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****** Page 1 ****** ABB MEASUREMENT & ANALYTICS I OPERATING INSTRUCTION CL3020 CLD NOx analyzer NOx: -0.002 PPM 02: 20.79% CL3020 Measurement made easy

****** Page 2 ****** 2 Table CL3020 OPERATING INSTRUCTION of Contents Important precautions Ol/CL3020-EN REV. A Use dry, oil-free instrument air only Safety notice Model CL3020 specifications Performance specifications Features Mechanical specifications Overview Measurement configurations Theory of operation Chemiluminescence measurement of NO Zirconium oxide measurement of 02 Pneumatic design Analyzer setup and quick start procedure Connect the analyzer Apply power to the analyzer and check diagnostics Set analog outputs of the analyzer Calibrate the analyzer Display screens and details of operation Home screen, warnings, and alarms Calibration menu Diagnostic screen Trend screen Config screen Analog output scaling screen Analog output trim IP address screen QR code About screen Alarm screen screen Config alarms screen Troubleshooting Diagnostics and operating parameters Warnings and alarms Sample and ozone flow Converter temperature .10 .13 .13 .14 .15 .16 .17 .17 .18 .19 .20 .20 .21 .22 .23 .23 .24 .24 .25 .26 .26 .26 .26 .27

****** Page 3 ****** CL3020 OPERATING INSTRUCTION Ol/CL3020-EN REV. A Gas concentration readings System checks Electrical connections and fuse Leak checking Component information Oxygen sensor module Ozonator NOx reaction cell Converter Main board Digital communications Setting the IP address Modbus over TCP/IP Analyzer fault register Remote operation via VNC Spare parts 3 .27 .27 .27 .28 .28 .28 .28 .28 .29 .29 .30 .30 .30 .30 .32 .33 .12 .17 .17 .. 18 .. 18 .. 19 List of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Functional pneumatics diagram Home screen Home screen showing active alarm Home screen showing furnace and ozonator warnings Home screen showing main menu choices Calibration menu, for NOx1 gas Numeric entry of calibration bottle value using pop-up keypads…. 19 Diagnostic screen Trend screen Config screen: Sub-screens for further configuration Analog output scaling screen Analog output trim screen IP address screen QR code snapshot screen About screen Alarm screen, with one alarm cleared and two others active Config alarm screen .20 .20 .. 21 22 .. 22 ..23 ..23 24 24 ..25

****** Page 4 ****** 4 CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A List of Tables Table 1 Table 2 Table 3 Table 4 Table 5 1/0 Analog output pin assignments (typical) 14 Expected flows and temperatures during normal analyzer operation 15 Analyzer fault register bit assignments 31 Modbus register map 31 Analyzer spare parts list 33

****** Page 5 ****** CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A Important precautions Use dry, oil-free instrument air only Caution: This instrument will be damaged if used with in- strument air that is not completely dry and oil- free. Ensure instrument air has —40 oc dew point and has been filtered to remove all oil and particu- lates. Safety notice This instrument operates from potentially lethal line voltage. In addition, some internal components operate at high temperature and can cause seri- ous burns. Observe all precautions when using this device, and particularly be sure that all devices connected to the instrument are safely wired and properly grounded. Always disconnect power to the instrument before opening the enclosure or servicing. 5 Caution: The analyzer should not be operated without the cover in place and the cooling fan fully opera- tional. The exterior surface of the converter furnace and tubes will rise to nearly 80 oc if operated without the cover in place. Serious burns can result if the proper precautions are not taken.

****** Page 6 ****** 6 CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A Model CL3020 specifications Performance specifications Measurement technology Measurement range Full scale range Zero noise Zero calibration drift Span noise Span calibration drift Linearity error Response time NO? converter efficiency Features NOx Chemiluminescence using all solid-state detection O to 1000 ppm Continuously adjustable from 5 to 1000 ppm < 0.04 PPM Better than ± 0.1 PPM < 0.25% of reading Better than ± 1% of reading < 2% of high calibration value across range from zero to full scalel T 95 95% 02 Amperometric Zirconium oxide cell O to 25 % 02 Continuously adjustable from 5 to 25 % 02 < 0.02 % 02 Better than ± 0.1 % 02 < 0.02 0/002 Better than ± 0.1 % 02 < 1% of high calibration gas value across range from zero to full scalel T 95 IOOO kOhm) devices. Actual live outputs are shown for reference Note the “gear” icon to the left of each channel. Selecting this icon brings up the Analog output trim screen for each channel, as described below.

****** Page 22 ****** 22 CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A Analog Output Scaling Chan Gas 1 2 3 4 NOx1 NOx2: 02: 0.0 0.0 0.0 20mA 500.0 2000.0 25.0 Type: Units PPM PPM 0/002 4—20 Live mA 4.07 e 4.04 17.30 e Not Assigned Figure 11 Analog output scaling screen Analog output trim screen Each analog output channel may be trimmed independently from its own screen, as shown in Figure 12. Under normal operation, the output is in “live” mode, but it may be forced to either the high or low limits by selecting the corresponding box. When the output is so forced, the corresponding trim field is active and may be used to adjust the actual output up or down to make up for any system discrepancies. In this manner, the analog loops and any external data acquisition system may be calibrated independent of gas concentration readings. This may also be used for troubleshooting external connections. Note that when any outputs are forced high or low, a warning is displayed to the user in the warning banner in the lower portion of any main screen. The “Next” and “Return” buttons allow the user to cycle through other ana- log channels and/or return to the main analog output screen. Output# 1 NOx1 High Trim Next Return 4.07 mA Force High Live Force Low Low Trim Figure 12 Analog output trim screen

****** Page 23 ****** CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A IP address screen The IP address screen is available from the Config screen. Either a static or dynamic IP address screen may be specified. 23 Furnace Enabled Setpoint: 40C an Actual: 3 Power: 1 Ozonator Enabled Time: 15 sec log Outputs ress About Figure 13 IP address screen QR code A standard QR code (2D barcode) image, as shown in Figure 14, may be dis- played for capture and analysis by any mobile device with barcode scanning capability. Scanning with a mobile device will provide a text description of the analyzer configuration, status, and current readings that can be sent to support personnel for troubleshooting assistance. Configuration QR Code Use QR Code scanner to send configuration via email or text Line Count: 49 Characters: 1058 Return Figure 14 QR code snapshot screen

****** Page 24 ****** 24 CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A About screen The About screen, as shown in Figure 15, shows the current software ver- sions for the system. CL3020 Display Version: Modbus Version: 1000000 Retum Analyzer Firmware: 1600000 Figure 15 About screen Alarm screen The alarm screen is shown in Figure 16, accessible from the home screen by touching the red triangle. An active, or historical but uncleared, alarm sets the corresponding bit in the fault register, and causes the red alarm icon to flash on any main screen. If an alarm condition is still being met (causing the alarm), the alarm listing will be highlighted red. If the alarm condition is no longer being met (not alarmed), the text will no longer be highlighted in red, but still visible in the alarm history. The history can be cleared by tapping the “Clear” button. Only alarms that are no longer active may be cleared; if an alarm condition is still occurring it will reactivate and not remain cleared. To access the sub-menus allowing configuration of each alarm, touch the Config Alarms button on this screen. Active Time 12/4/2017 PM 2/4/2017 PM 4/2 Text Furnace Temp 34.70001 C Ozone Flow 1.60001 sccm am Ie Clear Config Alarm Figure 16 Alarm screen, with one alarm cleared and two others active

****** Page 25 ****** CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A Config alarms screen 25 Each alarmable temperature and flow is configurable, as shown in Figure 17, in this case for the furnace temperature. While factory defaults settings should normally not require modification, allowing these to be configurable enables the user to operate the analyzer in custom configurations for unique applications or for testing purposes, while still having meaningful alarm conditions. A target value and deviation from the target may be set in the corresponding boxes. Note in the case of a control loop, like furnace temperature, this is only the target for the alarm, not the control setpoint temperature. Previous Furnace Temp Target: Max Dev: 400.0 20.0 Live: 34.7 Alarm Enabled Fault Enabled Figure 17 Config alarm screen Return

****** Page 26 ****** 26 CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A Troubleshooting Below is troubleshooting information on the analyzer, as well as information on many of the sub-assemblies within the unit. Before troubleshooting the analyzer, read through the diagnostic and operating parameters explana- tions to help narrow down any problems. Warning: Potentially lethal line voltage, lethal high voltage (within the ozone generator), and dangerously hot tubing and subassemblies are present within the analyzer. Service within the analyzer should be performed only by qualified, trained personnel, and only after the unit has been unplugged and al- lowed to cool for at least one hour with the cover off. Diagnostics and operating parameters The diagnostics on the analyzer display much instrument status infor- mation (see diagnostics screen). From these readings, it is usually possible to narrow down the source of any problems: Warnings and alarms The Home screen of the display will display the presence of any warnings or alarms. Carefully check this information to troubleshoot any problems, for example if NOx is not responding it may be the case that the ozonator has been left disabled. Sample and ozone flow Because these two flow rates are intimately related, it is important to con- sider them together. Sample flow is the amount of flow drawn through the sample inlet through the analyzer. Ozone flow is the amount of feed air pulled through the ozonator. A critical flow orifice located in the exhaust fitting of the NOx cell deter- mines the total flow (sample and ozone flow combined). This total flow rate should be approximately 230 SCCM per channel. One may determine several things by inspecting the NOx sample and ozone flow meters: • If the both flows are correct, it is very unlikely that there are pneumatic problems within the analyzer.

****** Page 27 ****** CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A 27 • If the both flow are low, there may leaks in the analyzer, the critical flow exhaust orifice may blocked, the sample inlet may be blocked, the ex- haust may be blocked or not vented properly, or the vacuum at the rear of the analyzer may be inadequate. • If the ozone flow is too low, the ozone air feed orifice may be blocked, there may be a leak in the ozone supply tubing, or the compressed air supply to the instrument may be faulty. • If the sample flow is too low, the sample orifice may be blocked, there may be a leak in the sample tubing, or the sample supply to to the instru- ment may be blocked • If either or both flows are too high, check for pressurization of sample or instrument air (inadequate or blocked vents), or other blockages. For ex- ample, if the ozone flow is restricted, one indication may be higher than normal sample flow, and vice versa. Converter temperature The converter furnace temperature is maintained at 400 oc. The tempera- ture should not vary by more than two degrees. If it is not at the proper value, the furnace heater, thermocouple, or relay could be at fault. Gas concentration readings The 02 value should be stable to approximately 0.02% (absolute). Instability or inaccurate readings could be caused by leaks or a faulty 02 sensor mod- ule. The NOx reading should be stable to better than 0.25% or reading, or 0.02 PPM, whichever is greater. Instability or inaccurate readings could be caused be leaks, a faulty ozonator, or a faulty NOx sensor or sensor board. System checks Component failures within the analyzer are relatively uncommon. Most per- formance or reliability problems are due to improper system connections, leaks, faulty electrical connections, or improper configuration, in that order. Before opening the analyzer enclosure, double-check that the external con- nections and supply of conditioned sample gas, compressed air, and line voltage are correct. The following may aid in troubleshooting if the analyzer is not functioning properly and no faults are apparent form the diagnostic information. Electrical connections and fuse Be sure all connectors on the main board are firmly seated and that all wires within these connectors are firmly attached. There is a fuse holder on the main power inlet of the analyzer, serviceable from the analyzer back panel.

****** Page 28 ****** 28 CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A Leak checking Leaks may cause many non-obvious problems, a leak check is highly recom- mended when servicing or troubleshooting gas analyzers for any reason. Leak checking should be done under vacuum, never pressure with the fol- lowing procedure: 1. 2. 3. 4. Seal the sample and instrument air inlet(s) on the back of the analyzer. Connect a vacuum pump to the exhaust port, with an isolation valve in between the pump and the analyzer, and a vacuum gauge on the ana- lyzer side of the isolation valve. Open the isolation valve, pump the analyzer down, and record the vac- uum reading. Close the isolation valve. The isolated analyzer pressure should not in- crease more than 2 Torr/second. If leaks are found, check all fittings for tightness, and locate the leak by pro- gressively isolating parts of the analyzer. In general, if a leak is present it will be very noticeable, not subtle. A slight apparent leak within the ozonator is acceptable; a metered sweep of the ozonator assembly is designed to mini- mize stray ozone within the analyzer enclosure. Component information Information on service replacement of many of the analyzer components is given below. Only proceed to investigation of components after thoroughly checking pneumatic and electrical connections both inside and external to the analyzer as noted above. “Part-swapping” without clear indication of component failure is not a recommended troubleshooting or repair tech- nique. Oxygen sensor module This is serviced as a unit. If approximately 9VDC is present on pins 1 and 2 of the five-pin connector, and oxygen readings are unstable, nonlinear, or inac- curate, replace this module. If 9VDC is not present, examine connections. Ozonator Lethal voltage is present with the ozonator: Do not attempt to service the ozone generator, and never open its enclosure or allow tools to come near it when the analyzer is energized. The ozonator hums audibly when operating, if power is being supplied to this unit (24VDC) and there is no hum, the ozonator should be replaced. NOx reaction cell The NOx reaction cell has several fittings and the NOx sensor mounted on it.

****** Page 29 ****** CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A 29 The exhaust fitting on the back of the cell houses the critical flow orifice. It may be changed by disconnecting the tube leading into the furnace and un- screwing the fitting. The orifice and fitting are replaced as an assembly. If the readings have dropped, or if the analyzer has been subjected to am- monia, it may be necessary to clean the window on the sensor: 1. 2. 3. 4. 5. Turn off power to the analyzer and remove vacuum from the exhaust port. Remove the two screws holding the detector assembly to the reaction cell and remove the detector assembly. Wipe off the optical window of the sensor through this port with deion- ized water or rubbing alcohol to remove any film or deposits. Do not use harsh solvents or abrasive materials. Reinstall the detector assembly. Energize analyzer, and apply vacuum. Leak check if readings unstable. Converter The converter has a cartridge heater and a thermocouple. The heater ele- ment and thermocouple connect to the main board near the back of the an- alyzer. The converter is typically replaced as an assembly, although the ther- mocouple and heater may be field replaced by experienced service person- nel. The heater assembly should be replaced if either side of the heater shows less than 1 MQ resistance to the shell or if the heater resistance is not approximately 70 Q. The power control relay for the heater is socketed near the rear of the board and may require replacement if the converter power supply has been short- circuited. The molybdenum charge may be replaced, consult factory for de- tails. Main board If the main board must be replaced, the analyzer should be de-energized and all connections removed before attempting to remove the board.

****** Page 30 ****** 30 CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A Digital communications The model CL3020 analyzer can act as a MODBUS server (slave) and may also be operated remotely via any standard PC or mobile VNC viewer. Addi- tionally, a QR-code, i.e. 2D barcode, may be scanned by a mobile device to capture a complete snapshot of instrument status that can easily be sent to remote troubleshooting personnel. Setting the IP address The IP address for the analyzer is normally set to a static value of, and can be changed by tapping the IP Address button on the Config Screen. Either a static or dynamically assigned (DHCP) address can be specified. Modbus over TCP/IP The CL3020 can serve as a MODBUS slave over TCP/IP. The MODBUS regis- ter map is shown in Table 4. Analyzer fault register The 32-bit analyzer fault register reflects the alarm status of the analyzer, whereas any non-zero value represents an alarm condition. The fault regis- ter bit assignments are listed in Table 3. The lowest bit (O) is set to true if any alarm is present allowing for quick reading of a single bit for overall alarm status. The fault register is also available in float data-type represen- tation of the 32-bit value to allow it to be read along with many other input registers using a single read command. Bit 1…5 6 7 8 9 10 11 12 13 15 16…31 Parameter Instrument Fault Reserved 02 Heater Sample Flow 1 Sample Flow 2 Ozonator Flow NOx1 Temp NOx2 Temp Ozonator Temp Furnace Temp Analyzer Temp Comms Error Reserved True (1) if Any alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Modbus server version 1.00100

****** Page 31 ****** CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A Table 3 Analyzer fault register bit assignments 31 Parameter Modbus Slave Version System Board Firmware Version Display Software Version Status (integer) Status (float) Concentration Gas NOx 1 Concentration Gas NOx 2 Concentration Gas 02 Reserved Raw Response Gas NOx 1 Raw Response Gas NOx 2 Raw Response Gas 02 Reserved Temperature Analyzer Temperature NOx 1 Cell Temperature NOx2 Cell Temperature Ozonator Temperature Furnace Heater Power Furnace Flow Sample 1 Flow Sample 2 Flow Ozone Stored Span Response NOx 1 Stored Zero Response NOx 1 Stored Span Response NOx 2 Stored Zero Response NOx 2 Stored Span Response 02 Stored Zero Response 02 Span Bottle Concentration Gas 1 Zero Bottle Concentration Gas 1 Span Bottle Concentration Gas 2 Zero Bottle Concentration Gas 2 Span Bottle Concentration Gas 3 Zero Bottle Concentration Gas 3 Converter Furnace Enabled Ozonator Enabled Register Data Num* 30001 30003 30005 30007 30021 30023 30025 30027 30029 30031 30033 30035 30037 30039 30041 30043 30045 30047 30049 30051 30053 30055 40101 40103 40105 40107 40109 40111 40113 40115 40117 40119 40121 40123 1 2 Type Int32 Int32 Int32 Int32 Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Float Bool Bool Notes Float of (Int32 Status) to allow all float reads Live concentration in gas-units Live concentration in gas-units Live concentration in gas-units Live signal response in % of available input Live signal response in % of available input Live signal response in % of available input degrees C degrees C degrees C degrees C degrees C Live furnace power in % Live sample 1 flow in cm3 Live sample 2 flow in cm3 Live ozone flow in crn3 Stored response in % of available input Stored response in % of available input Stored response in % of available input Stored response in % of available input Stored response in % of available input Stored response in % of available input Bottle concentration in gas-units Bottle concentration in gas-units Bottle concentration in gas-units Bottle concentration in gas-units Bottle concentration in gas-units Bottle concentration in gas-units True (1) enables furnace power True (1) enables ozonator power * Register numbers 30xxx are input registers, 40xxx are holding registers, x are output coils. Modbus server version 1.00100 Table 4 Modbus register map

****** Page 32 ****** 32 CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A Remote operation via VNC It is possible to operate the CL3020 remotely by any VNC viewer connected via TCP/IP. Every display and every action that is available from the analyzer display is duplicated on the remote device, with a mouse click or screen touch on the remote device serving as the same input as front screen touch commands. Any VNC viewer may be used, once the IP address of the analyzer is known. The VNC connection password is CL3020 (case sensitive) and cannot be changed. TCP port 5900 is used for the VNC connection and must not be blocked by any routers or firewalls between the analyzer and the remote de- vice.

****** Page 33 ****** Spare parts Part description Exhaust orifice fitting Sample orifice fitting Ozone orifice fitting NOx detector O-ring Fuse Oxygen sensor Ozone generator NO? furnace assembly Furnace media recharge NOx Detector Flowmeter Furnace relay Furnace heater Furnace thermocouple Furnace sample fittings Display Electronics board Fan Sample tubing, 5 ft Exhaust tubing, 2 ft Tubing tee CL3020 OPERATING INSTRUCTION I Ol/CL3020-EN REV. A 1000-1020 1000-1030 1000-1031 1000-1032 1000-1033 1000-1034 1000-1035 1000-1036 1000-1037 1000-1038 1000-1039 1000-1040 1000-1041 1000-1042 1000-1043 1000-1044 1000-1045 1000-1046 1000-1047 1000-1048 1000-1049 Part number 33 Recommended on-site quantity 2 2 2 2 2 1 (if configured) Optional None None None None None None None None None None None None None None Table 5 Analyzer spare parts list

****** Page 34 ****** ABB Automation GmbH Measurement & Analytics Stierstädter Str. 5 60488 Frankfurt am Main Germany Fax: Mail: +49 69 7930-4566 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 passible 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 whale or in parts — is forbidden wothaut prior written consent of ABB. C 2018 co z O








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