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42/24-30 EN Rev. 1

EL6010 Gas Analyzer in Category 2G Operator’s Manual

Guideline for Installation and Operation

Basic Steps

The following basic steps should be followed when installing and operating the
EL6010 gas analyzer.

Step Action

See

Page

Follow safety precautions

6, 7

Prepare the installation

Unpack the gas analyzer

Check gas path seal integrity

Install the gas analyzer

Connect the gas lines

Connect the electrical leads

Check the installation

Purge the gas path

Start the gas analyzer

Set the parameters

Calibrate the gas analyzer

Summary of Contents for EL6010

Page 1: ...Continuous Gas Analyzers EL6010 Operator s Manual 42 24 30 EN Rev 1 ...

Page 2: ......

Page 3: ...Continuous Gas Analyzers EL6010 Operator s Manual Publication No 42 24 30 EN Rev 1 Edition 07 04 ...

Page 4: ...stall the Gas Analyzer Unpack and Install the Gas Analyzer 13 Connect the Gas Lines 15 Connect Electrical Lines Safety Precautions 16 Control Unit Electrical Connections 17 Connection Analyzer Unit Control Unit 18 Further Electrical Connections 19 Power Supply Connection 20 Chapter 3 Gas Analyzer Operation Readout 21 Operation 22 Menu 23 Chapter 4 Start the Gas Analyzer Check the Installation 24 S...

Page 5: ...tegrity 44 Chapter 8 Status Messages Troubleshooting Blinking Screen 45 Status Messages 46 Troubleshooting 48 Call for Service 49 Chapter 9 Gas Analyzer Shutdown and Packing Gas Analyzer Shutdown 50 Gas Analyzer Packing 51 Appendix Application and Design 52 Analyzer Units 53 Control Unit 54 EL6010 Uras14 Metrological Data 55 EL6010 Magnos106 Metrological Data 56 EL6010 Caldos17 Metrological Data 5...

Page 6: ...formation for individual gas analyzers EL6010 Uras14 EL6010 Magnos106 and EL6010 Caldos17 1 2 3 Identifies reference numbers in figures Display Identifies a display on the screen Display Identifies a blinking display on the screen Symbols and Fonts Used in the Manual Ø Enter Back Identifies function keys Additional Informa tion on the Internet Additional information on ABB Analytical products and ...

Page 7: ...ng the EL6010 gas analyzer Step Action See Page Follow safety precautions 6 7 1 Prepare the installation 8 2 Unpack the gas analyzer 13 3 Check gas path seal integrity 13 4 Install the gas analyzer 14 5 Connect the gas lines 15 6 Connect the electrical leads 16 7 Check the installation 24 8 Purge the gas path 26 9 Start the gas analyzer 26 10 Set the parameters 27 11 Calibrate the gas analyzer 35 ...

Page 8: ...onal 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 EL6010 gas analyzer is used in other countries EL6010 Gas Analyzer Safety and Safe Operation The EL6010 gas analyzer is designed and tested in accordance with EN 60950 1992 A11 1997 Safety of Info...

Page 9: ...ny work All work on an gas analyzer that is open and con nected to power should only be performed by trained personnel who are familiar with the risks involved While connected to power the EL6010 gas analyzer housing should only be opened when the surrounding environment does not pose an explosion threat Charged Capacitors The EL6010 analyzer unit capacitors require 10 minutes to discharge after t...

Page 10: ... Avoid heat buildup Protection from Adverse Conditions Protect the gas analyzer from Cold Direct sunlight and heat Large temperature variations Strong air currents Accumulations of dust and dust infiltration Corrosive atmospheres Vibration Air pressure range 600 to 1250 hPa Relative humidity max 75 during storage and shipping 25 to 65 C EL6010 Caldos17 5 to 50 C EL6010 Magnos106 5 to 50 C Environm...

Page 11: ...le Gas Inlet Conditions Positive Pressure When specially equipped and when special conditions are fulfilled the gas ana lyzer is capable of measuring pressurized non flammable and flammable gases The sample gas should never be explosive The analyzer unit should have two ventilation openings Inlet Pressure pe 300 hPa 0 3 bar or pabs 1 400 hPa 1 4 bar Temperature EL6010 Uras14 5 to 45 C EL6010 Magno...

Page 12: ...he outlet pressure must not exceed the inlet pressure by more than the pressure loss across the analyzer Items Delivered Quantity Description 1 EL6010 CU Control Unit 1 EL6010 Analyzer Unit with attached connection cables for 24 VDC power supply and data transmission 1 Analyzer Data Sheet 1 Operator s Manual 42 24 30 EN 1 2 5 mm Hex Wrench Items Delivered 1 220 mm diam x 3 mm O Ring Analyzer Data ...

Page 13: ...Dimensional Diagram Figure 1 EL6010 CU Control Unit dimensions in mm 20 316 276 356 190 198 100 305 276 422 236 453 1 2 3 4 5 1 Hex Socket Head Screw to Secure the Housing Cover 2 Housing Cover 3 Cable Connections 4 Cable Compartment with Terminal Strip 5 Potential Compensation Connection ...

Page 14: ...ransmission Cable Opening 10 Potential Compensation Connection EL6010 Uras14 1 2 See 3 Analyzer Data Sheet 4 5 Purge Gas Inlet 1 6 Purge Gas Outlet 1 7 Pressure Sensor 3 8 Data Transmission Cable Opening 9 24 VDC Connection Cable Opening 10 Potential Compensation Connection 1 Option 2 Version for sample gas under positive pressure only 3 Standard for EL6010 Caldos17 EL6010 Uras14 Option for EL6010...

Page 15: ...s Analyzer 3 Remove the adhesive packaging residue from the control unit and the analyzer unit If there is shipping damage that points to improper handling file a damage claim with the shipper railway mail or freight carrier within seven days Make sure the enclosed accessories are not lost see Section Items Delivered page 10 Keep the shipping box and packaging material for future shipping needs Ga...

Page 16: ...gnos106 The EL6010 Magnos106 analyzer unit must be installed with the housing in the vertical position and the connection ports facing downward EL6010 Caldos17 EL6010 Uras14 The EL6010 Caldos17 and EL6010 Uras14 analyzer units can be installed with the housing in the vertical or horizontal position If installed vertically the connection ports must face downward For horizontal installation the O ri...

Page 17: ...ine in the analyzer bursts this can lead to a sample gas flow from both sides For this case steps must be taken to assure that the total sample gas flow on both sides cannot exceed the maximum value of 100 l h To avoid the development of an explosive mixture in the sample gas path the latter must be flushed with an inert gas prior to introducing flammable gases EL6010 Uras14 The Flowing Reference ...

Page 18: ... is interrupted inside or outside the gas analyzer or if the protective lead is disconnected Securing Electrical Lines All electrical wiring including the connections between the analyzer unit and the control unit must be firmly secured Shielded Lines Shielded lines must be routed through the metal wiring connectors The shield braid must be placed on the cable connectors Unused Cable Connections O...

Page 19: ...s 25 26 27 Limit Value1 28 29 30 Limit Value2 Digital Outputs Floating double throw contacts max contact load rating 30 VDC 1 A Relays are shown in the unpowered state The unpowered state is the failure mode fail safe 31 32 Sample Component1 33 34 Sample Component 2 Analog Outputs 4 20 mA common negative pole galvanically isolated from ground freely connectable to ground max gain relative to prote...

Page 20: ...cable and the 24 VDC connection cable must be firmly secured The cables are integral components of the analyzer unit s pressurized enclo sure system They should not be shortened to less than 1 meter in length and should not be damaged Figure 3 Connection of the Data Transmission Cable and the 24 VDC Connection Cable to the Control Unit 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Datenübertragungskabel Dat...

Page 21: ...es 6 Push the non rotating plastic insert 3 and seal ring 2 in the inter mediate opening 6 until it engages 7 Securely tighten the cap nut 1 Connecting the Shielded Data Trans mission and 24 VDC Connection Cables to the Control Unit 8 Connect the data transmission and 24 VDC connection cable leads according to their respective numbers to terminals 1 to 12 and 13 to 15 see connection diagram page 1...

Page 22: ...x 90 VA EL6010 CU EL6010 Caldos17 approx 40 VA 3 Install a breaker in the power supply line or a switched receptacle near the control unit to make sure the control unit can be completely sepa rated from the power source Mark the breaker so that its relationship to the protected device is clear Connecting the Power Supply to the Control Unit 4 Connect the power supply leads conductor cross section ...

Page 23: ...n the device will differ Number of Places after the Decimal Point 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 measuring span Span in physical units 5 5 50 50 500 500 Places 3 2 1 0 For the display of the measured value as a percentage of the whole measuring range Span two places are always shown after...

Page 24: ...if the finger is slid across from the side The pressure on the screen has no influence on the operation Keys The and Ø keys are used to select a menu item change a value The Enter key is used to activate a menu item accept an edited value activate a function The Back key is used to Return to the first item in a menu or to a previous menu cancel the editing of a value Time Out If the user does not ...

Page 25: ...alibration Span with cal cell Calibration reset Pressure adjustment Measure cal cell Setting parameters Parameters component Zero setpoint Span setpoint Filter Measuring range Active TC component Parameters limit Limit 1 Limit 2 Limit 1 hysteresis Limit 2 hysteresis Parameters modbus Modbus baudrate Modbus address Modbus type Information Drift Delta drift Software version Error list EL6010 Uras14 ...

Page 26: ...at the installation site zone rating explosion group temperature class match the information on the identification plate Are the control unit and the analyzer unit not installed outdoors Are the control unit and the analyzer unit securely fastened Operation with sample gases at positive pressures Is the device version designed for operation with sample gases at positive pressures The identificatio...

Page 27: ...unit not shortened to a length of less than 1 meter and not damaged Housing integrity Is the analyzer unit housing intact Are all flame barriers and screw plugs present If the analyzer units EL6010 Uras14 and Caldos17 are mounted horizon tally are the O rings which are placed between the housing floor and the housing as well as between the housing and the housing lid in the slots provided cleanly ...

Page 28: ...on purge gas flow should be limited to 10 liters hour The purge gas should not contain any sample gas components Step Action 1 Activate the gas analyzer power supply EL Series IR 2 0 4 22 04 2003 2 The screen initially displays the gas analyzer name and the software version CO 105 2 ppm After a brief time the screen switches displaying measured values 3 Blinking of part of the screen indicates tha...

Page 29: ...s menu Only parameters that blink in the display can be edited The following example should clarify the details of this general procedure Step Action Key Display Key CO 105 2 ppm 1 Enter Calibrate Access the menu 2 Ø Setting parameters Enter Select the Setting parameters menu 3 Ø Parameters component CO Enter Select the submenu 4 Ø Span setpoint 505 0 ppm CO Enter Select the parameter to be change...

Page 30: ...of the range in use 1 For an explanation of the term Reference Measuring Range see pages 29 to 31 Filter Filter 5 sec 1 sec 0 05 Non linear filter with two low pass time constants and switching threshold Filter 5 sec 1 sec 0 05 Time constant for constant measured value Value range 0 to 60 sec Filter 5 sec 1 sec 0 05 Time constant for measured value changes Value range 0 to 60 sec Filter 5 sec 1 se...

Page 31: ...ed after changing measuring range limits Reference Measuring Range The gas analyzer has a physical measuring range reference measuring range for each sample component The limits of this measuring range are defined by the minimum and the maximum value of the product of the gas concentration c and sample cell length l c l min and c l max Measuring Range Notes One measuring range can be selected with...

Page 32: ...0 5 Vol Calibration of the measuring range should be verified after changing measuring range limits Reference Measuring Range The gas analyzer has a physical measuring range reference measuring range The limits of this range are 0 Vol O2 and 100 Vol O2 Measuring Range Notes One measuring range can be selected within the limits of the reference measuring range It is factory set and calibrated to 0 ...

Page 33: ...valid for the sample components see Section EL6010 Caldos17 Metrological Data page 57 For the factory set component relative thermal conductivity it is rTC 0 to 60 000 The largest measuring range is 0 to 100 Vol or 0 Vol to saturation depending on the measuring task Measuring ranges within ignition limits cannot be provided Active TC component CO2 H2 Active sample component Active TC component CO2...

Page 34: ...nge ON or OFF Limit 1 CO OFF 400 0 ppm Direction of effect Value range or Alarm on underflow or overflow of limit Limit Limit 1 CO OFF 400 0 ppm Limit Value range Within the reference measuring range 1 Step Interval The limit adjustment step interval is 0 1 of the span of the reference measuring range 1 Limit 1 hysteresis 10 0 ppm Switching Hysteresis Switching Hysteresis Limit 1 hysteresis 10 0 p...

Page 35: ...tem via a Modbus link Modbus baudrate 19200 Baud Rate Baud Rate Modbus baudrate 19200 Value range 9600 or 19200 Modbus address 1 Address Address Modbus address 1 Value range 1 to 255 Modbus type RS232 Interface Type Interface Type Modbus type RS232 Value range RS232 or RS485 For detailed Modbus information see the EasyLine Modbus and M DDE Server technical information sheet Publication No 30 27 10...

Page 36: ...e factory The operator can enter any on site or application specific parameter changes in the column at the right Parameter Factory Setting User Setting Zero setpoint Span setpoint Filter Measuring range Active TC component Depending on the analyzer unit type Limit 1 OFF 0 Limit 2 OFF 0 Limit 1 hysteresis 0 Limit 2 hysteresis 0 Modbus baudrate 19200 Modbus address 1 Modbus type RS232 ...

Page 37: ...ng a multiple path valve EL6010 Uras14 Notes for Calibration For zero point calibration Inert gas e g nitrogen N2 or sample component free ambient air Test Gases For end point calibration Calibration cell optional or test gas mixture Concen tration 70 of the span value of the measuring range selected is recommended the maximum value is the span value of the reference measuring range Calibration Ce...

Page 38: ...nt see Section EL6010 Magnos106 Metrological Data page 56 If it is expected that due to a particular carrier gas specified by the customer with the order this zero point displacement is greater than 1 of the smallest selected measuring range then the gas analyzer will be calibrated in the factory with an average process gas and the deviation with respect to the carrier gas N2 will be corrected wit...

Page 39: ... about calibration via Modbus see the EasyLine Modbus and M DDE Server technical information sheet Publication No 30 27 100 EN A zero calibration must always be performed before a span calibration A zero calibration can also be performed separately Step Action Key Display Key 1 Enter Calibrate Enter Select the Calibrate menu 2 Ø Calibrate component CO Enter Select the sample component 3 Ø Zero cal...

Page 40: ...an with cal cell CO Enter Select Span calibration with calibration cell 10 Setpoint cal cell 8 52 Vol CO Enter The calibration cell set point is displayed 11 Connect zero gas Enter Connect the zero gas if this has not already been done 12 Meas value stable 8 49 Vol CO Enter Start calibration if the measured value reading is stable 13 Wait cal is running Calibration in progress 14 Accept calibratio...

Page 41: ...efault values Additionally the offset drift and amplification drift are electronically returned to initial calibration values see Section Drift Reading page 42 Step Action Key Display Key 1 Enter Calibrate Enter Select the Calibrate menu 2 Ø Calibrate component CO Enter Select the sample component 3 Ø Calibration reset CO Enter Select Calibration reset 4 Calibration reset Start cal reset Enter Sta...

Page 42: ...ly whenever the test gas is changed Before Measuring the Calibration Cell Prior to measuring the calibration cell the zero and span point of the applicable sample components must be calibrated with test gases Zero Gas Supply During calibration cell measurement the zero gas supply must be turned on Step Action Key Display Key 1 Enter Calibrate Enter Select the Calibrate menu 2 Ø Measure cal cell 1 ...

Page 43: ...order to prevent the sample gas pressure from causing a false pressure reading After calibrating the pressure sensor the zero and span points must be checked and recalibrated as needed Notes for EL6010 Magnos106 The EL6010 Magnos106 analyzer unit with no pressure sensor installed is cali brated at the factory for an air pressure of 1013 hPa If the air pressure at the instal lation site differs fro...

Page 44: ...ation drift values are determined cumulative and based on the last initial calibration performed Delta drift CO offs 0 ampl 0 Delta Drift Offset and amplification delta drift values are deter mined based on the last and next to last calibration performed via the Modbus Drifts are displayed as a percentage of the user set measuring range ...

Page 45: ...at a leak rate of 2 10 4 hPa l s The pressure drop method described in the Check Gas Path Seal Integrity section 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 paths are opened they must then be purged prior t...

Page 46: ...h to be tested 2 Connect a hose with a tee fitted with a shutoff valve to the inlet of the gas path to be tested 3 Connect the free end of the tee to the pressure gauge Blow air or nitrogen through the shutoff valve until the sample gas path is pressurized to a pe of approx 50 hPa 50 mbar Close the shutoff valve Maximum excess pressure pe 150 hPa 150 mbar 4 After opening the gas paths inside the a...

Page 47: ...The sample component name display blinks if a maintenance request condition has occurred The gas analyzer is in a state that will soon require user intervention The measured value is valid CO 105 2 ppm Failure The sample component name and measured value displays blink if a failure condition has occurred The gas analyzer is in a state that immediately requires user intervention The measured value ...

Page 48: ...alue If the drift value is under the value shown in the specifications the measured value is correct The detector involved will need to be changed soon If drift exceeds this value call for service 6 M F Amplification drift exceeds permissible range Change the associated detector Call for service Perform initial calibration only possible with test and calibration software TCT Permissible amplificat...

Page 49: ...age appears after warm up Check if the permissible ambient temperature range is being main tained see page 8 Check the connecting leads and plug connections Check the line seating in the insu lated jackets Check the thermal link and replace as necessary 20 M F Internal processor bus fault 21 M F Internal display bus fault 22 M F Internal I O bus fault Switch power supply off and on again Call for ...

Page 50: ... gas paths see page 44 for instructions Outlet pressure not equal to atmospheric pressure The outlet pressure should be equal to atmospheric pressure Exhaust gases should be routed to the atmosphere or to an exhaust pipe directly or via the shortest possible large diameter line Do not route exhaust gases via flow reducers or shutoff valves Unstable Measured Value Reading Vibration Take measures to...

Page 51: ...gas analyzer serial number F No Found on the identification plate and on the analyzer data sheet The gas analyzer Software Version Found in the Information menu item and on the analyzer data sheet An exact description of the problem or status as well as the status message number This information will enable service personnel to help you quickly When arranging for service due to a problem or status...

Page 52: ...ference gas supplies 2 Purge the gas lines and gas paths in the analyzer unit with dry fresh air or nitrogen for at least 5 minutes 3 Turn off the gas analyzer power supply Additional Steps for Long Term Shutdown 4 Remove the gas lines from the analyzer unit ports Tightly seal the gas ports 5 Disconnect the electrical wiring from the control unit connections Ambient Temperature Ambient temperature...

Page 53: ...uate for the gas analyzer s weight Packing 4 Mark the box as Fragile Material Step Action Place the gas analyzer in a 0 2 mm thick polyethylene bag add a drying agent such as silica gel and seal the bag air tight 1 Use an amount of drying agent appropriate for the package volume and the planned shipping schedule at least 3 months Additional Steps when Shipping Overseas 2 Also wrap the box in a lay...

Page 54: ...ammable gases The gas analyzers should not be used to measure corrosive gases Explosion Protection The gas analyzers in the EL6010 family are especially designed for use in explo sion risk areas They are certified in accordance with European Directive 94 9 EC ATEX Directive The housings are pressure tight capsules and fulfill Explosion Group IIC require ments For this reason the gas analyzers can ...

Page 55: ...bles each 3 meters in length are connected at the factory and are brought into the pressure tight cylinder via pressure tight cable openings Housing protection type is IP 54 O ring seals required when mounted horizontally Housing Purge To protect the analyzer unit sensor electronics against the entry of an aggressive atmosphere or corrosive sample gas components a purge gas can flow through the pr...

Page 56: ...tputs for status signals and threshold alarm signals and A Modbus interface RS485 or RS232 to transfer measured values and status signals to a host system and for controlling calibration Operation Four touch screen fields accessible through the control unit viewing glass allow safe operation of the gas analyzer without opening the housing The menu driven control system is uniform for all three gas...

Page 57: ...within ignition limits cannot be provided Measurement Ranges with Suppressed Zero Point Differential measurement with flowing reference gas Max suppression ratio of1 10 depending on the base level Influence Effects Flow Effect Flow rate in the 20 100 l h range 0 5 of span at a flow rate change of 10 l h Pressure Drop at Flame Barriers Sample Gas or Reference Gas Inlet Approx 40 hPa at a flow rate ...

Page 58: ... be estimated using the approximate values in the following table Associated Gas Concentration 100 Vol Zero in Vol O2 Hydrogen H2 0 28 Hydrogen Sulfide H2S 0 45 Argon Ar 0 26 Helium He 0 30 Neon Ne 0 13 Nitrogen N2 0 00 Nitrogen Oxide NO 43 00 Nitrogen Dioxide NO2 28 00 Nitrous Oxide N2O 0 20 Carbon Monoxide CO 0 01 Carbon Dioxide CO2 0 32 Carbon Oxysulfide COS 0 90 Ethane C2H6 0 46 Ethene C2H4 0 ...

Page 59: ...nt range The measurement range is freely adjustable It is factory set to relative thermal conductivity rTC 0 60 000 Largest Measurement Range 0 to 100 Vol or 0 Vol to saturation depending on measurement task Measurement ranges within ignition limits cannot be provided Measurement Range with Suppressed Zero Point See Sample Components and Smallest Measurement Ranges table Influence Effects The foll...

Page 60: ...58 EL6010 Gas Analyzer in Category 2G Operator s Manual 42 24 30 EN Rev 1 Declaration of Conformity Continued on next page ...

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Page 67: ...42 24 30 EN Rev 1 EL6010 Gas Analyzer in Category 2G Operator s Manual 65 EC Type Examination Certificate Continued on next page ...

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Page 72: ...s occur continuously or on a long term basis Zone 1 Covers areas in which explosive atmospheres may occasionally be present Zone 2 Covers areas in which explosive atmospheres are infrequently present or occur only for short periods of time Operation of Electrical Equipment in Category 2G in Zone 1 Only electrical equipment in category 2G with an EC type certification may be used in Zone 1 explosio...

Page 73: ...ction Against Electrical Shock and Part 540 Grounding Protective Leads and Potential Compensation Leads shall be observed Electrostatic Charges Avoid electrostatic discharges Observe the Guidelines for Avoiding Ignition Risks Due to Electrostatic Discharges published by the Executive Committee for the Industrial Professional Trade Associations Testing Prior to Initial Use The operator is required ...

Page 74: ...cal characteristics inductance capacitance current and voltage of test equipment should be noted when such equipment is activated Special attention is required if work is carried out on intrinsically safe circuits set up in conjunction with Zone 0 areas Explosion Risk The explosion risk should be eliminated prior to carrying out any repair work Personnel Qualifications Repair work should only be p...

Page 75: ...e Measuring Range 29 Test Gases 35 Electrical Connections 17 Error List 45 Explosion Protection 52 70 71 72 Filter T90 Time 28 Gas Connection 15 Gas Inlet Conditions 9 Gas Path Seal Integrity Verification Maintenance 43 Prior to Start up 13 Housing Purge 15 53 Page Inspection 43 Installation 14 Installation Location 8 Interface Type Modbus 33 Items Delivered 10 Limit 32 Low Pass 28 Measuring Range...

Page 76: ...bb com The Company s policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice Printed in the Fed Rep of Germany 07 04 ABB 2004 42 24 30 EN Rev 1 ABB Automation Products GmbH Analytical Division Stierstaedter Strasse 5 60488 Frankfurt am Main Germany Phone 49 69 7930 40 Fax 49 69 7930 4566 E Mail analytical mkt deapr de abb ...

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