ABB EL6010 Operator's Manual
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ABB EL6010 Operator's Manual

Continuous gas analyzers
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Continuous Gas Analyzers EL6010
Operator's Manual
42/24 30 EN Rev. 1

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Summary of Contents for ABB EL6010

  • Page 1 Continuous Gas Analyzers EL6010 Operator’s Manual 42/24 30 EN Rev. 1...
  • Page 3 Continuous Gas Analyzers EL6010 Operator’s Manual Publication No. 42/24 30 EN Rev. 1 Edition 07.04...

  • Page 4: Table Of Contents

    Contents Page Preface Guideline for Installation and Operation General Safety Precautions Special Safety Instructions for Operating the EL6010 Gas Analyzer Chapter 1 Preparation for Installation Installation Location Requirements Gas Inlet and Outlet Conditions Items Delivered Analyzer Data Sheet Control Unit: Dimensional Diagram...
  • Page 5 EC Type Examination Certificate Electrical Equipment in Explosion Hazard Zones: Legal Principles Electrical Equipment in Explosion Hazard Zones: Installation Instructions Electrical Equipment in Explosion Hazard Zones: Maintenance and Repair Instructions Index 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 6: Preface

    This operator’s manual contains all the information you will need to safely and Operator’s Manual efficiently install, start-up, operate and maintain the EL6010 gas analyzer. Note the information on the “Analyzer Data Sheet” shipped with every EL6010 gas analyzer. Symbols and Fonts...

  • Page 7: Guideline For Installation And Operation

    Install the gas analyzer Connect the gas lines Connect the electrical leads Check the installation Purge the gas path Start the gas analyzer Set the parameters Calibrate the gas analyzer 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 8: General Safety Precautions

    To maintain this condition and to assure safe operation, read and follow the safety information identified with the symbol in this operator’s manual. Failure to do so can put persons at risk and can lead to EL6010 gas analyzer damage as well as damage to other systems and instruments. Additional If the information in this operator’s manual does not cover a particular situation,...

  • Page 9: Special Safety Instructions For Operating The El6010 Gas Analyzer

    EL6010-... analyzer unit housing. When Safe Operation If it can be assumed that safe operation is no longer possible, the EL6010 gas Can no Longer be analyzer should be taken out of service and protected against inadvertent use.

  • Page 10: Preparation For Installation

    Note: The explosion protection is not impaired if the gas analyzer is operated at temperatures less than +5 °C and down to –20 °C. However in this temperature range the compliance with the metrological data cannot be guaranteed. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 11: Gas Inlet And Outlet Conditions

    Flammable gases that are explosive under the conditions encountered in analysis even when oxygen is excluded should be present in the mixture only in concentra- tions that are not critical to safety. The “Flowing Reference Gas” option is not available for the EL6010-Uras14. Definition – p...

  • Page 12: Items Delivered

    Water vapor content variations cause volume errors. Corrosive Gases The EL6010 gas analyzers must not be used for the measurement of corrosive gases. Gases like chlorine (Cl ) and hydrogen chloride (e.g. wet HCl) as well as gases or aerosols containing chlorine must be cooled or undergo prior absorption.

  • Page 13: Control Unit: Dimensional Diagram

    3 4 5 1 Hex Socket Head Screw to Secure the Housing Cover 2 Housing Cover 3 Cable Connections 4 Cable Compartment with Terminal Strip 5 Potential Compensation Connection 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 14: Analyzer Unit: Dimensional Diagram

    10 Potential Compensation Connection 1) Option 2) Version for sample gas under positive pressure only 3) Standard for EL6010-Caldos17, EL6010-Uras14; Option for EL6010-Magnos106. When measuring flammable and corrosive gases the pressure sensor connec- tion should not be joined with the sample gas path.

  • Page 15: Install The Gas Analyzer

    Unpack and Install the Gas Analyzer CAUTION! The EL6010-CU control unit weighs approx. 19 kg! The EL6010-... analyzer unit weighs approx. 26 kg! The following points should be observed: • Two persons are needed for unpacking and installation of the analyzer unit.

  • Page 16: Install The Gas Analyzer

    Unpack and Install the Gas Analyzer, continued EL6010-CU Control 4 M8 or M10 bolts (not supplied) are needed to install the EL6010-CU control unit. Unit Installation EL6010-... Analyzer 4 M8 bolts (not supplied) are needed to install the EL6010-... analyzer unit.

  • Page 17: Connect The Gas Lines

    • Housing purge (option) • Flowing reference gas for the EL6010-Uras14 (option) • Pressure sensor for EL6010-Uras 14, -Magnos106 (option) and -Caldos17 The actual gas connection layout of a delivered EL6010-... analyzer unit is shown in the applicable analyzer data sheet. Special Safety...

  • Page 18: Connect Electrical Lines - Safety Precautions

    Before the power supply is connected, make sure the power line voltage is in Supply is Connected the permissible range 85 to 250 VAC for operation of the gas analyzer. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 19: Control Unit: Electrical Connections

    30 “Broken analog output line” (see page 47). The respective jumper must be removed prior to connecting the electrical lines to the analog output terminals. 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 20: Connection Analyzer Unit - Control Unit

    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Control Unit 10 11 12 13 14 15 rot/red Datenübertragungskabel 24-V-DC-Anschlusskabel Data Transmission Cable 24-VDC Connection Cable Continued on next page EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 21: Further Electrical Connections

    8-12 mm OD Cable: Use seal ring 2 only. Pass the cable through the intermediate openings 4 in the connection box. Tighten cap nut 1 (torque to 2.5 Nm). 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 22: Power Supply Connection

    ) to the terminals N, L and PE (see connection diagram, page 17). The analyzer unit is supplied with 24 VDC ± 5 % from the control unit’s power Analyzer Unit Power Supply supply. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 23: Gas Analyzer Operation

    Blinking of part of the screen in measuring mode indicates that the gas analyzer or process system has experienced a fault. See Chapter “Status Messages, Troubleshooting”, page 45, for details on faults, causes and corrective actions. 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 24: Operation

    (time-out). The time-out function is deactivated if the user changes the value of a parameter or activates calibration. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 25: Menu

    Menu Menu The EL6010 gas analyzer menu structure is summarized below. Measured value display Menu Structure Calibrate (Overview) Calibrate component Zero calibration Span calibration Span with cal. cell EL6010-Uras14 only Calibration reset Pressure adjustment Measure cal. cell EL6010-Uras14 only Setting parameters...

  • Page 26: Start The Gas Analyzer

    “Do not open when an explosive atmosphere may be present!” Check the Installation Check the Installation Make sure the EL6010 gas analyzer is correctly installed before carrying out any start-up procedures. Use the following check list:...
  • Page 27 • Is the analyzer unit housing intact? • Are all flame barriers and screw plugs present? • If the analyzer units EL6010-Uras14 and -Caldos17 are mounted horizon- tally, are the O-rings, which are placed between the housing floor and the housing as well as between the housing and the housing lid in the slots provided, cleanly laid and not pinched? •...

  • Page 28: Start The Gas Analyzer

    After the warm-up phase (approx. 30 to 60 minutes) the gas analyzer is ready to operate. Calibrate the gas analyzer (see page 35). Start the sample gas flow. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 29: Set Parameters

    Return to the previous Back menu. 500.0 ppm CO Parameters component Return to the previous Back menu. Setting parameters Return to the measured Back value display. 105.2 ppm 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 30: Test Gas Concentration

    The ratio of the time constant for constant measured values to the time constant for measured value changes should be 5 :1. 1) For an explanation of the term “Reference Measuring Range” see pages 29 to 31. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 31: El6010-Uras14: Measuring Range

    ≤ 1:5. Smallest measuring range data of the individual sample components see Section “EL6010-Uras14: Metrological Data”, page 55. Measuring ranges within ignition limits cannot be provided. 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 32: El6010-Magnos106: Measuring Range

    ; the largest adjustable measuring range is 0 to 100 Vol.-% O Measuring ranges within ignition limits should not be attempted. The gas inlet conditions should be observed (see page 9). EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 33: El6010-Caldos17: Measuring Range

    The measuring range can be adjusted within the limits valid for the sample Notes components (see Section “EL6010-Caldos17: Metrological Data”, page 57). For the factory-set component “relative thermal conductivity” it is rTC = 0 to 60,000. The largest measuring range is 0 to 100 Vol.-% or 0 Vol.-% to saturation, depending on the measuring task.

  • Page 34: Limit Parameters

    The hysteresis adjustment step interval is 0.01 % of the span of the reference measuring range 1) For an explanation of the term “Reference Measuring Range” see pages 29 to 31. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 35: Modbus Parameters

    Interface Type RS232 Modbus type Value range: RS232 or RS485 RS232 For detailed Modbus information see the “EasyLine Modbus and M-DDE Server” technical information sheet (Publication No. 30/27-100 EN). 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 36: Factory And User Settings

    Measuring range Active TC component Limit 1 < Limit 2 < Limit 1 hysteresis Limit 2 hysteresis Modbus baudrate 19200 Modbus address Modbus type RS232 EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 37: Calibrate The Gas Analyzer

    Calibration Cell Use of a calibration cell allows the EL6010-Uras14 gas analyzer to be calibrated (Option) 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.

  • Page 38: El6010-Caldos17: Notes For Calibration

    The influence of carrier gases is seen in the form of a displacement of the zero Offset Correction point (see Section “EL6010-Magnos106: Metrological Data”, page 56). If it is expected that, due to a particular carrier gas specified by the customer with...

  • Page 39: Calibrate Sample Component

    Wait cal. is running Calibration in progress. Meas. value ok? Accept calibration Enter 0.00 Vol% CO reject calibration. Back Continued on next page 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...
  • Page 40 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. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 41: Perform Calibration Reset

    Start cal. reset! Wait cal. is running Calibration reset in progress. Calibration reset Calibration reset has ended. Press the Back key to return to displaying measured values. 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 42: El6010-Uras14: Measure Calibration Cell

    Wait cal. is running Measurement in progress. Meas. value ok? Accept the set point. Enter 8.51 Vol% CO Press the Back key to return to displaying measured values. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 43: Pressure Correction

    A change in atmospheric pressure by a certain amount will affect measured value readings. Pressure Sensor A pressure sensor is installed in the gas analyzer unit (in EL6010-Magnos106 as an Installed option). The effects of air pressure changes on the measured value are minimized by automatic internal pressure correction.

  • Page 44: Drift Reading

    Offset and amplification delta drift values are deter- offs 0% ampl mined 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. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 45: Inspection And Maintenance

    • All parts of the housing are fully tightened and secured with set screws? Measures taken after opening the • If the sample or reference gas path inside an EL6010-... analyzer unit has been gas paths inside the opened, the seal integrity should be tested with helium at a leak rate of analyzer unit <...

  • Page 46: Check Gas Path Seal Integrity

    After opening the gas paths inside the analyzer unit: Test period 15 minutes. Repeat steps 1 to 5 for all gas paths in the analyzer unit. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 47: Status Messages, Troubleshooting

    Error List menu item for each sample component (see page 46). To select the menu item, press the key twice. Error list This display indicates there are no errors present. no errors 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 48: Status Messages

    (see page 39) and then perform a calibration (see page 37). Measured value > 130 % of measuring range span. Continued on next page EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...
  • Page 49 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. 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 50: Troubleshooting

    • Check sample component drift reading (status messages 5 and 6, see page 46). Loss of sensitivity • Have the emitter and modulator assembly checked by the service department. EL6010-Uras14: Uneven emitter modulation EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 51: Call For Service

    This information is service ... needed so that service personnel can take any safety precautions required for harmful gases. 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 52: Gas Analyzer Shutdown And Packing

    Remove the gas lines from the analyzer unit ports. Tightly seal the gas ports. Disconnect the electrical wiring from the control unit connections. Ambient Temperature Ambient temperature during storage and transport: –25 to +65 °C EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 53: Gas Analyzer Packing

    Gas Analyzer Packing CAUTION! The EL6010-CU control unit weighs approx. 19 kg! The EL6010-... analyzer unit weighs approx. 26 kg. Two persons are needed for removal of the analyzer unit. Packing Step Action Tightly seal the gas ports with plugs.

  • Page 54: Application And Design

    The gas analyzers should not be used to measure corrosive gases. Explosion Protection The gas analyzers in the EL6010 family are especially designed for use in explo- sion risk areas. They are certified in accordance with European Directive 94/9/EC (“ATEX Directive”).

  • Page 55: Analyzer Units

    Essentially the gas analyzer is calibrated manually. External control of calibration is possible via the Modbus interface. The EL6010-Uras14 infrared analyzer unit can be equipped with optional gas-filled calibration cells that extensively eliminate reliance on test gases. Because of its very low sensitivity drift, the EL6010-Magnos106 oxygen analyzer unit routinely requires only a zero calibration, if the measuring range is larger than 0 to 5 Vol.-% O...

  • Page 56: Control Unit

    Power supply: II, Signal inputs and outputs: II Pollution Level Safe Isolation The power supply is galvanically isolated from other circuits by means of reinforced or double insulation. Operational low voltage (PELV) on low-voltage side. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 57: El6010-Uras14: Metrological Data

    Measurement ranges within ignition limits cannot be provided. Measurement Ranges with Suppressed Zero-Point Differential measurement with flowing reference gas. Max. suppression ratio of 1:10 depending on the base level. 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 58: El6010-Magnos106: Metrological Data

    Analyzer (Sample Chamber) Rust and acid resistant steel 1.4305, glass, platinum, rhodium, epoxy resin. FPM (Viton) seals, optional: FFKM75 (Chemraz™). Gas Lines and Connectors Rust and acid resistant steel 1.4571. EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 59: El6010-Caldos17: Metrological Data

    ≤ 0.5 % of span Analyzer (Sample Chamber) Sensor: Gold, silicon oxi nitride; Sample chamber: Stainless steel 1.4305 Seal: FFKM75 (Chemraz™) Gas Lines and Connectors Rust and acid resistant steel 1.4571 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 60: Declaration Of Conformity

    Declaration of Conformity Continued on next page EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...
  • Page 61 Declaration of Conformity, continued Continued on next page 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...
  • Page 62 Declaration of Conformity, continued Continued on next page EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...
  • Page 63 Declaration of Conformity, continued Continued on next page 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...
  • Page 64 Declaration of Conformity, continued Continued on next page EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...
  • Page 65 Declaration of Conformity, continued Continued on next page 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...
  • Page 66 Declaration of Conformity, continued EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...

  • Page 67: Ec Type Examination Certificate

    EC Type Examination Certificate Continued on next page 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...
  • Page 68 EC Type Examination Certificate, continued Continued on next page EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...
  • Page 69 EC Type Examination Certificate, continued Continued on next page 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...
  • Page 70 EC Type Examination Certificate, continued Continued on next page EL6010 Gas Analyzer in Category 2G Operator’s Manual 42/24-30 EN Rev. 1...
  • Page 71 EC Type Examination Certificate, continued 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 72: Electrical Equipment In Explosion Hazard Zones

    Legal Principles ElexV Set-up, installation and operation of the explosion-protection versions of the EL6010 gas analyzer in the Federal Republic of Germany is covered by the 13 December 1996 “Regulations on Electrical Equipment in Explosion Hazard Zones” (ElexV). Classification of...

  • Page 73: Electrical Equipment In Explosion Hazard Zones

    If the manufacturer or installer certifies that the electrical system meets ElexV requirements, no inspection prior to initial use is required. 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...

  • Page 74: Electrical Equipment In Explosion Hazard Zones

    Manufacturer’s Repairs can also be carried out by the manufacturer, e.g. on site by an ABB Repairs Service employee or at the manufacturer’s facility.

  • Page 75: Index

    Power Consumption Gas Inlet Conditions Test Gas Concentration Gas Path Seal Integrity Verification Test Gases Maintenance Time-out Prior to Start-up Troubleshooting Housing Purge 15, 53 Unpack User Settings 42/24-30 EN Rev. 1 EL6010 Gas Analyzer in Category 2G Operator’s Manual...
  • Page 76 ABB. the information contained herein without notice. ABB has Sales & Customer Support expertise Printed in the Fed. Rep. of Germany (07.04) in over 100 countries worldwide.

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