ABB EasyLine EL3020 Instructions For Installation Start-Up And Operation Download Page 75

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Installing the Gas Analyzer

Heated sample gas connection

Test gas outlet

Connection of test gas outlet - sample gas connection

Electrical connection to the heated sample gas connection

Heated sample gas connection

Heated sample gas line (example)

Note: One half of the cover of the heated sample gas connection has
been removed in the picture.

Summary of Contents for EasyLine EL3020

Page 1: ...EasyLine Continuous Gas Analyzers Models EL3020 EL3040 Software Version 3 4 Instructions for Installation Start up and Operation 41 24 400 EN Rev 6 ...

Page 2: ......

Page 3: ...Operator s Manual is protected by copyright The translation duplication and distribution in any form even in a revised edition or in extracts in particular as a reprint by photomechanical or electronic repro duction or in the form of storage in data processing systems or data networks are prohibited without the consent of the copyright holder and will be prosecuted under civil and criminal law ...

Page 4: ...nnections for Uras26 Model EL3040 44 Gas Connections for Uras26 with Magnos206 Model EL3020 46 Gas Connections for Uras26 with Magnos206 Model EL3040 48 Gas Connections for Uras26 with Caldos27 Model EL3020 50 Gas Connections for Uras26 with Caldos27 Model EL3040 52 Gas Connections for Limas23 Model EL3020 54 Gas Connections for Limas23 Model EL3040 55 Gas Connections for Limas23 with Magnos206 Mo...

Page 5: ...he Gas Analyzer 100 Display Measuring Mode 100 Operation Menu Mode 102 Menu 104 Notes on the Concept of Operation 105 Communication between the Gas Analyzer and the Computer 107 Gas Analyzer Calibration 111 Automatic Calibration Manual Start 111 Manual Calibration Execution 113 Maintenance 115 Fidas24 Standby Restart 115 Fidas24 Checking Combustion Gas Supply Line for Seal Integrity 116 Fidas24 Ch...

Page 6: ...lied with the gas analyzer CD ROM Software tools and technical documentation The CD ROM Software tools and technical documentation with the following contents is included in the scope of supply of the gas analyzer Software Tools Operator s Manuals Data Sheets Technical Information Certificates CD ROM Spare parts analytical Information on spare parts can be found on the CD ROM Spare parts analytica...

Page 7: ...e heeded during gas analyzer operation in order to avoid risks to the user NOTE identifies specific information on the operation of the gas analyzer as well as on the use of this manual 1 2 3 Identifies reference numbers in figures Display Identifies a display on the screen OK Identifies function keys ...

Page 8: ...ge 9 2 Follow safety precautions see page 10 3 Prepare for the installation provide the requisite material see page 14 4 Unpacking the gas analyzer see page 40 5 Check sample gas path seal integrity see page 119 6 Install the gas analyzer see page 68 7 Connect the gas lines see page 69 8 Connect the electrical leads see page 81 9 Check the installation see page 92 10 Purge the sample gas path see ...

Page 9: ...n hazardous environment The special requirements for the measurement of flammable gases see page 38 must be complied with The oxygen sensor and the modules of the integrated gas feed Option Integrated Gas Feed only in the EL3020 model not with Limas23 ZO23 Fidas24 may not be used for the measurement of flammable gases The explosion proof version of the gas analyzer with degree of protection II 3G ...

Page 10: ... electrical devices Safety precautions for working with gases acids condensates etc National Regulations The regulations standards and guidelines cited in this operator s manual are applicable in the Federal Republic of Germany The applicable national regulations should be followed when the device is used in other countries Device Safety and Safe Operation The device is designed and tested in acco...

Page 11: ...connection points Risks Involved in Working with an Open Device All work on a device that is open and connected to power should only be performed by trained personnel who are familiar with the risks involved When Safe Operation can no Longer be Assured If it is apparent that safe operation is no longer possible the device should be taken out of operation and secured against unauthorized use The po...

Page 12: ...stion gas feed is switched off after several unsuccessful ignition attempts If the flame goes out during operation the combustion gas feed is switched off if the following ignition attempts are unsuccessful The interior of the gas analyzer is not assigned to an explosion protection zone no explosive gas mixture can escape from it to the outside Conditions to be complied with by the end user The en...

Page 13: ...d be installed outside the analyzer house in the vicinity of the combustion gas supply cylinder line If there is no automatic shut off of the combustion gas supply to the gas analyzer in case of an instrument supply failure a visible or audible alarm must be triggered see page 129 When measuring flammable gases it must be made sure that in case of a failure of the instrument air supply or of the a...

Page 14: ...for attaching the electric lines in the mating plugs Micro porous filter see page 69 pre assembled CD ROM Software tools and technical documentation with software tools and technical documentation CD ROM Spare parts analytical with information on spare parts Instructions in brief for Installation Commissioning and Operation Analyzer data sheet Fidas24 Mains lead see page 91 length 5 m with 4 pin s...

Page 15: ...ustion gas supply line see page 29 Shut off valve in the combustion gas supply line see page 29 Sample gas Heated sample gas line recommended TBL 01 or unheated sample gas line PTFE or stainless steel tube with inside outside diameter 4 6 mm The fittings and O rings required for the connection are included in the scope of supply and delivery of the gas analyzer Flowmeter Flow Monitor Flowmeter or ...

Page 16: ...erning the cable cross section for connection of the I O modules The max capacity of terminals for stranded wire and solid wire is 1 mm2 17 AWG The stranded wire can be tinned on the tip or twisted to simplify the assembly When using wire end ferrules the total cross section may not be more than 1 mm2 i e the cross section of the stranded wire may not be more than 0 5 mm2 The PZ 6 5 crimping tool ...

Page 17: ...e safe installation and removal we recommend that the 19 inch housing is supported in a cabinet or rack with slide rails Short gas paths Install the gas analyzer as close as possible to the sampling location Install the gas conditioning and calibration modules as close as possible to the gas analyzer Adequate air circulation Provide for adequate natural air circulation around the gas analyzer Avoi...

Page 18: ...se plate and from behind gas connections The gas analyzer must not be put directly on a table The case apertures must not be closed The distance to adjacent built in components on the side must be at least 3 cm For installations in a closed cabinet the cabinet must have adequate ventilation at least 1 air change per hour The distance to adjacent built in components underneath floor plate and behin...

Page 19: ...125 VA for sample gas Inlet option Connection 4 pin plug connector connecting cable supplied Electrical safety Test to EN 61010 1 2001 Class of protection I Overvoltage category degree of pollution Power supply III 2 Signal inputs and outputs II 2 Safe isolation Galvanic isolation of the power supply from the other circuits by means of reinforced or double insulation Functional extra low voltage P...

Page 20: ...urement of flammable gases in a non hazardous environment The special requirements for the measurement of flammable gases see page 38 must be complied with Corrosive gases The analyzer may not be used for the measurement of corrosive gases Associated gases such as chlorine Cl2 or hydrogen chlorides e g wet HCl as well as gases or aerosols containing chlorine must be cooled or pre absorbed Limas23 ...

Page 21: ...agnos27 Sample Gas Inlet Conditions Temperature 5 50 C Positive pressure 2 100 hPa Flow 20 90 l h Flammable Gases The analyzer may not be used for the measurement of flammable gases Caldos27 Sample Gas Inlet Conditions Temperature 5 50 C Positive pressure 2 100 hPa Flow 10 90 l h min 1 l h Pressure drop 2 hPa at 60 l h N2 Flammable Gases The analyzer is suitable for the measurement of flammable ga...

Page 22: ...ble Gases If the gas analyzer is equipped with an integrated gas feed it may not be used for the measurement of flammable gases Note The integrated gas feed can be installed in model EL3020 as an option It cannot be used in the EL3040 model or in conjunction with the Limas23 ZO23 or Fidas24 analyzer Sample Gas Dew Point The dew point of the sample gas must be at least 5 C lower than the lowest amb...

Page 23: ...is carried out for the Magnos206 Uras26 Magnos27 automatic calibration IR sample component free test gas with O2 concentration in an existing measuring range or ambient air Same moisture content as process gas Calibration cells or span gas Uras26 Magnos27 manual calibration Zero gas for Uras26 respectively Magnos27 or IR sample component free test gas with O2 concentration in an existing measuring...

Page 24: ...ple component free gas Test gas for each sample component respectively for each detector Magnos206 Oxygen free process gas Process gas with known O2 concentration Magnos206 with suppressed measuring range Test gas with O2 concentration near the starting point of the measuring range Test gas with O2 concentration near the end point of the measuring range Magnos206 with single point calibration Test...

Page 25: ...temperature pressure and flow rate should be maintained constant to such a degree that the fluctuation influence on the accuracy of measurement is acceptable see also Chapter Analyzer Module Operating Data Corrosive Gases The presence of corrosive gases and catalyst poisons e g halogens gases containing sulphur and heavy metal dusts causes faster aging and or or destruction of the ZrO2 cell Flamma...

Page 26: ... checking the reference point and end point must be considered Purge gas If a housing purge is selected only in IP54 version purging may only be carried out with air not with nitrogen as the ambient air serves as a reference gas Gas Connections see section ZO23 Gas Connections Installation and sample conditioning ATTENTION The ingress of liquids into the analyzer module can cause serious damage in...

Page 27: ... ball valve 1 7 2 way ball valve 1 8 Air filter 1 9 Gas analyzer 10 Flowmeter without needle valve with alarm contact 11 Purge gas cylinder with N2 1 12 Test gas cylinder with e g 2 ppm of O2 in N2 2 13 Test gas cylinder with 8 ppm O2 in N2 1 14 Pump 1 15 Needle valve 1 1 Option 2 A hard mounted test gas cylinder is normally adequate The annual check of the reference point can also be carried out ...

Page 28: ...ent air 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 flowmeter downstream of the branch to the gas analyzer The gas analyzer takes 8 l h from the gas flow A surplus of approx 20 l h remains If several ZO23 analyzer modules are supplied with gas in parall...

Page 29: ...s Outlet Conditions The outlet pressure must be the same as the atmospheric pressure Flammable gases The gas analyzer may be used for the measurement of flammable gases provided that the flammable portion does not exceed 15 vol CH4 or C1 equivalents Process gases Instrument air Quality as per ISO 8573 1 Class 2 max particle size 1 µm max particle density 1 mg m3 max oil content 0 1 mg m3 dew point...

Page 30: ...by the end user for this purpose ABB recommends the use of a bulkhead fitting with an integrated flow restrictor which must be installed in the combustion gas supply line This bulkhead fitting can be purchased from ABB Combustion gas H2 Part Number 8329303 Combustion gas H2 He mixture Part number 0769359 Shut off valve in the combustion gas supply line A shut off valve must be installed in the com...

Page 31: ...nd point Calibration Quality Sample component or substitute gas component in nitrogen or synthetic air with concentration adjusted to the measuring range Inlet pressure pe 1000 100 hPa Flow 130 to 250 l h NOTE The Notes for Calibration must be considered Gas Connections See the sections Gas and Electrical Connections for Fidas24 Model EL3020 see page 66 and Gas and Electrical Connections for Fidas...

Page 32: ...contained in the analyzer data sheet Limas23 The pressure sensor is installed in the gas analyzer as standard It is internally connected in the outlet of the sample cell see also gas connections for the models EL3020 see page 54 and EL3040 see page 55 Magnos206 The pressure sensor is installed in the gas analyzer as an option It is connected to a connection port via an FPM hose see also gas connec...

Page 33: ...r and sample gas outlet must be connected to each other via a T piece and short lines to ensure a precise pressure correction The lines must be as short as possible or if this is not practicable the line must have a sufficiently wide internal diameter at least 10 mm so that the flow effect is minimized If the pressure sensor is connected to the sample gas feed path the sample gas may not contain a...

Page 34: ... oil content max 1 mg m3 dew point max 3 C NOTE For Uras26 the purging gas must not contain any constituents of the sample components Sample component constituents in the purging gas can falsify the measurement result ATTENTION Leaks may cause the purging gas to escape from the housing When applying nitrogen as purge gas appropriate precautionary measures must be taken against asphyxiation The pur...

Page 35: ...The housing has to be purged with nitrogen Purge gas flow 1 20 l h The purge gas flow must be monitored at the purging gas outlet Housing Purge in the Fidas24 The housing purge is implemented in the Fidas24 gas analyzer in such a way that a part approx 600 700 l h of the instrument air is conducted continuously through the housing as purging air This ensures that a flammable mixture cannot form in...

Page 36: ...3020 Dimensions in mm 19 inch Case Model EL3020 with Magnos27 Dimensions in mm NOTE Only the front view of the housing with its height differing from the standard dimension is depicted in this dimensional drawing Refer to the dimensional drawing above for other views and dimensions of the housing ...

Page 37: ...Preparation for Installation 37 Wall mounting Case Model EL3040 Dimensions in mm ...

Page 38: ...ast 3 cm The connection of the pressure sensor must not be connected to the sample gas feed path The sample gas lines and connections have to be made in stainless steel Prior to using the gas analyzer the corrosion resistance against the present sample gas must be tested Commissioning of the Gas Analyzer The sample gas feed path must be purged see page 93 with inert gas before the gas analyzer is ...

Page 39: ...losive atmospheres Part 15 Equipment protection by type of protection n Special Requirements The cables have to be properly inserted in the screwed cable glands and sealed by screwing the nut firmly in order to comply with degree of case protection IP65 Cable connectors not in use have to be closed with suitable vent plugs in order to ensure degree of case protection IP65 here as well If the insta...

Page 40: ...upply and delivery see page 14 from the shipping box Ensure that the accessories do not get lost 2 Remove the gas analyzer from the shipping box together with the respective protective packaging 3 Remove the protective packaging and place the gas analyzer in a clean location 4 Remove the adhesive packaging residues from the gas analyzer NOTES Keep the shipping box and the protective packaging for ...

Page 41: ...20 see page 58 Model EL3040 see page 59 ZO23 Model EL3020 see page 62 Model EL3040 see page 63 Caldos27 Model EL3020 see page 64 Model EL3040 see page 65 Fidas24 Model EL3020 see page 66 Model EL3040 see page 67 Requisite Material Screwed fittings with nozzles supplied or threaded connections with 1 8 NPT threads and PTFE sealing tape Installing the Gas Connections Screw out the yellow plastic scr...

Page 42: ... gas feed paths for NOx measurement with upstream converter Design Screwed fittings with hose nozzles stainless steel 1 4305 SAE 303 for hoses with 4 mm inner diameter supplied 21 Sample gas inlet 22 Test gas inlet on the solenoid valve with the option Integrated gas feed with solenoid valve pump filter capillary tube and flow sensor Design Screwed fittings with hose nozzles PVDF for hoses with 4 ...

Page 43: ...teel 1 4305 SAE 303 for hose with 4 mm inner diameter supplied 11 Sample gas inlet 12 Sample gas outlet with one sample cell 13 Sample gas outlet with two sample cells in series Design 1 8 NPT female thread stainless steel 1 4305 SAE 303 for threaded connections not supplied Note The oxygen sensor the option Integrated gas feed and the version with separate gas feed paths are not possible ...

Page 44: ...executed as flexible tubes or stainless steel pipes 1 not assigned 2 not assigned 3 Sample gas inlet 4 Sample gas outlet with one sample cell 5 Purge gas inlet for case 6 Purge gas outlet for case 7 not assigned 8 Sample gas outlet with two sample cells in series 9 Pressure sensor if internal gas lines are executed as stainless steel pipes 10 not assigned ...

Page 45: ...inless steel 1 4305 SAE 303 Connection of flexible tubes straight screwed fittings PP with nozzles for flexible tubes with inside diameter 4 mm supplied Connection of pipelines Threaded connections not supplied Notes If the internal gas lines are flexible tubes the pressure sensor standard and the oxygen sensor option are internally connected as follows in the outlet of sample cell 1 for a sample ...

Page 46: ...separate gas feed paths for NOx measurement with upstream converter Design Screwed fittings with hose nozzles stainless steel 1 4305 SAE 303 for hoses with 4 mm inner diameter supplied 21 Sample gas inlet 22 Test gas inlet on the solenoid valve with the option Integrated gas feed with solenoid valve pump filter capillary tube and flow sensor Design Screwed fittings with hose nozzles PVDF for hoses...

Page 47: ...ss steel 1 4305 SAE 303 for threaded connections not supplied Note The oxygen sensor the option Integrated gas feed and the version with separate gas feed paths are not possible Magnos206 Gas Connections 1 Sample gas inlet 2 Sample gas outlet Design 1 8 NPT female thread stainless steel 1 4305 SAE 303 Connection of flexible tubes straight screwed fittings PP with nozzles for flexible tubes with in...

Page 48: ...s lines executed as flexible tubes or stainless steel pipes 1 not assigned 2 not assigned 3 Sample gas inlet 4 Sample gas outlet with one sample cell 5 Purge gas inlet for case 6 Purge gas outlet for case 7 not assigned 8 Sample gas outlet with two sample cells in series 9 Pressure sensor if internal gas lines are executed as stainless steel pipes 10 not assigned ...

Page 49: ...ernal gas lines are flexible tubes the pressure sensor standard and the oxygen sensor option are internally connected as follows in the outlet of sample cell 1 for a sample cell and two separate feed paths in the outlet of sample cell 2 with two sample cells in series If the internal gas lines are stain steel pipes the oxygen sensor and the version with separate gas feed paths are not possible Mag...

Page 50: ...eparate gas feed paths for NOx measurement with upstream converter Design Screwed fittings with hose nozzles stainless steel 1 4305 SAE 303 for hoses with 4 mm inner diameter supplied 21 Sample gas inlet 22 Test gas inlet on the solenoid valve with the option Integrated gas feed with solenoid valve pump filter capillary tube and flow sensor Design Screwed fittings with hose nozzles PVDF for hoses ...

Page 51: ...inless steel 1 4305 SAE 303 for threaded connections not supplied Note The oxygen sensor the option Integrated gas feed and the version with separate gas feed paths are not possible Caldos27 Gas Connections 1 Sample gas inlet 2 Sample gas outlet Design 1 8 NPT female thread stainless steel 1 4305 SAE 303 Connection of flexible tubes straight screwed fittings PP with nozzles for flexible tubes with...

Page 52: ... lines executed as flexible tubes or stainless steel pipes 1 not assigned 2 not assigned 3 Sample gas inlet 4 Sample gas outlet with one sample cell 5 Purge gas inlet for case 6 Purge gas outlet for case 7 not assigned 8 Sample gas outlet with two sample cells in series 9 Pressure sensor if internal gas lines are executed as stainless steel pipes 10 not assigned ...

Page 53: ...ternal gas lines are flexible tubes the pressure sensor standard and the oxygen sensor option are internally connected as follows in the outlet of sample cell 1 for a sample cell and two separate feed paths in the outlet of sample cell 2 with two sample cells in series If the internal gas lines are stain steel pipes the oxygen sensor and the version with separate gas feed paths are not possible Ca...

Page 54: ...mas23 Gas Connections 1 Sample gas inlet 2 Sample gas outlet Design Screwed fittings with hose nozzles stainless steel 1 4305 SAE 303 for hoses with 4 mm inner diameter supplied Note The pressure sensor standard and the oxygen sensor option are connected internally in the outlet of the sample cell ...

Page 55: ...outlet for case Design 1 8 NPT female thread stainless steel 1 4305 SAE 303 Connection of flexible tubes Straight screwed fittings PP with nozzles for flexible tubes with inside diameter 4 mm supplied Connection of pipelines Threaded connections not supplied Note The pressure sensor standard and the oxygen sensor option are connected internally in the outlet of the sample cell ...

Page 56: ...ote The pressure sensor is connected internally in the outlet of the sample cell Magnos206 Gas Connections 1 Sample gas inlet 2 Sample gas outlet Design 1 8 NPT female thread stainless steel 1 4305 SAE 303 Connection of flexible tubes straight screwed fittings PP with nozzles for flexible tubes with inside diameter 4 mm supplied Connection of pipelines Threaded connections not supplied Note The sa...

Page 57: ...pplied Connection of pipelines Threaded connections not supplied Note The pressure sensor is connected internally in the outlet of the sample cell Magnos206 Gas Connections 1 Sample gas inlet 2 Sample gas outlet 3 not assigned 4 not assigned Design 1 8 NPT female thread stainless steel 1 4305 SAE 303 Connection of flexible tubes straight screwed fittings PP with nozzles for flexible tubes with ins...

Page 58: ...s outlet with the option Integrated gas feed connected ex works to 1 Sample gas inlet 4 Sample gas inlet with the option Integrated gas feed only with flow sensor without solenoid valve 6 Pressure sensor Design Screwed fittings with hose nozzles stainless steel 1 4305 SAE 303 for hoses with 4 mm inner diameter supplied 21 Sample gas inlet 22 Test gas inlet on the solenoid valve with option Integra...

Page 59: ... 11 Purge gas inlet for case 12 Purge gas outlet for case 13 Pressure sensor Design 1 8 NPT female thread stainless steel 1 4305 SAE 303 Connection of flexible tubes straight screwed fittings PP with nozzles for flexible tubes with inside diameter 4 mm supplied Connection of pipelines Threaded connections not supplied Note The pressure sensor is installed as an option ...

Page 60: ...Model EL3020 Magnos27 Gas Connections 1 Pressure sensor option 2 not used 3 Sample gas inlet 4 Sample gas outlet 5 Purge gas inlet analyzer 6 Purge gas outlet analyzer Design Screwed fittings with hose nozzles stainless steel 1 4305 SAE 303 for hoses with 4 mm inner diameter supplied ...

Page 61: ...5 Purge gas inlet analyzer 6 Purge gas outlet analyzer Design Screwed fittings with hose nozzles stainless steel 1 4305 SAE 303 for hoses with 4 mm inner diameter supplied Uras26 Gas Connections 1 Sample gas inlet 2 Sample gas outlet Design Screwed fittings with hose nozzles stainless steel 1 4305 SAE 303 for hoses with 4 mm inner diameter supplied ...

Page 62: ...ctions The sample chamber is connected to the sample gas inlet connection via a stainless steel tube on the inlet side and to the sample gas outlet connection via an FPM hose on the outlet side 1 Sample gas inlet 3 mm Swagelok 2 Sample gas outlet 1 8 NPT female thread for threaded connections not supplied ...

Page 63: ...tion via a stainless steel tube on the inlet side and to the sample gas outlet connection via an FPM hose on the outlet side 1 Sample gas inlet 3 mm Swagelok 2 Sample Gas Outlet 11 Purge gas inlet for housing 12 Purge gas outlet for housing Design of the gas connections unless stated otherwise 1 8 NPT female thread for threaded connections not supplied ...

Page 64: ...not supplied 3 Sample gas outlet with the option Integrated gas feed connected ex works to 1 Sample gas inlet 4 Sample gas inlet with the option Integrated gas feed only with flow sensor without solenoid valve 6 Pressure sensor Design Screwed fittings with hose nozzles stainless steel 1 4305 SAE 303 for hoses with 4 mm inner diameter supplied 21 Sample gas inlet 22 Test gas inlet on the solenoid v...

Page 65: ... assigned 4 not assigned 11 Purge gas inlet for case 12 Purge gas outlet for case 13 Pressure sensor Design 1 8 NPT female thread stainless steel 1 4305 SAE 303 Connection of flexible tubes straight screwed fittings PP with nozzles for flexible tubes with inside diameter 4 mm supplied Connection of pipelines Threaded connections not supplied ...

Page 66: ...2 Test gas outlet 33 Zero gas inlet 34 Span gas inlet 35 Combustion air inlet 36 Combustion gas inlet 37 Instrument air inlet 38 Exhaust air outlet Design Male fitting for connecting the exhaust air outlet stainless steel tube with outside diameter 6 mm included in the scope of supply and delivery of the gas analyzer 39 Sample gas inlet heated or unheated Design Screw joint for PTFE or stainless s...

Page 67: ... air inlet 36 Combustion gas inlet 37 Instrument air inlet 38 Exhaust air outlet Design Male fitting for connecting the exhaust air outlet stainless steel tube with outside diameter 6 mm included in the scope of supply and delivery of the gas analyzer 39 Sample gas inlet heated or unheated Design Screw joint for PTFE or stainless steel tube with outside diameter 6 mm 40 Pressure equalizing opening...

Page 68: ...zer 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 Requirements for the Gas Analyzer Model EL3020 for the Measurement of Flammable Gases An unimpeded exchange of air with the surroundings must be possible around the gas analyzer from beneath base plate and from behind gas connections The gas analyz...

Page 69: ...e gas inlet and if required before the purge gas inlet in order to be able to adjust and monitor the gas flow rate Provide for Gas Line System Flushing Install a shut off valve in the sample gas line definitely recommended with pressurized sample gas in order to provide a means for purging the gas line system by feeding in an inert gas e g nitrogen from the gas sampling point Evacuate Exhaust Gase...

Page 70: ...hrough leak points in the gas paths in the instrument can cause fires and explosions also outside the gas analyzer The lines and fittings must be clean and free of any residues e g particles left over from manufacturing Contaminants can enter the analyzer and damage it or lead to false measurement results NOTES The installation of gas connections is described in section Installing the Gas Connecti...

Page 71: ...for the housing purge see page 34 Connect see page 66 the instrument air line to the instrument air inlet of the analyzer module via a pressure regulator 0 to 6 bar Combustion Air Connection Connect see page 66 the combustion air line to the combustion air inlet of the analyzer module via a pressure regulator 0 to 1 6 bar Combustion Gas Connection See section Fidas24 Connecting the Combustion Gas ...

Page 72: ... the medium can be up to 200 C Lay the exhaust air line with a downward gradient The inside diameter of the exhaust line should be increased to 10 mm within no more than 30 cm from the exhaust outlet If a very long exhaust air line is used it s inside diameter must be much larger than 10 mm otherwise the pressure regulation in the gas analyzer may not work properly Do not conduct waste air via res...

Page 73: ...low restrictor in the combustion gas supply line which restricts the combustion gas flow to 10 l h of H2 or 25 l h of H2 He mixture This means that operation of the gas analyzer is safe even with a defect in the combustion gas feed path e g leaks 8 Install a shut off valve in the combustion gas supply line It is recommended that a pneumatic valve is installed this valve must be controlled by the i...

Page 74: ...The heated sample gas line is connected directly to the sample gas inlet In this respect the correct seat of the O rings must be ensured and also that the sample gas tube is inserted all the way in into the sample gas connection Unused sample gas inlets If the analyzer module draws in the sample gas through the sample gas line the unused sample gas inlets must be sealed with the screw plugs screwe...

Page 75: ...s outlet 2 Connection of test gas outlet sample gas connection 3 Electrical connection to the heated sample gas connection 4 Heated sample gas connection 5 Heated sample gas line example Note One half of the cover of the heated sample gas connection has been removed in the picture ...

Page 76: ...76 EasyLine EL3000 Series Commissioning Instructions Connection of the sample gas line to the heated sample gas connection Wall mount housing view from bottom right III 1 2 3 4 5 6 7 8 9 10 11 I II ...

Page 77: ...Installing the Gas Analyzer 77 19 inch housing view from top left 5 6 7 8 II III 9 10 11 1 2 3 4 I ...

Page 78: ...12 42 x 1 78 11 Waste gas tube Sample gas Connection of the sample gas line inlets on 19 inch housing on wall mount housing I from the rear from below II from above from the right III from below not possible the sample gas inlet must always be closed Maximum length of the sample gas line The maximum length of the heated sample gas line inside diameter 4 mm is 30 m Provide for Sample Gas Line Purgi...

Page 79: ... sample gas line The unheated sample gas connection has only one sample gas inlet If 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 a exhaust gas discharge line so that no positive pressure builds up in the analyzer module Connection of the sample gas line to the unhe...

Page 80: ...d G1 4 or with 6 Socket 7 Tapered ring 8 Compression fitting 9 Exhaust gas tube for 19 inch housing 10 Waste gas tube for wall mount housing Maximum length of the sample gas line The maximum length of the unheated sample gas line inside diameter 4 mm is 50 m Provide for Sample Gas Line Purging Install a shut off valve in the sample gas line definitely recommended with pressurized sample gas in ord...

Page 81: ...he illustration shows all the available I O module types and only represents an example of the I O modules equipment max 4 The actual equipment of the supplied gas analyzer can differ it is documented in the analyzer data sheet 6 Ethernet 10 100BASE T interface for configuration and software update and for transmission of the QAL3 data 7 Connection for equipotential bonding see page 90 capacity of...

Page 82: ... Screwed Cable Glands Type Use Recommendation Permissible cable diameter M20 Power supply 5 13 mm M25 Modbus Profibus 8 17 mm insert 5x 4 mm M25 Network connections 8 17 mm M25 3x analog outputs 8 17 mm insert 3x 7 mm M32 Digital inputs outputs 12 21 mm M32 Digital inputs outputs 12 21 mm ...

Page 83: ...ows all the available I O module types and only represents an example of the I O modules equipment max 4 The actual equipment of the supplied gas analyzer can differ it is documented in the analyzer data sheet 6 Ethernet 10 100BASE T interface for configuration and software update and for transmission of the QAL3 data 7 Connection for equipotential bonding see page 90 capacity of terminal max 4 mm...

Page 84: ...red to local protective ground potential 50 V working resistance max 750 Ohm Resolution 16 bit The output signal may not be less than 0 mA Design 4 pole or 8 pole plug in terminal strip Please refer to the information about the requisite material see page 89 Terminal Layout An analog output is allocated in the sequence of the sample components for each sample component The sequence of the sample c...

Page 85: ...le throw contacts max contact load rating 30 V 1 A The relays must always be operated within the specified data Inductive or capacitive loads are to be connected with appropriate protective measures freewheeling diodes for inductive and series resistors with capacitive loads Relays are shown in the unpowered state The unpowered state corresponds to the state in the event of a fault fail safe Desig...

Page 86: ...e 1 DO2 Alarm value 2 DO3 Alarm value 3 DO1 Alarm value 4 DO2 Alarm value 5 DO3 Alarm value 6 DO4 Alarm value 7 Alarm value 8 Alarm value 9 Alarm value 10 Measuring range switchover Measuring range feedback Sample component switchover Sample component feedback Bus DI 1 Bus DI 2 Bus DI 3 Bus DI 4 Bus DI 5 Bus DI 6 Bus DI 7 Bus DI 8 External failure 2 DI3 External maintenance request 2 DI4 1 if a pu...

Page 87: ...odule RS232 Interface Pin Signal 2 RxD 3 TxD 5 GND Design 9 pole male Sub D plug RS485 Interface Pin Signal 2 RTxD 3 RTxD 5 GND Design 9 pole female Sub D plug NOTE For detailed Information on Modbus refer to the Technical Information EL3000 EL3060 EL3010 C Modbus ...

Page 88: ...nce potential for VP 6 VP Supply voltage plus 5 V 7 P24 24 V output voltage plus max 0 2 A 8 RxD TxD N Receive send data N A line 9 not assigned Design 9 pole female Sub D plug MBP Interface not intrinsically safe Pin Signal 1 2 Shield 3 4 not assigned Design 4 pole plug in terminal strip Please refer to the information about the requisite material see page 89 NOTE For detailed information on Prof...

Page 89: ...ng tool of Weidmüller Co must be used for crimping the ferrules Max length of the RS485 leads 1200 m max transmission rate 19200 bit s Cable type 3 core twisted pair cable cable cross section 0 25 mm2 e g Thomas Betts Type LiYCY Max length of the RS232 leads 15 m The mating plugs socket housing for the plug in terminal strips on the I O modules are supplied Connecting the Signal Lines 1 Only for t...

Page 90: ...feeder near the gas analyzer or a switched socket outlet in order to be able to disconnect all the power from the gas analyzer if required Mark the mains isolator in such a way that the assignment of the devices to be disconnected can be clearly recognized 3 Attach the mains lead to the power supply connection of the gas analyzer and fasten the connector by means of the bracket 4 Connect the other...

Page 91: ...alyzer module 2 L 3 1 N PE The illustration shows the pin side of the plug 30 in the analyzer module see page 66 The operating voltage of the detector heating is automatically detected and switched The set voltage can be identified through two LEDs on the mains distribution card 115 230 V AC Connection to an Analyzer Module 1 Attach the supplied 115 230 V AC connecting cable with the 4 pole socket...

Page 92: ...onnected and laid 3 Are all signal lines see page 89 and power supply lines see page 90 correctly connected and laid 4 Are all devices needed for gas conditioning calibration and waste gas disposal correctly connected and ready for use 5 When measuring flammable gases Are the special requirements see page 38 being observed 6 When applying the explosion protected version in the degree of protection...

Page 93: ...tamination e g corrosive gases and dust deposits during start up Another reason is to prevent any explosive gas air formations that may be present in the sample gas feed path or the wall mount housing from igniting when the power supply is activated Purge gas Nitrogen Purging of the gas feed path Purge gas flow max 100 l h duration approx 20 s Purging of the wall mount housing Purge gas flow max 2...

Page 94: ...lay switches over to the measured value display Example 4 Check the configuration of the gas analyzer and alter if necessary 5 After the warm up phase has ended the gas analyzer is ready to carry out measurements Duration of the warm up phase Uras26 approx hour without thermostat approx 2 hours with thermostat Limas23 approx 2 hours Magnos206 approx 1 hour Magnos27 approx 2 4 hours Caldos27 approx...

Page 95: ...ed ambient air wait and until the measured value has stabilized duration approx 2 hrs Meanwhile purge the test gas valves and the gas supply line with oxygen free gas e g with nitrogen from a loop feeder or with sample gas flow rate 5 to 10 l h 3 Set reference point to 20 6 vol of O2 4 Feed span gas and wait until the measured value has stabilized duration max 2 hrs 5 Set end point value in accord...

Page 96: ...re values slowly increase after the power supply is switched on 4 Feed in instrument air combustion air and combustion gas H2 or H2 He mixture Adjust the pressure to the value specified in the analyzer data sheet with the corresponding external pressure regulator 5 The controlled variables of the internal pressure regulator are also displayed in the Controller values menu option C Air Combustion a...

Page 97: ...e respective solenoid valve in the analyzer automatically connects the combustion gas The combustible gas regulation attempts to adjust the pressure to the setpoint Adjust the controlled variables of the internal pressure regulators If the analyzer is not automatically put into service with the pressure values specified in the analyzer data sheet the controlled variables of the internal pressure r...

Page 98: ...me on Flame temp detector temp 30 C Combustion air ramp height reached Number of ignition attempts 10 Fidas24 is ready to measure after warm up phase Temperature of detector and sample gas connection 150 C yes yes yes yes yes no no no no no Depending on the number of ignition attempts the flame can take up to 10 minutes to ignite Depending on the length of the combustible gas supply line it is pos...

Page 99: ...s analyzer for at least 20 minutes 2 Switch on power supply of the gas analyzer 3 Turn on the combustion gas supply and adjust the combustion gas pressure 4 Check see page 118 the seal integrity of the combustion gas feed path 5 Turn on the sample gas supply ATTENTION The connection cable of the 115 230 V AC power supply for heating the detector and possibly the heated sample gas connection may no...

Page 100: ...ately with the inverted display this signals that the measured value exceeds the measuring range limits Status Icons An automatic calibration is executed The icon also appears in the menu title line in menu mode see page 102 A status message see page 122 is active The status signal Maintenance request is active The icon also appears in the menu title line in menu mode see page 102 The status signa...

Page 101: ... message is active press the key to display the message list see page 122 Number of Decimal Places When the screen displays the measured value in physical units e g ppm the number of places after the decimal point depends on the size of the set measuring range Span Places after the decimal point 0 05 5 0 5 4 5 3 50 2 500 1 500 0 For the display of the measured value as a percentage of the whole me...

Page 102: ...tton Operation Calibration Manual Calibration Zero Point Single Point Setup Calibration Data Test Gas Set Points Maintenance Diagnosis Device Status Status Messages Key Functions in Menu Mode 3 point menu Select menu item Return to the next higher menu OK Return to measuring mode Component list Select component or OK Call up selected component for processing Parameter list Selector Select paramete...

Page 103: ...n succession Each key stroke is acknowledged by display of the character The entered password remains active until the user returns to the measuring mode or the gas analyzer automatically switches over to the measuring mode through the time out function see page 102 Time out Function If the user does not press a key for more than approx 5 minutes during the selection of menu items the gas analyzer...

Page 104: ...104 EasyLine EL3000 Series Commissioning Instructions Menu Overview of the Menu This menu depends on the configuration of the gas analyzer ...

Page 105: ...art cancel automatic calibration also possible via digital inputs X X Activate deactivate cyclically time controlled automatic calibration X X X Cycle time of the automatic calibration X End point calibration together with zero point calibration X X Date and time of the next automatic calibration start of the cycle X X Test gas concentration X X X Purging times X X Output current response for auto...

Page 106: ...constant T90 time filter X X Active component X X X Modbus parameters2 X Profibus Parameters3 X Ethernet parameters X X Signal inputs and outputs I O connections X 2 NOTEFor detailed Information on Modbus refer to the Technical Information EL3000 EL3060 EL3010 C Modbus 3 NOTEFor detailed information on Profibus refer to the Technical Information EL3000 EL3060 PROFIBUS DP PA Interface ...

Page 107: ... on Modbus can be found in the technical information EL3000 Modbus and EL3010 C Modbus via TCP IP Setting up the communication between the gas analyzer and the computer Basically the following steps are required to set up the communication between the gas analyzer and computer 1 Check and set the TCP IP parameters in the gas analyzer and the computer 2 Establish and test the Ethernet connection 3 ...

Page 108: ... name consists of EL3K and the last six positions of the MAC address example EL3KFF579A If the parameter DHCP is set to off the Ethernet configuration is reset to the standard configuration default IP address this will prevent the inadvertent assignment of an IP address from a DHCP pool Addresses The IP address IP address mask and IP gateway address must be obtained from the system administrator N...

Page 109: ...2 Connection via an Ethernet network twisted pair cable with RJ45 connectors The cables are standard Ethernet cables and are not part of the scope of supply and delivery of the gas analyzer Test the Ethernet connection To test the Ethernet connection enter the following in the computer in Start Execute ping IP address with IP address IP address of the gas analyzer If the connection is OK the gas a...

Page 110: ... connection Receiving Configuration Data After communication has been started the configuration data can be received from the gas analyzer Menu File Receive Data or Sending Configuration Data After the configuration data been has edited it can be sent to the gas analyzer The configuration mode is active after an automatic cold restart of the gas analyzer Menu File Send Data or Saving Configuration...

Page 111: ... Warm up Phase has Ended The gas analyzer may not be calibrated until the warm up phase has been concluded Duration of the warm up phase Uras26 approx hour without thermostat approx 2 hours with thermostat Limas23 approx 2 hours Magnos206 approx 1 hour Magnos27 approx 2 4 hours Caldos27 approx hour Fidas24 approx 2 hours Start Automatic Calibration Manually ...

Page 112: ...orted the analyzer is in an undefined state with respect to the calibration For example the zero point calibration may have been completed and calculated but the end point calibration has not yet been carried out As a result the automatic calibration must be restarted after it has been aborted and allowed to run through to the end ...

Page 113: ... of the warm up phase Uras26 approx hour without thermostat approx 2 hours with thermostat Limas23 approx 2 hours Magnos206 approx 1 hour Magnos27 approx 2 4 hours Caldos27 approx hour Fidas24 approx 2 hours NOTES A zero point calibration must always be carried out before an end point calibration A zero point calibration can also be carried out on its own Manual calibration cannot be carried out w...

Page 114: ...he measured value display is stable 6 Store calibration or repeat calibration End point calibration with calibration cell option with Uras26 and Limas23 1 Select menu Calibration Cell 2 Select sample component or All only possible with Uras26 3 Connect zero reference gas if not already connected 4 Start calibration as soon as the measured value display is stable 5 Store calibration or repeat calib...

Page 115: ...on with test gas connection The status signal Maintenance Mode is active in the standby mode and the status message see page 122 no 411 Fidas24 Standby Mode is output the measured values are invalid NOTE If the Fidas24 is in the fail safe status see page 129 it cannot be set to the standby mode Resetting the Fidas24 to the measuring mode Operation Pump Standby Fidas Standby Fidas Restart The most ...

Page 116: ...normal pressure of the combustion gas i e approx 1 4 bar 3 Mark cylinder pressure indication on the high pressure gauge 4 Close the valve of the combustion gas cylinder 5 The display on the high pressure gauge it should not change measurably in 10 minutes A measurable change in the display is an indication of a leak in the combustion gas feed path between the cylinder pressure reducer and the comb...

Page 117: ...n the combustion gas path between the pressure reducer and the combustion gas inlet valve of the gas analyzer In this case the following measures are to be taken 1 Check the combustion gas line between the pressure reducer and gas analyzer with a leak detection spray A leak in this area must be remedied and another leak test must be performed before the gas analyzer is put into operation again 2 I...

Page 118: ...e combustion gas inlet to combustion gas nozzle With a leak detector measurement principle thermal conductivity sniff all the connection points 2 Inspection of the combustion gas feed path with negative pressure in the detector after the combustion gas nozzle Connect zero gas at the sample gas inlet Envelope all the connection points one after the other with a small gas cloud containing hydrocarbo...

Page 119: ...off valve Air or nitrogen ATTENTION If the seal integrity test is to be carried out with air and if flammable gas could be present in the sample gas feed path or is to be subsequently introduced the sample gas feed path must be purged with nitrogen beforehand The seal integrity test can be carried out with nitrogen instead Checking the Seal Integrity of the Sample Gas Feed Path 1 Seal the sample g...

Page 120: ...19 can be used as an alternative to the helium test To accomplish this increase the test pressure to a pe of approx 400 hPa 400 mbar and increase the test period to 15 minutes The maximum excess pressure pe 500 hPa 500 mbar Any time the gas path is opened it must then be purged prior to connecting the power supply This should remove any explosive gas air mixture in the gas path Purge gas Inert gas...

Page 121: ...tection II 3G Cleaning the Keyboard Overlay Due to the high surface resistance of the keyboard overlay R 1 Gigaohm the gas analyzer has to be operated and maintained in such a way that the risk of a hazardous electrical discharge is ruled out e g using only suitable cloth for cleaning ...

Page 122: ...isplay of the message list is called directly by pressing the key once Message List and Detail View The message list with the short text of the status messages is displayed in the menu item Status Messages The detail view of the individual status messages is called by pressing the key the time and date of arrival and clearance or the acknowledgement of the status message are displayed in the detai...

Page 123: ...arried out in the gas analyzer or the maintenance switch has been set to On The measured value is not a process measured value and is to be discarded S Overall Status The overall status is always set in conjunction with the status Error and for individual messages in conjunction with the status Maintenance request it is not set in conjunction with the status Maintenance mode Status Message Categor...

Page 124: ...27 W a The drift values exceed the QAL3 limits Repeat the calibration Maintenance of AMS required 250 A S aQ The analyzer could not be found Check the connectors and cabling 251 A S aQ The connection to the analyzer has been lost Check the connectors and cabling 252 A S aL The EEPROM data of the analyzer is defective Check the configuration with TCT 253 A S aL Communication with the analyzer is fa...

Page 125: ...nually calibrate the indicated detector at the end point This message is generated by automatic calibration Permissible range 15 of the sensitivity 6 of the sensitivity for measurements on plants subject to approval pursuant to the 27th and 30th Federal Regulation on Immissions 308 A S aQ A calculation error occurred during calculation of the measured value Switch the power supply off and on Notif...

Page 126: ...se Check whether the permissible ambient temperature range is being maintained Check the connecting leads and connectors Check the fit of the leads in the wire end ferrules Check the overtemperature cutout and replace if necessary 326 A S aL No new measured values from the analog digital converter Notify Service 327 A S a The measured value exceeds the value range of the analog digital converter N...

Page 127: ... A calculation error occurred during calculation of the measured value Switch the power supply off and on Notify Service 401 W a The flow is above or below the upper or lower alarm value 1 Check sample gas path Notify Service 402 A S a The flow is above or below the upper or lower alarm value 2 Check sample gas path Notify Service 403 A S a The flow controller output variable is beyond the valid r...

Page 128: ...The calibration could not be carried out because the measured value is unstable Check the test gas supply and infeed repeat the calibration 519 iQ The calibration could not be carried out because the preamplifier is overdriven Check the test gas supply and infeed repeat the calibration 529 W S iQ The calibration was stopped because no raw measured values can be recorded Check the test gas supply a...

Page 129: ...e flame must be restarted Operation Pump Standby Fidas Standby Fidas Restart Note The operating status Wait for restart means Heater on Combustion gas valve closed Instrument air valve open Housing purge on Combustion air pressure too high Reduce combustion air pressure note details in analyzer data sheet Fidas24 in the Fail safe Status If a serious fault has occurred in the analyzer module the an...

Page 130: ...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 is not in operation e g as a result of a supply voltage failure the supply gases must be shut off see section Gas Analyzer Shutdown If the gas analyzer is in operation an adequate instrument air supply must be verified If this is the case the status messages must be v...

Page 131: ...onnect the electrical leads from the gas analyzer Fidas24 Gas Analyzer Shutdown In the case of a temporary shutdown 1 Turn off the sample gas supply 2 Purge sample gas line with nitrogen for at least 5 minutes from the sampling point 3 Set the gas analyzer to standby operation see page 115 In case of corrosive and flammable gases set the gas analyzer to standby operation with detector purging 4 Sh...

Page 132: ... Turn on the gas analyzer power supply 3 Turn on the combustion gas supply and check the combustion gas pressure 4 Carry out a seal integrity test on the combustion gas line see page 116 5 Turn on the sample gas supply See also the instructions in the section Fidas24 Gas Analyzer Start up see page 96 Ambient Temperature Ambient temperature during storage and transport 25 to 65 C ...

Page 133: ...ation at least 3 months 3 Pack the gas analyzer in an adequately sized box lined with shock absorbing material foam or similar The thickness of the shock absorbing material should be adequate for the weight of the gas analyzer and the mode of dispatch When shipping overseas additionally line the box with a double layer of bitumen paper 4 Mark the box as Fragile Goods Ambient Temperature Ambient te...

Page 134: ...g the seal integrity of the combustion gas feed path in the gas analyzer 12 13 99 118 Connecting the Combustion Gas Line 71 73 Connecting the Gas Lines 70 Connecting the Sample Gas Line Heated Sample Gas Connection 74 Connecting the Sample Gas Line Unheated Sample Gas Connection 79 Gas Analyzer Start Up 94 96 132 Information on the safe operation of the gas analyzer 12 Power Supply Line Connection...

Page 135: ...Required for the Installation not supplied 15 Menu 102 104 Menu mode 102 Micro porous filter 69 Model EL3020 42 46 50 58 64 81 Model EL3040 44 48 52 59 65 82 N Notes on the Concept of Operation 105 108 O Operating the Gas Analyzer 100 Operation Menu Mode 100 101 102 103 P Packing 133 Packing the Gas Analyzer 133 Preface 6 Preparation for Installation 8 14 Pressure Sensor 32 Purge the sample gas pa...

Page 136: ...of continuous product improvement and the right is reserved to modify the information contained herein without notice Printed in the Fed Rep of Germany 11 14 ABB 2014 41 24 400 EN Rev 6 ABB Automation GmbH Analytical Stierstaedter Strasse 5 60488 Frankfurt am Main Germany Fax 49 69 7930 4566 E Mail cga de abb com ...

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ABB EasyLine EL3020, Instructions For Installation Start-Up And Operation

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