A-BEasyLine Continuous Gas Analyzers Models EL3020, EL3040 Software Version 3.3

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 

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. 

WARNING EXPLOSION HAZARD 

Substitution of components may impair suitability for Class I, Division 2. 

I/O connectors must only be connected to Class 2 circuits

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 

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

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 

 Mains lead (see page 88), length 5 m 

 Mating plugs (socket housing) for the electrical connection of the 

I/O modules (attached to the terminals of the I/O modules) 

 Screwdriver (required for attaching the electric lines in the mating 

plugs) 

 Micro-porous filter (see page 67) (pre-assembled) 

 CD-ROM "Software tools and technical documentation" with software 

tools and technical documentation 

 CD-ROM "Spare parts analytical" with information on spare parts 

 Instructions in brief for Installation, Commissioning and Operation 

 Analyzer data sheet 

Fidas24:

 Mains lead, length 5 m, with 4-pin socket connector and separate 

grounding connector for the power supply to the heating of the 

detector and the heated sample gas connection 

 Accessories pack with fittings and O-rings for connection of the 

sample gas line 

 Exhaust pipe with fitting nut and compression fitting

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 

 PTFE or stainless steel tubes with 4 mm inside diameter and 

PTFE or stainless steel tube with at least 10 mm inside diameter for 

waste air 

 Tube fittings 

 Pressure regulator 

 Flow restrictor in the combustion gas supply line (see page 30) 

 Shut-off valve in the combustion gas supply line (see page 30) 

Sample gas 

 Heated sample gas line (recommended: TBL 01) or 

unheated sample gas line (PTFE or stainless steel tube with 

inside/outside diameter 4/6 mm). 

The fittings and O-rings required for the connection are included in 

the scope of supply and delivery of the gas analyzer. 

Flowmeter/Flow Monitor 

 Flowmeter or flow monitor with a needle valve for adjustment and 

monitoring of the sample gas flow rate and purge gas flow rate if 

required 

 Notes for the selection and use of flowmeters: 

 Measuring range 7…70 l/h 

 Pressure drop < 4 hPa 

 Needle valve open 

Recommendation: Flowmeter 7…70 l/h, Part Number 23151-5-

8018474 

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. nitrogen, from the gas sampling point. 

Installation Material 

19-inch Case (Model EL3020) 

 4 oval head screws (Recommendation: M6; this depends on the 

cabinet/rack system) 

 1 pair of mounting rails (Design depends on the cabinet/rack system), 

length approx. 240 mm corresponding to approx. 2/3 of the case 

depth 

Wall-mounting Case (Model EL3040) 

 4 screws M8 or M10 

Signal Lines 

 Select conductive material which is appropriate for the length of the 

lines and the predictable current load. 

 Notes concerning the cable cross-section for connection of the 

I/O modules: 

 The max. capacity of terminals for stranded wire and solid wire is 

1 mm2

 (17 AWG). 

 The stranded wire can be tinned on the tip or twisted to simplify 

the assembly. 

 When using wire end ferrules, the total cross-section may not be 

more than 1 mm2

, i.e. the cross-section of the stranded wire may 

not be more than 0.5 mm2

. The PZ 6/5 crimping tool of 

Weidmüller & Co. must be used for crimping the ferrules. 

 Max. length of the RS485 leads 1200 m (max. transmission rate 

19200 bit/s). Cable type: 3-core twisted-pair cable, cable crosssection 0.25 mm2

 (e.g. Thomas & Betts, Type LiYCY). 

 Max. length of the RS232 leads 15 m. 

Power Supply Lines 

 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. 

 Provide a mains isolator or a switched socket-outlet, in order to be 

able to disconnect all the power from the gas analyzer if required. 

Requirements for the Installation Site, Power Supply 

NOTE 

For the analyzers ZO23 and Fidas24 the information contained in the 

sections "ZO23: Preparation for Installation" (see page 25) or "Fidas24: 

Preparation for Installation (see page 30)" must be considered in addition. 

Requirements for the Installation Site 

The gas analyzer is only intended for installation indoors. 

The max. altitude of the installation site may not exceed 2000 m above 

sea level. 

The installation site must be stable enough to bear the weight of the gas 

analyzer! 

To ensure safe installation and removal, we recommend that the 19-inch 

housing is supported in a cabinet or rack with slide rails! 

Short gas paths 

Install the gas analyzer as close as possible to the sampling location. 

Install the gas conditioning and calibration modules as close as possible 

to the gas analyzer. 

Adequate air circulation 

Provide for adequate natural air circulation around the gas analyzer. 

Avoid heat build-up. 

Mount (see page 66) several 19-inch housings with a minimum spacing of 

1 height unit between housings. 

Protection from adverse conditions 

Protect the gas analyzer from: 

 Cold 

 Exposure to heat from e.g. the sun, furnaces, boilers 

 Temperature variations 

 Strong air currents 

 Accumulation of dust and ingress of dust 

 Corrosive atmospheres 

 Vibrations