Advance Optima Continuous Gas Analyzers

AO2040-CU Ex
Central Unit in Category 2G

Operator’s Manual (Abridged) 41/24130 EN Rev. 3

Table of Contents

Page

Preface 3
General Safety Information 4
Special Safety Instructions for Handling the AO2040-CU Ex 5

Chapter 1 Installation
Unpacking and Installing the AO2040-CU Ex Central Unit 6
Dimensional Diagram 6
Connecting the Ignition Suppression Gas Line 7
Connecting Electrical Lines – Safety Instructions 8
Electrical Connections 9
Connecting Electrical Leads 9
AO2040-CU Ex Central Unit Electrical Equipment 10
AO2060-… Analyzer Module Connection 11
Connecting Non-Intrinsically Safe Signal Leads 13
ER 144A/Ex Isolation Amplifier for Condensate Monitor 13
Connecting Status Signal, Potential Compensation and Power Supply 14

Chapter 2 Operation and Maintenance

AO2040-CU Ex Central Unit Start-Up 15
Inspection and Maintenance 17

Appendix
Application and Design 18
Pressurized Enclosure System 19
Operating Specifications 20
Electrical Safety 21
Electromagnetic Compatibility 21
Electrical Equipment in Explosion Hazard Zones:
Installation, Maintenance and Repair Notes 22

2 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 41/24-130 EN Rev. 3

Preface

Content of the This operator’s manual for the AO2040-CU Ex central unit in Category 2G is a
Operator’s Manual supplement to the AO2000 Series continuous gas analyzers operator’s manual
(Publication No. 42/24-10 EN).
It should always be used in conjunction with the primary operator’s manual and
contains all the information required for proper and safe installation, start-up and
operation of the AO2040-CU Ex central unit.
Note the information on the “Analyzer Data Sheet” shipped with every AO2040-
CU Ex central unit.

Symbols and Fonts Identifies safety information to be heeded during AO2040-CU Ex

Used in the Manual central unit operation in order to avoid risks to the user.

Identifies specific information on operation of the AO2040-CU Ex

central unit as well as on the use of this manual.
1, 2, 3, … Identifies reference numbers in figures.

41/24-130 EN Rev. 3 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 3

General Safety Information

Requirements for In order to operate in a safe and efficient manner, the AO2040-CU Ex central unit
Safe Operation should be properly handled and stored, correctly installed and set-up, properly
operated and correctly maintained.

Personnel Only persons familiar with the installation, set-up, operation and maintenance of
Qualifications comparable equipment and certified as being capable of such work should work
on the AO2040-CU Ex central unit.

Special Information These include

and Precautions  The content of this operator’s manual.
 The safety information affixed to the AO2040-CU Ex central unit.
 Safety precautions for the installation and operation of electrical devices.
 Safety precautions for working with gases, acids, condensates, etc.
 Regulations, standards and guidelines for explosion protection.

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 AO2040-CU Ex central unit is used in other countries.

AO2040-CU Ex The AO2040-CU Ex central unit is designed and tested in accordance with
Central Unit Safety EN 61010 Part 1 / IEC 61010-1, “Safety Provisions for Electrical Measuring, Control,
and Safe Operation Regulation and Laboratory Instruments” and has been shipped ready for safe
operation.
To maintain this condition and to assure safe operation, read and follow the safety
information identified with the symbol in this manual. Failure to do so can put
persons at risk and can lead to AO2040-CU Ex central unit damage as well as
damage to other systems and instruments.

Additional If the information in this operator’s manual does not cover a particular situation,
Information ABB Service is prepared to supply additional information as needed.
Contact your local ABB Service representative. For emergencies, please contact:
ABB Service, Telephone: +49-(0)180-5-222580, Telefax: +49-(0)621-38193129031,
E-Mail: [email protected]

4 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 41/24-130 EN Rev. 3

Special Safety Instructions for Handling the AO2040-CU Ex

Observe Safety Before starting any work on the AO2040-CU Ex central unit, observe all explosion-
Precautions protection safety precautions.

Do Not Work Where While there is a risk of explosion, do not work on current-bearing components,
There is a Risk of except intrinsically safe circuits, and do not work with equipment that poses an
Explosion ignition hazard.

Potential Compen- The connection to the local potential compensation point must be made before all
sation Connection other connections.

Risks of Loss of The AO2040-CU Ex central unit can be hazardous if the potential compensation is
Potential Compen- interrupted inside or outside the central unit or if the potential compensation is
sation Continuity disconnected.

Proper Operating Be sure the AO2040-CU Ex central unit voltage setting matches the line voltage
Voltage before connecting the power supply.

Risks Involved in Current-bearing components can be exposed when the covers or parts are
Opening the Covers removed, unless this can be done without tools. Current can be present at some
connection points.

Risks Involved in The AO2040-CU Ex central unit must be disconnected from all power sources
Working with an Open before being opened for any work. All work on a central unit that is open and
AO2040-CU Ex connected to power should only be performed by trained personnel who are
Central Unit familiar with the risks involved.

Risks of Charged The AO2040-CU Ex central unit power supply capacitors require 10 minutes to
Capacitors discharge after the central unit is disconnected from all power sources. Observe
the safety precautions indicated on the housing components.

When Safe Operation If it is apparent that safe operation is no longer possible, the AO2040-CU Ex
can no Longer be central unit should be taken out of operation and secured against unauthorized
Assured use.
The possibility of safe operation is excluded:
 If the central unit is visibly damaged
 If the central unit no longer operates
 After prolonged storage under adverse conditions
 After severe transport stresses

41/24-130 EN Rev. 3 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 5

Chapter 1 Installation

Unpacking and Installing the AO2040-CU Ex Central Unit

CAUTION!
The AO2040-CU Ex central unit weighs approx. 28 kg! The following points
should be observed:
 Two persons are needed for unpacking and installation.
 The installation location must be stable in order to support the central
unit’s weight.

Items Included Qty. Description

1 AO2040-CU Ex Central Unit
1 Analyzer Data Sheet (in the system housing)
1 AO2000 Series Operator’s Manual (publication no. 42/24-10 EN)
1 AO2040-CU Ex Central Unit in Category 2G Operator’s Manual
(Abridged) (publication no. 41/24-130 EN)
1 Compressed Air Conditioning Filter

Installation Site The AO2040-CU Ex central unit can be installed in Zone 1 and Zone 2 explosion
hazard areas (see “Operating Specifications” section, page 20)
Do not install the AO2040-CU Ex central unit outdoors.

Dimensional Diagram

Figure 1
199
396 52 92
AO2040-CU Ex
31

Central Unit
Dimensional Diagram
46

(dimensions in mm)
220
289
450
439
590

413
599

444
572

6 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 41/24-130 EN Rev. 3

Connecting the Ignition Suppression Gas Line

Figure 2 1 Ignition Suppression

Gas Outlet with
Pressurized
Particle Trap
Enclosure System
2 Control Unit
Modules
3 Ignition Suppression
Gas Valve
4 Ignition Suppression
Gas Inlet DIN ISO G1/4

1 2 3 4

Ignition Suppression Use air as the ignition suppression gas (quality per ISO 8573-1, class 3; see
Gas “Operating Specifications” section, page 20).

Contamination of the Mechanical treatment of the ignition suppression gas line can lead to contamina-
Ignition Suppression tion of the gas line.
Gas Line
When the contamination gets to the ignition suppression gas valve, the valve does
not close completely and the ignition suppression gas flows into the housing with
the full working pressure of pe = 250–500 kPa (= 2.5–5 bar). An indication for a
possible damage to the housing is an outward vaulting of the display and control
unit key pad.
For a reliable retention of the contamination it is absolutely necessary to install the
delivered compressed air conditioning filter in the ignition suppression gas line.

Ignition Suppression Step Action

Gas Line Connection 1 Install the delivered compressed air conditioning filter as near as
(see Figure 2) possible in front of the ignition suppression gas valve 3 and connect it
to the ignition suppression gas inlet 4 (DIN ISO G 1/4).
Take care that the cable openings of the signal, control and
interface wiring remain accessible.
2 Connect the ignition suppression gas line to the ignition suppression
gas inlet of the compressed air conditioning filter.
Use a line with a cross-section large enough (depending on the
line length) to provide the required flow rate and the required
working pressure.

41/24-130 EN Rev. 3 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 7

Connecting Electrical Lines – Safety Instructions

CAUTION!
Follow all applicable national safety regulations for the preparation and
operation of electrical devices as well as the following safety precautions.

Changing Factory Factory internal wiring between the isolation relays and the system controller
Wiring and I/O board connectors can be changed by the user. However, no addi-
tional wiring should be added. Changes should be documented in the
analyzer data sheet. The addition of cables to device-internal wiring or the
installation of additional electrical equipment represents a change to the
electrical device and is hence forbidden. The operating specifications and
the routing instructions must be followed.

Potential The external potential compensation connection or the protective lead must
Compensation be connected to the local potential compensation point. The connection to
the local potential compensation point must be made before all other con-
nections. Minimum conductor section = 4 mm2. The AO2040-CU Ex central
unit can be hazardous if the potential compensation connection is inter-
rupted inside or outside the central unit or if the potential compensation
connection is loosened or removed.

Securing Electrical All electrical wiring, including the AO2040-CU Ex central unit wiring, must be
Lines firmly secured.

Shielded Lines Shielded lines (e.g. the system bus cable) must be routed through the metal
wiring connectors. The shield braid must be placed on the cable connectors.

Lines for Intrinsically The lines for intrinsically safe signals should only be connected to the blue
Safe Signals cable connectors. Inside the AO2040-CU Ex central unit they must be
separated from other lines by at least 8 mm. Only suitable electrical circuits
should be connected to the isolation modules terminals!

Lines for Zone 1 RS232, RS485 and Ethernet-10BASE-T interface leads must be routed
Communication via isolation relays factory-wired for this purpose. Leads should never be
Interfaces connected directly to the electronics module ports in the connection box.

Connecting the Before the power supply is connected, make sure the AO2040-CU Ex central
Power Supply unit operating voltage (see the identification plate) is set for the power line
voltage. The power supply lines should be connected to the control unit for
the pressurized enclosure system. They should never be connected directly
to the system housing ports. This will compromise the explosion protection
function.

Compromising Connecting external electrical leads to points in the connection box mounted
Explosion Protection on the AO2040-CU Ex central unit will compromise explosion protection. This
should be done only for maintenance purposes.

8 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 41/24-130 EN Rev. 3

Electrical Connections

Figure 3
Electrical
Connections

1 6 2 3 4 5 6 7

1 Cable opening M20 for power supply on the control unit for the pressurized
enclosure system
2 Cable openings for internal wiring connections
3 Connection plate with 6 black cable openings M20 for non-intrinsically safe
wiring (some cable openings are used for internal wiring connections)
4 Metallic cable opening M20 for the shielded system bus cable of the
AO2060-… analyzer module
5 Cable opening M20 for the 24-VDC connection cable of the
AO2060-… analyzer module
6 Potential compensation connectors
7 3 light blue cable openings M20 for intrinsically safe wiring

Connecting Electrical Leads

Threaded Cable Type of Connector Application

Connections Light blue M20 connector Intrinsically safe connecting leads
Black M20 connector Non-intrinsically safe connecting leads, AO2060-…
analyzer module 24 VDC connecting cable
Metallic M20 connector AO2060-… analyzer module system bus cable (see
page 12 for special notes and instructions)

Permissible Cable The M20 threaded connectors are suitable for cables with outer diameters of
Diameters 6-12 mm.

Sealing Unused  Only the manufacturer’s original equipment plugs should be used to close off the
Cable Connections threaded cable connectors.
 Unused cable connectors must be closed off with factory-provided plugs.
 Securely tighten the cap nuts on the unused cable connectors (torque to 2.5 Nm).

41/24-130 EN Rev. 3 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 9

AO2040-CU Ex Central Unit Electrical Equipment

Device Description
-K01 through -K04 Isolation relays (-K01 standard, -K02 through -K04 optional) for connection of
system bus and non-intrinsically safe signal leads, maximum load 30 VDC / 0.4 A
-K05 Terminal strip for connecting the 8-wire AO2060-… analyzer module system bus
cable leads not connected to isolation relay -K01
-Z01 Line filter for connecting the 3-wire AO2060-… analyzer module 24 VDC cable
-B01 Pressurized enclosure system control unit, power supply (230 VAC or 115 VAC,
non-adjustable) status signal pe < 1.2 hPa
-B02 Isolation amplifier for condensate monitor (option),
Type ER 144A/Ex, electrical connection see page 13
-B03.x Isolation amplifier for flow monitor (option),
Phoenix Contact Type MACX MCR-EX-SL-2NAM-RO
-B04.x Passive isolator for current output (option),
Phoenix Contact Type MACX MCR-EX-SL-IDSI-I
-B05.x Valve control unit for solenoid valves (option),
Phoenix Contact Type MACX MCR-EX-SL-SD-21-60-LP
-B06.x Isolation relay for switch contact (option),
Pepperl+Fuchs Type KFD0-RO-Ex2

Information about electrical connection of the isolation amplifiers is contained in

the respective data sheets of the manufacturers. These publications can be found
on the enclosed CD-ROM under AO2000 Series – Operator's Manuals.
Information about electrical data of the isolation amplifiers is contained in the
respective EC-Type Examination Certificates. These publications can be found
on the enclosed CD-ROM under AO2000 Series – Certificates.

10 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 41/24-130 EN Rev. 3

AO2060-… Analyzer Module Connection

Figure 4
-K01 -K05
Diagram for Con- GY/6
necting AO2060-… 13 11
BU/7
Analyzer Module to 23 12
PK/5
AO2040-CU Ex 33 13
RD/8
Central Unit 43 14
YE/4
53 15
3/BN
HIGH 63 16
2/WH
LOW 73
1/GN
GROUND 83

-Z01
BN
GNYE
BU

24 VDC System Bus

CAUTION!
The system bus and 24 VDC cables are integral components of the pressur-
ized enclosure system. They should not be shortened to less than 1 meter in
length and should not be damaged!

Continued on next page

41/24-130 EN Rev. 3 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 11

AO2060-… Analyzer Module Connection, continued

Connecting the Step Action

System Bus Cable to 1 Remove the cap nut from the metallic cable connector and remove
the AO2040-CU Ex the plastic insert and seal ring.
Central Unit
2 Strip the outer cover from approx. 10 mm of the system bus cable.
3 Slide the cap nut 1, seal ring 2 and plastic insert 3 over the system
bus cable 4.

1 2 3 4 5 6

4 Bend the shield braid 5 outward and fold it back over the plastic
insert 3.
5 Push the system bus cable into the intermediate opening 6 in the
metallic cable connector until the braid touches the opening and then
push it in and out several times.
6 Push the non-rotating plastic insert 3 and seal ring 2 in the inter-
mediate opening 6 until it engages.
7 Securely tighten the cap nut 1.
8 Connect the system bus cable leads to the isolation relay -K01 and to
terminal strip -K05 (see Figure 4).

Connecting the Step Action

24 VDC Cable to 1 Route the 24 VDC connecting cable into the AO2040-CU Ex central
the AO2040-CU Ex unit through a threaded connector.
Central Unit
2 Connect the 24 VDC connecting cable leads to line filter -Z01 (see
Figure 4).

12 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 41/24-130 EN Rev. 3

Connecting Non-Intrinsically Safe Signal Leads

Connecting Signal Connect non-intrinsically safe signal leads to the right side of isolation relays -K01
Leads to -K04.

ER 144A/Ex Isolation Amplifier for Condensate Monitor

Figure 5

E1 E2 E1 E2
ER 144A/Ex (-B02)
Connection Diagram

Connecting Signal Route the condensate monitor’s intrinsically safe signal leads through a bright blue
Leads cable connection and connect them to the terminals E1 and E2 on the right side of
the ER 144A/Ex isolation amplifier.
The total length of the connecting leads should not exceed 75 meters. Install the
supplied 100-k resistor parallel to the sensor and as close to the sensor as
possible. The 100-k resistor is already installed on the sensor in the stainless
steel version of the condensate monitor.

41/24-130 EN Rev. 3 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 13

Connecting Status Signal, Potential Compensation and Power Supply

Figure 6
Control Unit (-B01)
Connection Diagram
21
22
15
N

17
L

PE
PE

115 VAC or 230 VAC

(non-switchable), Status signal pe < 1.2 hPa
48-62 Hz, approx. 200 VA floating contact, max. 250 V, 5 A

CAUTION!
The AO2040-CU Ex central unit can be hazardous if the protective lead is
interrupted inside or outside the central unit or if the potential compensation
connection is loosened or removed. The power supply lines should be con-
nected to the control unit for the pressurized enclosure system. They should
never be connected directly to the system housing ports. This will compro-
mise the explosion protection function!

Connecting Potential Connect the AO2040-CU Ex central unit’s external potential compensation
Compensation connection and/or protective lead to the local potential compensation point.
Minimum conductor section = 4 mm2.

Connecting the Connect the minimum housing internal pressure underflow status signal (see
Status Signal “Pressurized Enclosure System” section, page 19) to terminals 21 and 22 on the
control unit (see Figure 10).

Connecting the Step Action

Power Supply 1 Make sure the AO2040-CU Ex central unit voltage setting (see
the identification plate) matches the line voltage.
2 Make sure the power supply leads have an adequately dimensioned
protective device (breaker).
Power consumption approx. 200 VA

3 Install an easily accessible breaker in the power supply line or a

switched receptacle near the AO2040-CU Ex central unit to make
sure the central unit can be completely separated from the power
source. Mark the breaker so that its relationship to the protected
device is clear.
4 Connect the power supply leads to the terminals 15 (N) and 17 (L) and
to the PE terminal on the control unit (see Figure 6).
The connections to the other terminals are part of the internal
wiring. They must not be changed.

14 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 41/24-130 EN Rev. 3

Chapter 2 Operation and Maintenance

CAUTION!
If the AO2040-CU Ex central unit must be opened for operation or mainte-
nance, the following safety information (which also appears on the central
unit housing) must be followed:
Before opening, disconnect power and wait 10 minutes!

AO2040-CU Ex Central Unit Start-Up

Installation Check Make sure the AO2040-CU Ex central unit is correctly installed before carrying out
any start-up procedures. Use the following check list:

Test 
Installation site conditions (zone, explosion group, temperature class)
match the information on the type plate?

AO2040-CU Ex central unit not installed outdoors? AO2040-CU Ex
central unit securely mounted? Ignition suppression gas flows freely?

(see “Unpacking and Installing the AO2040-CU Ex central unit”,
page 6)
AO2040-CU Ex central unit housing intact? Housing tightly sealed?
Unused cable connectors tightly sealed?

(see “Connecting Electrical Leads” section, page 9)
Ignition suppression gas lines correctly installed?
AO2040-CU Ex central unit can be adequately purged?

(see “Connecting the Ignition Suppression Gas Line” section, page 7)
All electrical lines properly routed, secured and connected?
(see “Connecting Electrical Leads – Safety Instructions” section,

page 8 and “Connecting Electrical Leads” section, page 9)
Line power matches operating voltage setting? (see type label)
Operating voltage cannot be changed.

Control unit cover securely closed? Bypass disengaged?
Ignition suppression gas pilot pressure within specified limits?

Ex-i circuit characteristics within requirements? At least 8 mm
between Ex-i circuit leads and other lines?

Continued on next page

41/24-130 EN Rev. 3 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 15

AO2040-CU Ex Central Unit Start-Up, continued

AO2040-CU Ex Step Action

Central Unit Start-Up 1 Turn on the power supply.
2 Turn on the ignition suppression gas supply.
3 After the preliminary purge is finished, the solenoid valve is switched
to “leak loss compensation”, and the power supply for the units in the
system housing is activated.

An ignition suppression gas pilot pressure of pe > 500 kPa (= 5 bar) can cause
problems during the preliminary purge.

Operational Checkout The following events will occur after the power supply is turned on:
Phase Description
1 The “Power”, “Maint” and “Error” LEDs light up.
2 The different booting phases are displayed on the screen.
Also the software version is displayed.
3 After a brief time the screen switches to measurement mode.
STATUS

4 The MESSAGE softkey appears on the screen. This indicates the possibility
of a temperature or flow problem during the warm-up phase. By
pressing the softkey the user can recall the status message summary
and view status message details.

CAUTION!
The system controller in the AO2040-CU Ex central unit does not have a
battery backup for use in case of power outages. The following data are lost
in the event of a power outage:
 Date and time settings,
 All logbook entries and all data, which are not saved with the “Save
configuration” function.
Do not install a battery in the AO2040-CU Ex central unit’s system controller
to handle a power outage!

16 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 41/24-130 EN Rev. 3

Inspection and Maintenance

Overriding the If no explosive atmosphere is present, the power supply for the units in the
Pressurized system housing can be turned on, even if the pressurized enclosure system is not
Enclosure System active.
To accomplish this it is necessary to activate the bypass in the control unit of the
pressurized enclosure system.

CAUTION!
With the bypass activated, the AO2040-CU Ex central unit should only be
used with the approval of the operations manager or his / her delegate.
Such approval may only be given
 if there is assurance that for the period needed for the work to be carried
out there will not be an explosive atmosphere present or
 the measures necessary to protect against explosions are in effect
(“fire permission certificate”).
In normal operation of the AO2040-CU Ex central unit the bypass must be
deactivated!

Bypass Activation Step Action

1 Remove the cover of the control unit of the pressurized enclosure
system.
2 Press BYPASS key.
3 Enter code “4711”.
4 Press MENU key. The ignition suppression gas supply is turned off
and “BYPASS” is blinking in the display.

Bypass Deactivation Step Action

1 Press BYPASS key.
2 Enter code “4711”.
3 Press MENU key. The ignition suppression gas supply is turned on.
4 Close the cover of the control unit.

Regular Inspection Proceed according to the checklist on page 15.

41/24-130 EN Rev. 3 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 17

Appendix

Application and Design

Intended Operation The AO2040-CU Ex central unit is intended for use in conjunction with the
AO2060-Caldos15, AO2060-Caldos17, AO2060-Magnos106 and AO2060-Uras14
analyzer modules to control and monitor measurement and control processes.

Design The system housing is designed as a wall-mount unit. It is designed for ignition
suppression “Pressurized Enclosure with Leak Loss Compensation” per
EN 60079-2. The control unit of the pressurized enclosure system is mounted on
the outside left sidewall of the system housing.

Circuitry Intrinsically safe and non-intrinsically safe signal circuits can be brought into the
AO2040-CU Ex central unit.
All non-intrinsically safe circuits that will remain powered when the pressurized
enclosure system is deactivated shall be connected to isolation relays. Intrinsically
safe circuits should be connected to suitable isolation modules.
The circuits under the display/control unit keypad sheet are intrinsically safe.

The system controller does not have a battery backup for use in case of power
outages.

18 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 41/24-130 EN Rev. 3

Pressurized Enclosure System

Figure 7
Pressure Control Valve System Housing
Pressurized
Particle Trap
Enclosure System
Design

Ignition Suppression
Gas Valve
q-prop. p-prop.

A P

Ignition Suppression Use air as the ignition suppression gas (quality per ISO 8573-1, class 3; see
Gas “Operating Specifications” section, page 20).
The ignition suppression gas is routed from the AO2040-CU Ex central unit to the
explosion-risk area. The control unit outlet opening contains a particle trap to
prevent the passage of sparks and glowing particles.

Preliminary Purge at The preliminary purge volume is factory-set and shown on the identification plate.
Start-Up After the preliminary purge is finished, the ignition suppression gas valve is
switched to “leak loss compensation”, and the power supply for the units in the
system housing is activated.

Purge During During operation, the ignition suppression gas flows to maintain a positive
Operation pressure of pe  2 hPa inside the system housing. A pressure control valve limits
the pressure inside the system housing.

Positive Pressure If the positive pressure falls below the pe = 0.8 hPa minimum value or exceeds the
Monitoring pe = 15 hPa maximum value, the power supply for the units in the system housing
is deactivated and the circuits connected to the isolation relays are completely
disconnected.
After the internal pressure again rises over the minimum value or falls below the
maximum value, a preliminary purge is carried out and the power supply and
connected circuits are reactivated.

Status Signal Output A status signal is output via a passive relay contact (EEx e terminals 21 and 22 in
the control unit, max. 250 V, 5 A) if the internal pressure falls below the factory-set
value pe = 1.2 hPa.
Operating Mode Relay Contact
Internal pressure pe  1.2 hPa, ready, on closed
Internal pressure pe < 1.2 hPa, preliminary purge, bypass, open
pressurized enclosure failure

41/24-130 EN Rev. 3 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 19

Operating Specifications

EC Type Examination DMT 03 ATEX E 006

Certificate

Designation II 2G Ex px e d [ib] IIC T4

Level of Protection Device Group II

Category 2G

Explosion Protection Ignition Protection Type Pressurized enclosure “p” with leak loss compensation
Explosion Group IIC
Temperature Class T4

Ambient Temperature Operation +5 to +50 °C

Storage and Transport –25 to +65 °C

Power Supply Input Voltage 230 VAC or 115 VAC (non-switchable), 48 to 62 Hz

Power Consumption Approx. 200 VA

Signal Circuits Intrinsically Safe Circuits Connection via isolation modules (e.g. condensation
monitor or flow rate monitor); connection data are
shown on the modules EC Type Examination
Certificates (see enclosed CD-ROM).
Non-Intrinsically Safe Connection via isolation relays (e.g. measurement
Circuits signals, status signals), max. 30 VDC / 0.4 A

Gas Data Internal Volume 36 l

Minimum Flow Rate
Preliminary Purge 1 l/sec
Operation Leak loss compensation, approx. 40 l/h at 2 hPa
Preliminary Purge Volume 320 l / 1100 l without / with isolation modules
Preliminary Pressure pe = 250 to 500 kPa
Min. Positive Pressure pe  0.8 hPa
Max. Positive Pressure pe  15 hPa
Ignition Suppression Gas Air, quality per ISO 8573-1, class 3 (max. particle size
40 μm, max. oil content 1 mg/m3, max. pressure dew
point +3 °C)

Housing Design Wall-mount housing

Housing Protection Type IP 54
Dimensions see dimensional drawing (Figure 1, page 6)
Weight Approx. 28 kg

20 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 41/24-130 EN Rev. 3

Electrical Safety

Test per EN 61010-1:2001

Protection Class I
Overvoltage Power supply: III/ 2
Category / Signal inputs and outputs: II / 2
Pollution Level
Safe Isolation The electronics module power supply is galvanically isolated from other circuits by
means of reinforced or double insulation. Protective extra low voltage (PELV) on
low-voltage side

Electromagnetic Compatibility

Noise Immunity Tested to EN 61326-1:2006.

Inspection severity: Industrial area, fulfills at least the rating “continuously
monitored operation” to Table 2 of EN 61326.
Emitted Interference Tested to EN 61326-1:2006, EN 61000-3-2:2006 and EN 61000-3-3:1995 +
A1:2001 + A2:2005.
Limit value class B for interference field strength and interference voltage is met.

41/24-130 EN Rev. 3 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 21

Electrical Equipment in Explosion Hazard Zones:
Installation, Maintenance and Repair Notes

Installation per The electrical device shall be installed according to EN 60079-14 “Electrical
EN 60079-14 Equipment in Gas Explosion Hazard Areas”, Part 14: “Electrical Equipment in
Explosion Hazard Areas”.

Potential Compensation The requirements of EN 60079-14 shall be observed.

Electrostatic Charges Avoid electrostatic discharges.

Monitoring and The condition of electrical systems in explosion risk areas must be monitored.
Inspection As necessary, and at least every three years, the system shall be inspected by a
qualified electrician if it is not under continuous monitoring by a responsible
engineer.

Work on Electrical The power supply must be disconnected before performing any work on electrical
Systems systems in explosion risk areas. The breaker is to be fitted with an appropriate
label, e.g. “Do Not Turn On – Risk of Explosion”. This does not apply to devices
that are opened during operation, e.g. registration apparatus, or to devices which
have been expressly type certified for such operation.

Work on Intrinsically Work may be performed on intrinsically safe circuits in explosion risk areas even
Safe Circuits while power is connected. However, the electrical characteristics (inductance,
capacitance, current and voltage) of test equipment should be noted when such
equipment is activated. Special attention is required if work is carried out on
intrinsically safe circuits set up in conjunction with Zone 0 areas.

Explosion Risk The explosion risk should be eliminated prior to carrying out any repair work.

Personnel Repair work should only be performed by qualified personnel.

Qualifications

Original Parts Only original parts should be used for repairs.

Testing Prior to If repair work is carried out on components of electrical equipment, on which the
Recommissioning explosion protection depends, an expert must check and certify that the essential
explosion protection characteristics of the apparatus correspond to the construc-
tion and design of the apparatus described in the certificate before it is returned
to service.

Manufacturer’s Repairs can also be carried out by the manufacturer, e.g. on site by an ABB
Repairs Service employee or at the manufacturer’s facility. In this case the repair carried
out and the subsequent inspection will be shown on the device identification
plate. An inspection by an expert is not required in such a case.

22 AO2040-CU Ex Central Unit Operator’s Manual (Abridged) 41/24-130 EN Rev. 3

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41/24130 EN Rev. 3

Printed in the Fed. Rep. of Germany (07.10)

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