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EasyLine Continuous Gas Analyzers Models EL3020, EL3040 Software Version 3.4 Instructions for Installation, Start-up and Operation 41/24 400 EN Rev. 6...
EasyLine Continuous Gas Analyzers Models EL3020, EL3040 Software Version 3.4 Instructions for Installation, Start-up and Operation Publication No. 41/24 400 EN Revision 6 Edition November 2014 This 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.
EasyLine EL3000 Series Commissioning Instructions Contents Preface..............................6 Guideline for Installation and Commissioning..................8 Safety Information ..........................9 Intended Application ...................9 Safety Information ..................10 Fidas24: Information on the safe operation of the gas analyzer....12 Preparation for Installation ........................14 Scope of Supply and Delivery ..............14 Material Required for the Installation (not supplied) ........15 Requirements for the Installation Site, Power Supply......17 Sample Gas Inlet and Outlet Conditions ..........20...
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Contents Fidas24: Connecting the Sample Gas Line (Heated Sample Gas Connection) ....................74 Fidas24: Connecting the Sample Gas Line (Unheated Sample Gas Connection) ....................79 Electrical Connections Model EL3020 .............81 Electrical Connections Model EL3040 .............82 Electrical Connections Analog Output Modules ........84 Electrical Connections Digital I/O Module ..........85 Electrical Connections Modbus Module ...........87 Electrical Connections Profibus Module...........88 Connecting the Signal Lines ..............89...
Information on spare parts can be found on the CD-ROM "Spare parts analytical", which is enclosed with the gas analyzer. Internet You will find information on ABB Analytical products and services on the Internet at "http://www.abb.com/analytical". Service contact If the information in this operator's manual does not cover a particular situation, ABB Service will be pleased to supply additional information as required.
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Preface Symbols and Typefaces in the Operator's Manual ATTENTION identifies safety information to be 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, ...
EasyLine EL3000 Series Commissioning Instructions Guideline for Installation and Commissioning Basic Steps The following basic steps should be followed for the installation and commissioning of the gas analyzer: Please note the information on the intended application (see page 9). Follow safety precautions (see page 10). Prepare for the installation, provide the requisite material (see page 14).
Safety Information Safety Information Intended Application Intended Application of the Gas Analyzer The gas analyzer is designed for continuous measurement of the concentration of individual components in gases or vapors. Any other use is not as specified. The specified use also includes taking note of this operator's manual. The gas analyzer may not be used for the measurement of ignitable gas/air or gas/oxygen mixtures.
EasyLine EL3000 Series Commissioning Instructions Safety Information Requirements for Safe Operation In order to operate in a safe and efficient manner the device should be properly handled and stored, correctly installed and set-up, properly operated and correctly maintained. Personnel Qualifications Only persons familiar with the installation, set-up, operation and maintenance of comparable devices and certified as being capable of such work should work on the device.
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Safety Information Risks of a Disconnected Protective Lead The device can be hazardous if the protective lead is interrupted inside or outside the device or if the protective lead is disconnected. Risks Involved in Opening the Covers Current-bearing components can be exposed when the covers or parts are removed, even if this can be done without tools.
EasyLine EL3000 Series Commissioning Instructions Fidas24: Information on the safe operation of the gas analyzer ATTENTION The gas analyzer uses hydrogen as a combustion gas! All the information and instructions contained in this operator's manual must be complied with without fail to ensure safe operation of the gas analyzer! Measures of the manufacturer The following measures ensure that the enrichment of combustion gas or...
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Safety Information The seal integrity of the combustion gas line (see page 116) outside the gas analyzer and the combustion gas feed path (see page 118) in the gas analyzer must be checked on a regular basis. The maximum combustion gas flow (see page 29) may not be exceeded.
EasyLine EL3000 Series Commissioning Instructions Preparation for Installation Scope of Supply and Delivery Scope of Supply and Delivery Gas analyzer model EL3020 (19-inch housing) or model EL3040 (wall-mount housing) Screwed fittings with tubing connectors for the connection of flexible tubes ...
Preparation for Installation Material Required for the Installation (not supplied) Gas Connections For the connection of pipelines: Threaded connections with a 1/8 NPT thread and PTFE sealing tape Fidas24: Use only metal threaded connectors! Fidas24: Gas lines Process gases, test gases and waste air ...
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EasyLine EL3000 Series Commissioning Instructions Shut-off Valve Install a shut-off valve in the sample gas line (definitely recommended with pressurized sample gas). Purging of the gas line system Provide a means for purging the gas line system by feeding in an inert gas, e.g.
Preparation for Installation Requirements for the Installation Site, Power Supply NOTE For the analyzers ZO23 and Fidas24 the information contained in the sections "ZO23: Preparation for Installation" or "Fidas24: Preparation for Installation (see page 29)" must be considered in addition. Requirements for the installation site The gas analyzer is only intended for installation indoors.
EasyLine EL3000 Series Commissioning Instructions Climatic conditions Air Pressure 600...1250 hPa Relative humidity max. 75 %, slight condensation permissible Ambient temperature for storage and transport –25...+65 °C during operation +5...+45 °C Uras26 in combination with another analyzer, Limas23, Fidas24 +5...+40 °C 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...
Preparation for Installation Housing design Model Housing design Degree of protection Weight EL3020 19-inch housing IP20 approx. 7...15 kg EL3040 Wall-mount housing IP65 approx. 13...21 kg Power supply Input voltage 100...240 V AC (– 15 %, + 10 %), 50...60 Hz (± 3 Hz) Power consumption max.
EasyLine EL3000 Series Commissioning Instructions Sample Gas Inlet and Outlet Conditions NOTE For the analyzers ZO23 and Fidas24 the information contained in the sections "ZO23: Preparation for Installation" or "Fidas24: Preparation for Installation (see page 29)" must be considered in addition. ATTENTION The gas analyzer may not be used for the measurement of ignitable gas/air or gas/oxygen mixtures.
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Preparation for Installation Magnos206 Sample Gas Inlet Conditions Temperature +5…+50 °C Positive pressure 2…100 hPa Flow 30…90 l/h Flammable Gases The analyzer is suitable for the measurement 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 If the sample gas contains Cl , HCl, HF or other corrosive components,...
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EasyLine EL3000 Series Commissioning Instructions Oxygen Sensor Flammable Gases The oxygen sensor may not be used for the measurement of flammable gases. Other Requirements The H O dew point of the sample gas must be at least 2 °C. The oxygen sensor may not be used if the sample gas contains the following components: H S, compounds containing chlorine or fluorine, heavy...
Preparation for Installation Test Gases for Calibration NOTE For the analyzers ZO23 and Fidas24 the information contained in the sections "ZO23: Preparation for Installation" or "Fidas24: Preparation for Installation (see page 29)" must be considered in addition. Analyzer(s) Test gas for the zero-point calibration Test gas for the end-point and the single-point calibration calibration...
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EasyLine EL3000 Series Commissioning Instructions Analyzer(s) Test gas for the zero-point calibration Test gas for the end-point and the single-point calibration calibration Limas23 with calibration cells or air or Calibration cells or (automatic calibration) UV sample component-free gas test gas for each sample component Limas23 without calibration or air or...
Preparation for Installation ZO23: Preparation for Installation Sample gas ATTENTION The gas analyzer may not be used for the measurement of ignitable gas/air or gas/oxygen mixtures. Sample Gas Inlet Conditions Temperature +5…+50 °C 70 hPa Inlet pressure Flow 4…20 l/h The sample gas flow rate must be kept constant at ±0.2 l/h in the specified range.
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EasyLine EL3000 Series Commissioning Instructions Test Gases Reference point (= electrical zero) Clean ambient air; its oxygen concentration can be calculated from the value for dry air and the factor for the consideration of the water vapor content. Example: Water vapor content at 25 °C and 50 % relative humidity = 1.56 Vol.-% of O ...
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Preparation for Installation Example of sample conditioning Sampling point with primary shut-off valve Multi-way ball valve 3/2-way ball valve Fine-control valve Flowmeter with needle valve and alarm contact 2-way ball valve 2-way ball valve Air filter Gas analyzer 10 Flowmeter without needle valve, with alarm contact Purge gas cylinder with N 12 Test gas cylinder with e.g.
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EasyLine EL3000 Series Commissioning Instructions Gas Sampling The nominal diameter of the line from the sampling point to the first switch-over valve should be 4 mm. A bypass can be positioned upstream of the first switch-over valve, in order to obtain a faster analysis. With a nominal diameter of 4 mm, the bypass should be longer than 3 m, in order to prevent back diffusion from the ambient air.
Preparation for Installation Fidas24: Preparation for Installation Sample gas Sample Gas Inlet Conditions Temperature Thermostat temperature (thermostat temperature for sample gas path, detector and air jet injector 200 °C, pre-set ex works to 180 °C) Inlet pressure = 800 to 1200 hPa Flow Approx.
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/He mixture. Suitable measures outside the gas analyzer must be provided 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: ...
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Preparation for Installation Test Gases Zero-point Calibration Quality Nitrogen, Quality 5.0, synthetic air or catalytically cleaned air with an organic C content < 1 % of span Inlet pressure = 1000 ± 100 hPa Flow 130 to 250 l/h End-point Calibration Quality Sample component or substitute gas component in nitrogen or synthetic air with concentration adjusted to...
EasyLine EL3000 Series Commissioning Instructions Pressure Sensor NOTE A pressure sensor cannot be installed in the ZO23 and Fidas24 gas analyzers. Uras26 The pressure sensor is installed in the gas analyzer as standard. Depending on the design of the gas analyzer, it is internally connected as follows (see also Gas Connections for the models EL3020 (see page 42) and EL3040 (see page 44)): ...
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Preparation for Installation Caldos27 The pressure sensor is installed in the gas analyzer as standard. It is connected to a connection port via an FPM hose (see also gas connections for the models EL3020 (see page 64) and EL3040 (see page 65)).
EasyLine EL3000 Series Commissioning Instructions Housing Purge Housing Design Remark: Housing purge in the Fidas24 is described in a separate section, see below. Housing Purge is only possible with the wall-mount housing (EL3040 model). The purging gas connectors (1/8-NPT female thread) are factory- installed based on orders.
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Preparation for Installation Housing Purge during Operation Purge gas flow: max. 20 l/h (constant) at the instrument inlet Positive pressure of = 2 to 4 hPa purging gas: With a purge gas flow of 20 l/h at the instrument inlet, the purge gas flow at the instrument outlet due to leakage will amount to approx.
EasyLine EL3000 Series Commissioning Instructions Dimensional Drawings 19-inch Case (Model EL3020) 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.
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Preparation for Installation Wall-mounting Case (Model EL3040) Dimensions in mm...
EasyLine EL3000 Series Commissioning Instructions Special Requirements for the Measurement of Flammable Gases NOTE The version for the measurement of flammable gases and vapors and the explosion-proof version with degree of protection II 3G are different versions of the gas analyzer and designed for different applications. Installation of the Gas Analyzer ...
Preparation for Installation Explosion-proof Design in Degree of Protection II 3G NOTE The version for the measurement of flammable gases and vapors and the explosion-proof version with degree of protection II 3G are different versions of the gas analyzer and designed for different applications. Description The gas analyzer model EL3040 in degree of protection II 3G has been tested for explosion protection and is suitable for use in hazardous areas...
EasyLine EL3000 Series Commissioning Instructions Installing the Gas Analyzer Unpacking the Gas Analyzer ATTENTION Depending on its design, the gas analyzer weighs 7 to 15 kg (19-inch case – Model EL3020) and 13 to 21 kg (wall-mounting case – Model EL3040)! Unpacking and transporting requires two persons! Unpacking the Gas Analyzer Remove the accessories (see scope of supply and delivery (see page...
Installing the Gas Analyzer Installing the Gas Connections NOTES We strongly recommend that you install the gas connections before the gas analyzer is installed, since the gas ports are now easily accessible. The fittings must be clean and free of residue! Contaminants can enter the analyzer and damage it or lead to false measurement results! Do not use sealing compound to seal the gas connections! Constituents of the sealing compound can lead to false measurement results! Use...
EasyLine EL3000 Series Commissioning Instructions Gas Connections for Uras26 (Model EL3020) Uras26: Gas Connections for Flexible Tubes (internal gas lines executed as flexible tubes) Sample gas inlet Gas feed path 1 without option "Integrated gas feed" Sample gas outlet Gas feed path 1 Sample gas outlet with the option "Integrated gas feed", connected ex works to 1 Sample gas inlet Gas feed path 1 Sample gas inlet...
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Installing the Gas Analyzer Uras26: Gas Connections for Pipelines (internal gas lines executed as stainless steel pipes) Pressure sensor Design: Screwed fitting with hose nozzle (stainless steel 1.4305/SAE 303) for hose with 4 mm inner diameter (supplied) Sample gas inlet 12 Sample gas outlet with one sample cell 13 Sample gas outlet with two sample cells in series...
EasyLine EL3000 Series Commissioning Instructions Gas Connections for Uras26 (Model EL3040) Uras26: Gas Connections with 1 Gas Feed Path (internal gas lines executed as flexible tubes or stainless steel pipes) not assigned not assigned Sample gas inlet Sample gas outlet with one sample cell Purge gas inlet for case Purge gas outlet for case not assigned...
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Installing the Gas Analyzer Uras26: Gas Connections with 2 Separate Gas Feed Paths (internal gas lines executed as flexible tubes) not assigned not assigned Sample gas inlet gas feed path 1 Sample gas outlet gas feed path 1 Purge gas inlet for case Purge gas outlet for case Sample gas inlet gas feed path 2 Sample gas outlet gas feed path 2...
EasyLine EL3000 Series Commissioning Instructions Gas Connections for Uras26 with Magnos206 (Model EL3020) Uras26: Gas Connections for Flexible Tubes (internal gas lines executed as flexible tubes) Sample gas inlet Gas feed path 1 without option "Integrated gas feed" Sample gas outlet Gas feed path 1 Sample gas outlet with the option "Integrated gas feed", connected ex works to 1 Sample gas inlet Gas feed path 1 Sample gas inlet...
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Installing the Gas Analyzer Uras26: Gas Connections for Pipelines (internal gas lines executed as stainless steel pipes) Pressure sensor Design: Screwed fitting with hose nozzle (stainless steel 1.4305/SAE 303) for hose with 4 mm inner diameter (supplied) Sample gas inlet 12 Sample gas outlet with one sample cell 13 Sample gas outlet with two sample cells in series Design:...
EasyLine EL3000 Series Commissioning Instructions Gas Connections for Uras26 with Magnos206 (Model EL3040) Uras26: Gas Connections with 1 Gas Feed Path (internal gas lines executed as flexible tubes or stainless steel pipes) not assigned not assigned Sample gas inlet Sample gas outlet with one sample cell Purge gas inlet for case Purge gas outlet for case not assigned...
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Installing the Gas Analyzer Uras26: Gas Connections with 2 Separate Gas Feed Paths (internal gas lines executed as flexible tubes) not assigned not assigned Sample gas inlet gas feed path 1 Sample gas outlet gas feed path 1 Purge gas inlet for case Purge gas outlet for case Sample gas inlet gas feed path 2 Sample gas outlet gas feed path 2...
EasyLine EL3000 Series Commissioning Instructions Gas Connections for Uras26 with Caldos27 (Model EL3020) Uras26: Gas Connections for Flexible Tubes (internal gas lines executed as flexible tubes) Sample gas inlet Gas feed path 1 without option "Integrated gas feed" Sample gas outlet Gas feed path 1 Sample gas outlet with the option "Integrated gas feed", connected ex works to 1 Sample gas inlet Gas feed path 1 Sample gas inlet...
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Installing the Gas Analyzer Uras26: Gas Connections for Pipelines (internal gas lines executed as stainless steel pipes) Pressure sensor Design: Screwed fitting with hose nozzle (stainless steel 1.4305/SAE 303) for hose with 4 mm inner diameter (supplied) Sample gas inlet 12 Sample gas outlet with one sample cell 13 Sample gas outlet with two sample cells in series Design:...
EasyLine EL3000 Series Commissioning Instructions Gas Connections for Uras26 with Caldos27 (Model EL3040) Uras26: Gas Connections with 1 Gas Feed Path (internal gas lines executed as flexible tubes or stainless steel pipes) not assigned not assigned Sample gas inlet Sample gas outlet with one sample cell Purge gas inlet for case Purge gas outlet for case not assigned...
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Installing the Gas Analyzer Uras26: Gas Connections with 2 Separate Gas Feed Paths (internal gas lines executed as flexible tubes) not assigned not assigned Sample gas inlet gas feed path 1 Sample gas outlet gas feed path 1 Purge gas inlet for case Purge gas outlet for case Sample gas inlet gas feed path 2 Sample gas outlet gas feed path 2...
EasyLine EL3000 Series Commissioning Instructions Gas Connections for Limas23 (Model EL3020) Limas23: Gas Connections Sample gas inlet 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.
Installing the Gas Analyzer Gas Connections for Limas23 (Model EL3040) Limas23: Gas Connections 13 Sample gas inlet 14 Sample gas outlet Purge gas inlet for case 12 Purge gas 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)
EasyLine EL3000 Series Commissioning Instructions Gas Connections for Limas23 with Magnos206 (Model EL3020) Limas23: Gas Connections Sample gas inlet 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 is connected internally in the outlet of the sample cell.
Installing the Gas Analyzer Gas Connections for Limas23 with Magnos206 (Model EL3040) Limas23: Gas Connections 13 Sample gas inlet 14 Sample gas outlet Purge gas inlet for case 12 Purge gas 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)
EasyLine EL3000 Series Commissioning Instructions Gas Connections for Magnos206 (Model EL3020) Magnos206: Gas Connections Sample gas inlet 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) Sample gas outlet...
Installing the Gas Analyzer Gas Connections for Magnos206 (Model EL3040) Magnos206: Gas Connections Sample gas inlet Sample gas outlet not assigned not assigned 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)
EasyLine EL3000 Series Commissioning Instructions Gas Connections for Magnos27 (Model EL3020) Magnos27: Gas Connections Pressure sensor (option) not used Sample gas inlet Sample gas outlet Purge gas inlet analyzer Purge gas outlet analyzer Design: Screwed fittings with hose nozzles (stainless steel 1.4305/SAE 303) for hoses with 4 mm inner diameter (supplied)
Installing the Gas Analyzer Gas Connections for Magnos27 with Uras26 (Model EL3020) Magnos27: Gas Connections Sample gas inlet Sample gas outlet Purge gas inlet analyzer 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 Sample gas inlet...
EasyLine EL3000 Series Commissioning Instructions Gas Connections for ZO23 (Model EL3020) ZO23: Gas Connections 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. ®...
Installing the Gas Analyzer Gas Connections for ZO23 (Model EL3040) ZO23: Gas Connections 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. ®...
EasyLine EL3000 Series Commissioning Instructions Gas Connections for Caldos27 (Model EL3020) Caldos27: Gas Connections Sample gas inlet 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) Sample gas outlet...
Installing the Gas Analyzer Gas Connections for Caldos27 (Model EL3040) Caldos27: Gas Connections Sample gas inlet Sample gas outlet not assigned not assigned 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)
EasyLine EL3000 Series Commissioning Instructions Gas and Electrical Connections for Fidas24 (Model EL3020) Fidas24: Gas and Electrical Connections 30 Power supply 115 V AC or 230 V AC for heating the detector and sample gas inlet (4-pin plug connector, connecting cable supplied) 31 Electrical connection to the heated sample gas inlet (hard mounted) 32 Test gas outlet 33 Zero gas inlet...
Installing the Gas Analyzer Gas and Electrical Connections for Fidas24 (Model EL3040) Fidas24: Gas and Electrical Connections 30 Power supply 115 V AC or 230 V AC for heating the detector and sample gas inlet (4-pin plug connector, connecting cable supplied) 31 Electrical connection to the heated sample gas inlet (hard mounted) 32 Test gas outlet 33 Zero gas inlet...
EasyLine EL3000 Series Commissioning Instructions Installing the Gas Analyzer ATTENTION The installation site must be stable enough to bear the weight (see page 17) of the gas analyzer! The 19-inch housing must be supported in the cabinet or the rack with mounting rails! Requisite material (not supplied) 19-inch Case (Model EL3020)
Installing the Gas Analyzer Connecting the Gas Lines Connect the Flexible Tubes Push the flexible tubes with inside diameter = 4 mm onto the nozzles and secure by means of hose clamps. Connect the Pipelines Connect the stainless steel pipes to the fittings according to good professional practice and making allowance for the tightness requirements.
EasyLine EL3000 Series Commissioning Instructions Fidas24: Connecting the Gas Lines ATTENTION The relevant safety regulations for working with flammable gases must be complied with. The fittings of the gas paths in the gas analyzer may not be opened. The gas paths can become leaky as a result. However, if the fittings of the gas paths in the gas analyzer have been opened (only by trained personnel), a seal integrity test with a leak detector (thermal conductivity) must always be carried out after they...
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Installing the Gas Analyzer Connection of Process Gases and Test Gases Exhaust gas Combustion air p = 1200 ± 100 hPa Instrument air p = 4000 ± 500 hPa Combustion gas p = 1200 ± 100 hPa Flow Pneumatic restrictor shut-off valve Switch-over station with safety valve...
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EasyLine EL3000 Series Commissioning Instructions Exhaust Air Connection Conduct exhaust air directly into the atmosphere at zero pressure through a line with a large internal diameter which is as short as possible, or into a gas discharge line. Use an exhaust air line of PTFE or stainless steel! The temperature of the medium can be up to 200 °C! Lay the exhaust air line with a downward gradient.
Installing the Gas Analyzer Fidas24: Connecting the Combustion Gas Line Connecting the Combustion Gas Line Cleaning the Combustion Gas Line Pump cleaning agent (alkaline cleaner, stainless steel pickling agent) through the stainless steel tube. Thoroughly rinse the tube with distilled water. Purge the tube for several hours at a temperature of >...
EasyLine EL3000 Series Commissioning Instructions Fidas24: Connecting the Sample Gas Line (Heated Sample Gas Connection) ATTENTION If a plastic vent plug has been inserted in the sample gas inlet in the factory, it must be removed without fail before commissioning the analyzer module! Material of the Sample Gas Line Use a sample gas line of PTFE or stainless steel! (Recommendation: use...
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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.
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EasyLine EL3000 Series Commissioning Instructions Connection of the sample gas line to the heated sample gas connection Wall-mount housing (view from bottom right)
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Installing the Gas Analyzer 19-inch housing (view from top left)
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EasyLine EL3000 Series Commissioning Instructions Connection of the sample gas line Heated sample gas line (tube with inside/outside diameter 4/6 mm) O-ring 6.02 x 2.62 Socket O-ring 12.42 x 1.78 Connection of a further sample gas line (tube with outside diameter 6 mm): either with male fitting with a tapered ISO external thread G1/4”...
Installing the Gas Analyzer Fidas24: Connecting the Sample Gas Line (Unheated Sample Gas Connection) ATTENTION If a plastic vent plug has been inserted in the sample gas inlet in the factory, it must be removed without fail before commissioning the analyzer module! Connection of the sample gas line The unheated sample gas connection has only one sample gas inlet.
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EasyLine EL3000 Series Commissioning Instructions Connection of the sample gas line Sample gas line (heated or unheated, PTFE or stainless steel tube with inside/outside diameter 4/6 mm) Connection either with O-ring 6.02 x 2.62 Socket O-ring 12.42 x 1.78 or with Male fitting with a tapered ISO external thread G1/4”...
Installing the Gas Analyzer Electrical Connections Model EL3020 Electrical Connections Power supply connection (see page 90) (3-pole grounded-instrument connector to EN 60320-1/C14, mains lead supplied) Digital I/O module (see page 85) NOTE The illustration shows all the available I/O module types and Analog output module (see page 84) only represents an example of the I/O modules equipment (max.
EasyLine EL3000 Series Commissioning Instructions Electrical Connections Model EL3040 Screwed Cable Glands Type Use (Recommendation) Permissible cable diameter Power supply 5–13 mm Modbus/Profibus 8–17 mm (insert 5x 4 mm) Network connections 8–17 mm 3x analog outputs 8–17 mm (insert 3x 7 mm) Digital inputs/outputs 12–21 mm Digital inputs/outputs...
Installing the Gas Analyzer Electrical Connections Power supply connection (see page 90) (3-pole grounded-instrument connector to EN 60320-1/C14, mains lead supplied) Digital I/O module (see page 85) NOTE The illustration shows all the available I/O module types and Analog output module (see page 84) only represents an example of the I/O modules equipment (max.
EasyLine EL3000 Series Commissioning Instructions Electrical Connections Analog Output Modules Signal AO1+ AO1– AO2+ AO2– AO3+ AO3– AO4+ AO4– Analog Outputs AO1 to AO4 0/4...20 mA (pre-set ex works to 4...20 mA), common negative pole, electrically isolated to ground, can be connected to ground as required, in this regard, max.
Installing the Gas Analyzer Electrical Connections Digital I/O Module Digital Inputs DI1 to DI4 Opto-electronic coupler with 24 V DC As an alternative, activation by floating contacts with an external voltage of 12–24 V DC or by Open- Collector drivers PNP or NPN. Digital Outputs DO1 to DO4 Floating double-throw contacts, max.
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EasyLine EL3000 Series Commissioning Instructions Digital input and output Standard assignment Standard assignment signals Digital I/O module 1 Digital I/O module 2 Failure Maintenance request Maintenance mode Overall status Start automatic calibration Stop automatic calibration Disable automatic calibration Sample gas valve Zero gas valve Span gas valve 1 Span gas valve 2...
Installing the Gas Analyzer Electrical Connections Modbus Module RS232 Interface Signal Design: 9-pole male Sub-D plug RS485 Interface Signal RTxD– RTxD+ Design: 9-pole female Sub-D plug NOTE For detailed Information on "Modbus", refer to the Technical Information "EL3000, EL3060, EL3010-C – Modbus".
EasyLine EL3000 Series Commissioning Instructions Electrical Connections Profibus Module RS485 Interface Signal Explanation – not assigned 24 V output voltage, ground RxD/TxD-P Receive/send data plus, B line – not assigned DGND Data transmission potential (reference potential for Supply voltage plus (5 V) 24 V output voltage plus, max.
Installing the Gas Analyzer Connecting the Signal Lines NOTES Follow local regulations on installing and connecting electrical wiring. Lay the signal lines separately from the power supply lines. Lay analog and digital signal lines separately from each other. Mark the cables or mating plugs in such a way that they can be clearly assigned to the corresponding I/O modules.
EasyLine EL3000 Series Commissioning Instructions Connecting the Power Supply Lines Requisite Material If the supplied mains lead is not used, select conductive material which is appropriate for the length of the lines and the predictable current load. Equipotential Bonding The gas analyzer has a connection marked with the symbol for the connecting line to the equipotential bonding on the building side.
Installing the Gas Analyzer Fidas24: Power Supply Line Connection to 115/230 V AC 115/230-V-AC-connection cable A connecting cable is supplied for the 115/230 V AC power supply for heating the detector and, if applicable, the heated sample gas connection (length 5 m, cable cross-section 3 x 1.5 mm ) with a 4-pole socket connector for the connection to the analyzer module.
EasyLine EL3000 Series Commissioning Instructions Starting Up the Gas Analyzer Check the Installation Check the Installation Is the gas analyzer securely fastened (see page 68)? Are all gas lines (see page 69) including that of the pressure sensor correctly connected and laid? Are all signal lines (see page 89) and power supply lines (see page 90) correctly connected and laid? Are all devices needed for gas conditioning, calibration and waste...
Starting Up the Gas Analyzer Purge the sample gas path Purge before Start-up Prior to starting up the gas analyzer and feeding in the sample gas, the sample gas feed path and, where necessary, the wall-mount housing must be purged (see page 34). One reason is to ensure that the sample gas path and the wall housing are free of contamination, e.g.
EasyLine EL3000 Series Commissioning Instructions Gas Analyzer Start-Up NOTE The notes in the sections "ZO23: Gas analyzer start-up (see page 95)" and "Fidas24: Gas analyzer start-up (see page 96)" must also be considered for the ZO23 and Fidas24 analyzers. Starting Up the Gas Analyzer Switch on the power supply of the gas analyzer.
Starting Up the Gas Analyzer ZO23: Gas Analyzer Start-Up Gas Analyzer Start-Up Procedure, Initial Calibration at the Installation Site Turn on the gas analyzer power supply. After approx. 15 minutes, the sample cell has reached its operating temperature. If required, the gas analyzer can be calibrated at the reference point (see step 3) and the end-point (see step 5).
EasyLine EL3000 Series Commissioning Instructions Fidas24: Gas Analyzer Start-Up Fidas24: Start-up of the Gas Analyzer Switch on the power supply, heating-up phase, feed in supply gases Switch on the power supply of the gas analyzer and the heaters of the Fidas24. The name of the gas analyzer and the number of the software version are shown in the display while booting.
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Starting Up the Gas Analyzer The following status messages are active during the heating-up phase: "Operating temperature": the temperature of the detector has not yet reached the threshold. "Flame error": the flame has not yet ignited. "Temperature limit value 1, 2": the temperature of the detector (T- Re.D) and possibly of the heated sample gas connection (T-Re.E) is over or below the upper or lower limit value 1 (2).
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EasyLine EL3000 Series Commissioning Instructions Ignition of the flame 12 The flame ignites automatically: Temperature Status message: of detector and sample gas Operating temperature connection > 150 °C? ressure values Status message: operating gases adjustable Pressure error to set-point? Check pressure values of operating gases Glow plug switched on...
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Starting Up the Gas Analyzer NOTE New and still unused sample gas lines and sampling probes can release hydrocarbons over a longer period after initial start-up. Therefore, it can take a longer time until the measured value drift has reached an acceptable value.
EasyLine EL3000 Series Commissioning Instructions Operating the Gas Analyzer NOTE All the illustrations of the displays in this operator's manual are examples. The displays on the instrument will normally differ from these. Display - Measuring Mode Display in Measuring Mode In measuring mode, the screen displays the name, the measured value in numerals and the physical unit of the measured value for each sample component.
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Operating the Gas Analyzer Key Functions in Measuring Mode Switch over the display of each individual measured value; in addition to the digital display, an analog bar with information on the range limits is shown in this display. Reduce or increase the contrast of the display. When a status message is active, press key first.
EasyLine EL3000 Series Commissioning Instructions Operation - Menu Mode Display in Menu Mode Structure of the Menus Starting from the main menu, each menu (see page 104) contains a maximum of three menu items ("3-point menu"). Each menu option is assigned to one of the three keys , and ;...
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Operating the Gas Analyzer Entering the Password As soon as the user wishes to access a password-protected menu or a password-protected value change, he is requested to enter the password. In this respect, the numbers 1, 2 and 3 are assigned to the three keys , and , as shown in the illustration.
Operating the Gas Analyzer Notes on the Concept of Operation Concept of Operation The concept of operation of the gas analyzers is designed in such a way that the functions required in normal operation are operated and configured directly on the instrument. On the other hand, the functions which are only seldom required, e.g.
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EasyLine EL3000 Series Commissioning Instructions Function Instrument Configurator Modbus Component parameters: Measuring range parameters Alarm value parameters Low pass time constant (T90 time, filter) Active component Modbus parameters Profibus Parameters Ethernet parameters Signal inputs and outputs (I/O connections) NOTEFor detailed Information on "Modbus", refer to the Technical Information "EL3000, EL3060, EL3010-C –...
Operating the Gas Analyzer Communication between the Gas Analyzer and the Computer Communication via Ethernet Communication between the gas analyzer and the computer is executed via an Ethernet connection, either as a point-to-point connection or via a network. The Ethernet connection enables communication ...
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EasyLine EL3000 Series Commissioning Instructions Set the IP address in the gas analyzer Setup Device settings Ethernet Parameters The parameters which have to be input depend on the DHCP setting: DHCP on: Network name (max. 20 characters, no blanks or special characters), DHCP off: IP address, IP address mask and IP gateway address.
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Operating the Gas Analyzer Set the IP address in the computer Start – Settings – Network connections, right click on "Local Area Connection" – Properties – Tab "General": Select Internet Protocol (TCP/IP), Properties – Tab "General": Use the following IP address: – Enter IP address (see the following example).
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EasyLine EL3000 Series Commissioning Instructions Start the communication between the gas analyzer and the computer Communication between the configurator and the gas analyzer is started in the menu "Options – Communication Properties…" or by clicking the symbol . Input either the IP address or the network name (server name) of the gas analyzer (see the following example of a point-to-point connection).
Gas Analyzer Calibration Gas Analyzer Calibration Automatic Calibration: Manual Start Menu path Operation Calibration Automatic Calibration Wait until the 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.
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EasyLine EL3000 Series Commissioning Instructions Abort Automatic Calibration Manually NOTE If the automatic calibration is aborted, 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.
Gas Analyzer Calibration Manual Calibration: Execution Menu Path Operation Calibration Manual Calibration Wait until the 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. ½ hour without thermostat, approx. 2 hours with thermostat Limas23: approx.
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EasyLine EL3000 Series Commissioning Instructions Calibrate the Sample Component Manually Zero-point Calibration Select menu Zero point/Single point Select individual sample component or "All" (according to the configuration in the ECT dialog "Manual Calibration"). Check zero point set point and adjust if required. Connect zero reference gas (if it is not automatically connected).
Maintenance Maintenance Fidas24: Standby / Restart Definitions Standby mode: heater on, combustion gas valve closed, combustion air valve closed, instrument air valve closed, housing purging on, zero gas valve open for standby with detector purging. Fail-safe status: heater off, combustion gas valve closed, instrument air valve closed, housing purging on, zero gas valve open.
If these conditions are not provided or the prescribed materials are not available, a seal integrity test must be carried out by ABB after sales service. Regular inspection of the seal integrity of the combustion gas supply line...
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In this case, the gas analyzer may not be returned to service on any account! The combustion gas inlet valve must be replaced by ABB Service. After conclusion of the seal integrity test, set the combustion gas...
If these conditions are not provided or the prescribed materials are not available, a seal integrity test must be carried out by ABB Service. Regular seal integrity check of the combustion gas path in the gas analyzer The gas analyzer must be in operation (flame on).
Maintenance Checking the Seal Integrity of the Sample Gas Feed Path When should the seal integrity of the sample gas feed path be checked? The seal integrity of the sample gas feed path should be checked regularly. We recommend that the seal integrity of the sample gas feed path is checked before commissioning (see page 94) the instrument at the installation site, since it may have been affected during transport of the gas analyzer (e.g.
EasyLine EL3000 Series Commissioning Instructions Important Note for the Gas Analyzer Version for Measurement of Flammable Gases Measures Taken after Opening the Gas Paths inside the Gas Analyzer If the sample gas feed path inside the gas analyzer has been opened, the seal integrity should be tested with helium at a leak rate of –4 <...
Maintenance Important Note for the Explosion-protected Version in Degree of Protection 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.
EasyLine EL3000 Series Commissioning Instructions Status Messages, Troubleshooting Status Messages - List Menu Path Maintenance Diagnosis Device Status Status Messages If a status message is active, the display 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...
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Status Messages, Troubleshooting Legend for the Table "Status Messages" Status Signals Status "Failure" A status has occurred in the gas analyzer which requires the immediate intervention of the user. The measured value is invalid. Status "Maintenance A status has occurred in the gas analyzer which will soon require the Request"...
EasyLine EL3000 Series Commissioning Instructions Status Messages No. Status Message Reaction/Troubleshooting 110 A S a The instrument is booting. 116 A S a The Profibus module is installed in the Install the Profibus module in slot X20/X21. wrong slot! The interface is therefore not operative.
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Status Messages, Troubleshooting No. Status Message Reaction/Troubleshooting 304 W aQ The amplification drift exceeds half the Monitor the drift. The measured value is permissible range. valid as long as the drift remains below the value specified in the measurement data. The detector concerned will have to be exchanged in the near future.
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EasyLine EL3000 Series Commissioning Instructions No. Status Message Reaction/Troubleshooting 321 A S a The temperature of the detector is below Status message during the warm-up the minimum temperature. phase. If the status message appears following the warm-up phase: Check the overtemperature cutout and replace if necessary.
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Status Messages, Troubleshooting No. Status Message Reaction/Troubleshooting 359 A S a The intensity measured at the detector Notify Service. exceeds or falls below alarm value 2. 360 A S a The filter wheel could not be initialized. If the status message is active for longer than 5 minutes, the filter wheel is blocked.
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EasyLine EL3000 Series Commissioning Instructions No. Status Message Reaction/Troubleshooting iQ A calibration error has occurred in the Calibration will be terminated. Notify instrument. Service. 503 W S iQ The sensitivity is too low! The calibration Incorrect test gas! Check the test gas has been terminated.
Status Messages, Troubleshooting Fidas24: Troubleshooting Flame does not ignite Air in the combustion gas line When connecting or replacing the combustion gas bottle, make sure that no air penetrates into the combustion gas supply line. Air which has penetrated the combustible gas supply line results in the flame in the analyzer going out.
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EasyLine EL3000 Series Commissioning Instructions Failure of instrument air supply Shutting-off gas supply if instrument air supply fails It must be ensured that the gas supply to the analyzer module is shut off if the instrument air supply fails. As a rule, this is ensured by installing a pneumatic shut-off valve in the gas supply line (recommendation (see page 29));...
Shutting Down and Packing the Gas Analyzer Shutting Down and Packing the Gas Analyzer Shutting Down the Gas Analyzer Shutting Down the Gas Analyzer In the case of a temporary shutdown: Shut off the sample gas. Purge the gas lines and gas feed paths in the gas analyzer with dry fresh air or nitrogen for at least 5 minutes.
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EasyLine EL3000 Series Commissioning Instructions Fidas24: Gas Analyzer Restart Feed in instrument air and combustion air and purge the gas analyzer for at least 20 minutes. Turn on the gas analyzer power supply. Turn on the combustion gas supply and check the combustion gas pressure.
Shutting Down and Packing the Gas Analyzer Packing the Gas Analyzer Packing Remove adapters from the the gas ports and tightly seal the gas ports. If the original packaging is not available, wrap the gas analyzer in bubble wrap or corrugated cardboard. When shipping overseas, additionally shrink-wrap the gas analyzer air-tight in 0.2 mm thick polyethylene film adding a drying agent (such as silica gel).
EasyLine EL3000 Series Commissioning Instructions Index Fidas24 Checking Combustion Gas Supply Line for Seal Integrity • 13, 73, 116, 132 19-inch case • 42, 46, 50, 58, 64, 81 Checking the seal integrity of the combustion gas feed path in the gas analyzer •...
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Index Gas Connections for Uras26 with Caldos27 (Model EL3020) • 41, 50 Gas Connections for Uras26 with Caldos27 Packing • 133 (Model EL3040) • 41, 52 Packing the Gas Analyzer • 133 Gas Connections for Uras26 with Magnos206 Preface • 6 (Model EL3020) •...
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ABB has Sales & Customer Support expertise The Company’s policy is one of continuous product in over 100 countries worldwide. improvement and the right is reserved to modify the information contained herein without notice. www.abb.com Printed in the Fed. Rep. of Germany (11.14) ...