 48: ...gned 3 Sample gas inlet gas path 1 4 Sample gas outlet gas path 1 For a measuring cell and for two measuring cells with separate gas paths 5 Purge gas inlet housing 6 Purge gas outlet housing 7 Sample...

Page 49: ...traight screw in socket PP with hose nozzles for hoses with inside diameter 4 mm included in scope of delivery Connection of piping screw in fittings not included in scope of delivery 2 Sample gas out...

Page 50: ...ed option with flow sensor only without solenoid valve Pressure sensor For Pressure sensor connected to the outside by hose option 5 Sample gas inlet gas path 2 For second sample gas or flowing refere...

Page 51: ...tlet For two sample cells in series Note The oxygen sensor the integrated gas feed option and the version with separated gas paths are not possible Magnos28 Gas Connections Pos Connection Supplementar...

Page 52: ...n scope of delivery 2 Not assigned 3 Sample gas inlet gas path 1 4 Sample gas outlet gas path 1 For a measuring cell and for two measuring cells with separate gas paths 5 Purge gas inlet housing 6 Pur...

Page 53: ...se lines straight screw in socket PP with hose nozzles for hoses with inside diameter 4 mm included in scope of delivery Connection of piping screw in fittings not included in scope of delivery 2 Samp...

Page 54: ...feed option with flow sensor only without solenoid valve Pressure sensor For Pressure sensor connected to the outside by hose option 5 Sample gas inlet gas path 2 For second sample gas or flowing ref...

Page 55: ...as outlet For two sample cells in series Note The oxygen sensor the integrated gas feed option and the version with separated gas paths are not possible Caldos27 gas connections Pos Connection Supplem...

Page 56: ...gned 3 Sample gas inlet gas path 1 4 Sample gas outlet gas path 1 For a measuring cell and for two measuring cells with separate gas paths 5 Purge gas inlet housing 6 Purge gas outlet housing 7 Sample...

Page 57: ...es straight screw in socket PP with hose nozzles for hoses with inside diameter 4 mm included in scope of delivery Connection of piping screw in fittings not included in scope of delivery 2 Sample gas...

Page 58: ...4 mm inside diameter included in scope of supply 2 Sample gas outlet 3 Sample gas outlet With optional solenoid valve factory connected to sample gas input Pos 1 6 Pressure sensor For Pressure sensor...

Page 59: ...4 mm included in scope of delivery Connection of piping screw in fittings not included in scope of delivery 14 Sample gas outlet 11 Pressure sensor For Pressure sensor connected to the outside by hos...

Page 60: ...h optional solenoid valve Screwed fittings with hose nozzles PVDF for hoses with 4 mm inside diameter included in scope of supply 22 Test gas inlet Note The oxygen sensor is not possible in combinatio...

Page 61: ...ozzles for hoses with inside diameter 4 mm included in scope of delivery Connection of piping screw in fittings not included in scope of delivery 14 Sample gas outlet 11 Pressure sensor For Pressure s...

Page 62: ...1 4305 Connection of hose lines straight screw in socket PP with hose nozzles for hoses with inside diameter 4 mm included in scope of delivery Connection of piping screw in fittings not included in...

Page 63: ...rewed fittings with hose nozzles PVDF for hoses with 4 mm inside diameter included in scope of supply 22 Test gas inlet Note The oxygen sensor is not possible in combination with Magnos28 The pressure...

Page 64: ...crew in socket PP with hose nozzles for hoses with inside diameter 4 mm included in scope of delivery Connection of piping screw in fittings not included in scope of delivery 14 Sample gas outlet 11 P...

Page 65: ...tion of hose lines straight screw in socket PP with hose nozzles for hoses with inside diameter 4 mm included in scope of delivery Connection of piping screw in fittings not included in scope of deliv...

Page 66: ...less steel 1 4305 for hoses with 4 mm inside diameter included in scope of supply 4 Sample gas inlet For Integrated gas feed option with flow sensor only without solenoid valve 6 Pressure sensor 21 Sa...

Page 67: ...n fittings not included in scope of delivery 2 Sample gas outlet 3 Not assigned 4 Not assigned 11 Purge gas inlet housing 12 Purge gas outlet housing 13 Pressure sensor 14 Not assigned Note The pressu...

Page 68: ...less steel 1 4305 for hoses with 4 mm inside diameter included in scope of supply 4 Sample gas inlet For Integrated gas feed option with flow sensor only without solenoid valve 6 Pressure sensor 21 Sa...

Page 69: ...m inside diameter included in scope of supply 6 Pressure sensor option For analyzer module 1 For flammable sample gases Common sensor for analyzer module 1 and analyzer module 2 Caution Do not connect...

Page 70: ...flammable sample gases common sensor for Magnos28 and Caldos27 Caution Do not connect the pressure sensor in the sample gas path Screwed connections with hose nozzles stainless steel 1 4305 for hoses...

Page 71: ...Magnos28 Factory connected to Magnos28 sample gas inlet 1 Screwed connections with hose nozzles stainless steel 1 4305 for hoses with 4 mm inside diameter included in scope of supply 2 Sample gas inle...

Page 72: ...pe of delivery Connection of piping screw in fittings not included in scope of delivery 2 Sample gas outlet 11 Purge gas inlet housing 12 Purge gas outlet housing 13 Pressure sensor 14 Not assigned No...

Page 73: ...t assigned 3 Sample gas inlet 4 Sample gas outlet 5 Purge gas inlet analyzer 6 Purge gas outlet analyzer Note The pressure sensor see Pressure sensor on page 33 is installed as an option For a precise...

Page 74: ...zer Pressure sensor For the pressure sensor connected to the outside by hose option not in combination with Uras26 with two cells and separate gas paths Uras26 Gas connections Pos Connection Supplemen...

Page 75: ...The measuring chamber is connected to the sample gas inlet connection via a stainless steel tube inlet side and to the sample gas outlet connection via a FPM hose outlet side Pos Connection Supplemen...

Page 76: ...s The measuring chamber is connected to the sample gas inlet connection via a stainless steel tube inlet side and to the sample gas outlet connection via a FPM hose outlet side Pos Connection Suppleme...

Page 77: ...fittings not included in scope of delivery 2 Sample gas outlet 3 Sample gas outlet For Integrated gas feed option factory connected to 1 sample gas inlet Screwed connections with hose nozzles stainle...

Page 78: ...ainless steel 1 4305 for hoses with 4 mm inside diameter included in scope of supply 6 Pressure sensor For analyzer module 1 for flammable sample gases Common sensor for analyzer module 1 and analyzer...

Page 79: ...n 1 Sample gas inlet NPT female thread stainless steel 1 4305 Connection of hose lines straight screw in socket PP with hose nozzles for hoses with inside diameter 4 mm included in scope of delivery C...

Page 80: ...ction cable included in scope of supply 31 Power supply output Electrical connection to the heated sample gas connection Permanently connected 32 Test gas outlet NPT female thread for threaded connect...

Page 81: ...to the heated sample gas connection Permanently connected 32 Test gas outlet NPT female thread for threaded connections not included in scope of supply 33 Zero point gas inlet 34 End point gas inlet...

Page 82: ...ons for the Fidas24 gas analyzer If the gas analyzer is installed in a closed cabinet adequate ventilation of the cabinet must be provided at least 1 change of air per hour Special conditions for the...

Page 83: ...to the sample gas inlet connect the sample gas line to the long hose piece with the hose nozzle Installing the flowmeter Install a flowmeter or flow monitor with needle valve before the sample gas in...

Page 84: ...articular hold the male fittings gas connections in place when connecting the gas lines When laying and connecting the gas lines adhere to the installation instructions provided by the manufacturers o...

Page 85: ...e Clean combustion gas line 1 Pump a cleaning agent alkaline cleaner stainless steel pickling solution through the stainless steel pipe 2 Rinse the pipe thoroughly with distilled water 3 Purge the pip...

Page 86: ...lets must be sealed using the screw plugs installed at the factory When the sample gas is under gauge pressure a sample gas inlet must be open and connected to an exhaust gas line so that there is no...

Page 87: ...O ring 12 42 1 78 Connection of an additional sample gas line tube with outside diameter 6 mm either with 5 Screw in connector G Alternatively with 6 Socket 7 Wedge ring 8 Clamping ring Closure 9 Scr...

Page 88: ...f the sample gas is under positive pressure a T piece must be connected between the sample gas line and the sample gas inlet The free connection of the T piece must be connected to an exhaust gas disc...

Page 89: ...ss steel tubing with a 4 6 mm inside outer diameter Connection either with 2 O ring 6 02 2 62 3 Socket 4 O ring 12 42 1 78 Alternatively with 5 Screw in connector G Alternatively with 6 Socket 7 Wedge...

Page 90: ...elevant national safety regulations for installing and operating electric systems 1 Power supply connection see Connecting the power supply on page 97 3 pin grounded instrument connector in accordance...

Page 91: ...age 94 3 Analog output module see Analog output modules on page 93 4 Modbus module see Modbus Module on page 96 5 Profibus module see PROFIBUS Module on page 96 6 Ethernet 10 100BASE T interface for c...

Page 92: ...Cable glands model EL3040 Type Application recommended Permissible cable diameter M20 Power supply 5 to 13 mm M25 Modbus Profibus 8 to 17 mm insert 5 4 mm M25 Network 8 to 17 mm M25 3 analog outputs 8...

Page 93: ...o ground max gain relative to protective ground potential 50 V max load 750 Ohm Resolution 16 bit The output signal cannot be lower than 0 mA Version 4 pole or 8 pole plug in terminal strip with count...

Page 94: ...r driver Digital outputs DO1 to DO4 Potential free changeover contacts maximum contact load capacity 30 V 1 A Relays must at all times be operated within the specified data range Inductive or capaciti...

Page 95: ...ump on off Limit 1 DO2 Limit 2 DO3 Limit 3 DO1 Limit 4 DO2 Limit 5 DO3 Limit 6 DO4 Limit 7 Limit 8 Limit 9 Limit 10 Measuring range switch over Measuring range feedback Measuring component switch over...

Page 96: ...terface Version 9 pin sub D female connector Pin Signal Description 1 not assigned 2 M24 24 V output voltage ground 3 RxD TxD P Receive transmit data plus B line 4 not assigned 5 DGND Data transmissio...

Page 97: ...opposite connectors to the plug in terminal strips on the I O modules Connecting the power supply NOTICE Damage to the gas analyzer Damage to the gas analyzer due to condensing sample gas during comm...

Page 98: ...s isolator or a switched socket in the power supply line close to the gas analyzer so that all the poles of the gas analyzer can be disconnected from the power supply if necessary Label the supply cir...

Page 99: ...ged If the device no longer operates After prolonged storage under adverse conditions After severe transport stresses Installation Check 1 Is the gas analyzer securely fastened see Gas Analyzer Instal...

Page 100: ...housing purge is always active when pressurized air is on that is also when the instrument air valve is closed Gas analyzer start up Note For the analyzers ZO23 and Fidas24 the instructions specified...

Page 101: ...ready for measurement connect sample gas Note For information on the test gases refer to ZO23 on page 25 Fidas24 Commissioning the gas analyzer Power up the power supply heat up phase connect operatin...

Page 102: ...the respective solenoid valve in the analyzer automatically connects the combustion gas The combustion gas regulation attempts to adjust the pressure to the set point Adjust output variables of the i...

Page 103: ...es and sampling probes may continue to emit hydrocarbons for an extended period after initial operation As a result it can take much longer for the measured value drift to reach an acceptable value Re...

Page 104: ...de there is a Function check status signal see Diagnosis error messages in the operating instruction and the status message no 411 Fidas24 Standby mode see Diagnosis error messages in the operating in...

Page 105: ...to 5 for all sample gas paths in the gas analyzer Dichtigkeit d Check the integrity of combustion gas path Combustion gas line The seal integrity of the combustion gas feed line must be regularly chec...

Page 106: ...nalyzer combustion gas inlet valve is leaky DANGER Explosion hazard Explosion hazard if there is a leak in the combustion gas inlet valve If a leak is detected at the combustion gas inlet valve Discon...

Page 107: ...d before you power up the power supply That way any explosive gas air mixture which might be present should be removed Purge gas nitrogen Purge gas volume 5 times the volume of the gas paths Purge gas...

Page 108: ...d measures must be taken The Overall Status or the Failure status of the gas analyzer must be monitored If the status appears the cause must be verified in the gas analyzer on site if the gas analyzer...

Page 109: ...ons OI Note All representations of the LCD indicator in these Commissioning Instruction are examples The indications on the IED will usually differ from this 1 LCD indicator 2 LCD display 3 Operating...

Page 110: ...tion of the measuring range limits appears on this indicator Decrease or increase the contrast of the LCD display If a status message is active First press the button OK Switch to menu mode see 110 If...

Page 111: ...n to the parameter list Discard changed value and return to the parameter list Password protection Access to the calibration as well as to the menus where the configuration of the device can be change...

Page 112: ...atically switches back to measurement mode see LCD display in measurement mode on page 109 The time out function is disabled as soon as the user changes the value of a parameter or starts a calibratio...

Page 113: ...the gas analyzer requires that the functions needed in normal operating mode are operated and configured directly on the device On the other hand those functions that are seldom needed for example wh...

Page 114: ...to point connection the IP addresses in the gas analyzer and in the computer must be matched Example Gas analyzer 192 168 1 4 Computer 192 168 1 2 Note If the gas analyzer is connected to a network wi...

Page 115: ...n Windows 7 Properties 4 in the network tab double click on Internet Protocol Version 4 TCP IPv4 5 In the General tab you can configure the IP settings see appropriate for the configuration of the gas...

Page 116: ...lyzer configuration data can be stored on the computer The saved configuration file can be processed later and sent to the gas analyzer File Save As menu or icon Release of communication via Modbus TC...

Page 117: ...lly trained personnel only Note For detailed information on the maintenance of the device consult the associated operating instructions OI 9 Decommissioning Decommissioning the gas analyzer In the cas...

Page 118: ...as ports and tightly seal the gas ports 2 If the original packaging is not available wrap the gas analyzer in bubble wrap or corrugated cardboard For overseas shipment always add a desiccant e g silic...

Page 119: ...de abb com www abb de prozessautomatisierung service 10Recycling and disposal Note Products that are marked with the adjacent symbol may not be disposed of as unsorted municipal waste domestic waste T...

Page 120: ...ww abb com analytical 12 Additional documents Note All documentation declarations of conformity and certificates are available in ABB s download area www abb com analytical Diagnosis error messages in...

Page 121: ...any Address Contact person Telephone Fax Email Device details Type Serial no Reason for the return description of the defect Was this device used in conjunction with substances which pose a threat or...

Page 122: ...a registered trademark of Merck KGaA Darmstadt Germany Modbus is a registered trademark of Schneider Automation Inc PROFIBUS PROFIBUS PA and PROFIBUS DP are registered trademarks of PROFIBUS PROFINET...

Page 123: ...EL3000 CONTINUOUS GAS ANALYZERS CI EL3000 EN REV C 123 Notes...

Page 124: ...notice With regard to purchase orders the agreed particulars shall prevail ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document We re...

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