ABB EasyLine EL3000 User manual

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ABB MEASUREMENT & ANALYTICS |
OPERATING INSTRUCTION | OI/EL3000-EN REV. D
EasyLine EL3000
Continuous gas analyzers
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ABB Measurement & Analytics
For your local
ABB contact, visit:
www.abb.com/contacts
For more product information, visit:
www.abb.com/analytical
So smart, they're simple
Measurement made easy
OI/EL3000
-EN Rev. D 07.2021
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EasyLine EL3020
EasyLine EL3040
Introduction
EasyLine
is a powerful yet cost-effective line of
devices for the measurement of gas
concentrations in numerous applications.
Automatic calibration and the use of superior ABB
calibration cell technology in the photometer
avoids the use of expensive test gas cyli
nders in
most applications.
Zero
-point calibration with ambient air
Various analyzer types available:
Combining different analyzers in a single housing
enables optimum economy and operational
efficiency for your application.
Additional Information
Additional documentation on EasyLine EL3000 is
available for download free of charge at
www.abb.com/analytical.
Alternatively simply scan this code:
—
We reserve the right to make technical changes or modify the contents of this document
without prior noti
ce. 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.
We reserve all rights in this document and in the subject
matter and illustrations contained
therein. Any reproduction, disclosure to third parties or utilization of its contents
– in whole
or in parts
– is forbidden without prior written consent of ABB.
© ABB 2021 3KXG112001R4201

2 EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D
Table of contents
1Safety ........................................................................ 4
General information and instructions.................................4
Warnings..................................................................................4
Warranty provisions...............................................................4
Intended use............................................................................5
Improper use...........................................................................5
Safety instructions.................................................................6
Fidas24 – Information for safe operation...........................7
Notes on data safety..............................................................8
Manufacturer’s address.........................................................9
Service address.......................................................................9
2Use in potentially explosive atmospheres........... 10
Notes on use in potentially explosive atmospheres........10
Explosion proof design in degree of protection II 3G ..... 11
3Design and function................................................13
Housing designs................................................................... 13
Available analyzer modules .................................................14
Available analyzer combinations........................................14
4Preparation for Installation ...................................15
Scope of delivery ..................................................................15
Material required for installation .......................................15
Requirements for the installation site............................... 17
Power supply.........................................................................18
Uras26 ....................................................................................19
Limas23 .................................................................................. 21
Magnos206............................................................................23
Magnos28 ..............................................................................25
Magnos27...............................................................................27
ZO23 .......................................................................................28
Caldos27................................................................................. 31
Fidas24...................................................................................33
Sample gas input and output conditions .........................35
Pressure sensor ....................................................................36
Housing purge ......................................................................37
Dimensions............................................................................38
Special conditions for the measurement of combustion
gases ......................................................................................41
5Installation.............................................................. 43
Unpacking the Gas Analyzer................................................43
Name plate ............................................................................43
Analyzer data sheet..............................................................43
Mounting the fittings on the gas analyzer....................... 44
Position and design of the gas connections ................... 45
Gas Analyzer Installation .....................................................85
Connecting the gas lines.................................................... 86
Fidas24 – Connect gas lines................................................87
Fidas24 – Connecting the combustion gas line .............. 88
Fidas24 – Connecting the sample gas line to the heated
sample gas connection....................................................... 89
Fidas24 – Connecting the sample gas line to the
unheated sample gas connection ......................................91
6Electrical connections ............................................93
Safety instructions .............................................................. 93
General Notes....................................................................... 93
Model EL3020 ....................................................................... 93
Model EL3040.......................................................................94
Analog output modules ......................................................96
Digital I/O module ............................................................... 97
Modbus®-Module ................................................................. 99
PROFIBUS®-Module ............................................................. 99
Connecting the Signal Lines.............................................100
Connecting the power supply .......................................... 100
7Commissioning .....................................................102
Safety instructions ............................................................ 102
Installation Check .............................................................. 102
Purge sample gas path and analyzer housing ............... 103
Gas analyzer start-up ........................................................ 103
8Operation...............................................................107
Safety instructions ............................................................ 107
LCD indicator...................................................................... 107
Menu Overview....................................................................110
Notes on the operating concept....................................... 111
Communication between gas analyzer and computer..112
9Calibration ............................................................. 115
Calibration control..............................................................115
Test gases............................................................................116
Set test gas concentration................................................117
Automatic calibration: Control .........................................118
Automatic calibration: settings........................................119
Automatic calibration: manual start ................................123
Manual calibration: calibration method...........................123
Manual calibration: execution ...........................................125
Uras26 – Instructions for calibration ...............................126
Limas23 – Instructions for calibration ............................ 128
Magnos206 – notes for calibration ................................. 130
Magnos28 – notes for calibration.....................................131
Magnos27 – notes for calibration .....................................133
ZO23 – Checking the reference point and end point .... 134
Caldos27 – Notes for calibration...................................... 134
Fidas24 – Notes for calibration........................................ 136
Fidas24 – Substitute gas calibration ...............................137
Fidas24 – Response factors and other relevant variables
138
Fidas24 – Conversion of concentration data................. 139
Oxygen sensor – Notes for calibration ........................... 140

EL3000CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D 3
10 Configuration ........................................................141
Measuring range switchover............................................. 141
Measuring range configuration with ECT.......................142
Measuring range configuration in the gas analyzer ......144
Uras26 – Change measuring range limits .......................145
Limas23 – Change measuring range limits.....................145
Magnos206 – Change measuring range limits...............146
Magnos28 – Change measuring range limits .................146
Caldos27 – Change measuring range limits....................147
Oxygen sensor – Changing measuring range limits...... 147
Limit values .........................................................................147
Set low-pass time constant ..............................................148
Active component selection .............................................149
Externally controlled measured component switch......149
Changing the physical unit for a sample component ...150
Sample components ..........................................................150
Configuring signal inputs and outputs........................... 152
Setting the IP address .......................................................153
Setting the date and time .................................................154
Selecting the user interface language.............................154
Configuring the user interface language........................155
Password .............................................................................156
Software updates...............................................................157
11 QAL3 monitoring ...................................................159
General information...........................................................159
Control cards.......................................................................160
Configuration of QAL3 monitoring.................................. 161
Display and print control chart.........................................162
Edit or delete QAL3 values ................................................163
Exporting or deleting QAL3 data......................................163
12 Diagnosis / Troubleshooting.............................. 164
Safety instructions.............................................................164
The Dynamic QR Code........................................................164
Status messages – Explanations......................................166
Status messages on the LCD display ..............................167
Possible status messages.................................................168
Troubleshooting................................................................. 173
Fidas24 – Troubleshooting................................................174
Notify Service......................................................................176
Returning devices...............................................................176
13 Maintenance .......................................................... 177
Safety instructions .............................................................177
Inspection ............................................................................177
Maintenance switch............................................................178
Perform calibration reset...................................................178
Uras26, Limas23 – measuring the calibration cell ..........179
Limas23 – Intensity display................................................179
Limas23 – Clean the sample cell....................................... 180
Limas23 – Replacing the UV lamp (EDL) ......................... 183
ZO23 – Function Test......................................................... 188
Fidas24 – Standby / Restart............................................. 189
Fidas24 – replace the sample gas filter in the heated
sample gas connection ..................................................... 190
Cleaning the Fidas24 air jet injector ................................191
Check the integrity of combustion gas path ..................192
Drift indicator..................................................................... 194
Pressure correction ........................................................... 194
Device test .......................................................................... 195
Instrument information .................................................... 198
Operate pump .................................................................... 198
Checking gas path leak tightness ................................... 199
Important instructions for measuring combustion gases
199
Important instructions for explosion-proof design in
degree of protection II 3G................................................. 199
14 Decommissioning ................................................ 200
Decommissioning the gas analyzer.................................200
Fidas24 – Shutting down the gas analyzer.....................200
Packing the Gas Analyzer.................................................. 201
15 Recycling and disposal .........................................202
16 Specification .........................................................202
Uras26.................................................................................. 203
Limas23 ...............................................................................204
Magnos206 .........................................................................205
Magnos28............................................................................206
Magnos27 ............................................................................ 207
ZO23.....................................................................................208
Caldos27 ..............................................................................209
Fidas24 ................................................................................ 210
Oxygen sensor.....................................................................211
17 Additional documents .......................................... 212
18 Appendix................................................................ 213
Return form..........................................................................213

4 EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D
1Safety
General information and instructions
These instructions are an important part of the product and
must be retained for future reference.
Installation, commissioning, and maintenance of the product
may only be performed by trained specialist personnel who have
been authorized by the plant operator accordingly. The specialist
personnel must have read and understood the manual and must
comply with its instructions.
For additional information or if specific problems occur that are
not discussed in these instructions, contact the manufacturer.
The content of these instructions is neither part of nor an
amendment to any previous or existing agreement, promise or
legal relationship.
Modifications and repairs to the product may only be performed
if expressly permitted by these instructions.
Information and symbols on the product must be observed.
These may not be removed and must be fully legible at all times.
The operating company must strictly observe the applicable
national regulations relating to the installation, function testing,
repair and maintenance of electrical products.
Warnings
The warnings in these instructions are structured as follows:
DANGER
The signal word ‘DANGER’ indicates an imminent danger.
Failure to observe this information will result in death or
severe injury.
WARNING
The signal word ‘WARNING’ indicates an imminent danger.
Failure to observe this information may result in death or
severe injury.
CAUTION
The signal word ‘CAUTION’ indicates an imminent danger.
Failure to observe this information may result in minor or
moderate injury.
NOTICE
The signal word ‘NOTICE’ indicates possible material damage.
Note
‘Note’ indicates useful or important information about the
product.
Warranty provisions
Using the device in a manner that does not fall within the scope
of its intended use, disregarding this manual, using
underqualified personnel, or making unauthorized alterations
releases the manufacturer from liability for any resulting
damage. This renders the manufacturer's warranty null and void.

EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D 5
Intended use
The gas analyzer is designed for continuous measurement of the
concentration of individual components in gases or vapors.
Any other use is not approved.
The intended use also includes taking note of this operating
instruction.
Note
The version for the measurement of flammable gases and the
explosion-proof design in degree of protection II 3G is designed
for various variants of the gas analyzer and for different
applications.
Measurement of flammable gases
DANGER
Explosion hazard
Explosion hazard when operating the gas analyzer in
potentially explosive atmospheres.
• Only operate the gas analyzer in the version with stainless
steel gas lines and gas connections (models EL3020 and
EL3040), for the measurement of flammable gases and
vapors, outside hazardous areas.
Observe the following information when measuring flammable
gases*:
• The gas analyzer may only be used for the measurement
of non-incendive gas / air or gas / oxygen mixtures.
• The special conditions for the measurement of flammable
gases (see Special conditions for the model EL3020 gas
analyzer for the measurement of flammable gases on
page 17) must be observed.
• The oxygen sensor, as well as the assemblies of the
integral gas feed (option “Integrated gas feed option –
only in model EL3020, not for Limas23, ZO23, Fidas24)
may not be used for the measurement of flammable
gases.
* A flammable gas is a gas that can be ignited by adding air.
Operation in hazardous areas
DANGER
Explosion hazard
Explosion hazard when measuring flammable gases in
hazardous areas.
• The gas analyzer in the explosion-proof design (model
EL3040) may only be used for the measurement of non-
flammable gases and vapors.
The model EL3040 gas analyzer is available in explosion-proof
design with degree of protection II 3G (see Use in potentially
explosive atmospheres on page 10).
Important safety instructions
In accordance with the EU Directive 2014/34/EU and the general
requirements for explosion protection and as specified in the
IEC 60079-0 standard, the scope of approvals for our explosion-
protected apparatus is limited to atmospheric conditions,
unless expressly stated otherwise in the certificates.
This also includes the sample gas that is fed in.
Definition of atmospheric conditions
Temperature
−20 to 60 °C
Pressure pabs
80 to 110 kPa (0.8 to 1.1 bar)
Ambient air with standard oxygen content, typically 21% vol.%
If the atmospheric conditions are not complied with, the
operator is obliged to guarantee the safe operation of our
devices in the absence of the recommended atmospheric
conditions, by means of further measures (e.g. evaluation of the
gas mixture or explosion pressure) and / or supplementary
protective devices.
Improper use
The following are considered to be instances of especially
improper use of the device:
• For use as a climbing aid, for example for mounting
purposes.
• For use as a bracket for external loads, for example as a
support for piping, etc.
• Material application, for example by painting over the
housing, name plate or welding/soldering on parts.
• Material removal, for example by spot drilling the
housing.

6 EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D
… 1 Safety
Safety instructions
Requirements for safe operation
In order to operate in a safe and efficient manner the device
should be properly handled and stored, correctly installed and
set-up, properly operated and correctly maintained.
Personnel qualifications
Only persons familiar with the installation, set-up, operation and
maintenance of comparable devices and certified as being
capable of such work should work on the device.
Special information and precautions
These include:
• The content of this operating instruction,
• The safety information affixed to the device,
• The applicable safety precautions for installing and
operating electrical devices,
• Safety precautions for working with gases, acids,
condensates, etc.
National regulations
The regulations, standards and guidelines cited in this
operator's manual are applicable in the Federal Republic of
Germany. The applicable national regulations should be followed
when the device is used in other countries.
Safety of the equipment and safe operation
The device was built and tested in accordance with
EN 61010 Part 1 ‘Safety regulations for electrical measuring,
control and laboratory equipment’ and it left the factory in
perfect condition.
To maintain this condition and to assure safe operation, read
and follow the safety instructions in this operating instruction.
Failure to do so can put persons at risk and can lead to device
damage as well as damage to other systems and devices.
Protective lead connection
The protective lead (ground) should be attached to the
protective lead connector before any other connection is made.
Risks of a disconnected protective lead
The device can be hazardous if the protective lead is interrupted
inside or outside the device or if the protective lead is
disconnected.
Potential equalization
• The external potential equalization connection of the
analyzer housing must be connected to the local potential
equalization.
• The local potential equalization must be connected before
any other connections are made.
• The connectors have a clamping range of max. 4 mm2.
Danger of interrupted potential equalization
The device can be hazardous if the protective lead is interrupted
inside or outside the device or if the protective lead is
disconnected.
DANGER
Explosion hazard
Explosion hazard when working on the potential equalization
or the potential equalization connection in an existing
hazardous atmosphere.
• Work on the potential equalization or the potential
equalization connection is prohibited if there is a
hazardous atmosphere.
Risks involved in opening the covers
Current-bearing components can be exposed when the covers or
parts are removed, even if this can be done without tools.
Current can be present at some connection points.
Risks involved in working with an open device
All work on a device that is open and connected to power should
only be performed by trained personnel who are familiar with the
risks involved.
When safe operation can no longer be assured
If it is apparent that safe operation is no longer possible, the
device should be taken out of operation and secured against
unauthorized use.
The possibility of safe operation is excluded:
• If the device is visibly damaged,
• If the device no longer operates,
• After prolonged storage under adverse conditions,
• After severe transport stresses.

EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D 7
Fidas24 – Information for safe operation
DANGER
Explosion hazard
Explosion hazard due to leaking combustion gas (hydrogen).
• All the information and instructions contained in this
Operating Instruction must be complied with without fail
to guarantee safe operation of the gas analyzer!
Measures of the manufacturer
The following measures ensure that the enrichment of
combustion gas or an explosive mixture of combustion gas and
ambient air cannot occur inside the gas analyzer during normal
operation:
• The tightness of the combustion gas feed path is
checked for a leakage rate of < 1 × 10–4 hPa⋅l/s before
delivery.
• The combustion gas/air mixture (before and after the
ignition point) is diluted in the detector with compressed
air.
• The combustion gas feed is not connected to the supply
during commissioning until the internal nominal
pressures have been set.
• The combustion gas feed is switched off if the internal
nominal pressures cannot be set during the ignition
phase (e.g. because of insufficient compressed air or
combustion air feed).
• The combustion gas feed is switched off after several
unsuccessful ignition attempts.
• If the flame goes out during operation, the combustion
gas feed is switched off if the following ignition attempts
are unsuccessful.
The interior of the gas analyzer cannot be allocated to an
(explosion protection-) zone; an explosive gas mixture cannot
escape to the outside.
Conditions to be complied with by the end user
The end user must comply with the following prerequisites and
conditions to ensure safe operation of the gas analyzer:
• The gas analyzer may be used for the measurement of
flammable gases provided that the flammable portion
does not up-scale 15 Vol.-% CH4oder C1 equivalents.
• The relevant safety regulations for working with
combustion gases must be complied with.
• The gas connection diagram (see Gas connections and
electrical connections Fidas24 (model EL3020) on
page 83 and Gas connections and electrical connections
Fidas24 (model EL3040) on page 84) must be complied
with when connecting the combustion gas and
combustion air.
• The combustion gas path in the gas analyzer must not be
opened! The combustion gas path can become leaky as a
result! Escaping combustion gas can cause fires and
explosions, also outside the gas analyzer!
• If the combustion gas path in the gas analyzer has been
opened nonetheless, it must be checked for leakage
(refer to Check the integrity of combustion gas path on
page 192), using a leak detector (leak rate < 1 × 10–4 hPa
l/s), once it has been closed again.
• The tightness of the combustion gas supply line (see
Check the tightness of the combustion gas line on
page 192) outside the gas analyzer as well as the
combustion gas path (see Combustion gas path in the
gas analyzer on page 193) in the gas analyzer must be
checked regularly.
• The maximum pressures of combustion gas and
combustion air (see Operational gases on page 33) may
not be up-scaled.
• The maximum combustion gas flow (see Combustion gas
on page 34) may not be up-scaled.

8 EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D
… 1 Safety
… Fidas24 – Information for safe operation
• The combustion gas flow rate must be limited to a
maximum of 10 l/h H2or 25 l/h H2/He mixture. Suited
measures (see Combustion gas on page 34) outside the
gas analyzer must be provided by the operator for this
purpose.
• In order to increase the safety level under the following
operational conditions, a shut-off valve (refer to
Combustion gas on page 34) must be installed in the
combustion gas supply line:
– when shutting down the gas analyzer,
– in case of instrument air supply failure,
– in case of a leak in the combustion gas path, inside
the gas analyzer.
This shut-off valve should be installed outside the
analyzer house in the vicinity of the combustion gas
supply (cylinder, line).
• Should the combustion gas supply to the analyzer module
not shut off automatically in the event of an instrument
air supply failure, an alarm that is visible or audible to the
operator must be triggered (refer to In case of
instrument air supply failure on page 175).
• When measuring combustion gases, it must be ensured
that if either the instrument air supply or the analyzer
module should fail, the sample gas supply to the analyzer
module will be shut off and the sample gas path purged
with nitrogen.
• The unobstructed exchange of air with the environment
must be possible around the gas analyzer. The gas
analyzer must not be directly covered. The openings in
the housing towards the top and at the side may not be
closed. The distance to laterally adjacent built-in
components must be at least 4 mm.
• If the gas analyzer is installed in a closed cabinet,
adequate ventilation of the cabinet must be provided (at
least 1 change of air per hour). The distance to adjacent
built-in components towards the top and at the side
must be at least 4 mm.
Notes on data safety
This product is designed to be connected to and to
communicate information and data via a network interface.
It is operator’s sole responsibility to provide and continuously
ensure a secure connection between the product and your
network or any other network (as the case may be).
Operator shall establish and maintain any appropriate measures
(such as but not limited to the installation of firewalls,
application of authentication measures, encryption of data,
installation of anti-virus programs, etc.) to protect the product,
the network, its system and the interface against any kind of
security breaches, unauthorized access, interference, intrusion,
leakage and / or theft of data or information.
ABB Ltd and its affiliates are not liable for damages and / or
losses related to such security breaches, any unauthorized
access, interference, intrusion, leakage and / or theft of data or
information.
Services and ports on the Ethernet interface
Port
Description
22/
tcp
Used only for software updates.
No direct access to the device.
502/tcp
Used for Modbus/TCP.
The device allows connection to any Modbus client. The port
must be activated via ECT, the port is delivered in a deactivated
state.
8100/tcp
Used for test a
nd calibration software Optima TCT Light.
Binary proprietary protocol.
The port is deactivated. It can be activated for TCT access via a
secure connection, and deactivated when the TCT access is
terminated

EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D 9
Access authorizations
Access to both the calibration functions and those functions
used to change the instrument configuration can be restricted
by means of password protection.
The password protection is not activated at the factory (except
in the case of gas analyzers used for emission monitoring).
It is recommended that the factory-set passwords be changed
by the operator, by means of the ECT software tool (“EasyLine
Configuration Tool”) (Password on page 156). This limits access
to both the ECT software tool itself and to the calibration and
configuration functions of the device.
Manufacturer’s address
ABB Automation GmbH
Measurement & Analytics
Stierstädter Str. 5
60488 Frankfurt am Main
Germany
Tel: [phone]
Email: [e-mail]
Service address
If the information in this Operating Instruction does not cover a
particular situation, ABB Service will be pleased to supply
additional information as required.
Please contact your local service representative.
For emergencies, please contact:
Customer service center
Tel: [phone]
Email: [e-mail]

10 EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D
2Use in potentially explosive atmospheres
Notes on use in potentially explosive atmospheres
Installation in accordance with IEC/EN 60079-14
(VDE 0165 Part 1)
The electric equipment must be installed in potentially explosive
atmospheres in accordance with IEC/EN 60079-14 (VDE 0165
Part 1) “Electric Equipment for Hazardous Gas Areas, Part 14:
Electric Systems in Potentially Explosive Atmospheres.”
Potential equalization
With regard to potential equalization, the provisions of
IEC/EN 60079-14 as well as DIN VDE 0100 Part 410 “Protection
against electric shocks” and Part 540 “Grounding, Protective
ground, Potential equalization conductors” must be observed.
Electrostatic charges
Electrostatic charges must be avoided. The professional
association rules for the “Prevention of ignition hazards due to
electrostatic charges (BGR 132) must be observed here.
Monitoring and review
Electric systems in potentially explosive atmospheres must be
monitored for proper condition.
As necessary, but at least every three years, they must be
inspected by an electrician, provided they are not constantly
monitored under the supervision of a responsible engineer.
Work on electric systems
Before any maintenance work is carried out on electric
installations in potentially explosive atmospheres, the
installations must be disconnected from the power supply.
The disconnect point must be identified with an appropriate
warning sign, for example, "Do not power-up – explosion hazard"
This does not apply to devices that may be opened as part of
normal operation, such as registration devices, or for which it is
expressly noted in the type examination certificate.
Maintenance work on the device where opening the housing or
part of the housing is necessary is only permitted in a non-
hazardous atmosphere.
DANGER
Risk of explosion!
There is an explosion hazard if the housing is opened in a
potentially explosive atmosphere:
• Before opening the housing, make sure that no flammable
or potentially explosive atmospheres are present.
Work on intrinsically safe circuits
Work on live systems may be carried out on intrinsically safe
circuits even in potentially explosive atmospheres.
However, the electric data (inductance, capacity, current and
voltage values) of the corresponding test equipment must be
observed during power-up.
Special attention is required when carrying out work on
intrinsically safe circuits that have been set up in connection
with zone 0
Explosion hazard
Before repairs, the explosion hazard must have been eliminated.
Competent personnel
Repair work may only be performed by competent personnel.
Original spare parts
Only original spare parts may be used for repairs.
Inspection prior to recommissioning
If repair work is carried out on parts of electric equipment on
which explosion protection depends, a specialist needs to
inspect and certify before recommissioning that the attributes
of the equipment in terms of design and version which are
essential for explosion protection match the equipment
described in the declaration.
Repairs by the manufacturer
Repairs can also be carried out by the manufacturer, for example
on-site by an ABB Service employee or at the manufacturing
plant.
In this case, a marking showing the performed repairs with
subsequent routine testing is affixed to the name plate.
Testing by a specialist is not required then.

EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D 11
Explosion proof design in degree of protection II 3G
Note
The version for the measurement of flammable gases and the
explosion-proof design in degree of protection II 3G is designed
for various variants of the gas analyzer and for different
applications.
Description
The model EL3040 gas analyzer in degree of protection II 3G is
tested for explosion protection and is suited for use in
potentially explosive atmospheres, with consideration of the
specification and the special conditions (see Special conditions
on page 12).
The gas analyzer is intended for indoor installation only.
In the gas analyzer, the Uras26, Magnos206, Magnos28 and
Caldos27 analyzers can be installed individually and in these
combinations: Uras26 with Magnos206 or Magnos28 or Caldos27
or oxygen sensor.
The gas analyzer may be used for measurement of non-
flammable gases and vapors.
The gas analyzer is marked in accordance with the European
directive 2014/34/EU as:
II 3G Ex ec nC IIC T4 Gc
In undisturbed operation there cannot be any sparking, arcing or
impermissible temperatures inside the device.
Explosion protection through: increased safety as well as
gasketed or encapsulated equipment.
Type examination certificate no. BVS 16 ATEX E 085 X.
Note
The measurement function of the analyzer is not part of the type
examination certificate.
Explosion protection
The gas analyzers are designed for use in potentially explosive
atmospheres.
The gas analyzers are certified in accordance with European
Directive 2014/34/EU (‘ATEX Directive’) as well as in accordance
with the relevant IEC standards.
Standards and directives
The gas analyzer was designed and manufactured in accordance
with the following standards:
• EN/IEC 60079-0
• EN/IEC 60079-7
• EN/IEC 60079-15
The gas analyzer must be designed, installed and operated in
accordance with the following standards and directives:
• EN/IEC 60079-14
• EN/IEC 60079-17
• EN/IEC 60079-19
Note
The full designation of the applied standards, including the date
of issue, is included in the declaration of conformity supplied
with the device.
Note
All documentation, declarations of conformity, and certificates
are available in ABB's download area.
www.abb.com/analytical

12 EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D
… 2 Use in potentially explosive atmospheres
… Explosion proof design in degree of protection II 3G
Characteristic values
System bus, computer
interfaces
Supply voltage
100
to 240 V AC
Power consumption
Maximum 187 VA
Pneumatic data
Purge gas
Inlet pressure
Maximum 1104 hPa
Measured gas
Non-flammable sample gas
Inlet pressure
Magnos28:
Maximum 1600 hPa absolute pressure
All other analyzer modules:
Maximum 1100
hPa absolute pressure or maximum
100 hPa gauge pressure
Flow rate (gas output
atmospheric)
Maximum 100
l/h
Temperature data
Ambient temperature
5 to 45 °C (41 to 113 °F)
Special conditions
• The cables must be inserted into the cable glands properly
and gasketed by tightening the screws so that the IP 65
housing protection is maintained.
Unused cable glands must be sealed with suited sealing
plugs, so that the IP 65 housing protection is guaranteed
here as well.
• During operation, the unused purge gas connections must be
sealed with sealing plugs.
• If there is an explosion hazard at the installation site of the
gas analyzer, the housing must not be opened when live and
the connectors must not be disconnected when live.
• Due to the low mechanical stability of the viewing glass, the
gas analyzer must be designed and operated in such a way
that mechanical damage to the viewing glass with an energy
greater than 2 J can be excluded. If the viewing glass
becomes nevertheless damaged to the point that the IP 65
housing protection is no longer met, the gas analyzer must
be decommissioned, secured against recommissioning and
repaired.
• Due to the low UV resistance of the plastic parts of the
housing, the gas analyzer must be designed and operated in
such a way that the effect of UV radiation can be excluded. If
the housing is nevertheless damaged by UV radiation to the
point that the housing protection IP 65 is no longer
maintained, the gas analyzer must decommissioned, secured
against recommissioning and repaired.
Replacing the battery
The battery may only be replaced in a non-hazardous
atmosphere.
Only the original battery type may be used as a spare part:
• Varta CR 2032 type no. 6032 or
• Renata type no. CR2032 MFR

EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D 13
3Design and function
Housing designs
EL3020, 19" plug-in unit in IP 20 (IP 40) design EL3040, field mount housing in IP 65 design
optionally as an explosion proof variant
1
LCD indicator
2
Gas and electrical connections
Figure 1: EasyLine EL3000 housing designs
The EL3020 gas analyzer model features a 19” housing with 3 HU (4 HU with Magnos27) and IP rating IP 20 (IP 40 in the version for
emissions monitoring).
The housing for the EL3040 gas analyzer model is designed as wall-mount housing with an IP rating of IP 65.

14 EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D
… 3 Design and function
Available analyzer modules
The following analyzer modules are available for selection:
• Uras26 infrared photometer
for the measurement of infrared-active gas components,
such as CO, NO, SO2
• Limas23 Ultraviolet photometer
for the measurement of NO, NO2and SO2
• Magnos206 oxygen analyzer
for the measurement of O2in process gas or in N2
• Magnos28 oxygen analyzer
for the measurement of O2in process gas or in N2
• Magnos27 oxygen analyzer
for the measurement of O2in flue gas or in N2
• ZO23 trace oxygen analyzer
for the measurement of O2in pure gases (N2, CO2, Ar)
• Caldos27 thermal conductivity analyzer
for the measurement of binary gas mixtures with
different thermal conductivity, such as Ar in O2, H2in Ar,
CH4in N2
• Fidas24 flame-ionization detector
for the measurement of hydrocarbons
• Electrochemical oxygen sensor
for the measurement of O2
Available analyzer combinations
Analyzer combination
EL3020
EL3040
Uras26 with Magnos206
•
•
Uras26 with Magnos28
•
•
Uras26 with oxygen sensor
•
•
Limas23 with Magnos206
•
•
Limas23 with Magnos28
•
•
Limas23 with oxygen sensor
•
•
Magnos28 with Magnos28
•
—
Magnos28 with Caldos27
•
—
Caldos27 with Caldos27
•
—
Uras26 with Magnos27
•
—
Uras26 with 2× oxygen sensors
•
—
Note
The Fidas24 and ZO23 analyzer modules cannot be combined
with other analyzer modules.

EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D 15
4Preparation for Installation
Scope of delivery
• Gas analyzer model EL3020 (19” housing) or model EL3040
(wall housing)
• Screwed fittings with tubing connectors for the connection
of flexible tubes
• Power cable, length 5 m, see Connecting the power supply
on page 100.
• Counter plug (socket housing) for the electrical connection
of the I/O modules (plugged into the I/O module
connections)
• Screwdriver (required for attaching the electric lines in the
counter plugs)
• Fine filtration (pre-assembled), see Installing the fine filter
on page 86.
• Commissioning Instruction
• Analyzer data sheet
Fidas24
• Power cable, length 5 m, with 4-pin female connector and
separate grounding connector for the power supply to the
detector heating and the heated sample gas connection.
Refer to Grid connection cable Fidas24 on page 101.
• Accessory bag with fittings and O-rings for the connection of
the sample gas lines
• Exhaust air pipe with connecting nut and locking ring
Commissioning Instruction
The gas analyzer is delivered with a commissioning manual.
The commissioning instruction is an extract from the operating
instruction, and it contains all the information required to install,
commission and operate the gas analyzer safely, for its intended
purpose.
The commissioning manual does not contain information
regarding calibration, configuration and maintenance of the gas
analyzer or about the Modbus® and PROFIBUS® interface.
Analyzer data sheet
The design of the gas analyzer that has been supplied is
documented in detail in the analyzer data sheet.
Material required for installation
Note
The materials listed below are not included in the scope of
delivery of the device, and must be provided by the customer.
Gas connections
For the connection of piping:
Threaded connections with ⅛ NPT thread and PTFE sealing
tape.
Fidas24: Gas lines
Process gases, test gases and waste air
• PTFE or stainless steel tubes with 4 mm inside diameter and
PTFE or stainless steel tube with min. 10 mm inside diameter
for waste air
• Tube fittings
• Pressure regulator
• Flow restrictors in the combustion gas supply line, see Flow
restrictor in the combustion gas supply line on page 34.
• Shut-off valve in the combustion gas supply line, see Shut-off
valve in the combustion gas supply line on page 34.
Sample gas
Heated sample gas line (recommended: TBL 01) or unheated
sample gas line (PTFE or stainless steel tube with inside/outside
diameter 4/6 mm).
The fittings and O-rings required for the connection are included
within the scope of delivery of the gas analyzer.
Flowmeter/flow controller
Flowmeters or flow controllers with needle valve for setting and
monitoring the sample gas flow as well as purge gas flow, if
necessary.
Information for the selection and use of flowmeters:
• Measuring range 7 to 70 l/h
• Pressure drop < 4 hPa
• Needle valve open
Recommendation:
Flowmeter 7 to 70 l/h,
Order number 23151-5-8018474

16 EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D
… 4 Preparation for Installation
… Material required for installation
Shut-off valve
Install a shut-off valve in the sample gas line (recommended
when the sample gas is pressurized).
Purging of the gas line system
Plan for the option of connecting an inert gas, such as nitrogen,
from the gas sampling point for purging the gas line system.
Installation Material
19″ housing (model EL3020)
• 4 raised head screws
(recommendation: M6; this depends on the cabinet/ rack
system)
• 1 pair mounting rails (design depending on the cabinet/
frame system), length approx. 240 mm corresponding to
approx. ⅔ the housing depth
Wall-mount housing (model EL3040)
4 M8 or M10 screws
Signal Lines
Select conductive material which is appropriate for the length of
the lines and the predictable current load.
Notes concerning the cable cross-section for connection of the
I/O modules:
• The maximum capacity of terminals for stranded or solid
conductors is 1 mm2(17 AWG).
• The stranded conductor may be tinned on the tip or
twisted for simplified connection.
• When using wire end ferrules the total section must not
exceed 1 mm2, i.e. the maximum stranded conductor
section cannot be greater than 0.5 mm2. The Weidmüller
PZ 6/5 crimping tool must be used for crimping the
ferrules.
Lengths and types of cables for the RS485 lines
• Maximum 1,200 m (transfer rate, maximum 19,200 bit/s).
• Three-core twisted-pair cable, conductor cross section
0.25 mm2(e.g. order number 746620)
Length of the RS232 lines
Maximum 15 m.
Mating connector (socket housing)
The required mating connector (socket housing) for the plug-
in terminal strips on the I/O modules is included in the scope
of delivery.
Power supply lines
• If the supplied power cable is not used, select conductive
material which is appropriate for the length of the lines and
the predictable current load.
• Provide a supply circuit isolator or a switched socket outlet
to be able to disconnect the power supply at all phases from
the gas analyzer if required.

EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D 17
Requirements for the installation site
Note
For the analyzers ZO23 and Fidas24, the instructions specified in
ZO23 on page 28 or Fidas24 on page 33 must be observed.
Installation site requirements
The gas analyzer is intended for indoor installation only.
The specification of the gas analyzer (see data sheet) is
applicable up to a height of 2000 m above sea level. Altitude
above 2000 m on request.
The installation site must be stable enough to bear the weight of
the gas analyzer!
For safe installation and disassembly, we recommend
supporting the 19” housing in the cabinet or rack with slide rails!
Short gas paths
Install the gas analyzer as close as possible to the sampling
location.
Install the gas conditioning and calibration modules as close as
possible to the gas analyzer.
Adequate air circulation
Provide for adequate natural air circulation around the gas
analyzer. Avoid heat build-up.
Mount several 19” housings with a minimum distance of 1 HE
between each housing, see Gas Analyzer Installation on page 85.
Protection from adverse ambient conditions
Protect the gas analyzer from the following influences:
• Cold,
• Exposure to heat from e.g. the sun, furnaces, boilers,
• Temperature variations,
• Strong air currents,
• Accumulation of dust and ingress of dust,
• Corrosive atmosphere,
• Vibration.
Climatic Conditions
Relative humidity
Maximum 75 %, no condensation
Ambient temperature
• During operation:
5 to 45 °C
• Uras26 in combination with another analyzer, Limas23,
Fidas24:
5 to 40 °C
Transport-/Storage temperature
−25 to 65 °C
Housing protection (IP rating)
Model EL3020 (19” housing)
IP 20, IP 40 (with version for emissions measurement)
Model EL3040 (wall-mounted enclosure)
IP 65
Special conditions for the model EL3020 gas analyzer for
the measurement of flammable gases
Unrestricted exchange of air with the environment must be
provided around the gas analyzer from the bottom (floor plate)
and from the rear (gas connections).
The gas analyzer may not be placed directly on a table.
The housing openings may not be closed. Spacing to adjacent
built-in components to the sides must be at least 3 cm.
If the gas analyzer is installed in a closed cabinet, adequate
ventilation of the cabinet must be provided (at least 1 change of
air per hour).
The spacing to adjoining fittings from the bottom (floor plate)
and from the back (gas connections) must be at least 3 cm.

18 EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D
… 4 Preparation for Installation
… Requirements for the installation site
Special conditions for the model EL3040 gas analyzer in
degree of protection II 3G
Protection against mechanical influences
Due to the low mechanical stability of the viewing glass, the gas
analyzer must be designed and operated in such a way that
mechanical damage to the viewing glass is excluded with an
energy greater than 2 J.
UV radiation protection
Due to the low UV resistance of the plastic parts of the housing,
the gas analyzer must be designed and operated in such a way
that the effect of UV radiation can be excluded.
Housing design
Model
Housing design
IP rating
Weight
EL3020
19” housing
IP 20 approx. 7 to 15 kg
EL3040
Wall-mount housing
IP 65
approx. 13 to 21 kg
Power supply
Electric information (entire device)
The power supply built into the system housing is used to supply
24 V DC to the analyzer module and the associated electronics.
Input voltage
100 to 240 V AC, −15/+10 %;
50 to 60 Hz, ±3 Hz
Power
Maximum 187 VA (without heaters from Fidas24)
Connection
3-pole cold device plug in accordance with EN 60320-1/C14
(Power cable included in scope of supply)
Battery
Application
Supply to the built-in clock in case of a voltage failure.
Type
• Varta CR 2032 type no. 6032 or
• Renata type no. CR2032 MFR
Note
Only the original types specified above may be used as a spare
part.
Electric information (analyzer modules)
Input voltage
24 V DC, ±5 %
Power consumption analyzer modules (DC)
Uras26:
Max. 95 W
Magnos206:
max. 50 W
Limas23:
max. 100 W
ZO23:
max. 35 W
Magnos28:
max. 50 W
Caldos27:
max. 17 W
Magnos27:
max. 35 W
Fidas24:
max. 50 W
Fidas24 Analyzer Module (AC)
Detector and Sample Gas Inlet Heaters
Input voltage
115 V AC or 230 V AC, ±15
% (max. 250 V AC), 50 to
60 Hz, ±3 Hz
Power
consumption
125
VA for detector
125 VA for sample gas inlet (option)
Connection
4
-pin male connector
(connection cable included in scope of supply)

EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D 19
Uras26
Sample gas
Sample gas inlet conditions
DANGER
Explosion hazard
Explosion hazard when measuring ignitable gas / air or
gas / oxygen mixtures
• The gas analyzer may not be used for the measurement of
ignitable gas / air or gas / oxygen mixtures
Uras26 – sample gas input conditions
Temperature
The sample gas dew point should be
at least 5 °C below the temperature
throughout the sample gas path. Otherwise a sample gas cooler or
condensate trap is required.
Pressure
The analyzer is operated under atmospheric pressure; the sample gas outlet is
open to atmosphere.
Internal pressur
e drop:
<
5 hPa at standard flow rate of 60 l/h.
Permissible absolute pressure range:
800
to 1250 hPa.
Operation under lower absolute pressure
(e.g.
at altitudes above 2000 m) on
request.
Gauge pressure in the sample cell:
max. 500
hPa.
Flow rate
20
to 100 l/h
Corrosive gases
The analyzer may not be used for measurement in corrosive
gases. Associated gases, such as chlorine (Cl2) or hydrogen
chlorides (such as wet HCl) as well as gases or aerosols
containing chlorine must be cooled or pre-absorbed.
Flammable gases
In the version with gas lines and gas connectors made of
stainless steel, the analyzer is suited for the measurement of
flammable gases in non-explosive environments.
The special conditions when measuring flammable gases must
be observed, see Special conditions for the measurement of
combustion gases on page 41.
Flowing reference gas
Gas inlet conditions as for sample gas
Pressure sensor
The pressure sensor is installed in the gas analyzer as standard,
see Pressure sensor on page 36.
The pressure sensor is connected to the sample gas path or a
connection socket at different positions depending on the
design of the gas analyzer, see Position and design of the gas
connections on page 45.
The connection of the pressure sensor is also documented in the
pneumatic diagram included in the device data sheet.
Gas connections
See Gas connections Uras26 (model EL3020) on page 46 and
Gas connections Uras26 (model EL3040) on page 48.

20 EL3000 CONTINUOUS GAS ANALYZERS | OI/EL3000-EN REV. D
… 4 Preparation for Installation
… Uras26
Test gases – Uras26
Analyzer(s)
Test gas for the zero calibration
Test gas for the end-point calibration
Uras26
with calibration cells
(automatic calibration)
N
2or air or sample component-free gas —
(calibration cells)
Uras26
without calibration cells
(automatic calibration)
N
2or air Span gas*
Uras26
without calibration cells
(manual calibration)
N
2or air Test gas for each sample component
Uras26 + Magnos206
/ Magnos28
(automatic calibration, i.e. Magnos206
/
Magnos28 with single-point calibration)
IR sample component
-free test gas with O2
concentration in an existing measuring range or ambient
air.
Calibration cells or span gas*
Uras26 + Magnos206
/ Magnos28
(manual calibration)
Zero point gas for Uras26 or Magnos206
/ Magnos28, or
for single
-point calibration for Magnos206 / Magnos28,
IR sample component
-free test gas with
O
2concentration in an existing measuring range or
ambient air.
Span gas for all sample components in the Uras26 and in
the Magnos206 / Magnos28 (possibly only for the
Uras26 if a single-point calibration is carried out for the
Magnos206 / Magnos28)
Uras26 + Magnos27
(automatic calibration)
IR sample component
-free test gas with O2
concentration in an existing measuring range or ambient
air.
Calibration cells or span gas*
Uras26 + Magnos27
(manual
calibration)
Zero point gas for Uras26 or Magnos27, or IR sample
component
-free test gas with O2-concentration in an
existing measuring range or ambient air.
Span gas for all sample components in Uras26 and
Magnos27
Uras26 + Caldos27
(automatic
calibration, i.e. Caldos27 with
single-point calibration)
IR sample component
-free test gas with a known and
constant rTC value (possibly also dried room air)
Calibration cells or span gas*
Uras26 + Caldos27
(manual
calibration)
Zero reference gas for Uras26 or Caldos27, or IR sample
component
-free test gas with a known rTC value
Span gas for all sample components in the Uras26 and
Caldos27 (possibly only for the Uras26 if a single-point
calibration is carried out for the Caldos27)
Uras26 + oxygen sensor
(automatic calibration)
IR sample component
-free test gas with O2
concentration in an existing measuring range or ambient
air.
Calibration cells or span gas*
Uras26 + Oxygen sensor
(manual
calibration)
IR sample component
-free test gas with O2
concentration in an existing measuring range or ambient
air.
Span gas for all sample components in Uras26
* Test gas mixture for multiple sample components possible if no or negligible cross-sensitivity is present
Dew point
The dew point of the test gases must be approximately equal to the dew point of the sample gas.
Note
The instructions for calibration must be observed, see Uras26 – Instructions for calibration on page 126.