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ABB EasyLine EL3000 Manual

Continuous gas analyzers
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A B B M E A S U R E M E N T & A N A L Y T I C S | C O M M I S S I O N I N G I N S T R U C T I O N | C I / E L 3 0 0 0 - E N R E V . C
EasyLine EL3000
Continuous gas analyzers
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Introduction
EasyLine EL3020
EasyLine EL3040
EasyLine is a powerful yet cost-effective line of
devices for the measurement of gas
concentrations in numerous applications.
Automatic calibration and the use of superior ABB
calibration cell technology in the photometer
avoids the use of expensive test gas cylinders in
most applications.
Zero-point calibration with ambient air
Various analyzer types available:
Combining different analyzers in a single housing
enables optimum economy and operational
efficiency for your application.
So smart, they're simple
Measurement made easy
Additional Information
Additional documentation on EasyLine EL3000 is
available for download free of charge at
www.abb.com/analytical.
Alternatively simply scan this code:

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Summary of Contents for ABB EasyLine EL3000

  • Page 1 Alternatively simply scan this code: Automatic calibration and the use of superior ABB calibration cell technology in the photometer avoids the use of expensive test gas cylinders in most applications.

  • Page 2: Table Of Contents

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Table of contents Electrical connections ..........90 Safety ................3 Safety instructions ..............90 General information and instructions ........3 General Notes ................. 90 Warnings ..................3 Model EL3020 ................. 90 Intended use ................4 Model EL3040 .................

  • Page 3: Safety

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C 1 Safety Warnings General information and instructions The warnings in these instructions are structured as follows: These instructions are an important part of the product and must be retained for future reference. DANGER Installation, commissioning, and maintenance of the product may only be performed by trained specialist personnel who have...

  • Page 4: Intended Use

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 1 Safety Intended use Operation in hazardous areas The gas analyzer is designed for continuous measurement of the DANGER concentration of individual components in gases or vapors. Explosion hazard Any other use is not approved. Explosion hazard when measuring flammable gases in The intended use also includes taking note of this operating hazardous areas.

  • Page 5: Safety Instructions

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Safety instructions Requirements for safe operation Protective lead connection In order to operate in a safe and efficient manner the device The protective lead (ground) should be attached to the should be properly handled and stored, correctly installed and protective lead connector before any other connection is made.

  • Page 6: Fidas24 - Information For Safe Operation

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 1 Safety Fidas24 – Information for safe operation Conditions to be complied with by the end user DANGER The end user must comply with the following prerequisites and Explosion hazard conditions to ensure safe operation of the gas analyzer: Explosion hazard due to leaking combustion gas (hydrogen).

  • Page 7: Notes On Data Safety

    (cylinder, line). ABB Automation GmbH and its subsidiaries do not accept • Should the combustion gas supply to the analyzer module liability for any damage and/or loss resulting from such...

  • Page 8: Manufacturer's Address

    ECT software tool itself and to the If the information in this Commissioning Instruction does not calibration and configuration functions of the device. cover a particular situation, ABB Service will be pleased to supply additional information as required. Please contact your local service representative.

  • Page 9: Use In Potentially Explosive Atmospheres

    Monitoring and review Repairs can also be carried out by the manufacturer, for example Electric systems in potentially explosive atmospheres must be on-site by an ABB Service employee or at the manufacturing monitored for proper condition. plant. As necessary, but at least every three years, they must be...

  • Page 10: Explosion Proof Design In Degree Of Protection Ii 3G

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 2 Use in potentially explosive atmospheres Explosion proof design in degree of protection II 3G Note The version for the measurement of flammable gases and the explosion-proof design in degree of protection II 3G is designed for various variants of the gas analyzer and for different applications.
  • Page 11 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Special conditions • The cables must be inserted into the cable glands properly and gasketed by tightening the screws so that the IP 65 housing protection is maintained. Unused cable glands must be sealed with suited sealing plugs, so that the IP 65 housing protection is guaranteed here as well.

  • Page 12: Preparation For Installation

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C 3 Preparation for Installation Material required for installation Scope of delivery Note • Gas analyzer model EL3020 (19” housing) or model EL3040 The materials listed below are not included in the scope of (wall housing) delivery of the device, and must be provided by the customer.
  • Page 13 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Shut-off valve Signal Lines Install a shut-off valve in the sample gas line (recommended Select conductive material which is appropriate for the length of when the sample gas is pressurized). the lines and the predictable current load. Purging of the gas line system Notes concerning the cable cross-section for connection of the I/O modules:...

  • Page 14: Requirements For The Installation Site

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation Requirements for the installation site Note Climatic Conditions For the analyzers ZO23 and Fidas24, the instructions specified in Relative humidity ZO23 on page 25 or Fidas24 on page 30 must be observed. Maximum 75 %, no condensation Installation site requirements Ambient temperature...

  • Page 15: Power Supply

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Power supply Electric information (entire device) Special conditions for the model EL3040 gas analyzer in The power supply built into the system housing is used to supply degree of protection II 3G 24 V DC to the analyzer module and the associated electronics.

  • Page 16: Uras26

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation Uras26 Sample gas Flowing reference gas Sample gas inlet conditions Gas inlet conditions as for sample gas DANGER Pressure sensor Explosion hazard The pressure sensor is installed in the gas analyzer as standard, Explosion hazard when measuring ignitable gas / air or see Pressure sensor on page 33.
  • Page 17 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Test gases – Uras26 Analyzer(s) Test gas for the zero calibration Test gas for the end-point calibration Uras26 with calibration cells or air or sample component-free gas — (automatic calibration) (calibration cells) Uras26 without calibration cells or air Span gas*...

  • Page 18: Limas23

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation Limas23 Pressure sensor Sample gas The pressure sensor is installed in the gas analyzer as standard, Sample gas inlet conditions see Pressure sensor on page 33. DANGER Explosion hazard The pressure sensor is connected to the sample gas path or a Explosion hazard when measuring flammable gases and...
  • Page 19 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Test gases – Limas23 Analyzer(s) Test gas for the zero calibration Test gas for the end-point calibration Limas23 with calibration cells or air or UV sample component-free gas Calibration cells or test gas for each sample (automatic calibration) component Limas23 without calibration cells...

  • Page 20: Magnos206

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation Magnos206 Sample gas Sample gas inlet conditions Corrosive gases If the sample gas contains Cl , HCl, HF or other corrosive DANGER components, the analyzer may only be used if the sample gas Explosion hazard composition has been taken into account by the manufacturer Explosion hazard when measuring ignitable gas / air or...
  • Page 21 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Test gases – Magnos206 Analyzer Test gas for zero point calibration and single-point Test gas for the end-point calibration calibration Magnos206 Oxygen-free process gas Process gas with a known O concentration Magnos206 suppressed measuring range •...

  • Page 22: Magnos28

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation Magnos28 Sample gas Sample gas inlet conditions Corrosive gases If the sample gas contains Cl , HCl, HF or other corrosive DANGER components, the analyzer may only be used if the sample gas Explosion hazard composition has been taken into account by the manufacturer Explosion hazard when measuring ignitable gas / air or...
  • Page 23 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Test gases – Magnos28 Analyzer Test gas for zero point calibration and single-point Test gas for the end-point calibration calibration Magnos28 Oxygen-free process gas Process gas with a known O concentration Magnos28 with a suppressed measuring •...

  • Page 24: Magnos27

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation Magnos27 Sample gas Tests gases – Magnos27 Sample gas inlet conditions DANGER Analyzer Test gas for the zero Test gas for the end-point calibration calibration Explosion hazard Magnos27 Oxygen-free process gas Process gas with a known...

  • Page 25: Zo23

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C ZO23 Sample gas Sample gas inlet conditions Associated gas effect Inert gases (Ar, N ) have no effect. Flammable gases (CO, H DANGER ) in stoichiometric concentrations to the oxygen content: Explosion hazard conversion O <...
  • Page 26 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation … ZO23 Installation and sample handling NOTICE Damage to the measuring cell The ingress of liquids into the analyzer module can cause serious damage including destruction of the sample cell. Note The following information on installation and the sample handling must be considered for the measurement and the execution of controlled calibrations (manual, automatic and externally controlled calibration).
  • Page 27 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas sampling Bypass The nominal diameter of the line from the sampling point to the The gas analyzer is connected to a gas flow in the bypass at a first switch-over valve should be 4 mm. constant flow rate (approx.

  • Page 28: Caldos27

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation Caldos27 Sample gas Pressure sensor Sample gas inlet conditions The pressure sensor is installed in the gas analyzer at the factory, see Pressure sensor on page 33. DANGER The pressure sensor is connected to a connection socket via an Explosion hazard...
  • Page 29 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Test gases – Caldos27 Analyzer Test gas for zero point calibration and single-point Test gas for the end-point calibration calibration Caldos27 Sample component-free test gas or process gas Test gas or process gas with a known sample component concentration Caldos27 with a suppressed Test gas with a sample component concentration near...

  • Page 30: Fidas24

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation Fidas24 Sample gas Operational gases Sample components Instrument air Hydrocarbons. The concentration of the gas components in the sample gas path must not exceed the temperature-dependent Parameter Value/Description LEL.
  • Page 31 This shut-off valve should be installed outside the analyzer house ordered and delivered in the intended version. in the vicinity of the combustion gas supply (cylinder, line). Combustion gas parameter ABB recommends the use of a pneumatic shut-off valve that is Quality Hydrogen (H /He mix actuated by the instrument air.

  • Page 32: Sample Gas Input And Output Conditions

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation Sample gas input and output conditions … Fidas24 Analyzers Test gases Analyzer Additional Information Test Gases for Zero Calibration Uras26 See Uras26 on page 16 Quality Nitrogen, Quality 5.0, synthetic air or catalytically Limas23 See Limas23 on page 18 cleaned air with an organic C <...

  • Page 33: Pressure Sensor

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Housing purge Housing design Special conditions for the model EL3040 gas analyzer in degree of protection II 3G Housing purging is only possible with the wall-mounted housing (model EL3040). The purge gas connectors (⅛ NPT female Flammable gases thread) are factory-installed in accordance with the order.
  • Page 34 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation … Housing purge Initial purging upon commissioning Housing purge* Purge gas Nitrogen Purge gas flow Maximum 200 l/h Purge time Approx. 1 hour Not for Fidas24, see for a separate description at Housing purge with Fidas24 on page 34.

  • Page 35: Dimensions

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Dimensions 19” housing (model EL3020) Dimensions in mm (in) Figure 2: 19” housing (model EL3020)
  • Page 36 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation … Dimensions 19” housing (model EL3020 with Magnos27) Dimensions in mm (in) Figure 3: 19″housing (model EL3020 with Magnos27) Note Only the front view of the housing (with its height differing from the standard dimension) is depicted in this dimensional drawing. Additional views and dimensions of the 19”...
  • Page 37 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Wall-mount housing (model EL3040) Dimensions in mm (in) A Consider free space to swivel the door Figure 4: Wall-mount housing (model EL3040)

  • Page 38: Special Conditions For The Measurement Of Combustion Gases

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 3 Preparation for Installation Special conditions for the measurement of combustion gases Installation of the gas analyzer DANGER • The pressure sensor must not be connected to the sample Explosion hazard gas path.
  • Page 39 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Commissioning of the gas analyzer • The sample gas path must be purged with inert gas before the gas analyzer is commissioned (see Purge sample gas path and analyzer housing on page 100). Operation and Maintenance of the Gas Analyzer •...

  • Page 40: Installation

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C 4 Installation Unpacking the Gas Analyzer Analyzer data sheet CAUTION Contents The analyzer data sheet contains the following information: Injury hazard due to heavy weight • Order Number (O-No.), Depending on the version, the gas analyzer weighs7 to 15 kg •...

  • Page 41: Mounting The Fittings On The Gas Analyzer

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Mounting the fittings on the gas analyzer General information Requisite Material To connect the gas lines to the gas analyzer, screw-in sockets Screw-in spud with hose nozzles (supplied) or screw-in fittings (fittings) are used in different designs. with ⅛...

  • Page 42: Position And Design Of The Gas Connections

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation Position and design of the gas connections The following pages list the location and execution of the gas connections of the individual analyzer modules and their combinations. The table below is used as an aid in navigating the connection descriptions. Position and design of the gas connections Analyzer module Model EL3020...
  • Page 43 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections Uras26 (model EL3020) Figure 5: Gas connections Uras26 (EL3020) Uras26: Gas connections for hose lines (internal gas lines made using hoses) Pos. Connection Supplementary information Version Sample gas inlet (gas path 1) Without ‘integrated gas feed’...
  • Page 44 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Uras26: Gas connections for pipelines (internal gas lines made stainless steel pipes) Pos. Connection Supplementary information Version Pressure sensor — Screwed connections with hose nozzles (stainless steel 1.4305) for hoses with 4 mm inside diameter (included in scope of supply) Sample gas inlet...
  • Page 45 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections Uras26 (model EL3040) Figure 6: Gas connections Uras26 (model EL3040) Uras26: Gas connections Pos. Connection Supplementary information Version Pressure sensor The pressure sensor is connected to the Pos. 1 terminal if ⅛...
  • Page 46 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Uras26 with Magnos206 (model EL3020) Figure 7: Gas connections Uras26 with Magnos206 (model EL3020) Uras26: Gas connections for hose lines (internal gas lines made using hoses) Pos.
  • Page 47 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Uras26: Gas connections for pipelines (internal gas lines made stainless steel pipes) Pos. Connection Supplementary information Version Pressure sensor — Screwed connections with hose nozzles (stainless steel 1.4305) for hoses with 4 mm inside diameter (included in scope of supply) Sample gas inlet —...
  • Page 48 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Uras26 with Magnos206 (model EL3040) Figure 8: Gas connections Uras26 with Magnos206 (model EL3040) Uras26: Gas connections Pos. Connection Supplementary information Version Pressure sensor...
  • Page 49 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Magnos206: Gas Connections Pos. Connection Supplementary information Version Sample gas inlet — ⅛ NPT female thread (stainless steel 1.4305) • Connection of hose lines: Sample gas outlet — straight screw-in socket (PP) with hose nozzles for Not assigned —...
  • Page 50 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Uras26 with Magnos28 (model EL3020) Figure 9: Gas connections Uras26 with Magnos28 (EL3020) Uras26: Gas connections for hose lines (internal gas lines made using hoses) Pos.
  • Page 51 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Uras26: Gas connections for pipelines (internal gas lines made stainless steel pipes) Pos. Connection Supplementary information Version Pressure sensor — Screwed connections with hose nozzles (stainless steel 1.4305) for hoses with 4 mm inside diameter (included in scope of supply) Sample gas inlet —...
  • Page 52 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Uras26 with Magnos28 (model EL3040) Figure 10: Gas connections Uras26 with Magnos28 (model EL3040) Uras26: Gas connections (internal gas lines made using hoses or stainless steel pipes) Pos.
  • Page 53 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Magnos28: Gas Connections Pos. Connection Supplementary information Version Sample gas inlet — ⅛ NPT female thread (stainless steel 1.4305) • Connection of hose lines: Sample gas outlet — straight screw-in socket (PP) with hose nozzles for hoses with inside diameter 4 mm (included in scope of delivery) •...
  • Page 54 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Uras26 with Caldos27 (model EL3020) Figure 11: Gas connections Uras26 with Caldos27 (model EL3020) Uras26: Gas connections for hose lines (internal gas lines made using hoses) Pos.
  • Page 55 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Uras26: Gas connections for pipelines (internal gas lines made stainless steel pipes) Pos. Connection Supplementary information Version Pressure sensor — Screwed connections with hose nozzles (stainless steel 1.4305) for hoses with 4 mm inside diameter (included in scope of supply) Sample gas inlet —...
  • Page 56 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Uras26 with Caldos27 (model EL3040) Figure 12: Gas connections Uras26 with Caldos27 (model EL3040) Uras26: Gas connections Pos. Connection Supplementary information Version Pressure sensor...
  • Page 57 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Caldos27: Gas Connections Pos. Connection Supplementary information Version Sample gas inlet — ⅛ NPT female thread (stainless steel 1.4305) • Connection of hose lines: Sample gas outlet — straight screw-in socket (PP) with hose nozzles not used —...
  • Page 58 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Limas23 (model EL3020) Figure 13: Gas connections Limas23 (model EL3020) Limas23: Gas connections Pos. Connection Supplementary information Version Sample gas inlet Without optional solenoid valve Screwed connections with hose nozzles (stainless steel 1.4305) for hoses with 4 mm inside diameter...
  • Page 59 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections Limas23 (model EL3040) Figure 14: Gas connections Limas23 (model EL3040) Limas23: Gas connections Pos. Connection Supplementary information Version Sample gas inlet — ⅛ NPT female thread (stainless steel 1.4305) • Connection of hose lines: Sample gas outlet —...
  • Page 60 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Limas23 with Magnos206 (model EL3020) Figure 15: Gas connections Limas23 with Magnos206 (model EL3020) Limas23: Gas connections Pos. Connection Supplementary information Version Sample gas inlet...
  • Page 61 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections Limas23 with Magnos206 (model EL3040) Figure 16: Gas connections Limas23 with Magnos206 (model EL3040) Limas23: Gas connections Pos. Connection Supplementary information Version Sample gas inlet — ⅛ NPT female thread (stainless steel 1.4305) •...
  • Page 62 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Magnos206: Gas Connections Pos. Connection Supplementary information Version Sample gas inlet — ⅛ NPT female thread (stainless steel 1.4305) • Connection of hose lines: Sample gas outlet —...
  • Page 63 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections Limas23 with Magnos28 (model EL3020) Figure 17: Gas connections Limas23 with Magnos28 (model EL3020) Limas23: Gas connections Pos. Connection Supplementary information Version Sample gas inlet Without optional solenoid valve Screwed connections with hose nozzles (stainless steel 1.4305) for hoses with 4 mm inside diameter Sample gas outlet —...
  • Page 64 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Limas23 with Magnos28 (model EL3040) Figure 18: Gas connections Limas23 with Magnos28 (model EL3040) Limas23: Gas connections Pos. Connection Supplementary information Version Sample gas inlet...
  • Page 65 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Magnos28: Gas Connections Pos. Connection Supplementary information Version Sample gas inlet — ⅛ NPT female thread (stainless steel 1.4305) • Connection of hose lines: Sample gas outlet — straight screw-in socket (PP) with hose nozzles for hoses with inside diameter 4 mm (included in scope of delivery) •...
  • Page 66 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Magnos206 (model EL3020) Figure 19: Gas connections Magnos206 (model EL3020) Magnos206: Gas Connections Pos. Connection Supplementary information Version Sample gas inlet —...
  • Page 67 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections Magnos206 (model EL3040) Figure 20: Gas connections Magnos206 (model EL3040) Magnos206: Gas Connections Pos. Connection Supplementary information Version Sample gas inlet — ⅛ NPT female thread (stainless steel 1.4305) • Connection of hose lines: Sample gas outlet —...
  • Page 68 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Magnos28 (model EL3020) Figure 21: Gas connections Magnos28 (model EL3020) Magnos28: Gas Connections Pos. Connection Supplementary information Version Sample gas inlet —...
  • Page 69 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections Magnos28 with Magnos28 (model EL3020) Figure 22: Gas connections Magnos28 with Magnos28 (model EL3020) Magnos28 – gas connections for direct connection (applies to both analyzer modules) Pos. Connection Supplementary information Version Sample gas inlet —...
  • Page 70 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Magnos28 with Caldos27 (model EL3020) Figure 23: Gas connections Magnos28 with Caldos27 (model EL3020) Magnos28 – gas connections for direct connection Pos.
  • Page 71 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Magnos28 with Caldos27 – gas connections for ‘Integral gas feed’ option with flow sensor Pos. Connection Supplementary information Version Sample gas outlet Factory-connected to Magnos28 sample gas inlet 1 Screwed connections with hose nozzles (stainless (gas path 1 / Magnos28) steel 1.4305) for hoses with 4 mm inside diameter (included in scope of supply)
  • Page 72 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Magnos28 (model EL3040) Figure 24: Gas connections Magnos28 (model EL3040) Magnos28: Gas Connections Pos. Connection Supplementary information Version Sample gas inlet —...
  • Page 73 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections Magnos27 (model EL3020) Figure 25: Gas connections Magnos27 (model EL3020) Magnos27: Gas Connections Pos. Connection Supplementary information Version Pressure sensor — Screwed connections with hose nozzles (stainless Not assigned — steel 1.4305) for hoses with 4 mm inside diameter (included in scope of supply) Sample gas inlet...

  • Page 74: Pos

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Magnos27 with Uras26 (model EL3020) Figure 26: Gas connections Magnos27 with Uras26 (model EL3020) Magnos27: Gas Connections Pos. Connection Supplementary information Version Sample gas inlet...
  • Page 75 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections ZO23 (model EL3020) Figure 27: Gas connections ZO23 (Model EL3020) ZO23: Gas Connections The measuring chamber is connected to the sample gas inlet connection via a stainless steel tube (inlet side) and to the sample gas outlet connection via a FPM hose (outlet side).

  • Page 76: Sample Gas Inlet

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections ZO23 (model EL3040) Figure 28: Gas connections ZO23 (model EL3040) ZO23: Gas Connections The measuring chamber is connected to the sample gas inlet connection via a stainless steel tube (inlet side) and to the sample gas outlet connection via a FPM hose (outlet side).

  • Page 77: Sample Gas Inlet

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections Caldos27 (model EL3020) Figure 29: Gas connections Caldos27 (model EL3020) Caldos27: gas connections Pos. Connection Supplementary information Version Sample gas inlet — ⅛ NPT female thread (stainless steel 1.4305) • Connection of hose lines: straight screw-in socket (PP) with hose nozzles Sample gas outlet...

  • Page 78: Pressure Sensor (Option)

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections Caldos27 with Caldos27 (model EL3020) Figures 30: Gas connections Caldos27 with Caldos27 (model EL3020) Caldos27 – gas connections for direct connection (applicable for both analyzer modules) Pos.
  • Page 79 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections Caldos27 (model EL3040) Figure 31: Gas connections Caldos27 (model EL3040) Caldos27: gas connections Pos. Connection Supplementary information Version Sample gas inlet — ⅛ NPT female thread (stainless steel 1.4305) • Connection of hose lines: Sample gas outlet —...
  • Page 80 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation … Position and design of the gas connections Gas connections and electrical connections Fidas24 (model EL3020) Figure 32: Gas connections and electric connections Fidas24 (model EL3020) Fidas24: Gas and electrical connections Pos.
  • Page 81 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Gas connections and electrical connections Fidas24 (model EL3040) Figure 33: Gas connections and electrical connections Fidas24 (model EL3040) Fidas24: Gas and electrical connections Pos. Connection Supplementary information Version Power supply (input) 115 V AC or 230 V AC for heating the detector and 4-pin male connector, connection cable included in sample gas inlet scope of supply...

  • Page 82: Gas Analyzer Installation

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation Gas Analyzer Installation Special conditions for the model EL3020 gas analyzer for NOTICE the measurement of flammable gases Damage to the device due to unsuited installation site Unrestricted exchange of air with the environment must be •...

  • Page 83: Connecting The Gas Lines

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Connecting the gas lines Provide for sample gas line purging NOTICE Install a shut-off valve in the sample gas line (highly Damage to the gas analyzer recommended for pressurized sample gas) and provide the Damage to the gas analyzer due to condensing sample gas option of introducing an inert gas, such as nitrogen, from the during commissioning.

  • Page 84: Fidas24 - Connect Gas Lines

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation Fidas24 – Connect gas lines Safety instructions Connection of process gases and test gases DANGER Explosion hazard Explosion hazard due to leaking combustion gas in the gas analyzer. • The leak tightness of the combustion gas supply line outside the gas analyzer as well as the combustion gas path in the gas analyzer must be checked regularly.

  • Page 85: Fidas24 - Connecting The Combustion Gas Line

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Fidas24 – Connecting the combustion gas line Test gas connection Clean combustion gas line. The test gas outlet is connected to the sample gas connection at 1. Pump a cleaning agent (alkaline cleaner, stainless steel the factory.

  • Page 86: Fidas24 - Connecting The Sample Gas Line To The Heated Sample Gas Connection

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation Fidas24 – Connecting the sample gas line to the heated sample gas connection NOTE Maximum length of the sample gas line The maximum length of a heated sample gas line (inner diameter Damage to the gas analyzer 4 mm) is 60 m.
  • Page 87 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Connection of the sample gas line to the heated sample gas connection Wall-mount housing (view from bottom right) 19” housing (view from top left) 1 Heated sample gas line Closure: (tube with inside/outside diameter 4 / 6 mm) 9 Screw plug 2 O-ring 6.02 ×...

  • Page 88: Fidas24 - Connecting The Sample Gas Line To The Unheated Sample Gas Connection

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 4 Installation Fidas24 – Connecting the sample gas line to the unheated sample gas connection Maximum length of the sample gas line NOTE The maximum length of the unheated sample gas line (inside Damage to the gas analyzer diameter 4 mm) is 50 m.
  • Page 89 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Connection of the sample gas line to the unheated sample gas connection 1 Sample gas line (heated or unheated, PTFE or stainless steel tubing with Alternatively, with: a 4/6 mm inside/outer diameter) 6 Socket Connection either with: 7 Wedge ring...

  • Page 90: Electrical Connections

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C 5 Electrical connections Safety instructions WARNING Risk of injury due to live parts. Improper work on the electrical connections can result in electric shock. • Connect the device only with the power supply switched off. •...

  • Page 91: Model El3040

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Model EL3040 Safety instructions Observe the relevant national safety regulations for installing and operating electric systems. 1 Power supply connection 4 Modbus module (see Connecting the power supply on page 97) (see Modbus®-Module on page 96) 5 Profibus module (3-pin grounded instrument connector in accordance with EN 60320-1/C14;...
  • Page 92 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 5 Electrical connections … Model EL3040 Figure 40: Cable glands model EL3040 Type Application (recommended) Permissible cable diameter Power supply 5 to 13 mm Modbus / Profibus 8 to 17 mm (insert 5 × 4 mm) Network 8 to 17 mm 3 ×...

  • Page 93: Analog Output Modules

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Analog output modules Terminal layout Analog outputs AO1 to AO4 0/4 to 20 mA (factory-set to 4 to 20 mA), common negative pole, electrically isolated from ground, freely connectible to ground, max. gain relative to protective ground potential 50 V, max. load 750 Ohm.

  • Page 94: Digital I/O Module

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 5 Electrical connections Digital I/O module Terminal layout Digital inputs DI1 to DI4 Optocouplers with internal 24 V DC power supply. Control system alternatively available with potential-free contacts, with external voltage 12 to 24 V DC or with PNP or NPN open-collector driver.
  • Page 95 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Standard assignment of digital inputs and digital outputs Function Digital I/O Module 1 Digital I/O Module 2 Failure Maintenance required Maintenance mode Overall status Start automatic calibration Stop automatic calibration Disable automatic calibration Sample gas valve Zero point gas valve Span gas valve 1...

  • Page 96: Modbus®-Module

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 5 Electrical connections Modbus®-Module PROFIBUS®-Module Terminal layout Terminal layout Image 45: PROFIBUS® module Figure 44: Modbus module RS485 interface RS232 Interface Version: 9-pin sub-D female connector Version: 9-pin sub-D male connector Signal Description Signal...

  • Page 97: Connecting The Signal Lines

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Connecting the Signal Lines Connecting the power supply Safety instructions NOTICE • Follow local regulations on installing and connecting Damage to the gas analyzer electrical wiring. Damage to the gas analyzer due to condensing sample gas •...
  • Page 98 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 5 Electrical connections … Connecting the power supply Grid connection cable Fidas24 Connect power supply lines A connection cable is provided for the power supply 1. Ensure that the power supply feeder has an adequately (115 / 230 V AC) for heating the detector and, if necessary, the dimensioned protective device (circuit-breaker).

  • Page 99: Commissioning

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C 6 Commissioning Safety instructions Installation Check 1. Is the gas analyzer securely fastened, see Gas Analyzer NOTICE Installation on page 82? Damage to the gas analyzer 2. Are all gas lines including that of the pressure sensor Damage to the gas analyzer due to condensing sample gas correctly connected and installed, see Installing the fittings during commissioning.

  • Page 100: Purge Sample Gas Path And Analyzer Housing

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 6 Commissioning Purge sample gas path and analyzer Gas analyzer start-up housing Note For the analyzers ZO23 and Fidas24, the instructions specified in Before the gas analyzer is commissioned and the sample gas is ZO23 –...
  • Page 101 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Fidas24 – Commissioning the gas analyzer ZO23 – Commissioning the gas analyzer Power-up the power supply, heat-up phase, connect Note operating gases We recommend starting the first calibration procedure at the 1. Switch on the power supply of the gas analyzer and the installation site on the day before the actual measurement heaters of the Fidas24.
  • Page 102 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 6 Commissioning … Gas analyzer start-up 6. During the heating phase, the following status messages are Adjust output variables of the internal pressure controllers displayed: If the analyzer cannot be commissioned automatically with the pressure values specified in the device data sheet, the manipulated variables of the internal pressure controllers must Message...
  • Page 103 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Igniting the flame 12. Flame ignition is automatic. On initial commissioning of the gas analyzers, it may occur that, depending on the position of the combustion gas line, there is not sufficient combustion gas available to ignite the flame at first.

  • Page 104: Fidas24 - Standby / Restart

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 6 Commissioning Fidas24 – Standby / Restart Setting Fidas24 back to measurement mode Definitions • Standby mode: ‘ Operation /  Pump / Standby /  Fidas Standby  Fidas Restart’ Heater on, combustion gas valve closed, combustion air valve closed, instrument air valve closed, housing purging The menu ‘Fidas Restart’...

  • Page 105: Checking Gas Path Leak Tightness

    Do not restart the gas analyzer. Maximum gauge pressure = 150 hPa. • Have the combustion gas valve replaced by the ABB 5. Close the shut-off valve. The pressure should not change Service team. measurably in 3 minutes. A sharp pressure drop is an indication of a leak inside the sample gas path.
  • Page 106 Disconnect the combustion gas supply. • Do not restart the gas analyzer. • Have the combustion gas valve replaced by the ABB Service team. 6. After conclusion of the seal integrity test, set the combustion gas pressure to normal pressure again, i.e. 1.2 bar.

  • Page 107: Important Instructions For Measuring Combustion Gases

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Important instructions for measuring Important instructions for explosion-proof combustion gases design in degree of protection II 3G Visual inspection Measures to take after each opening of the gas paths within the gas analyzer •...

  • Page 108: Failure Of Instrument Air Supply

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 6 Commissioning Failure of instrument air supply It must be ensured that the gas supply to the analyzer module is shut off if the instrument air supply fails. This is generally ensured by the installation of a pneumatic shut- off valve in the combustion gas supply line (refer to Shut-off valve in the combustion gas supply line on page 31);...

  • Page 109: Operation

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C 7 Operation Safety instructions LCD indicator When safe operation can no longer be assured Note If it is apparent that safe operation is no longer possible, the For detailed information on the operation and parameterization device should be taken out of operation and secured against of the device, consult the associated operating instructions (OI)! unauthorized use.
  • Page 110 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 7 Operation … LCD indicator Status Icons LCD display in menu mode Icon Description An automatic calibration is in progress, see Operating instruction. The icon also appears in menu mode in the menu title line, see LCD display in menu mode on page 110.
  • Page 111 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Password protection Button functions in menu mode Access to the calibration as well as to the menus where the configuration of the device can be changed can be password- protected. Password protection is not activated at the factory. Button 3-tier menu ...
  • Page 112 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 7 Operation … LCD indicator Status messages on the LCD display Enter password Menu path ‘ Maintenance /  Diagnosis /  Device Status /  Status Messages’ Figure 52: Password entry As soon as the user wants to access a password-protected menu or a password-protected value change, password entry is Figure 53: Menu ‘Status Messages’...

  • Page 113: Menu Overview

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Menu Overview This menu depends on the configuration of the gas analyzer Figure 55: Menu overview Notes on the operating concept The operating concept of the gas analyzer requires that the functions needed in normal operating mode are operated and configured directly on the device.

  • Page 114: Communication Between Gas Analyzer And Computer

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 7 Operation Communication between gas analyzer and computer Ethernet communication Setting the IP address Menu Path The communication between the gas analyzer and the computer runs via an Ethernet connection either as a point-to-point ‘...
  • Page 115 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Setting the IP address in the computer Adresses The IP address, IP address screen and IP gateway address need to be queried from the system administrator. Note The address bits variable from the address screen may not be set to 0 or 1 (broadcast addresses).
  • Page 116 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C … 7 Operation … Communication between gas analyzer and computer Release of communication via Modbus® TCP/IP In the EL3000, communication via Modbus® TCP/IP is blocked on Establish communication between configurator and gas all Ethernet interfaces by default.

  • Page 117: Maintenance

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C 8 Maintenance 9 Decommissioning Decommissioning the gas analyzer Safety instructions In the case of a temporary shutdown: WARNING 1. Shut off the sample gas. Risk of injury 2. Purge the gas lines and gas feed paths in the gas analyzer Risk of injury due to maintenance work being carried out with dry air or nitrogen for at least 5 minutes.

  • Page 118: Fidas24 - Shutting Down The Gas Analyzer

    Note 8. Disconnect the electrical leads from the gas analyzer. If the device is returned to ABB Service (e.g. for repair), the following points must be observed: • It is essential that the gases that were introduced into the gas analyzer are specified on the return form.

  • Page 119: Returning Devices

    Bear the following points in mind when disposing of them: All devices delivered to ABB must be free from any hazardous • As of 8/15/2018, this product will be under the open materials (acids, alkalis, solvents, etc.).

  • Page 120: Specification

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C 11 Specification Note The device data sheet is available in the ABB download area at www.abb.com/analytical. 12 Additional documents Note All documentation, declarations of conformity, and certificates are available in ABB's download area.

  • Page 121: Appendix

    EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C 13 Appendix Return form Statement on the contamination of devices and components Repair and/or maintenance work will only be performed on devices and components if a statement form has been completed and submitted.
  • Page 122 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Trademarks Extran is a registered trademark of Merck KGaA, Darmstadt, Germany Modbus is a registered trademark of Schneider Automation Inc. PROFIBUS, PROFIBUS PA and PROFIBUS DP are registered trademarks of PROFIBUS & PROFINET International (PI) Windows is a registered trademark of Microsoft Corporation.
  • Page 123 EL3000 CONTINUOUS GAS ANALYZERS | CI/EL3000-EN REV. C Notes...
  • Page 124 We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

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