ABB AZ200 770 User manual

Information INF09/027 Rev. D
Endura AZ20 oxygen monitor
Pumped reference air unit
1 Introduction
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
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
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.

2 Safety
2 INF09/027 Rev. D | Endura AZ20 oxygen monitor | Pumped reference air unit
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:
2.5 Restriction of Hazardous Substances (RoHS)
2.6 Product disposal
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.
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.

2 Safety
Endura AZ20 oxygen monitor | Pumped reference air unit | INF09/027 Rev. D 3
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)
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.

3 Installation
4 INF09/027 Rev. D | Endura AZ20 oxygen monitor | Pumped reference air unit
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
Dimensions in mm (in.)
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)
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.

3 Installation
Endura AZ20 oxygen monitor | Pumped reference air unit | INF09/027 Rev. D 5
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.
Fig. 3.3 Accessing the Terminal Block
B
C
A
Pump Identification
Label

3 Installation
6 INF09/027 Rev. D | Endura AZ20 oxygen monitor | Pumped reference air unit
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 E to 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.
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 A
and 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.
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
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)

4 Maintenance
Endura AZ20 oxygen monitor | Pumped reference air unit | INF09/027 Rev. D 7
4 Maintenance
4.1 Replacing the air filter
1. Remove the pump cover – see section 3.4, page 5.
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.
Note. Isolate the pump from power and air supplies before
replacing the air filter.
Fig. 4.1 Replacing the Air Filter
A
C
B
D

Contact us
INF09/027 Rev. D 10.2012
ABB Limited
Process Automation
Oldends Lane
Stonehouse
Gloucestershire GL10 3TA
UK
Tel:[phone]
Fax:[phone]
ABB Inc.
Process Automation
125 E. County Line Road
Warminster
PA 18974
USA
Tel:[phone]
Fax:[phone]
www.abb.com
Note
We reserve the right to make technical changes or
modify the contents of this document without prior
notice. With regard to purchase orders, the agreed
particulars shall prevail. ABB does not accept any
responsibility whatsoever for potential errors or possible
lack of information in this document.
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.
Copyright© 2012 ABB
All rights reserved