ABB Endura AZ40 User manual

—
ABB MEASUREMENT & ANALYTICS | COMMISSIONING INSTRUCTION | CI/AZ40-EN REV. A
Endura AZ40
Oxygen and carbon monoxide equivalent (COe) analyzer
Measurement made easy
Introduction
This document provides unpacking, installation,
connection, setup and basic operation details for
the AZ40-EN analyzer system. For comprehensive
product details, refer to Operating instruction
OI/AZ40-EN.
Contents
1 Overview / system dimensions.............................5
2 Environmental requirements.................................6
3 Mechanical installation...........................................7
4 Electrical installation ............................................12
5 Pneumatic installation..........................................18
6 System setup ..........................................................21
7 Calibration and sensor setup.............................. 28
8 Operation ............................................................... 30
9 Configuration (Advanced access level)............. 34
For more information
Further publications for the Endura AZ40 analyzer
are available for free download from:
www.abb.com/analytical
(see links and reference numbers below) or by
scanning this code:
Search for or click on
Data Sheet
Endura AZ40
Oxygen and carbon monoxide
equivalent (COe) analyzer
DS/AZ40-EN
Operating Instruction
Endura AZ40
Oxygen and carbon monoxide
equivalent (COe) analyzer
OI/AZ40-EN
—
Oxygen and carbon
monoxide equivalent
analyzer

2CI/AZ40-EN Rev. A
Health & Safety
Document symbols
Symbols that appear in this document are explained below:
Safety precautions
Be sure to read, understand and follow the instructions
contained within this manual before and during use of the
equipment. Failure to do so could result in bodily harm or
damage to the equipment.
Potential safety hazards
Process conditions and requirements
DANGER – Serious damage to health / risk to life
This symbol in conjunction with the signal word
'DANGER' indicates an imminent danger. Failure to
observe this safety information will result in death or
severe injury.
DANGER – Serious damage to health / risk to life
This symbol in conjunction with the signal word
'DANGER' indicates an imminent electrical hazard.
Failure to observe this safety information will result in
death or severe injury.
WARNING – Bodily injury
This symbol in conjunction with the signal word
'WARNING' indicates a potentially dangerous situation.
Failure to observe this safety information may result in
death or severe injury.
WARNING – Bodily injury
This symbol in conjunction with the signal word
'WARNING' indicates a potential electrical hazard.
Failure to observe this safety information may result in
death or severe injury.
WARNING – Bodily injury
High temperature
This symbol in conjunction with the signal word
'WARNING' indicates a potentially dangerous situation.
Failure to observe this safety information may result in
death or severe injury.
WARNING – Bodily injury
Pressurized equipment
Installation, operation, maintenance and servicing of
pressurized equipment must be performed:
— by suitably trained personnel only
— in accordance with the information provided in this
manual
— in accordance with relevant local regulations
CAUTION – Minor injuries
This symbol in conjunction with the signal word
'CAUTION' indicates a potentially dangerous situation.
Failure to observe this safety information may result in
minor or moderate injury. The symbol may also be used
for property damage warnings.
NOTICE – Property damage
This symbol indicates a potentially damaging situation.
Failure to observe this safety information may result in
damage to or destruction of the product and / or other
system components.
IMPORTANT (NOTE)
This symbol indicates operator tips, particularly useful
information or important information about the product
or its further uses. The signal word 'IMPORTANT
(NOTE)' does not indicate a dangerous or harmful
situation.
WARNING – Bodily injury Installation, operation,
maintenance and servicing must be performed:
— by suitably trained personnel only
— in accordance with the information provided in this
manual
— in accordance with relevant local regulations
WARNING – Bodily injury
Environmental conditions
— High air / equipment / structure temperatures, poor
air quality and adverse environmental conditions
may be present when the process is running.
— It is recommended that the process is shut down
before performing these procedures.
— The process must be cool enough to enable
shutdown, disconnection and removal of the sensor
in a safe manner and in accordance with relevant
local regulations.
— Appropriate PPE, including mask and goggles must
be worn when preparing the process for these
procedures.

CI/AZ40-EN Rev. A 3
Endura AZ40 sensor – fibrous material in probe assembly
Endura AZ40 sensor / probe – installation to pressurized
process
Endura AZ40 sensor – high operational temperature on
exposed parts
Endura AZ40 sensor – weight
WARNING – Serious damage to health
Fibrous material
— The sensor and probe assemblies (standard and
high temperature versions) contain fibrous material
that can be a health hazard if airborne.
— The material, predominantly – aluminosilicate
refractory fibres, CAS 142844-00-6. Refractory
ceramic fibres (RCF) are classified as:
– Category 1B carcinogen under regulation (EC)
No 1272/2008 – the classification, labelling and
packaging regulations.
– Category 2B carcinogen by inhalation by The
International Agency for Research on Cancer
(IARC).
— When removing the sensor cover and subsequent
maintenance activities, exposure to the airborne
fibres could occur. ABB have conducted air
sampling assessments within the breathing zone of
the operator and have identified that an exposure
limit of 1 fibre / cubic centimetre is unlikely to occur.
— Exposure to any carcinogen must be kept as low as
reasonably practicable.
— Appropriate PPE defined below, must be
worn when working with probe assemblies
(all installation, replacement, maintenance
procedures):
– A face fit tested, half mask conforming to EN140
(or equivalent) with a level 3 particulate filter
conforming to EN 143 (or equivalent).
– Disposable protective coveralls in accordance
with Type 5 ISO 13982-1:2004 (or equivalent).
– Goggles and gloves.
DANGER – Serious damage to health / risk to life
Pressurized equipment – do not install / remove /
the sensor / probe if the process is at positive
pressure
Installation, operation, maintenance and servicing of
pressurized equipment must be performed:
— by suitably trained personnel only
— in accordance with the information provided in this
manual
— in accordance with relevant local regulations
— when process conditions are suitable to allow
enough to enable installation / maintenance
WARNING – Bodily injury
High temperature on exposed surfaces
— During operation, exposed sensor surfaces can
reach 200 °C (392 °F).
— Ensure suitable PPE is available and is worn before
handling the sensor.
— Do not touch exposed surfaces until the sensor /
probe is cool enough to handle with PPE.
Fig. 1 High temperature points on exposed sensor surfaces during operation
WARNING – Bodily injury
– The sensor weighs 9.0 kg (20 lb). When fitted with
a probe / filter assembly, the combined sensor /
probe weight is dependent on probe length / type
plus filter option – refer to Operating instruction
OI/AZ40-EN for weight details.
– The sensor / probe assembly must be mounted in
accordance with the information supplied in
Operating instruction OI/AZ40-EN.
— Suitable lifting equipment must be available when
installing / removing the sensor / probe from the
process.

4CI/AZ40-EN Rev. A
Endura AZ40 analyzer – electrical
Endura AZ40 transmitter – weight
Safety standards
This product has been designed to satisfy the requirements of
IEC61010-1:2010 3rd edition 'Safety Requirements for
Electrical Equipment for Measurement, Control and Laboratory
Use' and complies with US NEC 500, NIST and OSHA.
Product symbols
Symbols that appear on this product are shown below:
Product recycling and disposal (Europe only)
End-of-life battery disposal
The transmitter contains a small lithium battery (located on the
processor / display board) that must be removed and disposed
of responsibly in accordance with local environmental
regulations.
Restriction of Hazardous Substances (RoHS)
WARNING – Bodily injury
To ensure safe use when operating this equipment, the
following points must be observed:
— up to 240 V AC may be present. Ensure the supply
is isolated before removing the terminal cover
— 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) can be obtained from
the Company, together with servicing and spares
information.
WARNING – Bodily injury
– The transmitter weighs 7.6 kg (17 lb) and must
be mounted in accordance with the information
supplied in Operating instruction OI/AZ40-EN.
— Suitable lifting equipment must be available when
installing / removing the transmitter from the
mounting.
Protective earth (ground) terminal.
Functional earth (ground) terminal.
Alternating current supply only.
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, indicates a
potential hazard (high temperature) 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.
Recycle separately from general waste under the
WEEE directive.
Electrical equipment marked with this symbol may not
be disposed of in European public disposal systems
after 12 August 2005. To conform to European local
and national regulations (EU Directive 2002/96/EC),
European electrical equipment users must now return
old or end-of-life equipment to the manufacturer for
disposal at no charge to the user.
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.
IMPORTANT (NOTE) For return for recycling, please
contact the equipment manufacturer or supplier for
instructions on how to return end-of-life equipment for
proper disposal.
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.

CI/AZ40-EN Rev. A 5
1Overview / system dimensions
The Endura AZ40 combustion gas analyzer continuously
samples and analyzes combustion waste gases for both
oxygen and carbon monoxide equivalent (COe).
The analyzer has 4 main assemblies:
— transmitter (controller / display unit), see Fig. 2
— sensor assembly (housing a zirconia-based oxygen sensor,
catalytic COe sensor and an air powered aspirator),
see Fig. 3
— smart sensor electronics (part of the sensor assembly),
see Fig. 3
— probe / filter assembly, see Fig. 3
The analyzer uses a close-coupled sampling system where the
sensor assembly is mounted directly against the process wall.
The sample is filtered and drawn through the sensor assembly
by the air powered aspirator.
This combination of a short sample path and pumped sample
provides a very rapid response to changing gas concentrations.
The gas sample is held above the sample dew point to provide
analysis on a 'wet' basis and prevent acid gases from
condensing in the sample path.Thermocouple inputs for
process temperature measurement enable calculations of
combustion efficiency.
Fig. 2 Endura AZ40 transmitter – main components / dimensions
Fig. 3 Endura AZ40 sensor assembly – main components / dimensions
Endura AZ40 Gas Analyser 85- 240v ~AC, 50/60Hz, 730W Max TYPENo: AZ40/XXXXXXXXXXXXXXX SERIALNo: 3K62000000000 TAGNo: DATEOF MANUFACTURE: W25/15
TRANSMITTER
Enclosurerating: IP66/NEMA4X EntryType: Communication:
54
(2.1)
270
(10.6) 300
(11.8)
300 (11.8)
153 (6)
136 (5.4)
46.5
(1.8)
46.5
(1.8)
54
(2.1)
40
(1.6)
84 (3.3)
53 (2.1)
58 (2.3)
330 (13)
Cable entries – mains power in/sensor signal input and user I/O
Zero gas inlet
Span gas inlet
Calibration gas outlet
M20 or 1/2in.
NPT entry
M25 or 3/4in. NPT entry
M20 or 1/2in.
NPT entry
367
(14.4)
92.4 (3.6)
127 (5) 154.5 (6.1)
141 (5.6)
Probe / Filter assembly
Smart sensor electronics Cable entries –
mains power in / signal outputs
Sensor data label
Instrument air inlet
Calibration gas inlet
Vacuum test port
Standard 2 in. ANSI mounting adapter

6CI/AZ40-EN Rev. A
2Environmental requirements
Siting – sensor orientation
Avoid locations where:
— obstructions or bends create turbulence in the gas flow and /
or hinder probe insertion and removal
— vibration induced by other plant or vortex shedding is present
— the probe may be subject to shock loading, for example,
close to ash hammers, within 3 m (9 ft.) of steam or liquid
process cleaning apparatus
Fig. 4 Environmental requirements
70 °C
(158 °F) Max.
– 20 °C
(–4 °F) Min.
0 to 95 %
Humidity
See page 35
for maximum
probe temperatures
and process pressure
range
–20°C
(–4 °F) Min.
70 °C
(158 °F) Max.
– 20 °C
(–4 °) Min.
IP66 / NEMA 4X IP55 / NEMA 4
1500 mm
(59 in.)
(approx.)
55 °C
(131 °F)
Max.
– 20 °C
(–4 °F)
Min.
CAUTION – Damage to equipment
Mount probe horizontally or vertically – perpendicular to
flow direction.

CI/AZ40-EN Rev. A 7
3Mechanical installation
Standard temperature probe assembly (primary and optional
filter arrangements) – all flange options
Referring to Fig. 5:
1. Apply a light coating of an anti-seize compound (suitable for
temperatures up to 200 °C [392 °F]) to both threaded ends
Aof probe Band to threaded end Cof (optional)
secondary filter.
2. Thread primary filter assembly Eand (optional) secondary
filter assembly Donto probe shaft B.
3. Thread the probe assembly with attached filter(s) onto the 1/4
inch NPT port Fon sensor assembly Gand tighten.
4. Apply an anti-seize compound (suitable for temperatures up
to 200 °C [392 °F]) to the threaded end of sensor aspirator
H.
5. Hand-tighten exhaust filter assembly Ionto sensor
aspirator thread H.
Fig. 5 Standard temperature probe assembly – all flange options

8CI/AZ40-EN Rev. A
High temperature probe and filter assembly
Referring to Fig. 6:
1. Apply an anti-seize compound (suitable for temperatures up
to 200 °C [392 °F]) to the threaded end of sensor aspirator
A.
2. Hand-tighten exhaust filter assembly Bonto sensor
aspirator thread A.
3. Fit the flange adapter Cto sensor assembly Dusing
4 hex nuts / washers.
4. Remove gland nut F, bush Gand lava seal Hfrom filter
assembly I.
5. Slide the gland nut F, bush Gand lava seal Honto
probe shaft Jwith chamfered side towards filter assembly
I.
6. Apply a light coating of an anti-seize compound (suitable for
temperatures up to 200 °C [392 °F]) to gland nut threads K.
7. Slide probe shaft Jinto sealing connector L.
8. Slide lava seal H, bush Ginto sealing connector Lthen
thread gland nut Fonto sealing connector Land tighten
finger-tight.
9. Adjust probe until the insulator cement joint just contacts
gland nut F.
10.Tighten gland nut F1/2a turn.
11.Check probe Jis held firmly. If movement is detected,
carefully tighten gland nut Fa further 1/6th of a turn.
12.Repeat step 11 until probe shaft Jis held firmly.
13.Apply a light coating of an anti-seize compound (suitable for
temperatures up to 200 °C [392 °F]) to the threaded end M
of probe shaft J.
14.Thread the probe with filter assembly into the 1/4inch NPT
port Nand tighten.
15.Align spacer Oto support the probe / filter assembly within
the standoff.
Fig. 6 High temperature probe and filter assembly

CI/AZ40-EN Rev. A 9
Mounting the probe
Preparing the stand-off – low temperature applications
Refer to Fig. 7 for flange options and recommended stand-off
pipe dimensions:
Fitting the stand-off – low temperature applications
Referring to Fig. 8:
1. Cut a hole in the outer wall / plate Awith the following
diameter:
— 63 mm (2.5 in.) for 2 in. NB schedule 40 tube
2. On the same centre line, cut a hole through the refractory B
with the following diameter:
— 50 mm (2 in.) for 2 in. NB schedule 40 tube
3. Weld the pipe section D(complete with flange E) in place.
4. Insulate the pipe section Dwith at least 25.4 mm (1 in.)
thick insulation material F. The pipe section may need to be
heated if it is longer than 152.4 mm (6 in.) or if mounted at a
site where the temperature is <4.4 °C (40 °F).
5. Temporarily cover opening Guntil the sensor / probe / filter
assembly is ready for installation.
Preparing the stand-off – high temperature applications
Refer to Fig. 9 for flange options and recommended stand-off
pipe dimensions:
WARNING – Bodily injury
— Ensure suitable lifting equipment and qualified
personnel are available when mounting the sensor /
probe / filter assembly.
Fig. 7 Recommended stand-off pipe dimensions – low temperature
applications
Standard (low temperature) probe
152 mm
(6 in.)
All flange
options
2 in. NB pipe
IMPORTANT (NOTE)
If possible, taper the exit hole C
approximately 15 °.
Fig. 8 Mounting – preparing the stand-off (low temperature applications)
Fig. 9 Recommended stand-off pipe dimensions –
high temperature applications
G
15º
High temperature probe only (3 in. NB pipe)
3 in. ANSI or
80 DIN flange
300 mm
(12 in.)
3 in. NB pipe

10 CI/AZ40-EN Rev. A
Fitting the stand-off – high temperature applications
Referring to Fig. 10:
1. Cut a hole in the outer wall / plate Awith the following
diameter:
— 89 mm (3.5 in.) for 3 in. NB schedule 40 tube
2. On the same centre line, cut a hole through the refractory B
with the following diameter:
— 76 mm (3 in.) for 3 in. NB schedule 40 tube
3. Weld the pipe section D(complete with flange E) in place.
4. Temporarily cover opening Funtil the sensor / probe / filter
assembly is ready for installation.
Standard temperature probe – ANSI 2 in. flange version
Referring to Fig. 11:
1. Remove 4 nuts and washers Afrom sensor assembly
threads B.
2. Feed probe / filter assembly Cthrough flange Dand
secure sensor body Bto flange Dusing 4 nuts and
washers A.
IMPORTANT (NOTE)
If possible, taper the exit hole C
approximately 15 °.
Fig. 10 Mounting – preparing the stand-off (high temperature applications)
15º
IMPORTANT (NOTE)
Before installing the probe / sensor assembly into the
process, complete transmitter installation as detailed on
page 12. Sensor assembly must have all services
connected with the transmitter ready for power up.
Fig. 11 Standard temperature probe – ANSI 2 in. flange version

CI/AZ40-EN Rev. A 11
Standard temperature probe – all other flange versions
Referring to Fig. 12:
1. Remove 4 nuts and washers Afrom sensor assembly
threads B.
2. Secure flange Cto sensor assembly threads Busing
4 nuts and washers (removed at step 1).
3. Feed flanged probe / filter / sensor assembly Dthrough
flange Eand secure flange Cto flange Eusing 4 nuts
and washers F(not supplied).
High-temperature probe
Referring to Fig. 13.
1. Feed flanged probe / filter / sensor assembly Athrough
flange B.
2. Secure flange Bto flange Cusing 4 nuts and washers D
(not supplied).
Mounting the transmitter
Referring to Fig. 14.
1. Fix the transmitter Ato a solid wall using 4 x fixings (not
supplied) at location B. Fixings must be capable of
supporting a minimum weight of 7.6 kg (16.65 lb.).
IMPORTANT (NOTE)
Before installing the probe / sensor assembly into the
process, complete transmitter installation as detailed on
page 12. The sensor assembly must have all services
connected with the transmitter ready for power up.
Fig. 12 Standard temperature probe – all other flange versions
IMPORTANT (NOTE)
Before installing the probe / sensor assembly into the
process, complete transmitter installation as detailed on
page 12. The sensor assembly must have all services
connected with the transmitter ready for power up.
Fig. 13 High temperature probe
Fig. 14 Mounting the transmitter

12 CI/AZ40-EN Rev. A
4Electrical installation
Customer-supplied cable specification
Wiring at the transmitter / sensor mains power terminals must
conform to the following specification:
Wiring at all other transmitter / sensor terminals must conform to
the following specification:
Temperature requirements – interconnecting cables
Signal: –20 to 105 °C (–4 to 221 °F)
Power: –40 to 105 °C (–40 to 221 °F) C(RU)AWM1/11 A/BFT1
DANGER – Serious damage to health / risk to life
— An external isolation device such as a switch or
circuit breaker conforming to local safety standards
must be fitted to the incoming mains power supply
cable prior to the transmitter. It must be fitted in
close proximity to the transmitter, within easy reach
of the operator and marked clearly as the isolation
device for the transmitter.
The internal sensor power switch on the transmitter
[SW1, see Fig. 20, page 17] is NOT a safety
isolation switch and is fitted for operational
purposes only.
— The probe must be bonded to local earth via the
external earth connection – see Fig. 20, page 17.
— Electrical installation and earthing (grounding) must
be in accordance with relevant national and local
standards.
— Remove all power from supply, relays and any
powered control circuits and high common mode
voltages before accessing or making any
connections.
— All connections to secondary circuits must have
basic insulation.
— After installation, there must be no access to live
parts, for example, terminals.
— Terminals for external circuits are for use only with
equipment with no accessible live parts.
— If the equipment is used in a manner not specified by
the Company, the protection provided by the
equipment may be impaired.
— The equipment conforms to Installation Category II of
IEC 61010.
— All equipment connected to the transmitter's
terminals must comply with local safety standards
(IEC 60950, EN61010-1).
USA and Canada Only
— The supplied cable glands are provided for the
connection of signal input and MODBUS
communication wiring ONLY.
— The supplied cable glands and use of cable / flexible
cord for connection of the mains power source to the
mains input and relay contact output terminals is not
permitted in the USA or Canada.
— For connection to mains (the mains input and relay
contact outputs), use only suitably rated field wiring
insulated copper conductors rated min. 300 V, 14
AWG, 90 °C. Route wires through suitably rated
flexible conduits and fittings.
CAUTION – Damage to equipment
— Make connections only as shown.
— Maintain environmental protection at all times.
— Ensure the seal and mating surfaces are clean to
maintain environmental rating.
– Ensure cable glands (if used) 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 blanking plugs where required.
— Inductive loads must be suppressed or clamped to
limit voltage swings.
— Operation of outputs is programmable.
Rigid
solid
Flexible
stranded AWG
0.2 to 6 mm20.2 to 4 mm224 to 10
Table 1 Mains power cable specifications
Rigid
solid
Flexible
stranded AWG
0.2 to 4 mm20.2 to 2.5 mm224 to 12
Table 2 Signal cable specifications

CI/AZ40-EN Rev. A 13
Mains power cables
Referring to Fig. 15:
1. Prepare the incoming power cable and transmitter to sensor
power cable for connection by cutting back the outer PVC
sheathing and wire ends to the dimensions shown below:
Signal cable
Referring to Fig. 16:
1. Prepare both ends of the signal cable by cutting back the
outer PVC sheathing and wire ends to the dimensions shown
below:
Mains power and signal cable connections
Mains power connections
Referring to Fig. 17, page 14:
1. Unlock and open transmitter door Ausing the supplied key,
unscrew 4 x PCB cover screws Band remove PCB cover
C.
2. Check sensor power switch Dis set to OFF (right position).
3. Remove cable gland (if used) at entry Eand slide over
transmitter end of incoming mains power cable Fin the
correct orientation.
4. Feed incoming mains power cable F(customer-supplied)
through entry Eand connect to transmitter terminal block
G. Refit cable gland (if used) at entry E.
5. Remove cable gland (if used) at entry Hand slide over
transmitter end Iof mains power cable Jin the correct
orientation.
6. Feed transmitter end Iof power cable Jthrough entry H
and connect to transmitter terminal block K. Refit cable
gland (if used) at entry H. Refit PCB cover C.
7. Unscrew 4 x sensor cover screws Land remove sensor
cover M.
8. Remove cable gland (if used) at sensor entry Nand slide
over sensor end Oof mains power cable Jin the correct
orientation.
9. Feed sensor end Oof power cable Jthrough entry N
and connect to sensor terminal block P. Refit cable gland (if
used) at entry N.
10.Check internal mains connector plug Qis plugged into the
correct socket for the supplied mains voltage (115 V [upper
socket] or 230 V [lower socket]).
— 115 V (upper socket)
— 230 V (lower socket)
11.Proceed to page 16 to make signal connections.
DANGER – Serious damage to health / risk to life
— The incoming mains supply cable must be isolated or
disconnected at the supply end of the cable before
making power connections at the transmitter and / or
sensor.
– Before making power connections between the
transmitter and sensor, set the sensor power switch
on the transmitter PCB to the OFF position – see
page 16. This internal switch on the transmitter is
NOT a safety isolation switch and is fitted for
operational purposes only.
Fig. 15 Incoming mains power cable and transmitter to sensor
power cable preparation
Fig. 16 Signal cable preparation – transmitter to sensor
5 mm
(0.25 in.) 5 mm (0.25 in.)
50 mm
(2.0 in.)
50 mm (2.0 in.)
Incoming power cable Transmitter to sensor power cable
Line in
Neutral in
Earth
Line out
Neutral out
Earth
Line in
Neutral in
Earth
5 mm (0.25 in.)
25 mm (1.0 in.)
Signal cable
D– (green) SCN (screen) D+ (white) V+ (red) COM (black) D– (green) SCN (screen) D+ (white) V+ (red) COM (black)
IMPORTANT (NOTE)
When all connections have been made, set the sensor
power switch Dto the ON position to provide power
to the sensor.

14 CI/AZ40-EN Rev. A
DANGER – Serious damage to health / risk to life
Sensor power switch SW1 supplies high voltage power (115 V or 230 V AC) to the sensor when set in the ON position.
This switch is NOT a transmitter safety isolation switch and is fitted for operational purposes only.
*Ensure mains connector is in correct position (115 V or 230 V) for application
Fig. 17 Mains power cable connections
115 V*
230 V*
High voltage power switch
transmitter to sensor –
DO NOT USE AS A
TRANSMITTER SAFETY
ISOLATION SWITCH
Line in
Neutral in
Earth
Line out
Neutral out
Earth
Line in
Neutral in
Earth

CI/AZ40-EN Rev. A 15
Signal cable connections
Referring to Fig. 18:
1. Fit a suitable cable gland / conduit fitting at entry A.
2. Feed transmitter end Bof signal cable Cthrough entry A
and connect to transmitter terminal block D. Secure with
cable gland / conduit fitting.
3. Close and lock transmitter door Eusing the supplied key.
4. Fit a suitable cable gland / conduit fitting at entry F.
5. Feed sensor end Gof signal cable Cthrough entry Fand
connect to sensor terminal block H. Secure with cable
gland / conduit fitting.
6. Refit sensor cover Iusing 4 x sensor cover screws J.
7. Proceed to page 16 for customer-made input / output
connections.
Fig. 18 Signal cable connections
D– (green) SCN (screen) D+ (white) V+ (red) COM (black)
D– (green) SCN (screen) D+ (white) V+ (red) COM (black) ck)

16 CI/AZ40-EN Rev. A
Customer-made connections at transmitter
DANGER – Serious damage to health / risk to life
The sensor power switch (SW1) supplies high voltage power (115 V or 230 V AC) to the sensor when set in the ON position.
It is fitted for operational purposes only and is NOT a transmitter safety isolation switch.
*Ensure mains connector is in correct position for application (115 V or 230 V)
Fig. 19 Customer-made connections at transmitter
DI1 DI2 DI3 DI4
AC COM
DC COM
1 2 3 4 5 6
N/C
C
N/O
N/C
C
N/O
N/C
C
N/O
N/C
C
N/O
N/C
C
N/O
N/C
C
N/O
1 2 3 4
+
–
+
–
+
–
+
–
1 2 3 4 5
V+ COM D + D –
SCN
1 – COM 2 – TX/RX– 3 – TX/RX+ 4 – TX– 5 – TX+
Line in Neutral in Earth Line out Neutral out Earth
Digital inputs Relays (digital outputs) Analog outputs Comms
Mains power connections –
see Fig. 17, page 14
Signal
connections
see Fig. 18,
page 15
Modbus connections
High voltage power switch
transmitter to sensor
Sensor power switch (DO NOT
attempt to use as a transmitter
safety isolation switch)

CI/AZ40-EN Rev. A 17
*Ensure mains connector is in correct position for application (115 V or 230 V)
Fig. 20 Customer-made connections at sensor assembly
SCN
D –
D +
Com
V +
External earth connection
115 V*
230 V*
Signal connections
see Fig. 18, page 15
Mains power
connections –
see Fig. 17,
page 14
Earth
N
L
Blowback
Blowback
Inlet T/C +
Inlet T/C –
Screen
Outlet T/C +
Outlet T/C –
Caution: Maximum cable length 30 m
(118 ft.) – lengths over 30 m (118 ft.)
require conduit or screen
Caution: Maximum cable length
30 m (118 ft.). Lengths over
30 m (118 ft.) require conduit
or screen.
Earth

18 CI/AZ40-EN Rev. A
5Pneumatic installation
Test gas and instrument air connections
Fig. 21 Schematic – pneumatic installation
+
–
+
–**
**
Mains power and
signal cables –
see page 12
Tubing line
arrangement
see NOTE below
Span gas***
regulated to 1 bar (15 psig)
Zero gas***
regulated to 1 bar (15 psig)
Pressure
regulator
set to
207 ±3 kPa
(30.0 ±0.5 psig)
Test gas to
sensor assembly
2-Stage
coalescing
filtration*
Test gas
flowmeter
Compressed
air supply
Instrument air supply
to sensor assembly
350 to 700 ±10 kPa
(50.0 to 100.0 ±1.5
psig)
Or
IMPORTANT (NOTE)
Slope tubing lines to sensor assembly 83.33 mm/m
(1 in/ft) minimum for a length of approximately 305 mm
(1 ft.) – 1/4in. copper or stainless steel tubing only.

CI/AZ40-EN Rev. A 19
*Use 2-stage filtration only – required efficiency for 0.01 micron
(particles and droplets, installed in order) 93 % and 99.99 %.
**Gauges are required only at setup. If gauges are fitted permanently, a
shut-off valve should be used to prevent leakage from the gauge.
***Avoid locations near sources of heat – ambient temperature must not
exceed 49 °C (120 °F).
— Zero test gas should be the test gas of lowest oxygen content.
— Span test gas should be the test gas of highest oxygen content.
— For maximum accuracy, combine the highest CO test gas (CO span)
with the lowest (1 % nominal) oxygen test gas.
— The oxygen span gas should have the zero CO content
(CO zero).
— The oxygen span gas may be air (20.95 % O2) – recommended.
Item Description
A
Instrument air supply to sensor assembly:
— supply required: 350 to 700 ±10 kPa (50.0 to 100.0 ±1.5
psig)
— the dew point at line pressure must be at least 10 °C (18 °F)
below the minimum local ambient temperature
at the plant site
— maximum particle size in the air stream at the instrument
must not exceed 3 microns
— maximum total oil or hydrocarbon content, exclusive of
non-condensables, must be as close as possible to 0 w/w %
or v/v %. – it must not exceed 1 ppm w/w or v/v under
normal operating conditions
BShut-off valve
C2-Stage coalescing filtration (self-draining)*
DInstrument air pressure regulator
E3-Way valve (optional for maintenance purposes only,
not necessary for operation)
FAspirator suction pressure port: — pressure required at port:
–51.7 to –65.5 kPa (–7.5 to –9.5 psig)
GAspirator suction pressure gauge (Magnahelic)**:
— pressure range: 0 to –69 kPa (0 to –10 psig)
HTest gas port (sensor test gas inlet)
IProbe filter / pressure gauge**:
— pressure range: 0 to 20 in H2O (inch WC)
J
Zero test gas (cylinder)***:
— mixed gas of O2/CO/N2balance
— nominal 1 % O2/ CO to be 80 to 100 % of the
CO range used
— must be certified for both O2and CO content
Table 3 Key to pneumatic installation schematic
K2-Stage cylinder regulator for zero test gas
— set to 1 bar (15 psig)
L
Span test gas (compressed air supply or cylinder)***:
— concentration of O2to be 80 to 100 % of the O2range
used
— compressed air supply may be used for a 0 to 25 %
O2range (recommended)
— cylinder gas must be certified for O2content
— compressed air line may be defined as 20.95 % O2
M2-Stage cylinder regulator for span test gas
— set to 1 bar (15 psig)
NFlowmeter, test gas line
Item Description
Table 3 Key to pneumatic installation schematic (Continued)

20 CI/AZ40-EN Rev. A
Setting up and recording pneumatic values
Referring to Fig. 22.
1. Perform a leak test on all pneumatic connections.
2. Attach a pressure measuring device to sensor assembly
instrument air supply tee fitting A. Verify that the instrument
air supply pressure is 207 ±3 kPa (30.0 ±0.5 psi) and adjust
the pressure if necessary.
3. Attach a pressure measuring device with a range of 0 to
–69 kPa (0 to –10 psig) to aspirator suction pressure port
B. Verify that the suction pressure is –51.7 to –65.5 kPa (–
7.5 to –9.5 psig).
Record the suction pressure in Table 4.
4. Attach a pressure measuring device (inches H2O) to test gas
port C. Measure the pressure with instrument air on to
obtain the sample pressure.
Record the sample pressure in Table 4.
5. Measure the pressure at test gas port Cwith the instrument
air turned off to obtain the duct pressure. Verify that the
sample duct is –5 to 5 kPa (–20 to 20 inches H2O).
Turn the instrument air back on after taking this
measurement.
Record the duct pressure in Table 4.
6. Calculate the filter pressure drop by subtracting the sample
pressure from the duct pressure. Verify that the filter pressure
drop is less than 2 kPa (8 inches H2O).
Record the filter pressure drop in Table 4.
Fig. 22 Pneumatic value check points on AZ40 sensor
+
–
+
–
Parameter Date New analyzer Pressure and flow limits
Sample pressure ____________ kPa (in. H2O) _____ _____
Duct pressure ____________ kPa (in. H2O) _____ ±5 kPa (±20 in. H2O)
Filter pressure drop
(duct pressure – sample pressure) ____________ kPa (in. H2O) 0.5 kPa (in. H2O) 2 kPa (8 in. H2O)
Aspirator suction pressure ____________ kPa (psig) 55 to 69 kPa (8 to 10 psig) 34 to 69 kPa (5 to 10 psig)
Minimum sample gas flowrate ____________ SCFH (i/min) 3.5 to 4.5 SCFH (1.6 to 2.1 i/m) 2.5 to 4.7 SCFH (1.2 to 2.2 l/m)
Table 4 Sensor assembly pressure and flow data