ABBModels EL3020, EL3040

EasyLine Continuous Gas Analyzers Models EL3020, EL3040 Software Version 3.3 Instructions for Installation, Start-up and Operation Publication No. 41/24400 EN Revision 5 Edition December 2012

Preface

Content of the Operator's Manual

These instructions in brief for installation, start-up and operation contain all the information necessary for the safe and compliant installation, startup and operation of the gas analyzer. Information on calibration, configuration and maintenance of the gas analyzer and the Modbus and Profibus is documented in the on-line help file of the operator's manual; the on-line help file can be found on the CD-ROM "Software tools and technical documentation", which is supplied with the gas analyzer (see below).

Further Information

Analyzer Data Sheet The version of the delivered gas analyzer is described in the "Analyzer Data Sheet" supplied with the gas analyzer. CD-ROM "Software tools and technical documentation" The CD-ROM "Software tools and technical documentation" with the following contents is included in the scope of supply of the gas analyzer:

 Software Tools 

 Operator's Manuals 

 Data Sheets 

 Technical Information 

 Certificates

CD-ROM "Spare parts analytical"

Information on spare parts can be found on the CD-ROM "Spare parts 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

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. Please contact your local service representative. For emergencies, please contact

Basic Steps

The following basic steps should be followed for the installation and commissioning of the gas analyzer:

1 Please note the information on the intended application (see page 9). 

2 Follow safety precautions (see page 10). 

3 Prepare for the installation, provide the requisite material (see page 14). 

4 Unpacking the gas analyzer (see page 41). 

5 Check sample gas path seal integrity (see page 119). 

6 Install the gas analyzer (see page 66). 

7 Connect the gas lines (see page 67). 

8 Connect the electrical leads (see page 79). 

9 Check the installation (see page 90). 

10 Purge the sample gas path (see page 91). 

11 Start up the gas analyzer (see page 92). 

12 Configure the gas analyzer.

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. The gas analyzer version with stainless steel gas lines and gas connections (EL3020 and EL3040 models) may be used for the measurement of flammable gases1 and vapors in a non-hazardous environment, The special requirements for the measurement of flammable gases (see page 39) must be complied with. The oxygen sensor and the modules of the integrated gas feed (Option "Integrated Gas Feed" – only in the EL3020 model, not with Limas23, ZO23, Fidas24) may not be used for the measurement of flammable gases. The explosion-proof version of the gas analyzer with degree of protection II 3G (see page 40) (EL3040 model) may be used for the measurement of non-flammable gases and vapors in a hazardous environment.

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

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.

Special Information and Precautions

These include

 The content of this operator's manual, 

 The safety information affixed to the device, 

 The applicable safety precautions for installing and operating electrical devices, 

 Safety precautions for working with gases, acids, condensates, etc.

National Regulations

The regulations, standards and guidelines cited in this operator's manual are applicable in the Federal Republic of Germany. The applicable national regulations should be followed when the device is used in other countries

Device Safety and Safe Operation

The device is designed and tested in accordance with the relevant safety standards and has been shipped ready for safe operation. To maintain this condition and to assure safe operation, read and follow the safety information in this operator's manual. Failure to do so can put persons at risk and can lead to device damage as well as damage to other systems and devices.

Protective Lead Connection

The protective lead (ground) should be attached to the protective lead connector before any other connection is made

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. Current can be present at some connection points.

Risks Involved in Working with an Open Device

All work on a device that is open and connected to power should only be performed by trained personnel who are familiar with the risks involved.

When Safe Operation can no Longer be Assured

If it is apparent that safe operation is no longer possible, the device should be taken out of operation and secured against unauthorized use. The possibility of safe operation is excluded:

 If the device is visibly damaged, 

 If the device no longer operates, 

 After prolonged storage under adverse conditions, 

 After severe transport stresses.

Measures of the manufacturer

The following measures ensure that the enrichment of combustion gas or an explosive mixture of combustion gas and ambient air cannot occur inside the gas analyzer during normal operation:

 The seal integrity of the combustion gas feed path is checked for a leakage rate of < 1 × 10–4 hPa l/s before delivery. 

 The combustion gas/air mixture (before and after the ignition point) is diluted in the detector with compressed air. 

 The combustion gas feed is not connected to the supply during startup until the internal nominal pressures have been set. 

 The combustion gas feed is switched off if the internal nominal pressures cannot be set during the ignition phase (e.g. because of insufficient compressed air or combustion air feed). 

 The combustion gas feed is switched off after several unsuccessful ignition attempts. 

 If the flame goes out during operation the combustion gas feed is switched off if the following ignition attempts are unsuccessful. The interior of the gas analyzer is not assigned to an (explosion protection) zone; no explosive gas mixture can escape from it to the outside.

Conditions to be complied with by the end user

The end user must comply with the following prerequisites and conditions to ensure safe operation of the gas analyzer:

 The gas analyzer may be used for the measurement of flammable gases provided that the flammable portion does not exceed 15 vol.% CH4 or C1 equivalents. 

 The relevant safety regulations for working with flammable gases must be complied with. 

 The gas connection diagram (see page 64) must be complied with when connecting the combustion gas and combustion air. 

 The combustion gas feed path in the gas analyzer may not be opened! The combustion gas feed path can become leaky as a result! Escaping combustion gas can cause fires and explosions, also outside the gas analyzer! 

 If the combustion gas feed path in the gas analyzer has been opened, however, it must always be checked for seal integrity (see page 118) with a leak detector after it has been sealed again (leakage rate < 1 × 10–4 hPa l/s).

 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 30) may not be exceeded. 

 The maximum pressures of combustion gas and combustion air (see page 30) may not be exceeded. 

 The combustion gas flow rate must be limited to a maximum of 10 l/h of H2 or 25 l/h of H2/He mixture. For this purpose, the end user has to provide suitable measures (see page 30) outside the gas analyzer. 

 A shut-off valve (see page 30) must be installed in the combustion gas supply line to increase the safety in the following operating states: 

 Shutting down the gas analyzer, 

 Failure of the instrument air supply, 

 Leakage in the combustion gas feed path inside the gas analyzer. This shut-off valve should be installed outside the analyzer house in the vicinity of the combustion gas supply (cylinder, line). 

 If there is no automatic shut-off of the combustion gas supply to the gas analyzer in case of an instrument supply failure, a visible or audible alarm must be triggered (see page 129). 

 When measuring flammable gases, it must be made sure that in case of a failure of the instrument air supply or of the analyzer module itself the sample gas supply to the analyzer module is shut off and the sample gas path is purged with nitrogen. 

 The unobstructed exchange of air with the environment must be possible around the gas analyzer. The gas analyzer may not be directly covered. The openings in the housing towards the top and at the side may not be closed. The distance to laterally adjacent built-in components must be at least 4 mm. 

 If the gas analyzer is installed in a closed cabinet, adequate ventilation of the cabinet must be provided (at least 1 change of air per hour). The distance to adjacent built-in components towards the top and at the side must be at least 4 mm.