ABB Endura AZ20 series User Manual
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ABB Endura AZ20 series User Manual

Combustion oxygen monitor
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See also: Maintenance Manual , Instruction Manual
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A B B M E A S U R E M E N T & A N A LY T I C S | U S E R G U I D E | I M/A Z 2 0 P - E N R E V. G
Endura AZ20 series probe
Combustion oxygen monitor
Introduction
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Superior technology
and quality from the
The Endura AZ20 is the latest in a long line of high-
world leader in oxygen
measurement
quality, combustion gas analyzers from ABB.
The sensor, based on a zirconium oxide cell, is
mounted at the tip of the probe that is inserted in
the flue duct. The resulting direct, in situ
measurement provides accurate and rapid oxygen
reading for combustion control / optimization and
emissions monitoring purposes.
Endura AZ20 has been designed for extended
periods of maintenance-free operation. The
modular design with reduced component count
improves the reliability and robustness of the
system and simplifies breakdown repair if it occurs.
Measurement made easy
Kits containing all the parts needed to complete on-
site repairs are available from ABB, ensuring that
service personnel can effect repairs quickly and
efficiently at minimum cost. The Endura AZ20 probe
has retained an easy-access cell arrangement,
similar to the proven ZFG2 probe. This ensures cell
replacement can be carried out on-site using readily
available, basic hand tools, even after long periods
of high temperature operation.
This User Guide should be used in conjunction with
the following publications:
• Transmitter User Guide (IM/AZ20E-EN)
• Maintenance Guide (IM/AZ20M–EN).

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Summary of Contents for ABB Endura AZ20 series

  • Page 1 ABB. site repairs are available from ABB, ensuring that service personnel can effect repairs quickly and The sensor, based on a zirconium oxide cell, is efficiently at minimum cost. The Endura AZ20 probe...
  • Page 2 Search for or click on Data Sheet Endura AZ20 oxygen monitor DS/AZ20-EN Combustion gas analysis User Guide Endura AZ20 series probe IM/AZ20P-EN Combustion oxygen monitor Maintenance Guide Endura AZ20 series probe IM/AZ20M–EN Combustion oxygen monitor...

  • Page 3: Table Of Contents

    Endura AZ20 Probe Flanges – All Probe Lengths ... 12 Appendix A – Principle of Operation ....... 29 Mounting Plates for ABB Standard Flanges .... 13 3.8.1 0.5 m (1.7 ft) Probe – Part No. AZ200 796 .. 13 Appendix B – Endura AZ20/ZFG2 Replacement Probe .. 30 3.8.2 1.0 to 4.0 m (3.3 to 13.1 ft) Probes –...

  • Page 4: Safety

    Endura AZ20 series probe Combustion oxygen monitor 1 Safety 1 Safety Information in this manual is intended only to assist our 1.2 Electrical Safety – CEI / IEC 61010-1:2001-2 customers in the efficient operation of our equipment. Use of This equipment complies with the requirements of CEI / IEC...

  • Page 5: Product Recycling Information

    In conformity with European local and national regulations, European electrical equipment users must now return old or end-of-life equipment ABB is committed to ensuring that the risk of to the manufacturer for disposal at no charge to the any environmental damage or pollution caused user.

  • Page 6: Restriction Of Hazardous Substances (Rohs)

    1.7 Safety Precautions user. Only personnel from ABB or its approved representative(s) Please read the entire manual before unpacking, setting up, or is (are) authorized to attempt repairs to the system and only operating this instrument.

  • Page 7: System Overview

    Endura AZ20 series probe Combustion oxygen monitor 2 System Overview 2 System Overview This User Guide provides the following information: Endura AZ20 oxygen probe measures oxygen concentration in flue gas using an in situ 'wet analysis' method.  schematics for systems fitted with or without restrictors The 'wet analysis' method avoids measurement error (typically (including test gas and reference air requirements) –...

  • Page 8: Mechanical Installation

    Endura AZ20 series probe Combustion oxygen monitor 3 Mechanical Installation 3 Mechanical Installation 3.1 General Installation Requirements Warning.  Before installing the probe, check the probe data and the alteration labels on the head of the probe – see Section 3.3.

  • Page 9: Siting

    Output Signals Relays Endura AZ20 Probe Cable (ABB Supplied) – Max. 100 m (300 ft.) *Can withstand 35 kPa (5.1 psi) – positive or negative (pressure compensation required above 5 kPa [0.7 psi] – transmitter can supply fixed pressure compensation) **Transmitter does not contain a reference air supply for the probe.

  • Page 10: Pneumatic Connections

    Endura AZ20 series probe Combustion oxygen monitor 3 Mechanical Installation 3.5 Pneumatic Connections Caution.  The configuration option of having flow restrictors fitted to the probe determines the way the reference air and test gas flow is controlled. Ensure the instructions for the pneumatic connections are followed accurately – an incorrect configuration at the probe can cause errors and / or permanent damage.

  • Page 11: Pneumatic Connections For Probes With Restrictors

    Endura AZ20 series probe Combustion oxygen monitor 3 Mechanical Installation 3.5.2 Pneumatic Connections for Probes with Restrictors AutoCal Probe Non-AutoCal Probe Vent to Dry Area Vent to Dry Area (Unrestricted Flow) (Unrestricted Flow) Reference Reference Clean Dry Oil-free Clean Dry Oil-free...

  • Page 12: Pneumatic Connections For Probes Without Restrictors

    Endura AZ20 series probe Combustion oxygen monitor 3 Mechanical Installation 3.5.3 Pneumatic Connections for Probes without Restrictors Non-AutoCal Probe AutoCal Probe Vent to Dry Area Vent to Dry Area (Unrestricted Flow) (Unrestricted Flow) Reference Air *Shut-off ***ABB **ABB Valve Flowmeter...

  • Page 13: Overall Dimensions

    Endura AZ20 series probe Combustion oxygen monitor 3 Mechanical Installation 3.6 Overall Dimensions 3.6.1 Remote Endura AZ20 Probe Dimensions in mm (in) Dimensions from Flange to Probe Cell in m (ft) 384 (15.2) 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5 or 4.0 (1.7, 3.3, 5.0, 6.6, 8.2, 9.9, 11.5, 13.1)

  • Page 14: Endura Az20 Probe Flanges - All Probe Lengths

    Endura AZ20 series probe Combustion oxygen monitor 3 Mechanical Installation 3.7 Endura AZ20 Probe Flanges – All Probe Lengths Note. These flanges are not pressure rated. Dimensions in mm (in). Flange Type 4-Hole Flanges (Ø) (PCD) 152.4 120.6 ANSI 2 in 150 (6.00)

  • Page 15: Mounting Plates For Abb Standard Flanges

    In addition to the probe flange, the probe can be supplied with a The 1.0 to 4.0 m (3.3 to 13.1 ft) probe mounting plates comprise mounting plate assembly for use with ABB Standard flanges the following items: (see Table 3.2, page 12) if specified.

  • Page 16: Mounting

    Endura AZ20 series probe Combustion oxygen monitor 3 Mechanical Installation 3.9 Mounting Note. Mount integral probes with the transmitter at the top of the probe head. Mount remote probes with the conduit at the bottom of the probe head. 3.9.1 Probe...

  • Page 17: M (1.64 Ft) Probe To Large Probe Adapter Plate Mounting

    Mounting Note. The following procedure enables a 0.5 m (1.7 ft) probe to be fitted into a large probe (1.0 to 4.0 m [3.3 to 13.1 ft]) ABB Standard flange hole. 1. Locate the adapter gasket on the existing mounting plate.

  • Page 18: End Of Life Disposal

    Endura AZ20 series probe Combustion oxygen monitor 3 Mechanical Installation 3.10 End of Life Disposal Both the integral and remote transmitters contain a small lithium battery that must be disposed of responsibly in accordance with local environmental regulations. The remainder of the equipment does not contain any substance that causes undue harm to the environment and must be disposed of in accordance with the Directive on Waste Electrical and Electronic Equipment (WEEE).

  • Page 19: Connections

    Endura AZ20 series probe Combustion oxygen monitor 4 Connections 4 Connections 4.1 Electrical Safety Warning.  The transmitter is not fitted with a switch therefore a disconnecting device such as a switch or circuit breaker conforming to local safety standards must be fitted to the final installation.

  • Page 20: Cable Preparation

    Endura AZ20 series probe Combustion oxygen monitor 4 Connections 4.2 Cable Preparation 4.2.1 Endura AZ20 Probe to Remote Endura AZ20 Referring to Fig. 4.2: Transmitter 1. Expose the signal and screen wires by cutting the outer insulation sheath and screen foil and inner (heater) Warning.
  • Page 21 Endura AZ20 series probe Combustion oxygen monitor 4 Connections Green (TC+) Screen 2 Screen Foil 1 White (TC–) Grey (ACJC) White / Green Violet (ACJC) (AutoCal SV1) Screen 1 Blue* (Heater) White / Red (AutoCal SV COM) Black (Cell –)

  • Page 22: Electrical Connections

    Endura AZ20 series probe Combustion oxygen monitor 4 Connections 4.3 Electrical Connections 4.3.1 Endura AZ20 Probe Transmitter Connections Notes.  Non-AutoCal probes are not fitted with the 6-way AutoCal terminal block or pressure switch / solenoid valve block.  For probes fitted with AutoCal, make standard connections (steps 1 to 5), then AutoCal connections as detailed in Section 4.3.2, page 21.

  • Page 23: Autocal Connections At Endura Az20 Probe

    Endura AZ20 series probe Combustion oxygen monitor 4 Connections 4.3.2 AutoCal Connections at Endura AZ20 Probe 1. Make standard connections – see section 4.3.1, page 20, steps 1 to 5. Referring to Fig. 4.4: 2. Remove terminal plug from probe terminal block taking care not to disturb the existing wiring 3.

  • Page 24: Gas And Air Connections

     on systems without restrictors, pressure is still set to 1 bar (15 psi) then flow is restricted by valves on flowmeters *ABB recommend our 5 µm / Oil Coalescing Filter Regulator – see Appendix , page 36. 4.4.2 Connection Types Note.

  • Page 25: Test Gas Inlets

    Endura AZ20 series probe Combustion oxygen monitor 4 Connections 4.4.4 Test Gas Inlets If the probe is connected permanently to the test gas supply Two test (calibration) gas inlets are provided for in situ AutoCal pipework: probe testing using a test gas.

  • Page 26: Vent

    Filter Regulator to supply reference air – see Appendix D, page 36.  If oil vapor is suspected, use an ABB Reference Air Pump to supply reference air to the probe – see Appendix D, page 30. IM/AZ20P–EN Rev. G...

  • Page 27: Internal Test Gas And Reference Air Tubes

    Endura AZ20 series probe Combustion oxygen monitor 4 Connections 4.4.8 Internal Test Gas and Reference Air Tubes Reference Test Gas Tube Test Gas Tube Reference Air Tube to Sensor to Sensor Air Tube Test Test Gas 2 Gas 1 ACJC ACJC Fig.

  • Page 28: Start-Up And Operation

    Endura AZ20 series probe Combustion oxygen monitor 5 Start-up and Operation 5 Start-up and Operation 5.1 Preparation 5.2 Setting Up Test Gases 1. If the probe is not connected permanently to test gas This section prepares the system for manual and automatic...

  • Page 29: Autocal System Without Restrictors

    Endura AZ20 series probe Combustion oxygen monitor 5 Start-up and Operation 5.2.2 AutoCal System without Restrictors 5.2.3 Non-AutoCal System with Restrictors To set up an AutoCal system without restrictors: To set up an Non-AutoCal system with restrictors: 1. Make test gas and reference air connections as detailed in 1.

  • Page 30: Endura Az20 Probe Specification

    Endura AZ20 series probe Combustion oxygen monitor 6 Endura AZ20 Probe Specification 6 Endura AZ20 Probe Specification Physical Operating requirements Probe insertion lengths Reference air 0.5 m (1.7 ft.) 2.5 m (8.2 ft.) Regulated Probes with restrictors 1 bar (15 psi), 1.0 m (3.3 ft.)

  • Page 31: Appendix A - Principle Of Operation

    Endura AZ20 series probe Combustion oxygen monitor Appendix A – Principle of Operation Appendix A – Principle of Operation The Endura AZ20 probe's zirconia cell is a thimble-shaped sensing element fitted with inner and outer electrodes at its closed end.

  • Page 32: Appendix B - Endura Az20/Zfg2 Replacement Probe

    Note. For Endura AZ20/ZFG2 replacement probe test gas and connection details at the existing ZMT transmitter or ZDT-FG analyzer, refer to the following manuals:  IM/ZDT-FG – copies of the IM/ZDT/FG manual can be downloaded from the ABB web site (www.abb.com).  IM/ZMT – copies of the IM/ZMT manual can be downloaded from the ABB website (www.abb.com).

  • Page 33: Endura Az20/Zfg2 Replacement Probe Conduit Electrical Connections

    Endura AZ20/ZFG2 replacement probe, refer to the ZFG2 probe manual (this manual can be downloaded from the ABB web site at (www.abb.com) or by clicking the following link: IM/ZFG2).  The Endura AZ20/ZFG2 replacement probe must be installed using the new conduit supplied with the probe.

  • Page 34: Endura Az20/Zfg2 Replacement Probe

    Endura AZ20 series probe Combustion oxygen monitor Appendix B – Endura AZ20/ZFG2 Replacement Probe B.1.2 Endura AZ20/ZFG2 Replacement Probe – Conduit Reference Air Connections Referring to Fig. B.3: 1. For probes using the conduit (internal) Reference Air line: a. disconnect pipe at the hexagonal fitting b.

  • Page 35: Zdt-Fg Analyzer Connections

    Endura AZ20 series probe Combustion oxygen monitor Appendix B – Endura AZ20/ZFG2 Replacement Probe B.2 ZDT-FG Analyzer Connections Warning. Before disconnecting existing ZFG2 conduit, or connecting the new Endura AZ20/ZFG2 replacement probe conduit, ensure the power supply, any powered control circuits and high common-mode voltages are switched off.

  • Page 36: Zmt Transmitter Connections

    Endura AZ20 series probe Combustion oxygen monitor Appendix B – Endura AZ20/ZFG2 Replacement Probe B.3 ZMT Transmitter Connections Warning. Before disconnecting or connecting conduit, ensure the power supply, any powered control circuits and high common-mode voltages are switched off. B.3.1 Disconnecting the Existing ZFG2 Probe Referring to Fig.

  • Page 37: Appendix C - Using An External Automatic Calibration Panel

    Endura AZ20 series probe Combustion oxygen monitor Appendix C – Using an External Automatic Calibration Panel Appendix C – Using an External Automatic Calibration Panel Warning. Isolate the Endura AZ20 transmitter and external automatic calibration panel before making AutoCal connections.

  • Page 38: Appendix D - Accessories And Spares

    Endura AZ20 series probe Combustion oxygen monitor Appendix D – Accessories and Spares Appendix D – Accessories and Spares D.1 Documentation Part No. Description Part No. Description IM/AZ20M–EN Maintenance Guide Oil-coalescing Filter-Regulator: Download* the Maintenance NPT 5 µm AZ200 731 Guide from: BSP 5 µm...
  • Page 39 Sales Service Software...
  • Page 40 We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

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