Instrumentation8 Contious Gas Analizer

Continuous Gas Analyzers EL1020
Operators Manual
42/27 10 EN Rev. 2
Continuous Gas Analyzers EL1020
Operators Manual Publication No. 42/27 10 EN Rev. 2 Edition 02.05
This operators manual is protected by copyright. The right is reserved to pursue civil or criminal penalties if this publication is translated, reproduced (electronic, mechanical, photocopying, recording, etc.), stored in information retrieval systems or networks or transmitted in any form without the permission of the copyright holder.
Contents
Page Preface Guideline for Installation and Operation General Safety Precautions Safety Precautions for Handling Electronic Measurement Devices Chapter 1 Preparation for Installation Installation Location Requirements Sample Gas Inlet and Outlet Conditions, Test Gases Items Delivered Analyzer Data Sheet Identification Plate Dimensional Diagram Install the Gas Analyzer Unpack and Install the Gas Analyzer Gas Connections Connect the Gas Lines Connect the Electrical Lines Safety Precautions Electrical Connections Connect the Signal Leads Connect the Power Supply Leads Gas Analyzer Operation Readout Operation Menu Start the Gas Analyzer Check the Installation Purge the Sample Gas Path Start the Gas Analyzer Set Parameters Fundamentals Test Gas Concentration Filter EL1020-IR: Measuring Range EL1020-O2: Measuring Range EL1020-TC: Measuring Range Alarm Limit Parameters Modbus Parameters Factory and User Settings 4 5 6 7
8 9 10 10 10 11
Chapter 2
12 13 14 15 16 17 18
Chapter 3
19 20 21
Chapter 4
22 22 22
Chapter 5
23 24 24 25 26 27 28 29 30
EL1020 Gas Analyzer Operators Manual
42/27-10 EN Rev. 2
Contents
Page Chapter 6 Calibrate the Gas Analyzer Calibration Verification Test Gases EL1020-IR: Notes for Calibration EL1020-O2: Notes for Calibration EL1020-TC: Notes for Calibration Calibrate Sample Component Perform Calibration Reset EL1020-IR: Measure Calibration Cell Pressure Correction Drift Reading Maintenance Important Note for the Version for Measuring Flammable Gases Check Sample Gas Path Seal Integrity Status Messages, Troubleshooting Blinking Screen Status Messages Troubleshooting Call for Service Gas Analyzer Shutdown and Packing Gas Analyzer Shutdown Gas Analyzer Packing
31 31 31 32 32 33 35 36 37 38
Chapter 7
39 39
Chapter 8
41 42 44 45
Chapter 9
46 47
Appendix EL1020-IR: Gas Analyzer Structure EL1020-IR: Metrological Data EL1020-O2: Gas Analyzer Structure EL1020-O2: Metrological Data EL1020-TC: Gas Analyzer Structure EL1020-TC: Metrological Data Electrical Safety Index 48 48 50 50 52 52 53 54
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Preface
Content of the Operators Manual This operators manual contains all the information you will need to safely and efficiently install, start-up, operate and maintain the EL1020 gas analyzer.
Symbols and Fonts Used in the Manual
Identifies safety information to be heeded during gas analyzer operation in order to avoid risks to the user. Identifies specific information on operation of the gas analyzer as well as on the use of this manual. Analyzer Indicates specific information for individual gas analyzers EL1020-IR, EL1020-O2 and EL1020-TC. 1, 2, 3, ... Identifies reference numbers in figures.
Display Identifies a display on the screen. Display Identifies a blinking display on the screen. Enter Back Identifies function keys.
Additional Information The version of the delivered gas analyzer will be described in the Analyzer Data in the Analyzer Data Sheet supplied with each gas analyzer (see Section Analyzer Data Sheet, Sheet page 10).
Additional Information A CD-ROM with the following content is added to the gas analyzer: on CD-ROM Operators Manuals, Data Sheets, Technical Information Sheets, Spare Parts Lists, Certificates, Software Tools.
Additional Information Additional information on ABB Analytical products and services is available on the on the Internet Internet at http://www.abb.com/analytical.
Further Information
If the information in this operators manual does not cover a particular situation, ABB service is prepared to supply additional information as needed. Contact your local ABB service representative or ABB Service, Telephone: +49-1 80-5-12 35 80, Telefax: +49-6 21-3 81-51 35, E-Mail: callcenter.automation@de.abb.com
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Guideline for Installation and Operation

Basic Steps The following basic steps should be followed when installing and operating the EL1020 gas analyzer. Step 1 2 3 4 5 6 7 8 9 10 Action Follow safety precautions Prepare the installation Unpack the gas analyzer Check gas path seal integrity Install the gas analyzer Connect the gas lines Connect the electrical leads Check the installation Purge the sample gas path Start the gas analyzer Set the parameters EL1020-TC: Set active sample component See Page 6, 7 8 12 12 12 14 15 22 22 22 23 27
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General Safety Precautions

Intended Application The EL1020 gas analyzer is designed for continuous measurement of the concentration of individual components in gases or vapors. The EL1020 gas analyzer must not be used for measurement of explosive gas/air or gas/oxygen mixtures.
Requirements for Safe Operation
In order to operate in a safe and efficient manner, the gas analyzer should be properly handled and stored, correctly installed and set-up, properly operated and carefully maintained.
Personnel Qualifications
Only persons familiar with the installation, set-up, operation and maintenance of comparable equipment and certified as being capable of such work should work on the gas analyzer.
Special Information and Precautions
These include The content of this operators manual. The safety information affixed to the gas analyzer. Safety precautions for the installation and operation of electrical devices. Safety precautions for working with gases, acids, condensates, etc.
National Regulations
The regulations, standards and guidelines cited in this operators manual are applicable in the Federal Republic of Germany. The applicable national regulations should be followed when the gas analyzer is used in other countries.
Gas Analyzer Safety and Safe Operation
The gas analyzer is designed and tested in accordance with EN 61010 Part 1, Safety Provisions for Electrical Measuring, Control, Regulation and Laboratory Instruments and has been shipped ready for safe operation. To maintain this condition and to assure safe operation, read and follow the safety information identified with the symbol in this operators manual. Failure to do so can put persons at risk and can lead to gas analyzer damage as well as damage to other systems and instruments.
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Safety Precautions for Handling Electronic Measurement 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 Disconnect- The gas analyzer can be hazardous if the protective lead is interrupted inside or ed Protective Lead outside the gas analyzer 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 Gas Analyzer
The gas analyzer must be disconnected from all power sources before being opened for any work. All work on a gas analyzer that is open and connected to power should only be performed by trained personnel who are familiar with the risks involved.
Use of Proper Fuses
Never use patched fuses. Do not short-circuit the fuse holder contacts.
When Safe Operation can no Longer be Assured
If it is apparent that safe operation is no longer possible, the gas analyzer should be taken out of operation and secured against unauthorized use. The possibility of safe operation is excluded: If the gas analyzer is visibly damaged If the gas analyzer no longer operates After prolonged storage under adverse conditions After severe transport stresses
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Chapter 1
Preparation for Installation
Installation Location Requirements

Short Gas Paths Install the gas analyzer as close as possible to the sampling location. Locate the gas conditioning and calibration assemblies as close as possible to the gas analyzer.
Adequate Air Circulation
Provide for adequate natural air circulation around the gas analyzer. Avoid heat buildup.
Protection from Adverse Conditions
Protect the gas analyzer from: Cold Direct sunlight and heat Large temperature variations Strong air currents Accumulations of dust and dust infiltration Corrosive atmospheres Vibration
Environmental Conditions
Air pressure range 600 to 1250 hPa Relative humidity max. 75 % Ambient temperature during storage and shipping 25 to +65 C in operation EL1020-TC +5 to +50 C EL1020-O2 +5 to +50 C EL1020-IR w/o O2 sensor +5 to +45 C with O2 sensor +5 to +40 C
Power Supply
Input voltage Power consumption
Connection
85 to 250 VAC, 47 to 63 Hz EL1020-TC max. 40 VA EL1020-O2 max. 90 VA EL1020-IR max. 40 VA 3-prong grounded instrument plug per EN 60320 / C14
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Sample Gas Inlet and Outlet Conditions, Test Gases

Sample Gas Inlet Conditions Temperature Pressure pe EL1020-IR EL1020-O2 EL1020-TC 1) 2) 3) 4) Definition +5 to +45 C +5 to +50 C +5 to +50 C 2 to 100 hPa 2 to 100 hPa
3) 3)
Flow 20 to 160 l/h 10 to 190 l/h

4)
Pressure Drop 1) < 4 hPa < 2 hPa < 2 hPa
2 to 500 hPa 2) 20 to 100 l/h
for 60 l/h N2 for flammable gases: 2 to 100 hPa (max. 500 hPa) max. pe = 1000 hPa min. 1 l/h
pe = pabs pamb where pe = positive pressure, pabs = absolute pressure, pamb = atmospheric pressure The sample gas dew point should be at least 5 C below the lowest ambient temperature throughout the sample gas path. Otherwise a sample gas cooler or condensate trap is required. Water vapor content variations cause volume errors. The sample gas may not be flammable if the O2 sensor is used. When using the O2 sensor the H2O dew point must be 2 C. The O2 sensor must not be used with dry sample gases. The O2 sensor must not be used if the associated gas contains the following components: H2S, chlorine or fluorine compounds, heavy metals, aerosols, mercaptane, base components. The gas analyzer must not be used for the measurement of corrosive gases. Gases like chlorine (Cl2) and hydrogen chloride (e.g. wet HCl) as well as gases or aerosols containing chlorine must be cooled or undergo prior absorption. Please note the following for the measurement of flammable gases: The sample gas lines in the gas analyzer must be designed in the form of stainless steel pipes. The tightness of the sample gas feed path must be checked regularly. Housing purge is not required. One of the openings for the hose fittings must be open and sufficiently ventilated. If the gas analyzer is fitted in a rack, a natural exchange of air with the environment must be possible. If the gas analyzer is fitted in an enclosed cabinet, adequate external ventilation must be provided. Before using the gas analyzer the corrosion resistance against the specific sample gas must be checked. In case of failure the pressure in the containment system must not exceed the maximum value pe = 500 hPa (EL1020-IR) or pe = 1000 hPa (EL1020-O2 and EL1020-TC). The outlet pressure must not exceed the inlet pressure by more than the pressure loss across the analyzer. Please refer to Chapter 6 Calibrate the Gas Analyzer (see page 31) for information on test gases for calibration of the individual gas analyzers. EL1020 Gas Analyzer Operators Manual 9
Sample Gas Dew Point
Specifics for the Use of an O2 Sensor
Corrosive Gases
Flammable Gases
Gas Outlet Conditions
Test Gases for Calibration 42/27-10 EN Rev. 2
Items Delivered
Items delivered Quantity 1 1 1 1 4 1 2 1 1 Description EL1020 gas analyzer Power cord, 2 meters long 6-pin female multipoint connector for analog outputs 12-pin female multipoint connector for digital outputs Adhesive pads for mounting the device on a table Fine filter (Part No. 806539) Operators manuals (English and German) CD-ROM with software and documentation Analyzer data sheet (inside the device)
Analyzer Data Sheet

Contents of the Analyzer Data Sheet The analyzer data sheet contains the following information: Order number (A-No.) Part number (P-No.) Serial number (F-No.) Production date Power supply (voltage, frequency, consumption) Software version Sample components and measuring ranges Serial numbers of installed components The analyzer data sheet is in a sleeve affixed to the back of the sensor CPU board attachment plate.
Where is the analyzer data sheet located?
Identification Plate
Figure 1 Identification Plate (Example)
ABB
Made in Germany
EL1020-IR
F.-No. 3.123456.1 Mains 85250 VAC, 4763 Hz, 40 VA Output 420 mA, max. 750 Sample Components CO 0500 ppm O2 025 Vol% Pressure Sensor yes Calibration Cells 0 / 1 Serial number Power supply voltage, frequency, consumption Output current, load Sample components and measuring ranges
Pressure sensor installed Number of calibration cells installed
10
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Dimensional Diagram
Figure 2 Dimensional Diagram (dimensions in mm)
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Chapter 2
Install the Gas Analyzer
Unpack and Install the Gas Analyzer

Gas Analyzer Unpacking Step 1 2 3 Action Remove the gas analyzer with the respective protective packaging from the shipping box. Remove the protective packaging and place the gas analyzer in a clean location. Remove the adhesive packaging residue from the gas analyzer.
If there is shipping damage that points to improper handling, file a damage claim with the shipper (railway, mail or freight carrier) within seven days. Make sure the enclosed accessories are not lost (see Section Items Delivered, page 10). Keep the shipping box and packaging material for future shipping needs.
Sample Gas Path Seal Integrity Verification
The seal integrity of the sample gas path is factory-tested. Since gas path seal integrity can be compromised during shipping of the gas analyzer (e.g. by strong vibration) a seal integrity check should be performed on site prior to startup. For information on checking gas path seal integrity see page 39.
Gas Analyzer Installation
The gas analyzer is intended for tabletop operation and rack mounting. For tabletop operation attach the adhesive pads supplied with the unit to the bottom of the housing. The four M5 tapped holes on the bottom of the housing can be used for rack mounting (see Figure 2 on page 11).
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Gas Connections
Figure 3 Gas Connections on Rear of Gas Analyzer
Sample Gas Ports Couplings for hose DN 4/6 or Couplings with 1/8 NPT internal threads in the version for measuring flammable gases
Sample Gas Inlet
Sample Gas Outlet
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Connect the Gas Lines

Connect the Gas Lines Step 1 2 3 4 Action Square cut the tubing. Slide the knurled nut and clamping ring over the end of the tubing. Slide the tubing end up to the stop on the bushing. Attach the knurled nut and tighten it by hand.
In the version for the measurement of flammable gases ensure that the gas lines (stainless steel pipes) are properly connected to the couplings with 1/8 NPT internal threads under consideration of the tightness requirements.
Install a Fine Filter
Install a fine filter ahead of the sample gas inlet. A fine filter (Part No. 806539) is supplied with the gas analyzer. When installing the fine filter note the direction of flow indicated by the arrow on the housing.
Install a Flow Meter
Install a flow meter or monitor with a needle valve ahead of the sample gas inlet in order to adjust and monitor the sample gas flow.
Provide for Gas Line System Flushing
Install a shutoff valve in the gas inlet line (this is definitely recommended for pressurized gases) and provide a means of flushing the gas line system via the sampling port with an inert gas, e.g. nitrogen.
Evacuate Exhaust Gases
Exhaust gases should be routed to the atmosphere or to an exhaust pipe directly or via the shortest possible large-diameter line. Do not route exhaust gases via flow reducers or shutoff valves. Process corrosive, toxic or flammable exhaust gases in an appropriate manner.
Start the sample gas supply only when the gas analyzer has reached room temperature and after the warm-up phase has ended (see Section Start the Gas Analyzer, page 22). Otherwise the sample gas can condense in a cold analyzer. Note the gas inlet conditions (see page 9).
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Connect the Electrical Lines Safety Precautions

CAUTION! Follow all applicable national safety regulations for the preparation and operation of electrical devices as well as the following safety precautions. The protective lead should be attached to the protective lead connector before any other connection is made. The protective lead connection is assured when the power cable supplied is used. The gas analyzer can be hazardous if the protective lead is interrupted inside or outside the gas analyzer or if the protective lead is disconnected. Current-bearing components can be exposed when covers or parts are removed, even if this can be done without tools. Current can be present at some connection points. Never use patched fuses. Do not short-circuit the fuse holder contacts. Install a circuit breaker near the gas analyzer in order to completely isolate the unit from the power supply. Mark the breaker so that its relationship to the protected device is clear.
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Electrical Connections
Figure 4 Electrical Connections on Rear of Gas Analyzer
1234 56 789
Service
DO/-X1
1 2 3 4
RS232/-X2
AO/-X4
RS485/-X3
DO/-X1
Digital outputs Pins 13 Overall status signal Pins 46 Alarm signal 1 Pins 79 Alarm signal 2 floating double-throw contacts, max. contact load rating 30 VDC / 1 A Relays are shown in the unpowered state. The unpowered state is the failure mode (fail safe). RS485 and RS232 interfaces for transferring measured values and status signals to host systems, e.g. to Windows applications via a DDE server. Modbus slave protocol in RTU (remote terminal unit) mode. It can use either the RS485 or RS232 interface. Configuration of the Modbus connection is described on page 29. Analog outputs Pins 1, 2 Sample component 1 Pins 3, 4 Sample component 2 (only for EL1020-IR) 4 to 20 mA, common negative pole, galvanically separated from ground, freely connectable to ground, max. gain vs. local protective ground potential 50 V, max. working resistance 750 . The output signal cannot be less than 0 mA.
RS232/-X2 RS485/-X3
AO/-X4
16
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Connect the Signal Leads

Material Required The wire type required depends on the length of the leads and the planned current load. The maximum conductor section is 1.5 mm2, or 16 AWG. The matching plugs (female connectors) for the analog and digital output terminal strips are part of the normally supplied accessories.
Analog Outputs
At the factory two jumpers are inserted in the matching plugs (female connectors) for the analog outputs. If no signal leads are installed, these jumpers close the output current circuit and prevent the display of status message 30 Broken analog output line (see page 43).
Modbus
The maximum line length is 1200 meters for RS485 and 15 meters for RS232. Configuration of the Modbus connection is described on page 29. For detailed Modbus information see the EL1020 Modbus and M-DDE Server technical information sheet (Publication No. 30/27-100 EN).
Connect the Signal Leads
Step 1 2
Action Connect the leads to the matching plugs (female connectors) according to the connection diagram (see page 16). Connect the matching plugs to the terminal strips.
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Connect the Power Supply Leads

Material Required The gas analyzer is supplied with a 2-meter long power cord fitted with a 3-prong grounded plug. If this power cord is not used, the wiring material required will depend on the length of the leads and the planned current load.
Connect the Power Supply Leads
Step 1 2
Action Make sure the power supply leads have an adequately dimensioned protective device (breaker). Install a breaker in the power supply line or a switched receptacle near the gas analyzer to make sure the analyzer can be completely isolated from the power source. Mark the breaker so that its relationship to the protected device is clear. Connect the power cord supplied to the gas analyzer power supply connection. Connect the other end of the power cord to the power source. The gas analyzer starts operation.
3 4
Start the sample gas supply only when the gas analyzer has reached room temperature and after the warm-up phase has ended (see Section Start the Gas Analyzer, page 22). Otherwise the sample gas can condense in a cold analyzer. Note the sample gas inlet conditions (see page 9).
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Chapter 3
Gas Analyzer Operation
Readout
Screen The lighted LCD screen consists of two lines of 20 characters each.
Display in Measuring Mode
CO
105.2 ppm
In measuring mode the screen displays the sample component name(s), the measured value in digits and the physical unit for the measured value. Press the key to display the measured value as a percentage of the measuring range (span).
CO
21.14 %Span
All screen displays shown in this operators manual are examples. As a rule, actual displays on the device will differ.
Number of Places after the Decimal Point
When the screen displays the measured value in physical units (e.g. ppm) the number of places after the decimal point depends on the size of the measuring span: Span (in physical units) Places < 5 5...< 50 50...< 500 500 3 2 1 0
For the display of the measured value as a percentage of the whole measuring range (%Span) two places are always shown after the decimal point. The number of decimal places when setting the parameters is the same as in the display in measuring mode.
Blinking Screen
Blinking of part of the screen in measuring mode indicates that the gas analyzer or process system has experienced a fault. See Chapter 8 Status Messages, Troubleshooting, page 41, for details on faults, causes and corrective actions.
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Operation
Keys The and keys are used to select a menu item change a value. The Enter key is used to activate a menu item accept an edited value activate a function. The Back key is used to return to the first item in a menu or to a previous menu cancel the editing of a value.
Time-Out
If the user does not use a key during a period longer than one minute during menu item selection, the gas analyzer will automatically revert to displaying measured values (time-out). The time-out function is deactivated if the user changes the value of a parameter or activates calibration.
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Menu
Menu The EL1020 gas analyzer menu structure is summarized below. see Page Menu Structure (Overview) Measured value display Calibrate Calibrate component Zero calibration Span calibration Span with cal. cell Calibration reset Pressure adjustment Measure cal. cell Setting parameters Parameters component Zero setpoint Span setpoint Filter Measuring range Active TC component Parameters limit Limit 1 Limit 2 Limit 1 hysteresis Limit 2 hysteresis Parameters modbus Modbus baudrate Modbus address Modbus type Information Drift Delta drift Software version Error list 41 38 38 EL1020-TC only 24 24 24 24 25 27 28 28 28 28 28 29 29 29 29 EL1020-IR only EL1020-IR only 33 33 34 34 35 37 36
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Chapter 4
Start the Gas Analyzer
Check the Installation

Check the Installation Step 1 2 3 Action Are all gas lines correctly connected? (see page 14) Are all signal and interface leads correctly routed and connected? (see page 17) Are all devices needed for gas conditioning, calibration and exhaust processing correctly connected and ready for use?
Purge the Sample Gas Path

Prestart Purge For the measurement of flammable gases the sample gas path must be purged before the gas analyzer is started. This should prevent the ignition of any explosive gas/air mixtures in the gas paths when the power supply is turned on. Purge gas Purge gas flow Purge time Inert gas, e.g. nitrogen max. 100 l/h approx. 20 sec.
Start the Gas Analyzer

Start the Gas Analyzer Step 1 2 Action Activate the gas analyzer power supply. The screen initially displays the gas analyzer name and the software version. After a brief time the screen switches displaying measured values. EL Series IR 2.0.4 22-04-2003 CO 105.2 ppm
4 5 6 7
Blinking of part of the screen indicates that a fault has occurred (see Section Blinking Screen, page 41). Check the parameters and adjust as needed (see page 23). After the warm-up phase (approx. 30 to 60 minutes) the gas analyzer is ready to operate. Verify the gas analyzer calibration (see page 31). Start the sample gas flow.
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Chapter 5
Set Parameters
Fundamentals
General Procedure The normal procedure for setting parameters is: 1. 2. 3. 4. 5. 6. Press Enter to access the menu. Select the Parameters menu item with the or key. Activate the Parameters menu item with the Enter key. Change the parameters with the or key. Confirm the change with the Enter key or cancel the change with the Back key. Use the Back key to return to the previous menu.
Only parameters that blink in the display can be edited. The following example should clarify the details of this general procedure. Step Action Key Display CO 105.2 ppm Key
Access the menu.
Enter
Calibrate
Select the Setting parameters menu. Select the submenu.
Setting parameters
Enter
Parameters component Enter CO Span setpoint 505.0 ppm CO Span setpoint 505.0 ppm CO Span setpoint 500.0 ppm CO Enter
Select the parameter to be changed. Edit the parameter value and confirm the change. Return to the previous menu. Return to the previous menu. Return to the measured value display.
Enter
Back
Parameters component Back CO Setting parameters Back
CO
105.2 ppm
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Test Gas Concentration

Zero Set Point Zero setpoint 0.0 ppm CO Zero setpoint 0.0 ppm CO Test gas concentration set point for zero calibration
Value range: Reference measuring range 1) start minus 25 % of span to reference measuring range end
Span Set Point
Span setpoint 500.0 ppm CO Span setpoint 500.0 ppm CO
Test gas concentration set point for span calibration
Value range: Reference measuring range 1) start to reference measuring range end plus 30 % of span
Step Interval
The set point adjustment step interval is 0.2 % of the span of the range in use.
1) For an explanation of the term Reference Measuring Range see pages 25 to 27.
Filter
Filter (T90 Time) Filter 5 sec Filter 5 sec Filter 5 sec Filter 5 sec Non-linear filter with two low pass time constants and switching threshold Time constant for constant measured value. Value range: 0 to 60 sec. Time constant for measured value changes. Value range 0 to 60 sec. Switching threshold as % of span of reference measuring range 1). On exceeding this value the time constant for measured value changes is effective. Value range: 0 to 9.99 %
1 sec 0.05 %
1 sec 0.05 %
1 sec 0.05 %
1 sec 0.05 %
Recommendation
The ratio of the time constant for constant measured values to the time constant for measured value changes should be 5 :1.
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EL1020-IR: Measuring Range

Measuring Range Measuring range 0.0 500.0 ppm Measuring range 0.0 500.0 ppm Measuring range The measuring range start value cannot be changed Measuring range end Value range: Within the reference measuring range
Step Interval
The measuring range adjustment step interval is 10 ppm or 0.5 Vol.-% or 5 mg/m3 or 0.5 g/m3, depending on the physical unit involved.
Calibration of the measuring range should be verified after changing measuring range limits.
Reference Measuring Range
The gas analyzer has a physical measuring range (reference measuring range) for each sample component. The limits of this measuring range are defined by the minimum and the maximum value of the product of the gas concentration c and sample cell length l (c l)min and (c l)max.
Measuring Range Notes
One measuring range can be selected within the limits of the factory-set reference measuring range. The adjustment range, based on the factory setting per customer order, is 1:5, or 1:8 for CO2. Smallest measuring range data of the individual sample components see Section EL1020-IR: Metrological Data, page 48. Measuring ranges within ignition limits cannot be provided.
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EL1020-O2: Measuring Range

Measuring Range Measuring range 0.00 - 25.00 Vol% Measuring range 0.00 - 25.00 Vol% Measuring range 0.00 - 25.00 Vol% Measuring range
Measuring range start Value range: Within the reference measuring range Measuring range end Value range: Within the reference measuring range
Step Interval
The measuring range adjustment step interval is 0.5 Vol.-%.
The gas analyzer has a physical measuring range (reference measuring range). The limits of this range are 0 Vol.-% O2 and 100 Vol.-% O2.
One measuring range can be selected within the limits of the reference measuring range. It is factory-set and calibrated to 0 to 25 Vol.-% O2. The smallest measuring range is 0 to 1 Vol.-% O2; the largest adjustable measuring range is 0 to 100 Vol.-% O2. Measuring ranges within ignition limits should not be attempted. The gas inlet conditions should be observed (see page 9).
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EL1020-TC: Measuring Range

Measuring Range Measuring range 0.0 - 100.0 Vol% Measuring range 0.0 - 100.0 Vol% Measuring range 0.0 - 100.0 Vol% Measuring range
Measuring range start Value range: Within the reference measuring range Measuring range start Value range: Within the reference measuring range
Step Interval
The measuring range adjustment step interval is 0.5 Vol.-%.
The gas analyzer has a physical measuring range (reference measuring range) for each sample component. The limits of this range are 0 Vol.-% and 100 Vol.-%.
The measuring range can be adjusted within the limits valid for the sample components (see Section EL1020-TC: Metrological Data, page 52). For the factory-set component relative thermal conductivity it is permanently set to rTC = 0 to 60,000. The largest measuring range is 0 to 100 Vol.-% or 0 Vol.-% to saturation, depending on the measuring task. Measuring ranges within ignition limits cannot be provided.
Active Sample Component
Active TC component CO2:H2 Active TC component CO2:H2
Active sample component
All the sample components listed in the Section EL1020-TC: Metrological Data are available (see page 52).
All sample components are precalibrated at the factory. After activating a sample component, check the zero and span points and recalibrate as necessary (see Chapter 6 Calibrate the Gas Analyzer, page 31). When a different sample component is activated, the gas analyzer reverts to the factory precalibrated state. This means that calibration values are lost and set point and measuring range limit settings are reset to the reference measuring range limits.
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Alarm Limit Parameters

Alarm Limit Parameters If only one sample component is present in the gas analyzer, two alarm limits can be set for this component. If there are two sample components in the gas analyzer, one alarm limit can be set per sample component. Switching hysteresis can be set for each of the alarm limits.
Alarm Limit
Limit 1 OFF > 400.0 ppm Limit 1 OFF > 400.0 ppm Limit 1 OFF > 400.0 ppm Limit 1 OFF > 400.0 ppm
CO
Alarm limit of the sample component displayed
CO
Activation. Value range: ON or OFF Direction of effect. Value range: < or > = Alarm on underflow or overflow of alarm limit Alarm limit. Value range: Within the reference measuring range 1)
CO
CO
Step Interval
The alarm limit adjustment step interval is 0.1 % of the span of the reference measuring range 1).
Switching Hysteresis
Limit 1 hysteresis 10.0 ppm Limit 1 hysteresis 10.0 ppm
Switching Hysteresis
Extent of switching hysteresis. Value range: Within the reference measuring range 1)
Step Interval
The hysteresis adjustment step interval is 0.01 % of the span of the reference measuring range 1).
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Modbus Parameters
Modbus Parameters Modbus parameters are set prior to connecting the gas analyzer to a PC or process control system via a Modbus link.
Baud Rate
Modbus baudrate 19200 Modbus baudrate 19200
Baud Rate
Value range: 9600 or 19200
Address
Modbus address 1 Modbus address 1
Address
Value range: 1 to 255
Interface Type
Modbus type RS232 Modbus type RS232
Interface Type
Value range: RS232 or RS485
For detailed Modbus information see the EL1020 Modbus and M-DDE Server technical information sheet (Publication No. 30/27-100 EN).
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Factory and User Settings

Factory and User Settings The following table lists the parameter settings made at the factory. The operator can enter any on-site or application-specific parameter changes in the column at the right. Parameter Zero setpoint Span setpoint Filter Measuring range Active TC component Limit 1 Limit 2 Limit 1 hysteresis Limit 2 hysteresis Modbus baudrate Modbus address Modbus type OFF OFF 0 0 19200 1 RS232 < < 0 0 Depending on the gas analyzer type Factory Setting User Setting
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Chapter 6
Calibrate the Gas Analyzer
Calibration Verification
Calibration Verification The gas analyzer is calibrated in the factory. Transport stresses as well as pressure and temperature conditions at the installation location may however influence the calibration. Thus it is recommended to verify the gas analyzer calibration at the installation location prior to start-up.
Test Gases
Test Gas Dew Point The test gas dew point must be nearly identical to the sample gas dew point.
Test Gas Supply
Test gases should be connected to the sample gas inlet (e.g. using a multiple-path valve).
EL1020-IR: Notes for Calibration

Test Gases For zero-point calibration: Inert gas, e.g. nitrogen (N2) or sample component-free ambient air For end-point calibration: Calibration cell (optional) or test gas mixture (Concentration: 70% of the span value of the measuring range selected is recommended; the maximum value is the span value of the reference measuring range) The zero point is stable over long periods of time. If needed, it can be calibrated with nitrogen (N2). Ambient air at 20.96 Vol.-% O2
Test gases for O2 sensor
Zero calibration Span calibration
Calibration Cell (Option)
Use of a calibration cell allows the EL1020-IR gas analyzer to be calibrated without using test gas containers. The calibration cell is filled with a test gas matched to the sample components and measuring ranges for which the gas analyzer is set up. It is routed to the beam path during span calibration. The calibration cell set point should be checked at long intervals (recommendation: once a year, see page 36 for instructions).
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31
EL1020-O2: Notes for Calibration

Test Gases For zero-point calibration: Oxygen-free process gas or nitrogen (N2) For end-point calibration: Process gas with a known oxygen concentration or dried air or test gas with concentration in the measuring range
Measuring Ranges with Suppressed Zero-Point
Zero-point and end-point of a measuring range with suppressed zero-point should only be calibrated with test gases with concentrations in the selected measuring range.
Carrier Gas Offset Correction
The influence of carrier gases is seen in the form of a displacement of the zero point (see Section EL1020-O2: Metrological Data, page 50). If it is expected that, due to a particular carrier gas specified by the customer with the order, this zero point displacement is greater than 1 % of the smallest selected measuring range, then the gas analyzer will be calibrated in the factory with an average process gas, and the deviation with respect to the carrier gas N2 will be corrected with the software function Carrier gas offset correction. This correction function has the effect that the influence of the carrier gas is minimized in the measuring operation. It is also active in the course of calibration while the concentration of the test gases is being measured. As a result, during zero-point and end-point calibration measured values are displayed which differ from the true measured value by the amount of the offset correction value. During calculation of the calibration however this correction function is switched off so that the offset correction value is not taken into account in the calibration results.
EL1020-TC: Notes for Calibration

Test Gases For zero-point calibration: Test gas or sample component-free process gas For end-point calibration: Test gas or process gas having a known sample component concentration
Measuring Ranges with Suppressed Zero-Point
Zero-point and end-point of a measuring range with suppressed zero-point should only be calibrated with test gases with concentrations in the selected measuring range.
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Calibrate Sample Component

Wait until End of Warm-up Phase The gas analyzer should only be calibrated after the end of the warm-up phase (that takes approx. 30 to 60 minutes).
Current Output During Calibration
Signals at the analog outputs (current outputs) track measured value changes during calibration.
Limits During Calibration
If limits are activated, they are also active during calibration.
Status Signal During Calibration
During calibration, the status signal Maintenance Mode is output on overall status digital output and via Modbus.
Calibration via Modbus
For information about calibration via Modbus see the EL1020 Modbus and M-DDE Server technical information sheet (Publication No. 30/27-100 EN).
A zero calibration must always be performed before a span calibration. A zero calibration can also be performed separately.
Calibrate Sample Component
Step 1
Action Select the Calibrate menu. Select the sample component. Select Zero calibration.
Key Enter
Display Calibrate
Key Enter
Calibrate component CO Zero calibration CO
Enter
Enter
Check the zero set point and adjust as needed. Turn on the zero gas supply. Start calibration if the measured value reading is stable. Calibration in progress.
Zero setpoint 0.00 Vol% CO Connect zero gas!
Enter
Enter
Meas. value stable? 0.53 Vol% CO Wait cal. is running
Enter
Accept calibration or reject calibration.
Meas. value ok? 0.00 Vol% CO
Enter Back
Continued on next page
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33
Calibrate Sample Component, continued

Step 9 Action Select Span calibration with test gas. Check the span set point and adjust as needed. Turn on the span gas supply. Start calibration if the measured value reading is stable. Calibration in progress. Key Display Span calibration CO Span setpoint 10.00 Vol% CO Connect span gas! Enter Key Enter
10
11
Enter
12
Enter
13
14
Accept calibration or reject calibration. Select Span calibration with calibration cell. The calibration cell set point is displayed. Connect the zero gas (if this has not already been done). Start calibration if the measured value reading is stable. Calibration in progress.
Meas. value ok? 10.00 Vol% CO Span with cal. cell CO Setpoint cal. cell 8.52 Vol% CO Connect zero gas!
Enter Back Enter
Option for EL1020-IR
10
Enter
11
Enter
12
Enter
13
14
Accept calibration or reject calibration.
Enter Back
This display shows that an error occurred during calibration and that calibration was unsuccessful. In this case, press Enter to return to the start of zero or span calibration, check the test gas concentration, correct as needed and repeat the calibration process.
Amplification error 0.00 Vol% CO
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Perform Calibration Reset

When should a calibration reset be performed? Perform a calibration reset only when the gas analyzer can no longer be calibrated with normal means. A possible cause of this is calibration with the wrong test gases.
What does the calibration reset do?
A calibration reset returns the gas analyzers calibration to factory default values. Additionally, the offset drift and amplification drift are electronically returned to initial calibration values (see Section Drift Reading, page 38).
Perform Calibration Reset
Step 1
Action Select the Calibrate menu. Select the sample component. Select Calibration reset.
Key Enter
Display Calibrate
Key Enter
Calibrate component CO Calibration reset CO Calibration reset Start cal. reset! Wait cal. is running
Enter
Enter
Start the calibration reset. Calibration reset in progress. Calibration reset has ended. Press the Back key to return to displaying measured values.
Enter
Calibration reset CO
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EL1020-IR: Measure Calibration Cell

Definition Measuring the calibration cell determines what calibration cell deflection is equivalent to the test gas calibration reading. This deflection is stored as the calibration cell set point.
When should the calibration cell be measured?
We recommend measuring the calibration cell once a year. Measurement of the calibration cell is also recommended after a user-set measuring range (see page 25) is calibrated for the first time with test gases and subsequently whenever the test gas is changed.
Before Measuring the Calibration Cell
Prior to measuring the calibration cell, the zero and span point of the applicable sample components must be calibrated with test gases.
Zero Gas Supply
During calibration cell measurement the zero gas supply must be turned on.
Measure Calibration Cell
Step 1
Action Select the Calibrate menu. Select Measure calibration cell. Turn on the zero gas supply. Start measurement if the measured value reading is stable. Measurement in progress. Accept the set point.
Key Enter
Display Calibrate
Key Enter
Measure cal. cell 1 CO Connect zero gas!
Enter
Enter
Enter
Enter
Press the Back key to return to displaying measured values.
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Pressure Correction
Air Pressure Effect A change in atmospheric pressure by a certain amount will affect measured value readings.
Pressure Sensor Installed
A pressure sensor is installed in the gas analyzers (in EL1020-O2 as an option). The effects of air pressure changes on the measured value are minimized by automatic internal pressure correction.
Pressure Sensor Calibration
If the indication of the internal pressure sensor differs from the current air pressure, the pressure sensor can be recalibrated. When measuring non-flammable sample gases, the pressure sensor can be connected to the sample gas outlet line via an external tee. In this case, the sample gas flow should be stopped when calibrating the pressure sensor in order to prevent the sample gas pressure from causing a false pressure reading. After calibrating the pressure sensor the zero and span points must be checked and recalibrated as needed.
Note for EL1020-O2
The EL1020-O2 gas analyzer with no pressure sensor installed is calibrated at the factory for an air pressure of 1013 hPa. If the air pressure at the installation site differs from 1013 hPa, the actual pressure can be corrected by manually entering a value (see instructions Calibrate Pressure Sensor, steps 1 to 3).
Calibrate Pressure Sensor
Step 1
Action Select the Calibrate menu. Select Pressure adjustment. Set the pressure set point. Start adjustment if the measured value reading is stable. Adjustment in progress.
Key Enter
Display Calibrate
Key Enter
Pressure adjustment
Enter
Pressure setpoint 1021 hPa Meas. value stable? 997 hPa Wait cal. is running
Enter
Enter
Accept the measured value. Press the Back key to return to displaying measured values.
Meas. value ok? 1021 hPa
Enter
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Drift Reading
Drift Drift offs CO 0% Offset and amplification drift values are determined cumulative and based on the last initial calibration performed.
0% ampl
Delta Drift
Delta drift offs 0% ampl
CO 0%
Offset and amplification delta drift values are determined based on the last and next-to-last calibration performed via the Modbus.
Drifts are displayed as a percentage of the user-set measuring range.
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Chapter 7
Maintenance
Important Note for the Version for Measuring Flammable Gases

Measures taken after opening the gas paths inside the analyzer unit If the sample gas path inside the gas analyzer has been opened, the seal integrity should be tested with helium at a leak rate of < 2 10-4 hPa l/s. The pressure drop method, described in the Check Sample Gas Path Seal Integrity section (see below) can be used as an alternative to the helium test. To accomplish this, increase the test pressure to a pe of approx. 400 hPa (= 400 mbar) and increase the test period to 15 minutes. The maximum excess pressure pe = 500 hPa (= 500 mbar). Any time the gas path is opened it must then be purged prior to connecting the power supply. This should remove any explosive gas/air mixture in the gas path. Purge gas for a non-flammable sample gas for a flammable sample gas Purge gas quantity Purge gas flow Purge duration Clean instrument air from areas free of any explosion risk Inert gas 5 times the volume of the gas paths Approx. 30 liters / hour At least 3 minutes
The purge gas should not contain any sample gas components.
Check Sample Gas Path Seal Integrity

When should seal integrity be checked? Sample gas path seal integrity should be checked periodically. It should be checked regularly when measuring flammable gases. It should always be checked after the sample gas path has been opened inside the gas analyzer.
Material Required
Quantity 1 1 1
Description Pressure gauge Tubing, approx. 1 meter in length Tee with shutoff valve Air or nitrogen Continued on next page
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Check Sample Gas Path Seal Integrity, continued

CAUTION! If the seal test is to be carried out with air and there is the possibility of a flammable gas being present in the sample gas path or if a flammable gas is to be introduced later, the sample gas path should first be purged with nitrogen. Otherwise the seal integrity test can be performed with nitrogen.
Sample Gas Path Seal Integrity Verification
Step 1 2 3 4
Action Plug the outlet of the sample gas path. Connect a hose with a tee fitted with a shutoff valve to the inlet of the sample gas path. Connect the free end of the tee to the pressure gauge. Blow air or nitrogen through the shutoff valve until the sample gas path is pressurized to a pe of approx. 50 hPa (= 50 mbar). Close the shutoff valve. Maximum excess pressure pe = 150 hPa (= 150 mbar). The pressure should not change measurably in 3 minutes. A sharp pressure drop is a sign of a leak in the sample gas path.
Figure 5 Seal Integrity Testing
50 hPa
Air or Nitrogen
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Chapter 8
Status Messages, Troubleshooting
Blinking Screen
Blinking Screen Blinking of part of the screen in measuring mode indicates that the gas analyzer or process system has experienced a fault.
Measured value exceeds / is below measuring range span
CO
753.2 ppm
The measured value reading blinks if the measured value of the sample component is < 100 % or > 130 % of measuring range span.
Maintenance Request
CO
105.2 ppm
The sample component name display blinks if a maintenance request condition has occurred. The status is output via Modbus. The gas analyzer is in a state that will soon require user intervention. The measured value is valid.
Failure
CO
105.2 ppm
The sample component name and measured value displays blink if a failure condition has occurred. The status is output on overall status digital output and via Modbus. The gas analyzer is in a state that immediately requires user intervention. The measured value is invalid.
Error List
Error list 30
CO
In the event of faults, the status message numbers are displayed in the Error List menu item for each sample component (see page 42). To select the menu item, press the key twice.
Error list no errors
CO
This display indicates there are no errors present.
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Status Messages
No. Status 1 2 M M F F Problem No new measured values from analog/digital converter. Measured value exceeds the analog/digital converter value range. Offset drift exceeds half the permissible range. Reaction / Solution Call for service. Check cable connections in the gas analyzer. Call for service.
7 8
M M
9 10
11
Observe the drift value. If the drift value is under the value shown in the specifications, the measured value is correct. If drift exceeds this value, call for service. Offset drift exceeds permissible Call for service. range. Perform initial calibration (with test and calibration software TCT). Permissible offset drift range: EL1020-IR: 250 % of measuring range, EL1020-O2: 150 % of measuring range, EL1020-TC: 150 % of measuring range. Drift reading see page 38. Amplification drift exceeds half the Observe the drift value. If the drift value is under the permissible range. value shown in the specifications, the measured value is correct. The detector involved will need to be changed soon. If drift exceeds this value, call for service. Amplification drift exceeds Change the associated detector. Call for service. permissible range. Perform initial calibration (with test and calibration software TCT). Permissible amplification drift range: 50 % of sensitivity. Drift reading see page 38. Delta offset drift exceeds Only generated during calibration via Modbus. Check permissible range. calibration plausibility. Delta amplification drift exceeds permissible range. Delta drift reading see page 38. An error occurred during calculaSwitch power supply off and on again. Call for service. tion of the measured value. Measured value < 100 % of Activate the zero and span point test gases to check measuring range span. measurement indication plausibility. If the measured value indication is OK, call for service. Otherwise perform a calibration reset (see page 35) and then perform a calibration (see page 33). Measured value > 130 % of measuring range span. Continued on next page
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Status Messages, continued

No. Status 12 M Problem Temperature compensation measured value exceeds the analog/digital converter value range. Pressure compensation measured value exceeds the analog/digital converter value range. Temperature controller measured value exceeds the analog/digital converter value range. Temperature above or below upper and/or lower limit 1. Temperature above or below upper and/or lower limit 2. Reaction / Solution Check the plug connections in the gas analyzer. Call for service. Check the plug connections in the gas analyzer. Check the sample gas pressure. Call for service. Check the plug connections in the gas analyzer. Call for service. Status messages during the warm-up phase. If the status message appears after warm-up: Check if the permissible ambient temperature range is being maintained (see page 8). Check the connecting leads and plug connections. Check the line seating in the insulated jackets. Check the thermal link and replace as necessary. Switch power supply off and on again. Call for service.
13
14
15 16
M M
20 21 22 30 No.
M M M M
F F F
Internal processor bus fault. Internal display bus fault. Internal I/O bus fault. Broken analog output line.
Check the analog output lines.
Number of status message displayed in error list Maintenance Request: Status is displayed on the screen and output via Modbus. The gas analyzer is in a state that will soon require user intervention. The measured value is valid. Failure: Status is displayed on the screen and output on overall status digital output and via Modbus. The gas analyzer is in a state that immediately requires user intervention. The measured value is invalid. Maintenance Mode: Status is output during calibration on overall status digital output and via Modbus.
Status M F
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Troubleshooting Flow Fault

Gas lines or filter dirty, plugged or leaking Disconnect the gas analyzer from the gas preparation system. Blow out the gas lines with compressed air or clear them mechanically. Change the filter elements and packings. Check gas line seal integrity. Disconnect the gas analyzer from the gas preparation system. Check the gas analyzer gas lines for crimping or loose connections. Check the integrity of the gas analyzer gas paths (see page 39 for instructions). The outlet pressure should be equal to atmospheric pressure. Exhaust gases should be routed to the atmosphere or to an exhaust pipe directly or via the shortest possible large-diameter line. Do not route exhaust gases via flow reducers or shutoff valves.
Gas analyzer gas paths crimped or leaking
Outlet pressure not equal to atmospheric pressure
Unstable Measured Value Reading

Vibration Take measures to reduce vibration. Increase the time constant (see page 24). Check the integrity of the gas analyzer gas paths (see page 39 for instructions). Check sample component drift reading (status messages 5 and 6, see page 42). Have the emitter and modulator assembly checked by the service department.
Gas path leakage
Loss of sensitivity
EL1020-IR: Uneven emitter modulation
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Call for Service

Who to contact for further help? Contact your local ABB service representative or ABB Service, Telephone: +49-1 80-5-12 35 80, Telefax: +49-6 21-3 81-51 35, E-mail: callcenter.automation@de.abb.com
Before you call for service ...
Before calling for service because of a problem or status message, determine whether there actually is an error and whether the gas analyzer is actually operating out of specifications.
When you call for service ...
When calling for service because of a problem or status message have the following information available: The gas analyzer serial number (F-No.) Found on the identification plate and on the analyzer data sheet. The gas analyzer software version Found in the Information menu item and on the analyzer data sheet. An exact description of the problem or status as well as the status message number. This information will enable service personnel to help you quickly. When arranging for service due to a problem or status message, always have the analyzer data sheet available as it contains valuable information that can help to identify the problem.
When returning the gas analyzer for service ...
When returning the gas analyzer to the service department, e.g. for repair, please indicate which gases have been supplied to the gas analyzer. This information is needed so that service personnel can take any safety precautions required for harmful gases.
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Chapter 9
Gas Analyzer Shutdown and Packing
Gas Analyzer Shutdown

Gas Analyzer Shutdown Step Action
Temporary Shutdown: 1 Turn off the sample gas and, if applicable, reference gas supplies. 2 Purge the gas lines and gas paths in the gas analyzer with dry fresh air or nitrogen for at least 5 minutes. 3 Turn off the gas analyzer power supply. Additional Steps for Long-Term Shutdown: 4 Remove the gas lines from the gas analyzer ports. Tightly seal the gas ports. 5 Disconnect the electrical wiring from the gas analyzer connections.
Ambient Temperature
Ambient temperature during storage and transport: 25 to +65 C
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Gas Analyzer Packing

Packing Step 1 2 3 Action Tightly seal the gas ports with plugs. If the original packaging is not available, wrap the gas analyzer in bubble foil or corrugated cardboard. Place the gas analyzer in an adequately sized box lined with cushioning material (foam or similar substance). The cushioning materials thickness should be adequate for the gas analyzers weight. Mark the box as Fragile Material.
Additional Steps when Shipping Overseas
Step 1
Action Place the gas analyzer in a 0.2-mm thick polyethylene bag, add a drying agent (such as silica gel) and seal the bag air-tight. Use an amount of drying agent appropriate for the package volume and the planned shipping schedule (at least 3 months). Also wrap the box in a layer of protective waterproof wrapping.
Ambient Temperature
Ambient temperature during storage and transport: 25 to +65 C
When returning the gas analyzer to the service department, e.g. for repair, please indicate which gases have been supplied to the gas analyzer. This information is needed so that service personnel can take any safety precautions required for harmful gases.
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Appendix
EL1020-IR: Gas Analyzer Structure

Figure 6 EL1020-IR Top View
1 2
1 2 3 4 5
Power supply Sensor-CPU board IR detector Pressure sensor O2 sensor
EL1020-IR: Metrological Data

Measuring Principle Non-dispersive infrared absorption in the = 2.5 to 8 m range Photometer for measuring 1 or 2 sample components An electrochemical O2 sensor can be used with the EL1020-IR infrared analyzer. In this case only a single IR sample component is possible. Sample Components and Measuring Ranges All available sample components are shown with the smallest possible measuring ranges in each case. When the gas analyzer is delivered it is set up for the sample components and measuring ranges ordered. CO CO2 SO2 CH4 NO O2 0 to 500 ppm 0 to 300 ppm 0 to 500 ppm 0 to 500 ppm 0 to 1000 ppm 0 to 5 Vol.-%
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EL1020-IR: Metrological Data, continued

Note The following measurement data are based on N2 as the associated gas. For other gas mixtures, the data shown can only be assumed to be attainable if the composition of the mixtures is known and if ABB Analytical has validated the suitability of the gas analyzer for the measuring task. The following data apply on condition that all influence effects such as flow, temperature and air pressure are constant. Linearity deviation Repeatability Zero drift Sensitivity drift Output signal variations Detection limit O2 Sensor Linearity deviation Repeatability Zero drift Sensitivity drift Detection limit Influence Effects Flow effect Associated gas effect / cross sensitivity 1 % of span 0.5 % of span 1 % of span per week 1 % of measured value per week 0.2 % of span at 2 and electronic T90 time = 5 sec. 0.5 % of span Linear at concentrations > 1 Vol.-% O2 0.5 % of span Stable over long-term due to absolute zero point 1 % of the measuring range per week 0.5 % of measuring range Flow rate in the 20-100 l/h range: within determination limits The knowledge of the sample gas composition is necessary for the analyzer configuration. Selectivity measure to reduce associated gas effect (optional): Installation of interference filters Ambient temperature in the +5 to +45C range: On zero: 1 % of span per 10C On sensitivity: 3 % of measured value per 10C On zero: No influence effect On sensitivity: 0.2 % of measured value per 1 % air pressure change Pressure sensor working range: pabs = 600 to 1250 hPa Voltage and frequency in permissible range: 0.2 % of span No influence effect Flow in permissible range: 2 % of measuring range Ambient temperature in the +5 to +40 C range: 0.2 Vol.-% O2 per 10C On zero: No influence effect On sensitivity: 0.2 % of measured value per 1 % air pressure change Approx. 30 min. T90 2 sec. for a gas flow rate of 60 l/h T90 30 s, depending on sample gas flow rate Tubing: Aluminum; Window: CaF2; Connection ports: Stainless steel 1.4571 FPM (Viton), PP, PVDF; in the version for measuring flammable gases: Stainless steel 1.4571 Polystyrol-ABS, Teflon, Viton PVC, Viton seals Stainless steel 1.4571
Stability
Temperature effect
Air pressure effect
Power supply effect Position effect O2 Sensor Flow effect Temperature effect Air pressure effect
Dynamic Response
Warm-up time T90 time
O2 Sensor Materials in Contact with the Sample Medium
T90 time Sample cell Gas lines and connectors
O2 Sensor
Sensor Housing body Gas connections
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EL1020-O2: Gas Analyzer Structure

Figure 7 EL1020-O2 Top View
1 2
4 3
1 2 3 4
Power supply Sensor-CPU board O2 detector Pressure sensor
EL1020-O2: Metrological Data

Measuring Principle Paramagnetic behavior of oxygen Magnetomechanical oxygen analyzer with short T90 time Smallest Measuring Range Note 0 to 2 Vol.-% O2
The following measurement data are based on N2 as the associated gas. For other gas mixtures, the data shown can only be assumed to be attainable if the composition of the mixtures is known and if ABB Analytical has validated the suitability of the gas analyzer for the measuring task. The following data apply on condition that all influence effects such as flow, temperature and air pressure are constant. Linearity deviation Repeatability Zero drift 0.5 % of span 0.5 % of span 0.03 Vol.-% O2 per week Following prolonged transport and storage time the drift can be higher during the first weeks of operation. 0.1 Vol.-% O2 per week or 1 % of measurement value per week (not cumulative), whichever is smaller. 0.5 % of smallest measurement range span at 2 and electronic T90 time (static / dynamic) = 3 / 0 sec 0.5 % of span
Stability
Sensitivity drift Output signal variations Detection limit
Continued on next page 50 EL1020 Gas Analyzer Operators Manual 42/27-10 EN Rev. 2
EL1020-O2: Metrological Data, continued

Influence Effects Flow effect Associated gas effect Flow rate in the 2060 l/h range: 0.1 Vol.-% O2 The effect of associated gases as a shift of the zero-point expressed in Vol.-% O2 can be estimated using the approximate values in the following table: Associated Gas Concentration 100 Vol.-% Hydrogen Argon Helium Neon Nitrogen Nitrogen Oxide Nitrogen Dioxide Nitrous Oxide Carbon Monoxide Carbon Dioxide Ethane Ethylene Methane Propane Propylene Temperature effect H2 Ar He Ne N2 NO NO2 N2O CO CO2 C2H6 C2H4 CH4 C3H8 C3H6 Zero-Point Shift +0.28 Vol.-% O2 0.26 Vol.-% O2 +0.30 Vol.-% O2 +0.13 Vol.-% O2 0.00 Vol.-% O2 +43.00 Vol.-% O2 +28.00 Vol.-% O2 0.20 Vol.-% O2 0.01 Vol.-% O2 0.32 Vol.-% O2 0.46 Vol.-% O2 0.29 Vol.-% O2 0.24 Vol.-% O2 0.98 Vol.-% O2 0.55 Vol.-% O2
Ambient temperature in the range +5 to +50 C: At zero-point: 0.02 Vol.-% O2 per 10 C On sensitivity: 0.2 % of measured value per 10 C Thermostat temperature 64 C At zero-point: No effect On sensitivity with no pressure correction: 1 % of measured value per 1 % air pressure change. The air pressure at the installation site can be adjusted manually in the analyzer. On sensitivity with automatic pressure correction using integrated pressure sensor (for measurement ranges with suppressed zero point): 0.01 % of measurement value per 1 % pressure change or 0.002 Vol.-% O2 per 1 % pressure change, whichever is greater. Pressure sensor working range: pabs = 6001250 hPa Voltage and frequency in permissible range: 0.2 % of span Zero-point shift 0.05 Vol.-% O2 per 1 deviation from horizontal location. Position has no effect on the hard-mounted unit. 1 hour T90 5 s at a sample gas flow of 60 l/h and electronic T90 time (static / dynamic) = 3 / 0 sec, gas change from N2 to air Stainless steel 1.4305, glass, platinum, rhodium, epoxy resin FPM (Viton), PP, PVDF; in the version for measuring flammable gases: Stainless steel 1.4571
Air pressure effect
Power supply effect Position effect
Dynamic Response
Warm-up time T90 time
Materials in Contact with the Sample Medium
Analyzer (sample chamber) Gas lines and connectors
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EL1020-TC: Gas Analyzer Structure

Figure 8 EL1020-TC Top View
1 2
1 2 3 4
Power supply Sensor-CPU board Pressure sensor Thermal conductivity detector
EL1020-TC: Metrological Data

Measuring Principle Difference in thermal conductivity of various gases Micromechanical silicon sensor with especially short T90 time Sample Components and Smallest Measurement Ranges From the following sample components (gas mixtures) one component can be selected. For each sample component the smallest measurement range and the smallest measurement range with suppressed zero point are given. N2 in Ar Ar in N2 Air in CO2 CO2 in Air N2 in CO2 CO2 in N2 N2 in CH4 CH4 in N2 Air in He He in Air Ar in He He in Ar N2 in He 0 6 Vol.-% 0 6 Vol.-% 010 Vol.-% 010 Vol.-% 010 Vol.-% 010 Vol.-% 0 6 Vol.-% 0 6 Vol.-% 0 3 Vol.-% 0 1 Vol.-% 0 3 Vol.-% 0 1 Vol.-% 0 3 Vol.-% 94100 Vol.-% 94100 Vol.-% 90100 Vol.-% 90100 Vol.-% 90100 Vol.-% 90100 Vol.-% 94100 Vol.-% 94100 Vol.-% 99100 Vol.-% 97100 Vol.-% 99100 Vol.-% 97100 Vol.-% 99100 Vol.-% He in N2 Ar in H2 H2 in Ar CO2 in H2 H2 in CO2 CH4 in H2 H2 in CH4 N2 in H2 H2 in N2 Ar in O2 O2 in Ar H2 in Air Air in H2 0 1 Vol.-% 0 3 Vol.-% 0 1 Vol.-% 0 3 Vol.-% 0 1 Vol.-% 0 3 Vol.-% 0 1 Vol.-% 0 3 Vol.-% 0 1 Vol.-% 010 Vol.-% 010 Vol.-% 0 1 Vol.-% 0 1 Vol.-% 97100 Vol.-% 99100 Vol.-% 97100 Vol.-% 99100 Vol.-% 97100 Vol.-% 99100 Vol.-% 97100 Vol.-% 99100 Vol.-% 97100 Vol.-% 90100 Vol.-% 90100 Vol.-%
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EL1020-TC: Metrological Data, continued

Note The following measurement data relate to the gas mixtures given in the table. For other gas mixtures, the data shown can only be assumed to be attainable if the composition of the mixtures is known and if ABB Analytical has validated the suitability of the gas analyzer for the measuring task. The following data apply on condition that all influence effects such as flow, temperature and air pressure are constant. Linearity deviation Repeatability Zero drift Sensitivity drift Output signal variations Detection limit Influence Effects 2 % of span 1 % of span 2 % of smallest given measurement range per week 0.5 % of smallest given measurement range per week 0.5 % of smallest measurement range span at 2 and electronic T90 time = 0 sec 0.5 % of span
Stability
The following data relate to the smallest measurement ranges given in the table. The influence effects may be larger for smaller measurement ranges. The influence effects will be larger at operating altitudes > 2000 meters. Flow effect Associated gas effect 0.5 % of span at a flow change of 10 l/h within detection limit for equal flow rates of sample and test gas If the sample gas contains components in addition to the sample component (binary gas mixture), this will result in erroneous measurements. Ambient temperature in the range +5 to +50 C: At each point in the measurement range: 1 % of span per 10 C, based on temperature at the time of calibration Thermostat temperature 60 C 0.25 % of span per 10 hPa for the smallest possible ranges given; for larger spans the effect is correspondingly lower. Pressure sensor working range: pabs = 6001250 hPa Voltage and frequency in permissible range: 0.2 % of span < 1 % of span up to 30 deviation from horizontal orientation Approx. 30 minutes T90 2 s for sample gas flow of 60 l/h Sensor: Gold, silicon oxi-nitride; Sample chamber: Stainless steel 1.4305 FPM (Viton), PP, PVDF; in the version for measuring flammable gases: Stainless steel 1.4571
Temperature effect
Air pressure effect
Power supply effect Position effect Dynamic Response Warm-up time T90 time Materials in Contact with the Sample Medium Analyzer (sample chamber) Gas lines and connectors
Electrical Safety
Electrical Safety Test Protection Class Overload Category Pollution Level Safe Isolation per EN 61010-1 I Power supply: II, Signal inputs and outputs: II 2 The power supply is galvanically isolated from other circuits by means of reinforced or double insulation. Operational low voltage (PELV) on low-voltage side.
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53
Index
Page Address (Modbus) Analyzer data sheet Alarm limit Baudrate (Modbus) Calibration Calibrate sample component Calibration cell measuring (EL1020-IR) Calibration reset Drift reading Set points Test gases via Modbus Connecting Gas lines Power supply leads Signal leads Connections Electrical connections Gas connections Decimal places Dimensional diagram Display Drift EL1020-IR Calibration cell Measure calibration cell Measuring range Metrological data Reference measuring range Structure Test gases EL1020-O2 Measuring range Metrological data Pressure sensor Reference measuring range Structure Test gases EL1020-TC Active sample component Measuring range Metrological data Reference measuring range Structure Test gases Electrical connections Electrical safety Error list Filter (T90 time) Fine filter installation Flow meter installation Gas connections Gas inlet conditions Gas line connection Gas path seal integrity verification Maintenance Prior to start-up 29 10 28 29 31 33 36 35 38 24 31 33 14 18 17 16 13 19 11 19 38 Identification plate Installation Installation location Interface type (Modbus) Items delivered Limit Low pass Measuring range EL1020-IR EL1020-O2 EL1020-TC Menu Modbus Calibration Connecting Parameters Operation Display Keys Menu Packing Parameter setting Power supply connection Pressure correction Pressure sensor calibration Purge (start-up) Safety instructions Screen Blinking Service Set points (calibration) Shutdown Signal leads connection Start-up Status messages Switching hysteresis (limit) T90 time Technical data Dimensional diagram EL1020-IR EL1020-O2 EL1020-TC Electrical connections Electrical safety Environmental conditions Gas connections Gas inlet conditions Power supply Test gas concentration Test gases Time-out Troubleshooting Unpack User settings Page 10 12 8 29 10 28 24
25 26 27 21 33 17 29
19 20 21 47 23 18 37 37 22 6, 7, 15 19 19, 41 45 24 46 17 22 42 28 24 11 48 50 52 16 53 8 13 9 8 24 9, 31 20 44 12 30
31 36 25 48 25 48 31 26 50 37 26 50 32 27 27 52 27 52 32 16 53 41 24 14 14 13 9 14 39 12
54
42/27-10 EN Rev. 2
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The Companys policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice. Printed in the Fed. Rep. of Germany (02.05) ABB 2005
ABB Automation GmbH Analytical Division Stierstaedter Strasse 5 60488 Frankfurt am Main Germany Phone: +49 69 7930 40 Fax: +49 69 7930 4566 E Mail: analytical mkt.deapr@de.abb.com
42/27 10 EN Rev. 2

Instrumentation8 Contious Gas Analizer

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Continuous Gas Analyzers EL1020

Continuous Gas Analyzers EL1020

Operators Manual Publication No. 42/27 10 EN Rev. 2 Edition 02.05

EL1020 Gas Analyzer Operators Manual

EL1020 Gas Analyzer Operators Manual

Symbols and Fonts Used in the Manual

EL1020 Gas Analyzer Operators Manual

Guideline for Installation and Operation

EL1020 Gas Analyzer Operators Manual

General Safety Precautions

Requirements for Safe Operation

Special Information and Precautions

Gas Analyzer Safety and Safe Operation

EL1020 Gas Analyzer Operators Manual

Safety Precautions for Handling Electronic Measurement Devices

Risks Involved in Opening the Covers

Risks Involved in Working with an Open Gas Analyzer

Use of Proper Fuses

When Safe Operation can no Longer be Assured

EL1020 Gas Analyzer Operators Manual

Preparation for Installation

Installation Location Requirements

Adequate Air Circulation

Protection from Adverse Conditions

Input voltage Power consumption

EL1020 Gas Analyzer Operators Manual

Sample Gas Inlet and Outlet Conditions, Test Gases

Flow 20 to 160 l/h 10 to 190 l/h

Pressure Drop 1) < 4 hPa < 2 hPa < 2 hPa

2 to 500 hPa 2) 20 to 100 l/h

Sample Gas Dew Point

Specifics for the Use of an O2 Sensor

Gas Outlet Conditions

Test Gases for Calibration 42/27-10 EN Rev. 2

Analyzer Data Sheet

Where is the analyzer data sheet located?

Pressure sensor installed Number of calibration cells installed

EL1020 Gas Analyzer Operators Manual

EL1020 Gas Analyzer Operators Manual

Install the Gas Analyzer

Unpack and Install the Gas Analyzer

Sample Gas Path Seal Integrity Verification

Gas Analyzer Installation

EL1020 Gas Analyzer Operators Manual

Sample Gas Inlet

Sample Gas Outlet

EL1020 Gas Analyzer Operators Manual

Connect the Gas Lines

Install a Fine Filter

Install a Flow Meter

Provide for Gas Line System Flushing

Evacuate Exhaust Gases

EL1020 Gas Analyzer Operators Manual

Connect the Electrical Lines Safety Precautions

EL1020 Gas Analyzer Operators Manual

EL1020 Gas Analyzer Operators Manual

Connect the Signal Leads

Connect the Signal Leads

EL1020 Gas Analyzer Operators Manual

Connect the Power Supply Leads

Connect the Power Supply Leads

EL1020 Gas Analyzer Operators Manual

Gas Analyzer Operation

Display in Measuring Mode