ABB Endura AZ20 series User manual

INFORMATION
Endura AZ20 – Pumped Reference Air Unit
N° INF09/027 Issue 3 Product Endura AZ20 Oxygen Systems Manual IM/AZ20P-EN
1Introduction
This publication details the installation, connection and
maintenance of an ABB Pumped Reference Air Unit. This pump
supplies reference air to any of the following ABB oxygen
probes:
AZ20, AZ25, AZ20/ZFG2 replacement, ZFG2 and ZGP2
4 pump models are available – see Table 1.1:
The internal air filter is a replaceable item (ABB part
number 0217463).
2 Safety
Information in this document is intended only to assist our
customers in the efficient operation of our equipment. Use of
this manual for any other purpose is specifically prohibited and
its contents are not to be reproduced in full or part without prior
approval of the Technical Publications Department.
2.1 Safety Precautions
Please read the entire document before unpacking, setting up,
or operating this pump.
Pay particular attention to all warning and caution statements.
Failure to do so could result in serious injury to the operator or
damage to the equipment.
To ensure the protection provided by this equipment is not
impaired, do not use or install this equipment in any manner
other than that which is specified in this manual.
2.2 Health & Safety
2.3 Electrical Safety – CEI / IEC 61010-1:2001-2
This equipment complies with the requirements of CEI / IEC
61010-1:2001-2 'Safety Requirements for Electrical Equipment
for Measurement, Control and Laboratory Use' and complies
with US NEC 500, NIST and OSHA.
If the equipment is used in a manner NOT specified by the
Company, the protection provided by the equipment may be
impaired.
2.4 Symbols – CEI / IEC 61010-1:2001-2
One or more of the following symbols may appear on the
equipment labelling:
Note. The pump cannot be used with multiple probes
simultaneously.
Description ABB Part Number
1/4BSP (Metric) 230 V AC 50 / 60 Hz AZ200 770
1/4BSP (Metric) 115 V AC 50 / 60 Hz AZ200 771
1/4NPT (Imperial) 230 V AC 50 / 60 Hz AZ200 772
1/4NPT (Imperial) 115 V AC 50 / 60 Hz AZ200 773
Table. 1.1 ABB Pumped Reference Air Unit Part Numbers
Health and Safety
To ensure that our products are safe and without risk to
health, the following points must be noted:
The relevant sections of these instructions must be
read carefully before proceeding.
Warning labels on containers and packages must be
observed.
Installation, operation, maintenance and servicing
must only be carried out by suitably trained personnel
and in accordance with the information given.
Normal safety precautions must be taken to avoid the
possibility of an accident occurring when operating in
conditions of high pressure and / or temperature.
Safety advice concerning the use of the equipment
described in this manual or any relevant Material Safety
Data Sheets (where applicable) may be obtained from the
Company address on the back cover, together with
servicing and spares information.
Protective earth (ground) terminal.
Functional earth (ground) terminal.
Direct current supply only.
Alternating current supply only.
Both direct and alternating current supply.
The equipment is protected through double
insulation.

Endura AZ20 Oxygen Systems
Endura AZ20 – Pumped Reference Air Unit 2 Safety
2INF09/027 Issue3
2.5 Restriction of Hazardous Substances (RoHS)
2.6 Product Disposal
2.7 Safety Recommendations
For safe operation, it is imperative that these service instructions
be read before use and that the safety recommendations
mentioned herein be scrupulously respected. If danger warnings
are not heeded to, serious material or bodily injury could occur.
2.8 Service and Repairs
Other than the serviceable items listed in this document, none of
the pump’s components can be serviced by the user. Only
personnel from ABB or its approved representative(s) is (are)
authorized to attempt repairs to the system and only
components formally approved by the manufacturer should be
used. Any attempt at repairing the pump in contravention of
these principles could cause damage to the pump and corporal
injury to the person carrying out the repair. It renders the
warranty null and void and could compromise the correct
working of the pump and the electrical integrity or the CE
compliance of the pump.
If you have any problems with installation, starting, or using the
pump please contact the company that sold it to you. If this is
not possible, or if the results of this approach are not
satisfactory, please contact the manufacturer's Customer
Service
2.9 Potential Safety Hazards
The following potential safety hazards are associated with
operating the system:
Electrical (line voltage)
This symbol, when noted on a product, indicates a
potential hazard which could cause serious
personal injury and / or death.
The user should reference this instruction manual
for operation and / or safety information.
This symbol, when noted on a product enclosure or
barrier, indicates that a risk of electrical shock and /
or electrocution exists and indicates that only
individuals qualified to work with hazardous
voltages should open the enclosure or remove the
barrier.
This symbol indicates that the marked item can be
hot and should not be touched without care.
This symbol indicates the presence of devices
sensitive to electrostatic discharge and indicates
that care must be taken to prevent damage to
them.
The European Union RoHS Directive and
subsequent regulations introduced in member
states and other countries limits the use of six
hazardous substances used in the
manufacturing of electrical and electronic
equipment. Currently, monitoring and control
instruments do not fall within the scope of the
RoHS Directive, however ABB has taken the
decision to adopt the recommendations in the
Directive as the target for all future product
design and component purchasing. .
Note. The following only applies to European customers.
ABB is committed to ensuring that the risk of any
environmental damage or pollution caused by any
of its products is minimized as far as possible. The
European Waste Electrical and Electronic
Equipment (WEEE) Directive (2002 / 96 / EC) that
came into force on August 13 2005 aims to reduce
the waste arising from electrical and electronic
equipment; and improve the environmental
performance of all those involved in the life cycle of
electrical and electronic equipment.
In conformity with European local and national
regulations (EU Directive 2002 / 96 / EC stated
above), electrical equipment marked with the above
symbol may not be disposed of in European public
disposal systems after 12 August 2005.
RoHS
Warning. The installation of the pump should be performed
exclusively by personnel specialized and authorized to work
on electrical installations, in accordance with relevant local
regulations.
Caution. This equipment has been tested and found to
comply with the limits for Class A digital device, pursuant to
Part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference
when the equipment is operated in a commercial
environment. This equipment generates, uses, and can
radiate radio frequency energy and, if not installed and used
in accordance with this instruction manual, may cause
harmful interference to radio communications. Operation of
this equipment in a residential area is likely to cause harmful
interference in which case the user is required to correct the
interference at his own expense.

Endura AZ20 Oxygen Systems
Endura AZ20 – Pumped Reference Air Unit 3Installation
INF09/027 Issue 3 3
3 Installation
3.1 Siting
Site the pump adjacent to the probe – see Fig. 3.1 for
environmental requirements.
3.2 Mounting
Overall dimensions are shown in Fig. 3.2. Mount the pump on a
flat secure surface using the 3 mounting lugs A.
3.3 Electrical Safety
Fig. 3.1 Environmental Requirements
Fig. 3.2 Dimensions and Mounting Lug Locations
IP66 (NEMA 4)
55 °C
(131 °F)
–20 °C
(–4 °F)
A
98
(3.9) R3.2 (0.1 )
210 (8.3)
179 (7.0)
150
(5.9)
71
(2.8)
Dimensions in mm (in.)
Warning.
Isolate the incoming power supply before accessing the
pump or making connections.
The pump 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. It must be fitted in close proximity
to the pump within easy reach of the operator and must
be marked clearly as the disconnection device for the
pump.
Electrical installation and earthing (grounding) must be
in accordance with relevant national and local
standards.
Use cable appropriate for the load currents: 3-core
cable rated 5A and 90 °C (194 °F) minimum, that
conform to either IEC 60227 or IEC 60245. The
terminals accept cables from 0.8 to 2.5 mm2
(18 to 14 AWG).
The pump conforms to Installation Category II of IEC
61010.
After installation, there must be no access to live parts,
for example, terminals.
If the pump is used in a manner not specified by the
Company, the protection provided by the equipment
may be impaired.
All equipment connected to the pump's terminals must
comply with local safety standards (IEC 60950,
EN601010-1).
Caution.
Always route power cables and air lines separately.
Make connections only as shown.
Maintain Environmental Protection at all times.
Ensure the seal and mating surfaces are clean to
maintain environmental rating.
Conduit connections must provide cable entry sealing.
Ensure cable glands are tightened after wiring. Do not
overtighten the plastic cable glands to avoid destroying
their sealing properties. Initially, tighten finger-tight, then
a further 1/2to 3/4turn using a suitable spanner or
wrench.
Fit a blanking plug where required.
Inductive loads must be suppressed or clamped to limit
voltage swings.

Endura AZ20 Oxygen Systems
Endura AZ20 – Pumped Reference Air Unit 3Installation
4INF09/027 Issue3
3.4 Accessing the Terminal Block
Referring to Fig. 3.3:
1. Loosen the 4 pump cover retaining screws A.
2. Remove the pump cover B.
3. Loosen cable gland Cto prepare for the incoming
power supply cable.
3.5 Electrical Connections
3.5.1 Preparation
Referring to Fig. 3.4:
1. Prepare the incoming power supply cable as follows:
a. cut the outer sheath back to leave 100 mm (4.0 in.)
sleeved wires A
b. cut the sleeved wires back to leave 5 mm (0.2 in.)
tails B
2. Pass the cable through cable gland C.
3.5.2 Making Connections
Referring to Fig. 3.4, make mains connections as detailed in
steps 1 to 5. The mains power supply must be 115 or 230 V AC,
50 / 60 Hz depending on the pump model (refer to Fig. 3.3 and
Table 1.1, page 1).
1. Prepare the incoming power supply cable as follows:
a. cut the outer sheath back to leave 100 mm (4.0 in.)
sleeved wires A
b. cut the sleeved wires back to leave 5 mm (0.2 in.)
tails B
2. Pass the cable through cable gland C.
3. Connect the neutral (blue wire D) to the terminal block to
match the existing connection.
4. Connect the earth wire Eto the pump’s internal earth
connection.
5. Connect the live (brown) wire Fto the terminal block to
match the existing live connection.
6. Refit the pump cover by reversing the procedure in
Section 3.4.
Fig. 3.3 Accessing the Terminal Block
B
C
A
Pump Identification
Label
Warning. Ensure the live (brown) wire is protected
with a 1.6 A Type F fuse.
Fig. 3.4 Electrical Connections
B
F
A
C
E
D

Endura AZ20 Oxygen Systems
Endura AZ20 – Pumped Reference Air Unit 4 Maintenance
INF09/027 Issue 3 5
3.6 Reference Air Connections
Referring to Fig. 3.5:
1. It is important that air to the pump inlet is clean and dry.
If necessary, connect a pipe to the pump (suction) inlet
Aand ensure the other end of the pipe is located in a
clean, dry area.
2. Connect the pumped reference air outlet Bdirectly to
the reference air inlet on the probe – refer to individual
probe manuals for reference air connection details.
3. A flow restrictor Cin the pump outlet line ensures the
correct flow is delivered without further regulation from the
pump. Ensure the flow restrictor is in place to protect
pump components.
4 Maintenance
4.1 Replacing the Air Filter
1. Remove the pump cover – see Section 3.4.
Referring to Fig. 4.1:
2. Disconnect the top tube Afrom air filter B.
3. Disconnect the lower tube Cfrom air filter B.
4. Release clip Dand carefully remove air filter Bby
pulling it out of the clip.
5. Discard air filter B.
6. Fit a new filter by reversing steps 1 to 4.
Caution. Failure to observe this requirement causes
damage to both the pump and the probe.
Fig. 3.5 Pumped Reference Air Unit Inlet and Outlet
A B
C
Inlet (Suction)
See step 1
Outlet
(Delivery)
Warning. Isolate the pump from power and air supplies
before replacing the air filter.
Fig. 4.1 Replacing the Air Filter
A
C
B
D

INF09/027 Issue 3
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Printed in UK (05.10)
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