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Endura AZ25 series probe

Combustion oxygen monitor

3 Mechanical installation

12

OI/AZ25P–EN Rev. E

3.5.5 Test gas and reference air supply configurations – AutoCal systems with restrictors

Fig. 3.7 System using air as test gas 1 and
bottled gas as (optional) test gas 2

Endura AZ25 probe

Endura AZ25

AutoCal unit

Clean dry oil-free instrument air

INPUT

: 10 bar (145 psi) max.

OUTPUT

: 1 bar (15 psi) max.

5 µm / Oil

coalescing

filter regulator

Test gas 1 /
1 bar (15 psi)

Non-return

valve

Test gas 2 (optional) from bottled gas –
adjusted to 1 bar (15 psi) output

Reference air supply:
restrictor in probe limits
flow to 0.3 to 0.5 l/min
(0.64 to 1.06 scfh)
at 1 bar (15 psi)

Test gas supply:
restrictor in probe limits
flow to l/min (2.118 scfh)
at 1 bar (15 psi)

TG1

TG2

Test gas 2

Fig. 3.8 System using 2 bottled test gases

Endura AZ25 probe

Endura AZ25

AutoCal unit

Test gas 1 from bottled gas –
adjusted to 1 bar (15 psi) output

Reference

air pump

5 µm / Oil

coalescing

filter regulator

OR

Non-return

valve

Test gas 2 (optional) from bottled gas –
adjusted to 1 bar (15 psi) output

Clean dry oil-free instrument air

INPUT

: 10 bar (145 psi) max.

OUTPUT

: 1 bar (15 psi) max.

Reference air supply: restrictor
in probe limits flow to 0.3 to 0.5
l/min (0.64 to 1.06 scfh)
at 1 bar (15 psi)

Test gas supply:
restrictor in probe limits
flow to l/min (2.118 scfh)
at 1 bar (15 psi)

TG1

TG2

Test gas 2

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Summary of Contents for Endura AZ25 Series

Page 1: ...eres The sensor based on a zirconium oxide cell is mounted at the tip of the probe that is inserted directly into the furnace The resulting direct in situ measurement provides an accurate and rapid oxygen reading for combustion control optimization and process quality control purposes The in situ technique provides a true oxygen measurement inside the process It eliminates equilibrium shift that i...

Page 2: ...AZ25 probe are available for free download from www abb com measurement or by scanning this code Search for or click on Data Sheet Endura AZ25 oxygen analyzer Combustion gas analysis DS AZ25 EN Addendum RoHS Directive 2011 65 EU RoHS II ADD MEASUREMENT 001 EN ...

Page 3: ... 16 3 8 Mounting Endura AZ25 AutoCal unit 18 3 9 Mounting Endura AZ25 probe 18 3 10 End of life disposal 19 3 10 1 Endura AZ25 system weights probe cable transmitter AutoCal unit 19 4 Electrical connections 20 4 1 Electrical entry types 20 4 2 Endura AZ25 system without AutoCal 21 4 2 1 Cable preparation 6 core sensor cable Endura AZ25 remote transmitter to Endura AZ25 probe 21 4 2 2 Cable connect...

Page 4: ...must be taken to avoid the possibility of an accident occurring when operating in conditions of high pressure and or temperature Safety advice concerning the use of the equipment described in this manual or any relevant Material Safety Data Sheets where applicable may be obtained from the Company address on the back cover together with servicing and spares information Protective earth ground termi...

Page 5: ...ean local and national regulations EU Directive 2002 96 EC European electrical equipment users must now return old or end of life equipment to the manufacturer for disposal at no charge to the user Note For return for recycling please contact the equipment manufacturer or supplier for instructions on how to return end of life equipment for proper disposal Note The following applies only to Europea...

Page 6: ...ention to all warning and caution statements Failure to do so could result in serious injury to the operator or damage to the equipment To ensure the protection provided by this equipment is not impaired do not use or install this equipment in any manner other than that which is specified in this manual 1 9 Safety conventions The European Union RoHS Directive and subsequent regulations introduced ...

Page 7: ...travention of these principles could cause damage to the instrument and corporal injury to the person carrying out the repair It renders the warranty null and void and could compromise the correct working of the instrument and the electrical integrity or the CE compliance of the instrument If you have any problems with installation starting or using the instrument please contact the company that s...

Page 8: ...stem equipment comprises a process mounted AZ25 probe controlled by a remote AZ25 transmitter and where required an optional automatic calibration unit The AZ25 has a zirconia cell and a thermocouple assembly within the probe The zirconia cell produces a signal proportional to the oxygen partial pressure of the sample The thermocouple measures the temperature of the cell for automatic temperature ...

Page 9: ...ubject it to hammer blows or other sharp shocks The probe contains fragile ceramic components that can be damaged Visually inspect equipment for damage before installing Do not install damaged or faulty equipment It is recommended to retain the protective probe packing materials to allow for re shipping in the unlikely event of a return Caution The details on each probe label are unique to the cel...

Page 10: ...n maximum length 100 m 328 ft Endura AZ25 probe Endura AZ25 remote transmitter Output signals Relays Mains supply 600 C 1112 F 1400 C 2552 F Maximum temperature is sheath dependant refer to Section 6 page 31 Fig 3 3 Endura AZ25 system with AutoCal Output signals Relays Mains supply 6 Core screened sensor cable coded option 600 C 1112 F 1400 C 2552 F IP66 NEMA 4X 20 C 4 F 55 C 131 F 20 C 4 F ABB 14...

Page 11: ...he reference air and test gas flow is regulated by flowmeters with integral needle valves fitted in the delivery lines to the sensor one flowmeter is required in each delivery line Endura AZ25 AutoCal unit test gas 1 2 and vent Metric Imperial 1 4 in BSP female threaded entry supplied with 6 mm OD compression fitting 1 4 in NPT female threaded entry supplied with 1 4 in OD compression fitting Tabl...

Page 12: ... sensor cable probe to AutoCal unit length coded option ABB 14 core cable remote transmitter to AutoCal unit length coded option Metal M16 gland or 1 2 in NPT adaptor Test gas connection 6 mm stub see Section 3 5 4 page 11 for pneumatic requirements Test gas es out from AutoCal VENT connection to test gas inlet at probe Maximum combined cable length 100 m 328 ft Mains supply Endura AZ25 AutoCal un...

Page 13: ...ion configurations schematic AZ25 X X X 1 X AZ25 X X X 3 X KEEP TIGHTLY CLOSED WHEN NOT IN USE REF AIR 3KS0000000 067 AZ25 XXXXXXXXXXXXX Serial No Code No I P THC Is probe fitted with a restrictor Yes No Is probe connected to AutoCal Yes No Reference air supply ABB air pump Refer to the product code on the probe data label inside the probe head to identify system configuration Is probe connected t...

Page 14: ...ctor in probe limits flow to 0 3 to 0 5 l min 0 64 to 1 06 scfh at 1 bar 15 psi Test gas supply restrictor in probe limits flow to l min 2 118 scfh at 1 bar 15 psi TG1 TG2 Test gas 2 Fig 3 8 System using 2 bottled test gases Endura AZ25 probe Endura AZ25 AutoCal unit Test gas 1 from bottled gas adjusted to 1 bar 15 psi output Reference air pump 5 µm Oil coalescing filter regulator OR Non return va...

Page 15: ...n 2 118 scfh STP Reference air supply 0 3 to 0 5 l min 0 64 to 1 06 scfh Clean dry oil free instrument air INPUT 10 bar 145 psi max OUTPUT 1 bar 15 psi max TG1 TG2 Test gas 2 Fig 3 10 System using 2 bottled test gases Endura AZ25 probe Endura AZ25 AutoCal unit Clean dry oil free instrument air INPUT 10 bar 145 psi max OUTPUT 1 bar 15 psi max Reference air pump OR Non return valve 5 µm Oil coalesci...

Page 16: ...justed to 0 3 to 0 5 l min 0 64 to 1 06 scfh STP Shut off valve for test gas runs 10 m 33 ft ABB flowmeter adjusted to 1 l min 2 118 scfh STP Test gas supply 1 l min 2 118 scfh Fig 3 12 System using 2 bottled test gases Endura AZ25 probe Reference air pump 3 Way valve 5 µm Oil coalescing filter regulator Test gas 1 bottled gas adjusted to 1 bar 15 psi output Test gas 2 optional bottled gas adjuste...

Page 17: ...in 900 mm 901 mm 35 47 in 1000 mm 956 mm 37 64 in 1250 mm 1251 mm 49 25 in Test gas entry Reference air entry Termination head 115 4 35 88 3 46 2 off 16 0 63 cable entries Mounting flange Probe outer sheath 27 5 1 08 diameter 130 5 12 Dimensions in mm in Fig 3 14 Overall dimensions Endura AZ25 AutoCal unit with wall pipe mounting bracket 125 4 9 70 27 6 Ø 8 5 0 33 Wall Pipe mount bracket includes ...

Page 18: ...16 185 7 28 12 0 47 18 0 70 145 5 70 JIS 65 5K 155 6 10 12 0 47 15 0 59 130 5 12 JIS 80 5K 180 7 08 12 0 47 19 0 75 145 5 71 Table 3 3 4 Hole probe flange types and dimensions A B C D Flange type A B C Ø D PCD 6 Hole flanges ABB standard 101 3 97 6 0 24 7 3 0 29 80 3 15 Table 3 4 6 Hole probe flange types and dimensions A B C D Flange type A B C Ø D PCD 8 Hole flanges ANSI 4 in 150 228 6 9 0 12 0 ...

Page 19: ...rs and nuts 160 6 3 160 6 3 7 0 27 16 0 63 Table 3 6 ABB flange mounting plate dimensions B C A D 6 M6 Studs equispaced on 80 3 15 PCD Flange type A B C Holes drilled by customer ZGP2 heritage 125 4 92 5 0 2 Fixing holes location quantity to be drilled by customer Table 3 7 ABB blank heritage flange dimensions A B C Flange type A B C 1 in male thread 1 in NPT BSP 69 8 2 74 15 0 59 45 1 77 Table 3 ...

Page 20: ...eading to thermal shock and failure of the sensor This problem is most likely to occur on such installations where the plant is shut down regularly over the week end Additionally take care to protect the head of the probe from the elements in out door installations Raising the temperature of the probe as rapidly as possible will assist in reducing the level of condensation This is not possible on ...

Page 21: ...lb 4 6 kg 10 0 lb Table 3 10 Endura AZ25 probe with aluminous porcelain sheath Probe version Total probe length Probe only packed unpacked Probe Tx packed unpacked 500 mm 23 62 in 686 mm 27 01 in 4 7 kg 10 2 lb 2 2 kg 4 7 lb 7 2 kg 15 7 lb 4 7 kg 10 2 lb 700 mm 27 56 in 831 mm 32 72 in 5 0 kg 10 9 lb 2 5 kg 5 4 lb 7 5 kg 16 4 lb 5 0 kg 10 9 lb 800 mm 31 50 in 931 mm 36 56 in 5 2 kg 11 3 lb 2 7 kg ...

Page 22: ...inals for external circuits are for use only with equipment with no accessible live parts If the equipment is used in a manner not specified by the Company the protection provided by the equipment may be impaired All equipment connected to the transmitter s terminals must comply with local safety standards IEC 60950 EN601010 1 Caution Make connections only as shown Maintain Environmental Protectio...

Page 23: ... Red Cell Blue ACJC Screen with drain Orange ACJC Black Cell Green TC 6 core screened sensor cable probe to transmitter maximum length 100 m 328 ft coded option Wire colors 6 core sensor cable Transmitter end cut to 100 mm 4 in including drain wire Probe end cut to 10 mm 0 4 in Endura AZ25 probe Endura AZ25 remote transmitter Transmitter end cut to 10 mm 0 4 in Cut outer insulation sheath and scre...

Page 24: ...ain at probe head back and isolate only do not connect these items at probe Connect drain from 6 core cable at transmitter to the transmitter internal earth stud only do not connect to transmitter terminal SCN connector or transmitter external earth Fig 4 2 Cable connections 6 core sensor cable Endura AZ25 remote transmitter to Endura AZ25 probe Endura AZ25 probe Green White Red Black Orange Blue ...

Page 25: ...d screen foil cut back and isolated drain wire connected to AutoCal unit outer terminal block SCN connector see Fig 4 5 page 25 14 core cable at Endura AZ25 transmitter outer insulation sheath and screen foil cut back and isolated drain wire connected to transmitter internal terminal earth stud see Fig 4 5 page 25 The maximum combined 6 core plus 14 core cable run is 100 m 328 ft coded option Fig ...

Page 26: ...robe Cut the screen screen foil and drain at probe head back and isolate ONLY do not connect these items at probe Connect drain from 6 core cable at AutoCal unit to the AutoCal terminal block INNER SCN connector ONLY Fig 4 4 Cable connections 6 core sensor cable Endura AZ25 AutoCal unit to Endura AZ25 probe Endura AZ25 probe Green White Red Black Orange Blue T C T C Cell Cell ACJC ACJC 6 Core sens...

Page 27: ... Green Green T C White White White T C SCN Screen 2 SCN not used drain connected to Tx internal earth stud Screen 2 Screen 1 cut back N A Brown not used Brown not used Brown cut back Not used Blue not used Blue not used Blue cut back Not used Table 4 6 Cable connections 14 core cable Endura AZ25 AutoCal unit to Endura AZ25 remote transmitter Wire colors 14 core screened cable Transmitter end cut t...

Page 28: ...ndura AZ25 remote transmitter Terminal connections at Endura AZ25 AutoCal unit ACJC Violet ACJC Grey Cell Red Cell Black T C Green T C White SCN Screen 14 core transmitter cable connections P2 White Yellow P COM White Black P1 White Orange SV1 White Green SV COM White Red SV2 White Blue Brown Blue NOT USED Brown Blue NOT USED Cell Red Cell Black ACJC Violet ACJC Grey T C Green T C White NOT USED S...

Page 29: ...ng in the transmitter If the probe is connected permanently to the test gas supply pipework fit a high quality corrosion resistant stainless steel solenoid valve manually operated valve or non return valve that is leak tight even at zero back pressure in the pipework as close to the test gas inlet valve as possible keep the valve closed when the calibration system is not in use Refer to Section 3 ...

Page 30: ...and out of test gas lines refer to Section 3 5 page 9 for schematics of all configuration options 4 4 8 Internal test gas and reference air tubes AutoCal unit Note The reference air supply must be to instrument air standards clean dry and free of oil vapor and particle contamination see schematics in Section 3 5 page 9 ABB recommend using the ABB 5µm Oil Coalescing Filter Regulator to supply refer...

Page 31: ... page 9 for test gas and reference air supply configurations 5 2 1 AutoCal System with restrictors To set up an AutoCal system with restrictors 1 Make test gas and reference air connections as detailed in Section 3 5 5 page 12 2 Turn on Test Gas 1 and set the pressure to a nominal 1 bar 15 psi 3 At the transmitter check the Calibrate AutoCal Hardware Hardware Type parameter is set to Internal 4 At...

Page 32: ... bar 15 psi and set the flow on the flowmeter to 1 l min 2 118 scfh 6 Turn gas off at the transmitter by pressing then turn Test Gas 1 off at the supply 7 Repeat steps 2 to 6 for Test Gas 2 if present 8 Refer to IM AZ20E EN to perform a calibration when required 5 2 3 Non AutoCal System with restrictors To set up an Non AutoCal system with restrictors 1 Make test gas and reference air connections ...

Page 33: ...ressure 5 kPa 0 7 psi positive or negative Operating requirements Reference air Regulated supply probes with restrictors reference air supply set to 1 bar 15 psi gives flow of 0 3 to 0 5 l min 0 64 to 1 06 scfh flowmeters not required probes without restrictors 1 bar 15 psi flowmeters required with flow set to 0 3 to 0 5 l min 0 64 to 1 06 scfh Pumped supply probes with without restrictors require...

Page 34: ... heritage ABB products Endura AZ25 probe to ZDT transmitter IM ZDT GP Endura AZ25 probe to ZMT transmitter IM ZDT Endura AZ25 transmitter to ZGP2 probe IM ZGP2 These manuals can also be downloaded from www abb com measurement Important If making electrical connections between the Endura AZ25 probe and heritage ABB products do not make connections to the ACJC terminal block connectors in the Endura...

Page 35: ... AZ200 770 AZ200 771 AZ200 772 AZ200 773 ABB reference air pump 1 4 BSP Metric 230 V AC 50 60 Hz 1 4 BSP Metric 115 V AC 50 60 Hz 1 4 NPT Imperial 230 V AC 50 60 Hz 1 4 NPT Imperial 115 V AC 50 60 Hz Application dependant see Table B 1 ABB Flowmeter Flowmeter Type Part Number 1 4 NPT Flowmeter Reference Air 0 1 to 0 85 l min 0 21 to 1 8 scfh STP 1 4 BSP Flowmeter Reference Air 0 1 to 0 85 l min 0 ...

Page 36: ...Endura AZ25 series probe Combustion oxygen monitor Notes 34 OI AZ25P EN Rev E Notes ...

Page 37: ...Endura AZ25 series probe Combustion oxygen monitor Notes OI AZ25P EN Rev E 35 ...

Page 38: ...Endura AZ25 series probe Combustion oxygen monitor Notes 36 OI AZ25P EN Rev E ...

Page 39: ...Sales Software Service ...

Page 40: ...t and in the subject matter and illustrations contained therein Any reproduction disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB Copyright ABB 2018 All rights reserved 3KXA722200R4201 ABB Limited Measurement Analytics Oldends Lane Stonehouse Gloucestershire GL10 3TA UK Tel 44 0 1453 826661 Fax 44 0 1453 829671 Mail i...

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