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ABB Advance Optima caldos25, Operator'S Manual

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ABB Advance Optima caldos25 Operator'S Manual Download Page 233

42/24-10 EN Rev. 9 

Appendix 1: Gas Analyzer Overview 

A-1-1 

Appendix 1 

Gas Analyzer Overview 

 

Gas Analyzer 

  

Components 

The AO2000 Series Continuous Gas Analyzers consist of: 

•

 analyzer modules and 

•

  a central unit. 

The central unit consists of: 

•

  the electronics module, consisting of the system controller, the I/O modules 

(optional) and the power supply, and 

•

  the system housing with the display and control unit. 

A gas module can be connected to supply gases to an analyzer module. 

  

Equipment Levels 

The smallest gas analyzer equipment level is made up of the central unit and one 
analyzer module. Up to four analyzer modules for measuring up to six sample 
components can be connected to a central unit. 

  

System Housing 

Electronics module, power supply and an analyzer module can be installed 
together in one system housing. Additional analyzer modules are installed in 
separate system housings. 

  

Power Supply 

A supply voltage of 100–240 VAC is required for the central unit. The analyzer 
modules are powered with 24 VDC from the central unit power supply or from 
separate power supplies. 

  

System Bus 

The system controller, the analyzer modules and the I/O devices are intercon-
nected via the system bus. The system bus is linear in design and has a maximum 
length of 350 meters. 

  

Interfaces 

Various types of interfaces can be used by the gas analyzer to communicate with 
external systems. These include an available Ethernet interface (TCP/IP protocol), 
the RS232 and RS485 interfaces (Modbus protocol) as well as the RS485 and the 
(non-intrinsically safe) MBP interfaces (Profibus DP or Profibus PA protocol). 

  

Explosion Protection 

Special gas analyzer versions are available for use in explosion risk areas: 

•

  The AO2060-Caldos15, -Caldos17, -Magnos106 and -Uras14 analyzer modules 

in category 2G are designed to “Flame-proof Enclosure” (Ex d) ignition protec-
tion and are suitable for measurement of flammable gases and non-flammable 
gases. 

•

  The AO2040-CU Ex central unit in category 2G is designed to “Pressurized 

Apparatus with Leak Compensation” (Ex p) ignition protection. 

•

  The category 3G versions are suitable for measurement of flammable gases 

(“safety concept”) and non-flammable gases. 

Summary of Contents for Advance Optima caldos25

Page 1: ...Advance Optima Continuous Gas Analyzers AO2000 Series Software Version 5 0 Operator s Manual 42 24 10 EN Rev 9 ...

Page 2: ......

Page 3: ...rotected by copyright The translation duplication and distribution in any form even in a revised edition or in extracts in particular as a reprint by photomechanical or electronic repro duction or in the form of storage in data processing systems or data networks are prohibited without the consent of the copyright holder and will be prosecuted under civil and criminal law ...

Page 4: ...on not delivered 1 10 List of Figures Related to Installation 1 11 Guideline for Installation and Start Up 1 12 Chapter 2 Gas Analyzer Unpacking and Installation Gas Analyzer Unpacking 2 1 Gas Analyzer Identification 2 2 Dimensional Diagrams 2 4 Gas Connections Installation 2 5 Gas Analyzer Installation 2 6 Chapter 3 Gas Line Connection Magnos206 Gas Connections 3 1 Magnos27 Gas Connections 3 2 Ma...

Page 5: ...nection 4 10 Signal Control and Interface Line Connection 4 13 Power Supply Line Connection Safety Notes 4 15 Power Supply Line Connection to the Analyzer Module 4 16 Power Supply Line Connection 4 18 Chapter 5 Gas Analyzer Start Up Installation Check 5 1 Gas Path and Housing Initial Purge 5 2 Power Supply Activation 5 3 Warm Up Phase 5 4 Operation 5 5 Chapter 6 Gas Analyzer Operation Display and ...

Page 6: ... Time 7 C 1 Selecting User Interface Language 7 C 2 Changing the Password 7 C 3 Inhibit Operation 7 C 4 Setting Up System Modules 7 C 5 Adding a System Module 7 C 7 Replacing a System Module 7 C 8 Removing a System Module 7 C 9 Saving the Configuration 7 C 10 Configuring Status Signals 7 C 11 Configuring an Ethernet Connection 7 C 12 Configuring a Modbus Connection 7 C 13 Configuring Profibus 7 C ...

Page 7: ...y Controlled Calibration 8 B 6 Output Current Response 8 B 6 Section C Notes for Calibrating Analyzer Modules Caldos25 Notes for Calibrating 8 C 1 Caldos27 Notes for Calibrating 8 C 2 Caldos27 Single Point Calibration with Standard Gas 8 C 3 Caldos25 and Caldos27 Substitute Gas Calibration 8 C 4 Limas11 Notes for Calibrating 8 C 5 Magnos206 Notes for Calibrating 8 C 7 Magnos206 Single Point Calibr...

Page 8: ... Disposable Filter Replacement 9 25 Pump Activation Pump Output Adjustment 9 26 Changing Analog Output Current Range 9 27 Air Pressure Correction 9 28 Air Pressure Value Correction 9 29 Calibration Reset 9 30 Basic Calibration 9 31 Cross Sensitivity Alignment 9 32 Carrier Gas Alignment 9 33 Chapter 10 Status Messages Troubleshooting Process Status 10 1 System Status Status Messages 10 2 System Sta...

Page 9: ...ons A 2 3 Magnos206 Operating Specifications A 2 4 Magnos27 Operating Specifications A 2 5 Uras26 Operating Specifications A 2 6 Oxygen Sensor Operating Specifications A 2 7 Electrical Safety A 2 8 Electromagnetic Compatibility A 2 8 Appendix 3 ZO23 Trace Oxygen Analyzer Module Safety Information A 3 1 Requirements at the Installation Site A 3 2 Sample Gas Inlet Conditions A 3 2 Test Gases A 3 3 C...

Page 10: ...tected versions of the AO2000 Series gas analyzers in Category 3G for measurement of flammable gases For these analyzer modules and gas analyzers separate operator s manuals are available which are listed in the Additional Publications table below Title Publication No Advance Optima AO2000 Series Continuous Gas Analyzers Data Sheet 10 24 1 20 EN Function Blocks Descriptions and Configuration 30 24...

Page 11: ...afety information to be heeded during gas analyzer operation in order to avoid risks to the operator Identifies specific information on operation of the gas analyzer as well as on the use of this manual Module Name Indicates specific information for individual analyzer modules 1 2 3 Identifies reference numbers in the figures Display Identifies a message in the display Input Identifies a user entr...

Page 12: ...Update If a software update involves a modification or expansion of functionality this is indicated by changing the version number following the first decimal point The operator s manual is accordingly revised and a new edition is published This is reflected by increasing the publication number by one Software Version Operator s Manual Edition Publication Number 1 0 42 24 10 0 1 1 42 24 10 1 1 2 4...

Page 13: ...on affixed to the gas analyzer The applicable safety precautions for installing and operating electrical devices Safety precautions for working with gases acids condensates etc 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 gas analyzer is...

Page 14: ...ing with an Open Gas Analyzer The gas analyzer must be disconnected from all power sources before being opened for any work All work on a gas analyzer that is open and connected to power should only be performed by trained personnel who are familiar with the risks involved Charged Capacitors The capacitors in the gas analyzer power supply discharge after 10 minutes when the gas analyzer is disconn...

Page 15: ...fication plate Designation II 3G EEx nAC II T4 X Description In undisturbed operation there cannot be any sparking arcing or impermissible temperatures inside the device For further information please refer to the Declaration of Conformity which can be found on the CD ROM delivered with the gas analyzer Special Conditions for Operation in Hazardous Areas The device must be switched off when it is ...

Page 16: ......

Page 17: ...eat Large temperature variations Strong air currents Accumulations of dust and dust infiltration Corrosive atmospheres Vibration see Vibrations page 1 2 Air pressure range 600 to 1250 hPa Relative humidity max 75 Environmental Conditions Ambient temperature range at storage and transport 25 to 65 C Ambient temperature range during operation with analyzer module installed in a system housing withou...

Page 18: ...analyzer modules apply Analyzer Module Vibrations Caldos25 max 0 04 mm at 5 to 30 Hz Caldos27 max 0 04 mm at 5 to 55 Hz 0 5 g at 55 to 150 Hz Limas11 max 0 04 mm at 5 to 55 Hz 0 5 g at 55 to 150 Hz Magnos206 max 0 04 mm at 5 to 20 Hz Magnos27 max 0 04 mm at 5 to 60 Hz Uras26 max 0 04 mm at 5 to 55 Hz 0 5 g at 55 to 150 Hz slight transient effect on sample value in the region of the beam modulation...

Page 19: ...5 C below the ambient temperature throughout the sample gas path Otherwise a sample gas cooler or condensate trap is required Water vapor can result in cross sensitivity 2 When there is a direct sample chamber connection the maximum sample gas dew point is 55 C Water vapor can result in cross sensitivity 3 pe pabs pamb where pe positive pressure pabs absolute pressure pamb atmospheric pressure 4 F...

Page 20: ...50 ppm H2O Not suitable for measurement of Highly corrosive gases e g gases containing chlorine H2SO4 SO3 fluorine compounds Fluorine compounds Wet gases containing chlorine H2SO4 SO3 fluorine compounds Toxic Gases Housing purge 20 l h with sample component free air or with N2 Housing purge 20 l h with sample component free air or with N2 Cell purge 1 with N2 or with sample component free air with...

Page 21: ...onal Span calibration without calibration cells Test gas for each detector or measurement component Span gas concentration 70 to 80 of the end value of the largest measurement range For suppressed ranges Span gas concentration within the suppressed range if possible equal to the end value only for Uras26 Water vapor must be absorbed using a cooler Automatic and externally controlled calibration Te...

Page 22: ...l h max approx 20 sec Central Unit with or without Analyzer Module 200 l h max approx 1 hr Analyzer separately Caldos25 Caldos27 Magnos206 Magnos27 200 l h max approx 3 min Purge Gas Flow Rate during Operation Purge gas flow rate at device inlet max 20 l h constant Purge gas positive pressure pe 2 to 4 hPa Because of leakage losses the purge gas flow rate at the device output is approx 5 to 10 l h...

Page 23: ...ntral unit a distinction has to be made between three cases The analyzer module can be powered by the central unit power supply if the optional power line filter Z01 is installed in the central unit and no analyzer module is installed in the central unit If only one analyzer module is installed in the system housing the AO2000 power supply installed in the system housing can be used If two analyze...

Page 24: ...nput Current max 2 2 A Line Frequency Range 50 60 Hz 3 Hz Power Consumption max 187 W Output Voltage 24 VDC 5 Power Supply Specifications Line Power Connection 3 pin grounded instrument connector per EN 60320 C14 Module Power Consumption System Controller approx 15 W I O Modules approx 10 W per module Caldos25 max 25 W Caldos27 max 12 W Limas11 max 85 W Magnos206 max 50 W Magnos27 max 35 W MultiFI...

Page 25: ...rounded instrument connector and separate grounded two pin plug 1 System bus termination resistor Standard Equipment Plastic tubing connectors quantity equal to the number of gas ports Quantity Description Connection cables for analyzer module 24 VDC power supply Connection cables tees and terminating resistors for the system bus per order Terminal strips to connect I O modules per order Options d...

Page 26: ... 17 AWG The stranded conductor may be tinned on the tip or twisted for simplified connection When using wire end ferrules the total section should not exceed 1 mm2 i e the maximum stranded conductor section is 0 5 mm2 The Weidmüller PZ 6 5 crimping tool must be used for crimping the ferrules Maximum line length 1200 meters 3940 feet transmission rate max 19200 bit s for RS485 Signal Lines Maximum ...

Page 27: ... sample gas or flowing reference gas 3 5 Limas11 standard cell quartz cell cell with center connection 3 6 Limas11 quartz cell with PFA tubes 3 7 Limas11 safety cell 3 8 Uras26 3 9 Electrical connections Electronics module 4 1 Profibus module 4 2 Modbus module 4 3 2 way analog output module 4 4 4 way analog output module 4 5 4 way analog input module 4 6 Digital I O module 4 7 System bus plug 4 11...

Page 28: ...onnections ports 2 5 4 Check gas path seal integrity 2 5 5 Install the gas analyzer 2 6 Connect the gas lines Analyzer module gas connections 3 1 to 3 9 6 Connect the gas lines 3 13 Connect the electrical leads Connection diagrams 4 1 to 4 8 System bus 4 10 Signal control and interface lines 4 13 7 Power supply lines 4 16 4 18 Start up the gas analyzer Check the installation 5 1 Purge the gas path...

Page 29: ...acking or other packaging materials from the shipping box 2 Take off the foam packing and other packaging and place the gas analyzer in a clean area Unpacking 3 Clean the adhesive packaging residue from the gas analyzer If there is shipping damage which points to improper handling file a damage claim with the shipper railway mail or freight carrier within seven days Make sure that none of the encl...

Page 30: ...the system housing identification plates are inside the right sidewall and on the left sidewall inside the wall mount housing The analyzer module identification plate is located externally on the connection board except for analyzer modules with direct connection to the sample chamber Also each analyzer has its own identification plate The electronics module identification plate is located externa...

Page 31: ...utlet Connection Drawings Additionally you and ABB Automation Service can document on the analyzer data sheet any maintenance work or modifications performed on your gas analyzer Where is the analyzer data sheet located The analyzer data sheet is located in a sleeve which is affixed to the inner side of the left side wall 19 inch rack mount housing or to the inner side of the door wall mount housi...

Page 32: ...ams is flange mounted to the IP 54 housing Observe the installation location requirements see Page 1 1 The connecting lines require additional installation clearance approx 100 mm When installing the wall mount housing note that clearance approx 60 mm is required on the left side to allow the door to swing open The 19 inch housing and the wall mount housing should be installed with vertical orient...

Page 33: ...s on the gas module are made of plastic PVDF Do not use metal tubing connectors or threaded connectors The gas connection ports on the Caldos25 versions for flowing reference gas and for corrosive sample gas are made of plastic PVC C Do not use metal tubing connectors or threaded connectors Step Action 1 Remove the yellow stopper screws 5 mm Allen screws from the connection ports Screw the tubing ...

Page 34: ...9 inch housing must be supported with rails in the bay or rack Neither the 19 inch nor the wall mount housings use hinges to secure the housing cover The cover can drop when opened Quantity Fastener not supplied What materials are needed 19 inch housing 4 Oval head screws Recommendation M6 this depends on the cabinet shelf system 1 pair Rails Design depends on cabinet shelf system Wall mount housi...

Page 35: ...4 Purge Gas Outlet Analyzer 2 7 Purge Gas Inlet Housing 1 8 Purge Gas Outlet Housing 1 also with Flow Sensor 9 Pressure Sensor 1 1 10 Pressure Sensor 2 1 Pneumatics Module 1 11 Sample Gas Inlet 12 End Point Gas Inlet with 3 solenoids 13 Test Gas Zero Point Gas Inlet with 1 or 3 solenoids 14 Sample Gas Outlet Connect with Inlet 1 1 Option Gas Connections 2 not in version with performance test for e...

Page 36: ...sing 1 also with Flow Sensor 3 4 Sample Gas Inlet 5 Purge Gas Inlet Analyzer 6 Purge Gas Outlet Analyzer 7 Sample Gas Outlet 8 9 Pressure Sensor 1 1 10 Pressure Sensor 2 1 Pneumatics Module 1 11 Sample Gas Inlet 12 End Point Gas Inlet with 3 solenoids 13 Test Gas Zero Point Gas Inlet with 1 or 3 solenoids 14 Sample Gas Outlet Connect with Inlet 4 Gas Connections 1 Option ...

Page 37: ...ion only in Wall Mount Housing Figure 3 3 1 2 10 9 4 7 6 8 5 1 Purge Gas Inlet Housing 1 2 Purge Gas Outlet Housing 1 also with Flow Sensor 4 Sample Gas Inlet 5 Purge Gas Inlet Analyzer 6 Purge Gas Outlet Analyzer 7 Sample Gas Outlet 8 9 Pressure Sensor 1 1 10 Pressure Sensor 2 1 Gas Connections 1 Option ...

Page 38: ... Gas Inlet Analyzer 4 Purge Gas Outlet Analyzer 7 Purge Gas Inlet Housing 1 8 Purge Gas Outlet Housing 1 also with Flow Sensor 9 Pressure Sensor 1 1 10 Pressure Sensor 2 1 Pneumatics Module 1 11 Sample Gas Inlet 12 End Point Gas Inlet with 3 solenoids 13 Test Gas Zero Point Gas Inlet with 1 or 3 solenoids 14 Sample Gas Outlet Connect with Inlet 1 Gas Connections 1 Option ...

Page 39: ...nce Gas Inlet 2 6 Reference Gas Outlet 2 7 Purge Gas Inlet Housing 1 8 Purge Gas Outlet Housing 1 also with Flow Sensor 9 Pressure Sensor 1 1 10 Pressure Sensor 2 1 Pneumatics Module 1 2 11 Sample Gas Inlet 12 End Point Gas Inlet with 3 solenoids 13 Test Gas Zero Point Gas Inlet with 1 or 3 solenoids 14 Sample Gas Outlet Connect with Inlet 1 1 Option Gas Connections 2 Not in version for corrosive ...

Page 40: ...s Inlet with 1 or 3 solenoids 1 3 1 Option 2 only for standard cell with PTFE hoses Gas Connections 3 not for version with PTFE hoses This connection diagram applies for the following versions of the Limas11 analyzer module Standard cell with FPM or PTFE hoses Quartz cell with FPM hoses Center connection cell made of aluminum with FPM or Cr hoses 60 C Center connection cell made of quartz with PTF...

Page 41: ...nection 3 7 Limas11 Gas Connections Quartz Cell with PFA Tubes Figure 3 7 7 1 3 4 6 BUS Service 24 V DC 1 Sample Gas Inlet 3 Purge Gas Inlet Housing 1 4 Sample Gas Outlet 6 Purge Gas Outlet Housing 1 7 Pressure Sensor Gas Connections 1 Option ...

Page 42: ...onnections Safety Cell Figure 3 8 7 1 2 3 4 5 6 BUS Service 24 V DC 1 Sample Gas Inlet 2 Sample Gas Outlet 3 Purge Gas Inlet Housing 1 4 Purge Gas Inlet Sample Cell 5 Purge Gas Outlet Sample Cell 6 Purge Gas Outlet Housing 1 7 Pressure Sensor Gas Connections 1 Option ...

Page 43: ...s and gas paths in series 9 Reference Gas Inlet Gas Path 11 10 Reference Gas Outlet Gas Path 11 Pneumatics Module 1 11 Sample Gas Inlet Gas Path 1 12 End Point Gas Inlet with 3 solenoids or Sample Gas Inlet Gas Path 2 only with Flow Sensor 13 Test Gas Zero Point Gas Inlet with 1 or 3 solenoids or Sample Gas Outlet Gas Path 2 only with Flow Sensor 7 14 Sample Gas Outlet Gas Path 1 Connect with Inle...

Page 44: ...alibration Magnos206 with single pt calibration Limas11 with calibration cells Uras26 with calibration cells Option Flow monitoring e g for flowing reference gas or purge gas external needle valve required Figure 3 12 Analyzer Module and Gas Module without Solenoid Valves O2 P MG E c opt Gas Module External test gas connection for Caldos27 Magnos206 Magnos27 Limas11 Uras26 Option Flow monitoring e...

Page 45: ...asurement ranges the pressure sensor port and the sample gas outlet must be connected via a tee and short lines Please observe that the exhaust line is kept as short as possible or if longer lines are necessary that the inner diameter is sufficiently large 10 mm Notes for Proper Pressure Sensor Operation Please observe the following notes for the proper operation of the pressure sensor Remove the ...

Page 46: ... should not be purged in series with the MultiFID14 analyzer module CAUTION For joint purging of the analyzer and central unit the purge gas must first be routed through the central unit and then through the analyzer Flow direction inversion and leaks in the sample gas path can result in damage to electronics by corrosive sample gas components An analyzer module used to measure corrosive sample ga...

Page 47: ...re than three analyzer modules in series Gas Line Connection Connect the gas lines made of a material appropriate for the measurement task to the installed gas ports Evacuate Exhaust Gases Exhaust gases should be routed to the atmosphere or to an exhaust pipe directly or via the shortest possible large diameter line Do not route exhaust gases via flow reducers or shutoff valves Process corrosive t...

Page 48: ......

Page 49: ...X01 Power Supply Connection Page 4 18 X07 System Bus Port Page 4 10 X08 X09 Ethernet 10 100 1000BASE T Interface I O Modules 5 slots Options Profibus Module Page 4 2 Modbus Module Page 4 3 2 Way Analog Output Module Page 4 4 4 Way Analog Output Module Page 4 5 4 Way Analog Input Module Page 4 6 X20 to X29 Digital I O Module Page 4 7 Potential Compensation Connection Page 4 18 The connection drawin...

Page 50: ...e 4 not used 5 DGND Data Transmission Potential Reference Potential for VP 6 VP Supply Voltage Plus 5 V 7 P24 24 V Output Voltage Plus max 0 2 A 8 RxD TxD N Receive Transmit Data N A Line 9 not used Design 9 pin Sub D female connector MBP Interface non intrinsically safe 1 2 Shield 3 4 not used Design 4 pin terminal strip for stranded or solid conductors with a maximum section of 1 mm2 17 AWG Note...

Page 51: ...ion 4 3 Modbus Module Electrical Connections Figure 4 3 Modbus Module Connection Diagram 1 6 1 6 RS232 RS485 RS232 Interface 2 RxD 3 TxD 5 GND Design 9 pin Sub D male connector RS485 Interface 2 RTxD 3 RTxD 5 GND Design 9 pin Sub D female connector ...

Page 52: ...vanically separated from ground freely connectable to ground max gain vs local protective ground potential 50 V max working resistance 750 Ω Resolution 16 bit The output signal cannot be lower than 0 mA Design 4 pin terminal strip for stranded or solid cable with a maximum section of 1 mm2 17 AWG Observe the information on needed materials see page 4 13 Standard Terminal Connections section see pa...

Page 53: ...to 4 20 mA common negative pole galvanically separated from ground freely connectable to ground max gain vs local protective ground potential 50 V max working resistance 750 Ω Resolution 16 bit The output signal cannot be lower than 0 mA Design 8 pin terminal strip for stranded or solid cable with a maximum section of 1 mm2 17 AWG Observe the information on needed materials see page 4 13 Standard ...

Page 54: ... C AI2 AI4 I I C C 24 V GND 0 to 20 mA into 50 Ω 0 to 20 mA into 50 Ω 0 to 20 mA into 50 Ω 0 to 20 mA into 50 Ω external sensor Power supply for AI1 AI4 Analog Inputs 0 to 20 mA into 50 Ω 24 V Current Output 24 VDC for supply of an external sensor fused with 100 mA resettable fuse Design 2x5 pin terminal strip for stranded or solid cable with a maximum section of 1 mm2 17 AWG Observe the informati...

Page 55: ...2 24 VDC or with open collector drivers PNP or NPN DO1 DO4 Digital Outputs Floating double throw contacts max contact load rating 30 V 1 A Relays must at all times be operated within the specified data range Inductive or capacitive loads are to be connected with suitable protective measures self induction recuperation diodes for inductive loads and series resistors for capacitive loads Design 2x12...

Page 56: ...Adjust End Point Measuring Range Control DO1 Measuring Range Feedback DO2 Measuring Range Feedback DO3 Measuring Range Feedback DO4 Measuring Range Feedback DI1 Measuring Range Switchover DI2 Measuring Range Switchover DI3 Measuring Range Switchover DI4 Measuring Range Switchover Limit Values DO1 Limit Value DO2 Limit Value DO3 Limit Value DO4 Limit Value DI1 Calibration Cells In Out DI2 Hold Curr...

Page 57: ... module Alarm values An alarm value is allocated for each sample component in the order of the sample components Measuring range control can be implemented for all sample components with more than one measuring range Each digital I O module includes 4 digital inputs DI for the measuring range switch over and 4 digital outputs DO for the measuring range feedback signal Sample component with Assignm...

Page 58: ...supplied with the unit see Figure 4 8 Figure 4 8 One System Housing Terminating Resistor on the Electronics Module PS AM EM BUS AM Analyzer Module EM Electronics Module PS Power Supply BUS System Bus Internal Terminating Resistor Multiple System Housings If the gas analyzer functional components are installed in several system housings they must be interconnected externally via the system bus see ...

Page 59: ...ng information if using other than the standard system bus cables and plugs to extend the system bus For extension purposes a shielded 4 conductor cable with twisted pairs and a wire section 0 5 mm2 should be used Number and section of conductors 2 x 2 x 0 25 mm2 Inductance approx 0 67 mH km Impedance approx 80 Ω Coupling 1 kHz approx 300 pF 100 m Operating capacitance Conductor Conductorapprox 12...

Page 60: ...lectronics and all analyzer modules 3 Connect the tees with the system bus cables 4 Place a terminating resistor on the open ends of each tee Adding an Analyzer Module to the System Bus see Figure 4 11 5 Set up the added analyzer module see Setting Up System Modules section page 7 C 5 Figure 4 11 Multiple Analyzer Modules Connection via the System Bus BUS PS PS EM AM AM BUS AM Analyzer Modules EM ...

Page 61: ...nded conductor section is 0 5 mm2 The Weidmüller PZ 6 5 crimping tool must be used for crimping the ferrules Maximum line length 1200 meters 3940 feet transmission rate max 19200 bit s for RS485 Maximum line length 15 meters 50 feet for RS232 The matching female connector housings for the connection strips on the I O modules are supplied with the device Connection Box The IP 54 version of the syst...

Page 62: ... the cables through the connection box openings M20 Remove the plug from the insert the ring remains in place as a gasket and strain relief M32 Remove the plugs from the threaded connections Press the insert from the accessory kit over the cable seal off the free opening with the pin from the accessory kit 2 Connect the wiring to the connector housings according to the connection diagrams 3 Connec...

Page 63: ... the power cable supplied is used The gas analyzer can be hazardous if the protective lead is interrupted inside or outside the gas analyzer or if the protective lead is disconnected Only fuses of the specified type and rated current should be used as replacements Never use patched fuses Do not short circuit the fuse holder contacts If the power supply fuse fails some power supply switch component...

Page 64: ...e receptacle on one cable end is designed to connect to the 24 VDC male plug on the analyzer module or the I O base module see Figure 4 13 The wires on the free end of the connecting cable are intended for connection to The power supply filter Z01 in the central unit for an example see Figure 4 14 or An external power supply Figure 4 12 24 VDC Connecting Cable BN BU Figure 4 13 24 VDC Connection 1...

Page 65: ... or to the external power supply Extending the 24 VDC Connection Cable The 24 VDC connection cable has a wire section of 0 5 mm2 it is limited to a length of 5 meters 16 4 feet Note the following conditions if the connection cable has to be extended The extension cable must have a wire section of at least 2 5 mm2 The extension cable should be no more than 30 meters 98 ft long The extension cable s...

Page 66: ...all a breaker in the power supply line or a switched receptacle near the gas analyzer to make sure the gas analyzer can be completely separated from the power source Mark the breaker so that its relationship to the protected device is clear 3 Connect the power cord supplied to the X01 power supply connector in the electronics module and secure it with the clip Connect the other end of the power co...

Page 67: ...check list Check Is the gas analyzer securely fastened See Gas Analyzer Installation section page 2 6 Are all gas lines correctly connected See Chapter 3 Gas Line Connection Are all signal control interface power supply and if applicable system bus lines correctly placed and connected See Chapter 4 Electrical Connection Are all devices needed for gas preparation calibration and exhaust processing ...

Page 68: ...w and the duration of the purge process depend on the volume to be purged see the following table If the purge gas flow rate is lower than indicated the duration of the process must be increased correspondingly Volume to be Purged Purge Gas Flow Rate Duration Gas Path 100 l h max approx 20 sec Central Unit with or without Analyzer Module 200 l h max approx 1 hr Caldos25 Caldos27 Magnos206 Magnos27...

Page 69: ...n 1 The three 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 4 The STATUS 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 sta...

Page 70: ...1 hour Magnos27 2 to 4 hours Uras26 Approx 0 5 2 hours without with thermostat 1 See AO2000 Series Data Sheet publication number 10 24 1 20 EN for class details The warm up phase can take longer if the gas analyzer was not brought to room temperature before the power supply was activated During the warm up phase measurement values can be outside the ranges specified in the data sheet Warm Up Phase...

Page 71: ...190 l h Uras26 20 100 l h Oxygen Sensor 20 100 l h Adjusting Sample Gas Flow Rate Gas Module 30 160 l h Adjusting Reference Gas Flow Rate In the Caldos25 and Uras26 analyzer module versions with flowing reference gas the reference gas flow rates must be set to the same value as the sample gas flow rate For special applications of the Caldos25 the reference gas flow rate must be set to lower values...

Page 72: ......

Page 73: ...ns the display and control unit is located on the front face Figure 6 1 Display and Control Unit Error Maint Power 7 8 9 6 5 4 1 2 3 0 Status LED s Numeric Keypad Menu Line Information Field Softkey Line Screen with Softkeys Cancel Keys Display and Control Unit Operating Modes The display and control unit operating modes are Measurement Menu The display and control unit operating modes have no eff...

Page 74: ...ured value The measurement component designation The measurement range lower and upper limit values on the bar graph The analyzer type The analyzer name Values from up to six sample components can be displayed simultaneously It is user configurable which measurement values are shown on the screen and at which positions on the screen the measurement values are displayed In addition the user can con...

Page 75: ...ection page 6 12 It shows that the gas analyzer is being controlled from a remote HMI refer to the User Interface Priority section page 6 15 It shows that an automatic calibration process is running in the gas analyzer refer to the Automatic Calibration section page 8 A 4 Display of Status Messages When a status message is generated by the Message Generator function block its text is displayed as ...

Page 76: ...ower supply is on Maint The yellow Maint LED lights when the Maintenance Request status signal is active The STATUS MESSAGE softkey appears on the screen at the same time see page 6 7 Error The red Error LED lights when the Failure status signal or the overall status signal is active The STATUS MESSAGE softkey appears on the screen at the same time see page 6 7 Chapter 10 contains information on s...

Page 77: ...s directly with the numeric keys 0 through 9 decimal point minus sign Examples Test gas concentration Date and time Air pressure Password Any digits displayed cannot be overwritten They must be deleted with the BACKSPACE or CLEAR key before new digits can be entered Entering Text with the Numeric Keypad The Text Entry section see page 6 9 explains how to enter information such as sample component ...

Page 78: ...with the ENTER key are stored unconfirmed items are not accepted The Back key also allows the operator to clear gas analyzer help text and messages Meas The Meas key allows the operator to cancel a function or menu item and to return to the measured value display in measurement mode Only entries confirmed with the ENTER key are stored unconfirmed items are not accepted The gas analyzer automatical...

Page 79: ...on the screen Softkeys are also called keys in this manual The Softkeys in Measurement Mode The softkeys MENU and appear in measurement mode The STATUS MESSAGE softkey also appears if an error occurs MENU The MENU key is used to call the main menu and switch to menu mode when in measurement mode The key allows the operator to scroll to the next display page This key only allows forward scrolling T...

Page 80: ...on a dark background BACK SPACE The operator can use the BACKSPACE key to delete characters to the left of the cursor as in a PC keyboard CLEAR The operator can use the CLEAR key to delete all characters in a selected field ENTER The operator can use the ENTER key to Call up menu items for processing Start functions Confirm entries e g parameter settings The ENTER key is always at the right margin...

Page 81: ...rator enters text in the input mode The operator modifies already entered text in the edit mode Softkeys in the Input Mode The softkeys in the input mode have the following functions PREV PAGE NEXT PAGE The PREV PAGE and NEXT PAGE keys allow the operator to move to the previous or next keypad page CAPS The CAPS key allows the operator to switch between upper and lowercase letters EDIT The EDIT key...

Page 82: ... the display and is indicated above the display element In the example below this is key 4 see Fig 6 2 A field then appears for entering the value see Fig 6 3 Fig 6 2 Value Entry Display During Measurement Mode Example Setting the Pump Output Fig 6 3 Value Entry Entering a Value Example Description and Configuration The display element Value Entry is described on page 7 D 10 The configuration is d...

Page 83: ... display and that is indicated over the display element In the example this is key 4 see Fig 6 4 A softkey line then appears with the configured keys see Fig 6 5 Fig 6 4 Key Entry Display During Measurement Mode Example Switching Measuring Components Fig 6 5 Key Entry Using the Keys Example Description and configuration The display element Key Entry is described on page 7 D 12 The configuration is...

Page 84: ...word Every user group set up in the system has a password The password consists of six digits which can be entered via the numeric keypad Passwords are pre assigned for the factory set user groups User group Access to password levels Password Every user 0 None Maintenance team 0 1 471100 Specialist team 0 1 2 081500 Factory Setting Function block specialist 0 1 2 3 325465 CAUTION After entering th...

Page 85: ...r s level Duration of the Change Privilege The change privilege remains in effect until The analyzer automatically switches to measurement mode if the user has not pressed a key for more than about 5 minutes time out Or the user presses the Meas key twice in succession The change privilege remains in effect if the user presses the Meas key only once to return to measurement mode This is indicated ...

Page 86: ...le the HMI with the Level n 1 password has priority over an HMI with the Level n password An exception is the local HMI with Level n password which has priority over a remote HMI with a Level n password 1st User 2nd User Remote HMI has priority Local HMI has priority Remote HMI Level n Priority with Level n 1 Priority with Level n Local HMI Level n Priority with Level n 1 If a second user with an ...

Page 87: ...scription see the AO2000 Function Blocks Descrip tions and Configuration technical bulletin Publication No 30 24 200 EN Access Denied When a user tries to operate the gas analyzer via a locked HMI the following text is displayed after pressing the MENU key Access denied The gas analyzer operation is locked Cancel BACK Access Lock via Password Protection As an alternative to the above described com...

Page 88: ...re integrated into the gas analyzer Password Levels For each menu item its password level 0 1 2 3 is shown in the table For some menu items individual sub menu items are on a higher password level These applies especially to those sub menu items which allow access to function block applications Note The Change password menu item is not assigned to a specific password level To change a password the...

Page 89: ...e system 3 _ Calibration Correction 3 _ System _ Date Time 2 _ Language 2 _ Change password _ Setup system modules 2 _ Save configuration 1 _ Status signals 2 _ Network 2 _ Display 2 _ Maintenance Test _ System _ Atm pressure 2 _ Display test 0 _ Keyboard test 0 _ Analyzer spec adjustm _ Pump 1 _ Atm press anlz 2 _ Calibration reset 1 _ Basic calibration 2 _ Measure cal cell 1 _ Optical adjustm 2 ...

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Page 91: ...Range Switching Menu Path MENU Configure Component specific Measurement range Select component Selection All measurement ranges configured at the factory for a sample component are displayed Procedure Select the measurement range with the arrow keys and press ENTER to confirm The measurement range selected shown on the screen after switching to measurement mode ...

Page 92: ...to range function should be verified after changing measure ment range limits see page 7 A 6 Caldos25 Magnos27 Measurement ranges are factory set and cannot be modified Caldos27 Measurement ranges are freely selectable for binary gas mixtures They are factory calibrated for the largest possible measurement range There is a limit to the setting capability If for example the measurement ranges cross...

Page 93: ... maximum ratio of the spans is 1 20 The measurement ranges can be starting measurement ranges or suppressed measurement ranges Analyzer Module with Calibration Cells If a calibration cell is provided for the measurement component its set point will always be the upper end of the largest measurement range If the new measurement range is smaller than the old measurement range the associated calibrat...

Page 94: ...ndicated on the screen The number of decimal places cannot be increased The altered number of decimal places is shown on the screen after switching to measurement mode Number of Decimal Places When the screen displays the measured value in physical units e g ppm the number of places after the decimal point depends on the size of the set measur ing span Span in physical units 5 5 to 50 50 to 500 50...

Page 95: ...me constant Set Non linear Filter Magnos206 T90 1 Time constant for constant measured value Set T90 2 Time constant for measured value changes Set Threshold T90 2 applies to overshoot Set T90 2 should be adjusted T90 1 for the non linear filter The switching threshold in is generally based on the largest measurement range selected reference measurement range Recommendation for Magnos206 T90 1 3 se...

Page 96: ...er threshold values should be selected so that the gas analyzer is not constantly switching between two measurement ranges see the example below Assigned Measurement Ranges The measurement ranges to be included for autoranging can be initialized The number of measurement ranges available depends on the analyzer module The parameter cannot be selected if the analyzer module has only two measure men...

Page 97: ...d in physical units Set Procedure Hysteresis in physical units Set Standard Configuration As a rule limit value monitoring for those components to be measured by the gas analyzer is factory set This requires that there be enough digital outputs on the I O modules to handle the number of sample components Note Limit value monitors are factory set or user configured Limit Monitor function blocks Tec...

Page 98: ...nos27 analyzer modules Several sample components can be calibrated on these analyzer modules However there is always only one component measured and indicated Procedure Select the active component with the arrow keys and press ENTER to confirm Subsequently use the Measurement range menu item to select the range for the desired component The selected sample component and measurement range are shown...

Page 99: ...er instructions see page 7 C 2 or separately for both languages Text Length The length of the text for the module name is limited to 24 characters for a monolingual entry and limited to two times 10 characters for a bilingual entry Entering the Module Name When entering the module name use the same procedure as entering text see page 6 9 The changed module name is shown in the display after switch...

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Page 101: ...easurement value outputs the measurement signal from an analyzer module for subsequent processing in other function blocks Application Function Block Linking A function block is linked to other function blocks via its inputs and outputs A sequence of interlinked function blocks forms an application in the gas analyzer Various function blocks are factory linked to other function blocks to make appl...

Page 102: ...Component measurement value Hold Limit monitor and Digital output function blocks Figure 7 B 1 Limit monitor Alarm CO Comp meas value CO Digital output Alarm CO Hold Alarm CO Autocal Example Measurement Range Switching Feedback The measurement range switching feedback application see Figure 7 B 2 consists of a factory configured linkage between A Range control function block with several Digital i...

Page 103: ...42 24 10 EN Rev 9 Chapter 7 Gas Analyzer Configuration 7 B 3 The Function Block Sub menu Menu __ Calibrate __ Configure __ Component specific __ Calibration data __ Function blocks ...

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Page 105: ...e must be entered in month day year format Enter year with 4 digits Procedure Time Time must be entered in hour minute second format Enter seconds too Daylight Savings Time The gas analyzer is automatically set to daylight savings time Note This applies only when the time zone has been selected from the continent country city list and not from the GMT values list Factory Setting The gas analyzer i...

Page 106: ...as analyzer In the menu item Language the user can switch between these two languages Other Languages Other user interface languages can be loaded into the gas analyzer using the AO SMT Software Migration Tool AO SMT can be found on the CD ROM which is delivered with the gas analyzer These language pairs are available English German English French English Italian English Dutch English Spanish Engl...

Page 107: ...1 2 081500 Factory Setting Function block specialist 0 1 2 3 325465 Procedure Select the Change password menu item select the user group enter the old password enter the new password 6 digits re enter the new password leave the menu item with Back Password level 0 is not displayed in the Change password menu item CAUTION After entering the password for password level 3 you can access all of the fu...

Page 108: ...lyzer i e entering the main menu and thus switching to the menu mode can be password protected After inhibition the gas analyzer can only be operated when the level 1 password has been entered The level 3 password must be entered to configure the password protection Procedure Press the MENU ACCESS softkey in the Change password menu item and set the password protection ...

Page 109: ...dbus 2 way analog output 4 way analog output 4 way analog input digital I O External I O devices e g cooler I O board Analyzer Modules and External I O Devices Analyzer modules and external I O devices are connected to the system controller via the system bus They must be identified by their serial number see below in order to be recognized by the gas analyzer I O Modules I O modules are plugged o...

Page 110: ...block application to this system module during operation The standard function block applications with the respective connection layouts of the module are listed on page 4 8 Unknown System Module There are several reasons for a system module to have an Unknown status in the Setup system modules menu item Cause Corrective Action The system module was not found after the power supply was turned on s...

Page 111: ...for the new system module 4 In the list the new system module will be shown with a New status Adding a New Analyzer Module or a New I O Device 5 Save the configuration change by pressing ENTER or discard it by pressing Back Step Action 1 Select the Set Up System Modules menu item The list of the system modules existing in the system is displayed 2 Select the I O module which has been added and aut...

Page 112: ...ction CHANGE must be used The type and configuration of the new system module must match the charac teristics of the old system module When an existing I O module has been replaced with an I O module of the same type the new I O module is automatically recognized by the gas analyzer and its configuration is not necessary Step Action 1 Select the Set Up System Modules menu item The list of the syst...

Page 113: ... analyzer Step Action 1 Select the Set Up System Modules menu item The list of the system modules existing in the system is displayed 2 Select the system module to be removed and not replaced Press the DELETE softkey 3 This will irretrievably remove the system module s parameter settings and function block configuration 4 In the list the deleted system module s status will change to Deleted Removi...

Page 114: ...ly reverts to measurement mode by time out When the gas analyzer is booting the last saved valid configuration file is loaded Manual Saving The database can also be saved manually e g to buffer a large function block configuration Backup In addition to automatic and manual saving of the configuration a backup of the current configuration can be saved in a separate memory area It can be loaded e g ...

Page 115: ... available Individual status signals i e Error Maintenance Request and Maintenance Mode Overall status signal If the status signal configuration is changed from overall status signal to indi vidual status signal the digital outputs DO2 and DO3 of the standard function block application status signals externally controlled calibration which possibly are assigned to limit value signals will be overw...

Page 116: ...me max 20 characters no blanks and special characters DHCP off IP address IP address mask und IP gateway address Addresses IP address IP address mask and IP gateway address should be obtained from the network administrator Addresses of TCP IP classes D and E are not supported The address bits that can be varied in the address mask cannot all be set to 0 or 1 broadcast addresses Note The IP address...

Page 117: ... the gas analyzer Only then the Modbus menu item is displayed Parameters The gas analyzer supports the Modbus slave protocol with RTU remote terminal unit mode The Modbus access interval should be 500 ms The Modbus address can be set in the 1 255 range For Modbus type select the interface which connects the gas analyzer to the Modbus network RS232 or RS485 The data transfer default settings are sh...

Page 118: ...ud 3000 KBaud 6000 KBaud Profibus baudrate MBP interface set to 31250 Baud Profibus inputs Measured values Bus analog outputs Analog inputs Analog outputs Digital inputs Bus digital outputs Digital outputs Profibus map Profibus outputs Bus analog inputs Bus digital inputs Warm start With Warm start the Profibus stack is reset comparable with a power off on Profibus restart Cold start With Cold sta...

Page 119: ...the communication partners are not matched This may also cause damage in the function block applications Parameter Function Read Write Example BUS AI Bus analog inputs x x for analog value input into the function block application BUS AO Bus analog outputs x for analog value output from the function block application BUS DI Bus digital inputs x x for control of functions such as auto calibration m...

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Page 121: ...out The gas analyzer normally displays its measured values in a fixed sequence on the various screen pages This also holds true for the measured quantities of system modules that were added by the user see Setting Up System Modules section page 7 C 5 Since up to six values can be displayed on a page the number of system pages depends on the number of values The user cannot delete system pages The ...

Page 122: ...uts exist as function blocks in the system i e all of these measured quantities are displays of function blocks in the system Display Element Positioning on the Screen The display elements can be represented in two sizes A maximum of three large and six small display elements can be represented on a page Large and small display elements can be mixed with each other The positions are numbered as sh...

Page 123: ... of the value Softkeys in the Screen Overview The screen overview softkeys have the following functions PAGE LIST The PAGE LIST softkey calls up the page overview see page 7 D 4 NEW The NEW softkey starts the configuration of a new value e g Bar display or point display see page 7 D 9 Value entry see page 7 D 11 Key entry see page 7 D 13 DELETE The DELETE softkey deletes the value selected by the ...

Page 124: ...figured by user Softkeys in the Page Overview The page overview softkeys have the following functions PAGE ON OFF The PAGE ON OFF softkey toggles the selected screen page on or off NEW The NEW softkey starts the configuration of a new user page see page 7 D 6 DELETE The DELETE softkey deletes the page selected by the user Only empty user pages can be deleted ENTER The ENTER softkey allows the user...

Page 125: ...or user page Position The Position of a display element on a system page is determined by the system It can be changed by being exchanged with another display element The user can freely configure the position on a user page Style The Style of display depends on the source type The following display styles exist bar display point display value entry and key entry Examples of the different display ...

Page 126: ... Start configuring a new page with NEW Either Enter the page name The page overview is displayed 4 Or Go directly to the page overview In this case the system assigns the name Page where page number User Page Configuration 5 The new page will appear in the page overview No Assigned by the system status on Name Enter as in step 4 Usage 0 no values Type User ...

Page 127: ...e new page is a system page the display element is located in the first free position 5 user page the display element is located in the same position as the old page or if this is already taken in position 8 If this is taken the display element cannot be moved display 6 If the new page is a user page and other positions are free the position of the display element can be changed Select the paramet...

Page 128: ...s on a system page its position can only be exchanged with that of another display element the softkey Swap Display is pressed user page Its position can either be exchanged with that of another display element the softkey Swap Display is pressed or it can be moved to a free position the softkey Swap Display is not pressed 4 Select the desired position with the corresponding number key Moving a Di...

Page 129: ...ge is a system page the position of the display element is set by the system it can only be changed using Swap Display see page 7 D 8 7 user page the position must be configured 8 Select the parameter Position The nine possible positions are graphically represented free positions are identified with the position number 9 Select the position with the corresponding number key 10 Select the parameter...

Page 130: ...iptions and Configuration document No 30 24 200 EN Configuration The following are to be configured for the display element Value Entry see page 7 D 11 the start and end of the entry range the number of decimal places in the display two lines of text that are displayed when the display element is used and the password level on which the entry value can be changed Use Values are entered during meas...

Page 131: ...the parameter Type 8 Select display type Value entry This creates a constant function block whose system issued name Value page position is displayed in the parameter Source This name cannot be changed here it can only be changed by configuring the function block see Step 11 9 Select the parameter Config entry and configure the other parameters entry range decimal places text and access level 10 E...

Page 132: ...uration document No 30 24 200 EN Configuration The following are to be configured for the display element Key Entry see page 7 D 13 the number of keys 1 to 6 the keys are assigned to the softkeys the key type key or switch or option key the parameters for each key label value key released and value key pressed two lines of text that are displayed when the display element is used and the password l...

Page 133: ...rameter Type 8 Select the display type Key entry A single function block constant is created whose system default name Value page position is displayed in the parameter Source This name does not appear in the display If necessary it can be changed by configuring the function block see Step 11 9 Select the parameter Config keys and configure the other parameters key number key type label value rele...

Page 134: ... of the display elements and function blocks Figure 7 D 11 shows the results of the configuration example in the display on the left and the field for entering the value on the right This is retrieved by pressing key 4 during measurement see Operating by Value Entry section page 6 10 Figure 7 D 7 Function Block Configuration I1 I2 Pump FB Pump Constant FB Const Pump Step Action 1 Configure the dis...

Page 135: ...15 Example Entering and Displaying the Pump Output continued Figure 7 D 8 Configuring Value Entries Figure 7 D 9 Configuring Bar Display Figure 7 D 10 Linking Function Blocks Figure 7 D 11 Left Display with Elements Value Entry and Bar Display Right Value Entry ...

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Page 137: ...d by the internal clock or by an external control signal or manually via the gas analyzer s display and control unit Externally controlled calibration is triggered by an external control signal Warm up Phase Calibration should only be started after the warm up phase Analyzer Module Warm Up Phase Duration Caldos25 1 5 hours Caldos27 Approx 30 60 minutes for class 1 2 measurement ranges 1 Limas11 Ap...

Page 138: ...on Magnos206 with single point calibration Limas11 with calibration cells Uras26 with calibration cells Option Flow monitoring e g for flowing reference gas or purge gas external needle valve required MG Sample Gas NG Zero Gas Flow Flow Monitor O2 Oxygen Sensor P Pressure Sensor in Analyzer Module c E Analyzer Test Gas Dew Point The test gas dew point must be nearly identical to the sample gas dew...

Page 139: ...ent value to stabilize after manual calibration This interval is Test gas Sample gas purge time 4 x T90 or Test gas Sample gas purge time 1 x T90 1 3 x T90 2 The waiting period is the same as that following automatic calibration see Automatic Calibration section page 8 A 5 Calibration Data Setting the calibration data is described on page 8 B 2 Manual Calibration of an Analyzer Module Manual calib...

Page 140: ...signal Manually via the gas analyzer s display and control unit Internal Start Normally automatic calibration is started on a time interval basis by the internal clock The cycle time is initialized with the calibration data see Calibration Data for Automatic Calibration section page 8 B 3 External Start The Start automatic calibration control signal is needed for external starting of automatic cal...

Page 141: ...libra tion function block see Technical Bulletin 30 24 200 EN Externally controlled with the Start Automatic Calibration control signal with the Block Automatic Calibration control signal As per Interval Controlled Start Manually activated Automatic Calibration Start Block and Cancel with START with STOP Automatic calibration of an analyzer module is impossible when it is operated with the test an...

Page 142: ...es 8 A 2 to 8 A 6 1 Analyzer Module Gas Module Installed with 1 Solenoid To calibrate analyzer modules with simplified calibration procedures Caldos27 with single point calibration Magnos206 with single point calibration Limas11 with calibration cells Uras26 with calibration cells Oxygen Sensor Figure 8 A 2 Sample gas Test gas Analyzer module Electronics module System bus 1 Analyzer Module Gas Mod...

Page 143: ...tal output DO4 on Digital I O Module Status signals Externally controlled calibration standard function block application Figure 8 A 4 System bus Sample gas Test gas Analyzer module Electronics module Digital output 1 Analyzer Module External Gas Supply with 3 Solenoids To calibrate all analyzer modules with zero and span gas even without an integral gas module The external solenoids are controlle...

Page 144: ...the electronics module Digital output DO4 on Digital I O Module Status signals Externally controlled calibration standard function block application If the sample components of the individual analyzer modules show cross sensi tivities among each other it must be made sure by appropriate arrangement of additional solenoid valves that the test gas can be supplied separately to each analyzer module W...

Page 145: ...tact After the transition the High level must be present for at least 1 second 3 Standard function block applications 4 Uras26 analyzer module only External Control Arrangement For the Caldos25 Caldos27 Magnos206 and Magnos27 analyzer modules the external calibration control must be set up such that the zero point calibration always precedes end point calibration The external control unit must pro...

Page 146: ...art and end points of the other measurement ranges are then corrected electronically on the basis of the values established by this calibration A common calibration has no effect on the other sample components in the analyzer module In general the start point zero is calibrated in the smallest measurement range and the end point span is calibrated in the measurement range for which a suitable test...

Page 147: ...component measurement range Span in one range for another component for each detector All detector components and measurement ranges SC Sample and Substitute Gas Components MR Measurement Ranges per Component Setting the Calibration Method see Figure 8 A 7 The calibration method can be set separately for manual automatic and externally controlled calibration For common and substitute gas calibrati...

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Page 149: ...me __ Next cal date __ Next cal time __ Operating mode __ Test gas concentration __ Components for calibration __ Cancel management __ Advanced settings Pump Purge time meas cal gas Purge time zero span gas Purge time cal meas gas Hold time for chart rec Pressure switch activated for Single zero cal Single span cal Zero span cal Calibration method __ Ext controlled calibration __ Calibration metho...

Page 150: ...surement range Calibration Method The method for manual calibration needs to be set see also Calibration Methods section page 8 A 10 For select Common calibration The sample component and The measurement ranges for start and end point calibration for the selected component Substitute gas calibration The substitute gas components for start and end point calibration and The measurement range for the...

Page 151: ...tocalibration Test Gas Concentration The zero and span test gas concentrations to be used as set points for automatic calibration need to be set for the selected sample component and measurement range If the Limas11 or Uras26 analyzer module is equipped with calibration cells the test gas concentration does not have to be set Components for Calibration The sample components to be calibrated during...

Page 152: ...always or never be carried out alone i e without prior zero calibration Zero and Span Calibration Determines whether zero and span calibration will be carried out jointly always or never or at every nth automatic calibration Example Single Zero Calibration Always Single Span Calibration Never Common Zero and Span Calibration Every 7th This setting effects with a cycle time of 1 day a zero calibrat...

Page 153: ...int are outside the initialized limit values the failure of the validation is recorded in the logbook Either the maintenance request status is set or a calibration of the sample component is performed Validation Parameters The parameter settings for automatic calibration also apply to validation After selecting validation in the Operating mode parameter it must be set If the validation result shal...

Page 154: ...l calibration Calibration method parameter The Calibration method parameter is not available in the Limas11 and Uras26 analyzer modules since the externally controlled calibration is always run as common calibration Calculation Method Select whether the calibration is to be calculated as Offset calibration Amplification calibration Offset and amplification calibration Test Gas Concentration The ze...

Page 155: ...cen tration or substitute gas Test Gas for Corrected Sample Components During calibration cross sensitivity and or carrier gas corrections by other meas urement components are switched off Therefore a corrected measurement com ponent should be calibrated only using a test gas consisting of the measurement component and an inert gas like N2 Calibration with Substitute Gases If test gases are not av...

Page 156: ... Components During calibration cross sensitivity and or carrier gas corrections by other meas urement components are switched off Therefore a corrected measurement com ponent should be calibrated only using a test gas consisting of the measurement component and an inert gas like N2 Calibration with Substitute Gases If test gases are not available for calibration the Caldos27 analyzer module can be...

Page 157: ...2 10 000 rTC Ar 7 200 rTC CH4 14 000 rTC H2 60 000 rTC Set points for Standard Gas Air 10 070 rTC CO2 7 500 rTC He 50 000 rTC Calibration Method Standard gas calibration is fundamentally a substitute gas calibration without zero calibration see also Calibration Methods section page 8 A 10 The correction values are transferred to all the analyzer module s sample components and meas urement ranges C...

Page 158: ...Air 10 08 81 1 20 79 1 Coal Air 10 10 79 1 20 79 1 Calibration with Substitute Gases Since the test gases in this table are not available everywhere the analyzer module can be factory set for calibration with a substitute gas In this case an additional measurement range is calibrated for 0 20 Vol CO2 in N2 N2 and CO2 N2 mixtures are available practically everywhere Component 1 CO2 in Flue Gas Meas...

Page 159: ...calibration Water vapor must be absorbed using a cooler If the ambient air contains sample gas compo nents these must be removed with a suitable absorber Test Gases for Span Calibration without Calibration Cells A test gas is required for each measurement component for span calibration without calibration cells The span gas concentration should be 70 80 of the end value of the largest measurement ...

Page 160: ...number of corrections Up to that sample component which is affected by the largest number of corrections Sample components NO SO2 NO2 Cross sensitivity correction NO by SO2 and NO2 SO2 by NO2 NO2 not corrected Example Sequence for zero point calibration 1st NO2 2nd SO2 3rd NO For end point calibration likewise all sample components must be calibrated In doing so a corrected sample component should...

Page 161: ...inert gas like N2 Calibration with Substitute Gases If test gases are not available for calibration the Magnos206 analyzer module can be factory set for calibration with substitute gases see the Calibration Methods section page 8 A 10 Substitute gas calibration of the Magnos206 analyzer module is described using the example of Purity Measurement in CO2 on page 8 C 8 Single Point Calibration Single...

Page 162: ...tent as the process gas CAUTION In order to avoid accumulations of explosive gas mixtures do not use air as a test gas for single point calibration when measuring combustible gases Suppressed Measurement Ranges Single point calibration can also be done within a suppressed measurement range if the suppression ratio is 1 5 In this case as well the O2 concentration of the test gas must lie within the...

Page 163: ...ir Test gas concentration span gas n a Calibration data for manual calibration Calibration method Substitute gas calibration Zero component O2 in N2 Zero range 0 25 Vol O2 Span component n a Span range n a Test gas concentration zero gas 20 96 Vol O2 Test gas concentration span gas n a Calibration data for automatic calibration Calibration method Substitute gas calibration 1 Single zero calibratio...

Page 164: ...substitute gas In this case an additional measurement range is calibrated for 0 25 Vol O2 in N2 N2 and O2 N2 mixtures are available practically everywhere Component 1 O2 in CO2 Meas Range 1 0 1 Vol Meas Range 2 0 15 Vol Meas Range 3 0 25 Vol Meas Range 4 0 100 Vol Measurement Ranges Component 2 O2 in N2 Substitute Gas Meas Range 1 0 25 Vol Calibration Method Substitute Gas Calibration Zero Compone...

Page 165: ... Test Gas for Corrected Sample Components During calibration cross sensitivity and or carrier gas corrections by other meas urement components are switched off Therefore a corrected measurement com ponent should be calibrated only using a test gas consisting of the measurement component and an inert gas like N2 Calibration with Substitute Gases If test gases are not available for calibration the M...

Page 166: ...ibration with a substitute gas In this case an additional measurement range is calibrated for 0 25 Vol O2 in N2 N2 and O2 N2 mixtures are available practically everywhere Component 1 O2 in flue gas Meas Range 1 0 5 Vol Meas Range 2 0 10 Vol Measurement Ranges Component 2 O2 in N2 Substitute Gas Meas Range 1 0 25 Vol Calibration Method Substitute Gas Calibration Zero Component Component 2 Meas Rang...

Page 167: ...s sample gas compo nents these must be removed with a suitable absorber for CO HOPCALIT for CO2 Sodium hydroxide on substrate Test Gases for Span Calibration without Calibration Cells A test gas is required for each detector for span calibration without calibration cells In the case of automatic and externally controlled calibration a test gas mixture is required for all detectors since all are ca...

Page 168: ...t number of corrections Up to that sample component which is affected by the largest number of corrections Sample components CO2 CH4 C3H6 Cross sensitivity correction CO2 by CH4 CO2 by C3H6 C3H6 not corrected Example Sequence for zero point calibration 1st C3H6 2nd CH4 3rd CO2 For end point calibration likewise all sample components must be calibrated In doing so a corrected sample component shoul...

Page 169: ...Therefore when the oxygen sensor is to be calibrated with the following analyzer modules Magnos206 with single point calibration Limas11 with calibration unit Uras26 with calibration units the zero gas should contain the required concentration of oxygen In all other cases the span gas should contain the required concentration of oxygen External Control Arrangement The design of the external contro...

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Page 171: ... or reject calibration with Meas back to measurement value readout Span Calibration 8 Select the Span Gas 9 Turn on the span gas supply 10 If necessary change the test gas concentration shown 1 ENTER 11 When the sample value indication stabilizes initiate span calibration with ENTER 12 Accept the calibration result with ENTER or REPEAT calibration 2 back to step 10 or reject calibration with Back ...

Page 172: ...the cycle intervals initialized Step Action 1 Select the Automatic Calibration menu MENU Calibrate Automatic calibration Only zero calibration ZERO AUTOCAL Only span calibration SPAN AUTOCAL 2 Common zero and span calibration ZERO SPAN AUTOCAL Manual Stop of the Automatic Calibration The user can end the automatic calibration process by pressing the STOP softkey When automatic calibration is stopp...

Page 173: ...ormal Operation of the Gas Analyzer In normal operation the measured values from the installed analyzer modules are shown on the display screen and the green Power LED is lit Module Assembly Function Interval 9 Flow meter Sample Gas Flow Indication Caldos25 10 90 l h max 200 l h Caldos27 10 90 l h Limas11 20 100 l h Magnos206 30 90 l h Magnos27 20 90 l h Uras26 20 100 l h O2 Sensor 20 100 l h Gas ...

Page 174: ...herefore to all sample gas paths and in the Caldos25 and Uras26 analyzer modules to the reference gas path Step Action 1 Plug the outlet of the gas path to be tested 7 in the example 2 Connect plastic tubing with a tee fitted with a shutoff valve to the inlet of the gas path to be tested 4 in the example 3 Connect the free end of the tee to the pressure gauge Blow air or nitrogen through the shuto...

Page 175: ... supply 2 Open the wall housing door or the 19 inch housing front plate 3 Disconnect the thermal link from the thermostat connection terminals 2 4 Bend back the thermal link spring clips on the cable guide and pull the thermal link 1 from the cavity in the thermostat annular heater 5 Insert a new thermal link part number 0740712 in the cavity and close the spring clips 6 Connect the new thermal li...

Page 176: ...is varied by means of mechanical apertures and if necessary by turning the emitter case For this the system housing must be opened see Figure 9 4 page 9 5 Detector Arrangement Figure 9 3 shows the detector layout Detector numbers correspond to the numbers assigned to the series of measurement components as shown on the analyzer module identification plate Figure 9 3 Uras26 Analyzer Module Detector...

Page 177: ... case mounting screws 3 and insert the emitter wrench 6 in openings 4 7 Turn the emitter case 5 until the displayed value is minimized The minimum can be greater than 1 000 000 8 Tighten the emitter unit mounting screws 3 9 Repeat steps 5 8 until a minimum value is displayed 10 Close the 19 inch housing front plate or the wall housing cover If Then The emitter is replaced Perform a phase alignment...

Page 178: ... each sample component If the analyzer module is equipped with calibration units the calibration cells are automatically inserted in the beam path for span alignment Meanwhile zero gas must remain turned on Menu Path MENU Maintenance Test Analyzer spec adjustm Phase adjustm Step Action 1 Select the Phase adjustm menu item 2 Select the Sample component 3 Turn on the zero gas supply 4 Wait until the...

Page 179: ...a year We recommend measuring the calibration cells after end point calibration of a sample component with test gas or after any change in measurement range limits see Limas11 Uras26 Notes for Changing Measurement Range Limits section page 7 A 3 or after a relinearization see Limas11 Uras26 Relinearization section page 9 8 Before measuring the calibration cells Prior to measuring the calibration c...

Page 180: ... with varying concentrations are required for relinearization Number and Type of Meas Ranges Test Gas Concentration 1 Measurement Range Approx 40 60 of the measurement range end value center point gas 2 Measurement Ranges End value of smaller measurement range 2 Measurement Ranges 1 of which is suppressed Start value of suppressed measurement range Menu Path MENU Maintenance Test Analyzer spec adj...

Page 181: ...e hot approx 55 60 C 3 Disconnect the thermal link from the sample cell 1 and or the lamp 2 4 Release the spring clips and or retainer and pull the thermal link from the opening 5 Check the continuity of the thermal link if necessary insert a new thermal link part number 0745836 in the opening and secure it with the spring clips and or retainer 6 Connect the thermal link Close the system housing 7...

Page 182: ...to the analyzer module Turn off the gas analyzer power supply Open the wall housing door or the 19 inch housing cover 2 The sample cell is hot approx 55 C Sample cell removal Loosen the sample gas tubing pipe from the sample cell ports and housing wall and pull them from the housing 3 When removing the sample gas tubing pipe make sure no fluids drip into the housing The sample gas tubing pipe remo...

Page 183: ...page 9 2 Restarting the analyzer module Close the system housing 14 Light penetration during operation leads to erroneous measure ment values and measurement range overflows Intensity status message 15 Turn on the gas analyzer power supply 16 Wait for the warm up phase to end Start the sample gas supply 17 Check linearity Figure 9 6 Aluminum Sample Cell in the Limas11 Analyzer Module 2 1 1 2 1 All...

Page 184: ...y break when the sample cell is handled improperly Step Action Preparation for sample cell removal Quartz Sample Cell Cleaning See Fig 9 7 and 9 8 1 Turn off the sample gas supply to the analyzer module Turn off the gas analyzer power supply Open the wall housing door or the 19 inch housing cover 2 The sample cell is hot approx 55 C Sample cell removal Loosen the sample gas pipes 2 from the connec...

Page 185: ...ports facing toward the housing back wall and secure them by hand tightening the nuts 10 12 The threaded connections must never be tightened any more than hand tight Otherwise the connections may not be securely sealed 13 Place the sample cell 6 in its holder with the gas ports pointing to the left wall as seen from the front above 14 Install 2 mounting brackets 4 making sure that the notches for ...

Page 186: ...as analyzer power supply 21 Wait for the warm up phase to end Start the sample gas supply 22 Check linearity Figure 9 7 Quartz Sample Cells in the Limas 11 Analyzer Module 1 2 3 4 5 6 3 4 1 Threaded Fittings on Housing Back Wall 2 Sample Gas Tubes 3 Allen Screws 3 mm 4 Mounting Bracket 5 Elbow Pivot Fittings see Figure 9 8 for Components 6 Quartz Sample Cell Figure 9 8 Elbow Pivot Fitting Componen...

Page 187: ...n this manner the sample gas side of the cell is sealed so that it is gas tight One 28x2 FKM80 O ring seal is located on the periphery of each of the beam guide tubes The purge gas chamber is sealed so that it is gas tight to the outside by means of this seal The tightness of the sample cell has been tested in the factory for a leakage rate of 1 x 10 6 mbar l s Fig 9 9 Safety Cell in the Limas11 A...

Page 188: ...16 mm 1 Open end wrench 30 mm for sample cell with nominal length 216 mm 2 Open end wrenches 30 mm for sample cells with other nominal lengths 1 Vise 1 Vacuum pen 1 Small pair of tweezers Soft paper towels For cleaning the sample cell and the sample gas tubing 1 Circular brush with plastic bristles diameter approx 20 mm 2 Spray bottles Neutral detergent deionized water ethanol For drying Oil and d...

Page 189: ...a He leakage test CAUTION Toxic caustic or corrosive fluid may be contained in the sample cell This fluid can escape when the sample cell is opened In consequence of this suitable measures for the collection and disposal of the fluid are to be taken before removal of the sample cell Step Action Preparation for Sample Cell Removal 1 Turn off the sample gas and purge gas supply to the analyzer modul...

Page 190: ...d wrench in the vise in order to fix the sample cell in position and unscrew the two beam guide tubes 10 and 11 13 Take care that the cell windows do not fall out and that they are not damaged If the cell windows are stuck to the O ring seals they must be removed by flushing the sample cell with compressed air Wear safety glasses when working with compressed air Point the opening of the sample cel...

Page 191: ...il the detergent has been completely washed out Afterwards rinse with ethanol until the water has been washed out 20 Dry the sample cell and sample gas tubing with oil and dust free air 30 100 l h Clean the entire sample gas line system in the same way Sample Cell Installation 10 11 Carry out steps 21 to 23 on both sides of the sample cell in turn Insert a new O ring seal 22 1x1 6 FFKM70 12 in the...

Page 192: ...on the sample gas tubing 32 Insert the sample cell into the housing obliquely from above in such a way that the sample gas tubes project through the leadthroughs to the outside 33 Slowly lower the sample cell initially onto the side pointing to the beam splitter and then onto the side pointing to the measuring detector and insert in the fixing device 34 Clamp the purge gas hose 7 in the fixing dev...

Page 193: ... hot approx 60 C 3 Remove the cables to the light barrier boards 1 und 2 above the filter wheels 4 Remove the cables from the lamp 3 5 Loosen 2 fastening screws 4 of the support using a 3 mm Allen wrench 6 Remove the support with both filter wheels step motors and lamp 7 Loosen 2 fastening screws 5 of the lamp 3 using a 3 mm Allen wrench 8 Remove complete lamp 3 from the support 6 9 Loosen the 12 ...

Page 194: ...for the warm up phase to end 17 Perform an amplification optimization see Amplification Optimization section page 9 23 18 Recommendation Check sensitivity and linearity 2 4 1 4 3 Figure 9 11 Lamp EDL in the Limas11UV Analyzer Module 2 1 4 6 5 4 3 7 8 9 10 11 3 1 Light Barrier Board 1 2 Light Barrier Board 2 3 Lamp EDL 4 Fastening Screws of the Support 5 Fastening Screws of the Lamp 6 Support 7 Tem...

Page 195: ... the new lamp prior to installation Perform amplification optimization for all sample components thereby entering the serial number of the new lamp When a module has been removed or inserted in the beam path Write down the serial number of the installed lamp Perform amplification optimization for all sample components thereby entering an arbitrary lamp number Perform amplification optimization for...

Page 196: ...nt 4 Press the New Lamp or Optimize or Optimize All softkey After pressing New Lamp a window will be appear for entering the serial number of the new lamp After this the amplification optimiza tion procedure will run automatically for all sample components and cannot be interrupted 5 Wait for measurement value readings to stabilize and end the amplifi cation optimization procedure by pressing ENTE...

Page 197: ...Remove the hose clamps from both sides of the disposable filter and disconnect the hoses 4 Properly dispose of the contaminated filter Attach the hoses to the new disposable filter and fasten them with the hose clamps 5 Pay attention to the flow direction The flow direction Ö is marked on the disposable filter housing 6 Place the disposable filter in the support 7 Check the integrity of the analyz...

Page 198: ...deactivated manually for instance in emergency situations An emergency shutdown cannot be bypassed by automatic calibration Pump Output Adjustment The output of the pump installed in the internal gas module can be adjusted manually only when the pump is in operation If there is a flow sensor in the gas module its reading is shown when adjusting the pump output Menu Path MENU Maintenance Test Analy...

Page 199: ...in AO2000 Func tion Blocks Descriptions and Configuration Publication No 30 24 200 EN contains a detailed description of the function block Menu Path MENU Configure Function blocks Outputs Analog output Figure 9 14 Analog Output Function Block Parameters Changing Current Range The current range is changed using the User range parameter Selection The current range choices are 0 20 mA 2 20 mA and 4 ...

Page 200: ...dules have a pressure sensor MultiFID14 cannot be built in Use the MENU Diagnostic Information System overview menu item and select the appropriate analyzer module to determine if a pressure sensor is installed Operating Altitude Mean Air Pressure meters above mean sea level hPa mbar psi mm Hg Torr in Hg 200 1037 15 04 778 30 63 100 1025 14 87 769 30 28 0 1013 14 69 760 29 92 100 1001 14 52 751 29...

Page 201: ...pressure sensor is calibrated to 1013 hPa This is the reference pressure for the test gas concentration when measuring the calibration cells If the air pressure value needs to be changed the following items are also required Calibrate the sample components with test gases and then Measure the calibration cells Air Pressure Value Correction The current atmospheric pressure can be entered as a corre...

Page 202: ...st basic calibration The relative offset and amplification drift values are calculated between the last and next to last automatic calibration The absolute and relative offset and amplification drift values can be viewed in the MENU Diagnostic Information Module specific Status menu item When should a calibration reset be performed A calibration reset should be performed if an analyzer module can ...

Page 203: ...pling point Check prior to a Basic Calibration Prior to a basic calibration check and ensure That the gas analyzer is in proper operating condition That the sample conditioning units are in proper operating condition That the correct test gases are being used Test Gases The zero and or span calibration test gases are required for a basic calibration Performing the Basic Calibration The basic calib...

Page 204: ...nent concentration can be measured in two ways Using the analyzer module with which the sample component is measured internal cross sensitivity correction possible only with the Limas11 and Uras26 analyzer modules or With another AO2000 analyzer module or another analyzer external cross sensitivity correction The correction signal i e the measured value of the interference component is transferred...

Page 205: ...is an amplification correction When should a carrier gas alignment be performed A carrier gas alignment i e alignment of the carrier gas correction function should not be performed in normal operation We recommend checking the carrier gas correction once a year Test Gas for Carrier Gas Alignment A gas mixture with the appropriate concentrations of sample and interference components is required as ...

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Page 207: ...urement Range Limits If a sample component value is 130 or 100 of the measurement range span the sample component value in the display flashes A status message is also generated which is not entered into the logbook The thresholds established cannot be changed Transgression of Limit Values If a sample component value is above or below a limit value this status can be communicated as a binary signa...

Page 208: ...nfiguring the Message generator function block status messages from the analyzer and peripherals can be linked into the status message processing system see Technical Bulletin 30 24 200 EN AO2000 Function Blocks Descriptions and Configuration for details How are status messages processed see Figure 10 1 Status messages are shown on the screen and recorded in the log Status messages set a correspon...

Page 209: ...s gener ated By pressing the softkey the user can recall the status message summary and view status message details Logging Status Messages Status messages are logged Messages concerning a transient gas analyzer state with no direct effect on measurements are not logged Such messages include A password is active This system is temporarily under remote control Automatic calibration in progress ...

Page 210: ...ntenance Required The analyzer is in a state that will soon require user intervention The value is valid Maintenance Mode The gas analyzer is being calibrated or serviced Discard the value as a process measurement value Individual Status by Analyzer Module or Sample Component In principle the individual status signals apply to the entire gas analyzer system status However by configuring the Messag...

Page 211: ...nt The system operates normally after the status is cleared however the operator is aware of the status When the status is cleared the LED goes out and the status signal is reset The status message is only canceled after operator acknowledgment In this manner the operator is aware of the system malfunction Example No new measurement values from the analog digital converter Status Messages Requirin...

Page 212: ...up Status signal set a Status message appears Status ends LED goes out Status signal reset I Status message remains Acknowledge Status message canceled Status begins LED lights up Status signal set a Status message appears Acknowledge A Status message remains Status ends LED goes out Status signal reset Status message canceled Status Messages Requiring Acknowledgment and Intervention Status begins...

Page 213: ...led display Text Full text of the status message as shown in the detailed display O x Status message sets the overall status E x Status message sets the Error individual status M x Status message sets the Maintenance Request individual status F x Status message sets the Maintenance Mode individual status Reaction Remark Explanations and corrective measures in case of status messages Continued on n...

Page 214: ...sword is active To delete press the MEAS key on the measurement value display Not logged 110 System booting Not logged 111 This system is temporarily under remote control Not logged 112 Display control unit synchronizing with analyzer Please wait Not logged 113 The system time was changed from to Not logged 114 The system is saving the changed parameters Please wait 116 The Profibus Module is moun...

Page 215: ...ion error x x Notify service 216 The analyzer module has an internal program error x x Notify service Analyzer Modules 300 No new measurement values from analog digital converter x x Notify service 301 Measurement value exceeds the analog digital converter value range x x Check sample gas concentration Notify service 302 Offset drift exceeds half the permissible range x 303 Offset drift exceeds pe...

Page 216: ...tus message from the applicable pressure detector 313 Cross sensitivity correction is impossible for this component because the correction value is invalid x See the status message from the applicable correction detector 314 Carrier gas correction is impossible for this component because the correction value is invalid x See the status message from the applicable correction detector Auxiliary Dete...

Page 217: ...e is being maintained see page 10 19 Check the analyzer module thermal link and replace if necessary Pressure Regulator 326 No new measurement values from analog digital converter x x Notify service 327 Measurement value exceeds the analog digital converter value range x x Notify service 328 A computer error occurred during calculation of the measurement value x x Notify service 329 Pressure above...

Page 218: ...rement value range Value 100 MRS not logged Limas 356 Analyzer in warm up phase x x Status message during warm up phase If the status message appears after warm up a temperature error has occurred in the lamp or in the sample cell or in the measurement or reference detector amplifier Notify service 357 Limas motor optimization in progress x x Status message after warm up phase 358 Lamp intensity a...

Page 219: ...ts measurement x x 369 LS25 analyzer detector error x x 370 The beam transmission exceeds the permissible range x Low transmission 371 The temperature input signal exceeds the permissible range x T out of range 372 The pressure input signal exceeds the permissible range x P out of range 373 The flow sensor signal exceeds the permissible range x 374 The detector signal is too low for measurement x ...

Page 220: ...ice 405 A ZO23 function test has been performed For information 406 This ZO23 analyzer has failed the function test x Change test factor or check cell with test gas 407 A ZO23 function test is running x 408 The ZO23 function test is canceled x Keep sample gas concentration constant or use test gas Calibration 500 System bus communication defect 501 Requested function is not available on the system...

Page 221: ... done because the value is not stable 519 Preamplifier overflow error Calibration could not be performed because of preamplifier override 520 Initial zero calibration started For information 521 Initial zero calibration ended For information 522 Initial zero calibration interrupted For information 523 Initial zero calibration incomplete System bus communication defect during calibration For inform...

Page 222: ...limits for 537 Automatic validation out of limits for x User Configured Messages 800 An external error occurred during x x 801 A user defined error occurred during x x 802 A user defined maintenance requirement occurred during x 803 A user defined maintenance mode event occurred during x These Message Generator function block default texts are supplemented with the text prepared during function bl...

Page 223: ... x 1102 Condensate penetration in cooler x x Sample gas feed module pump is automatically turned off Check the system cooler and sample gas preparation 1103 Flow rate inadequate in cooler x Check the system cooler and sample gas preparation 1104 Cooler condensate level too high x 1105 Cooler condensate level too high x Empty the condensate bottle 1106 Cooler reagent level too low x Fill the reagen...

Page 224: ...t circuit Identify cause e g line break and repair Flow Problem External gas lines or filters dirty plugged or leaking Disconnect the gas analyzer from the gas preparation system Blow out the gas lines with compressed air or clear them mechanically Change the filter elements and packings Check gas line seal integrity Gas analyzer gas paths crimped or leaking Disconnect the gas analyzer from the ga...

Page 225: ...rafts Ambient temperature outside of permissible range Protect the gas analyzer from cold and heat sources such as the sun ovens and vats Maintain the permissible ambient temperature range Ambient temperature range during operation with analyzer module installed in a system housing without electronics module installed in a system housing with electronics module or with power supply only Caldos25 5...

Page 226: ...ge 9 3 for instructions Leaking thermostat or open purge gas connections Check the seal integrity between the thermostat chamber and the mounting flange tighten mounting bolts or replace O rings as needed Seal the analyzer purge gas inlet and outlet with sealing connectors Check the purge gas flow maximum operating level of 20 l h positive pressure pe 2 to 4 hPa and reduce as needed Unstable Readi...

Page 227: ...le measurement value readings Three different cases can be identified 1 If only the measurement receiver values have dropped the sample cell is probably contaminated Clean the sample cell see pages 9 10 9 12 or 9 15 for instructions 2 If all four values are have dropped by similar amounts then lamp intensity has probably decreased Perform an amplification optimization see page 9 23 for instruction...

Page 228: ...nstant T90 see page 7 A 5 for instructions Gas path leakage Check the integrity of the analyzer module gas paths and if applicable of the lines to the gas module see page 9 2 for instructions Loss of sensitivity Check the sensitivity variation Indication 75 The Maintenance request status signal appears The detector involved will need to be changed soon Indication 50 The Failure status signal appea...

Page 229: ...ng it and blowing it with compressed air Check the operation of the upstream sample gas cooler Inadequate gas supply Connect the flow meter ball chamber or pressure gauge directly to the gas supply pump and measure the pressure or vacuum Check the pump and change the membrane as necessary Check and if necessary replace the disposable filter see page 9 24 for instructions Check and if necessary rep...

Page 230: ...system housing identification plate inside the right wall of the 19 inch rack unit and inside the left wall of the wall mount housing as well as in the analyzer data sheet The system controller and system module software versions are found in the MENU Diagnostics Information System overview menu item An exact description of the problem or status as well as the status message text or number This in...

Page 231: ... gas supplies 2 Purge the gas lines and analyzer module with dry fresh air or nitrogen for at least 5 minutes 3 Turn off the gas analyzer power supply Long Term Shutdown 4 Remove the gas lines from the analyzer module ports Tightly seal the gas ports 5 Disconnect the electrical wiring from the electronic module and if applicable the analyzer module connections Ambient Temperature Ambient temperatu...

Page 232: ...nalyzer module to the service department e g for repair please indicate which gases have been supplied to the analyzer module This information is needed so that service personnel can take any safety precau tions required for harmful gases Step Action If the original packaging is not available wrap the gas analyzer in bubble foil or corrugated cardboard When shipping overseas additionally place the...

Page 233: ...dules are powered with 24 VDC from the central unit power supply or from separate power supplies System Bus The system controller the analyzer modules and the I O devices are intercon nected via the system bus The system bus is linear in design and has a maximum length of 350 meters Interfaces Various types of interfaces can be used by the gas analyzer to communicate with external systems These in...

Page 234: ...analyzer module Components Each analyzer module consists of A sensor The associated electronics with an integral processor Oxygen Sensor The electrochemical oxygen sensor is available as an option in combination with an analyzer module Gas Module Gas Module The gas module is used to supply gases to the gas analyzer A fully equipped gas module contains the following elements One gas supply pump One...

Page 235: ...ia the system bus The interfaces for controlling associated systems and for communicating with external systems are located on the system controller Ethernet 10 100 1000 BASE T interfaces and on the I O modules I O Modules The I O modules are attached and directly connected to the system controller board There are various types of I O modules The 2 way analog output module has two analog outputs T...

Page 236: ...ions or conduits The housing is generally purged via the analyzer module purge gas ports Separate purge gas ports are installed to purge a central unit that has no analyzer module installed Display and Control Unit Display and Control Unit Components The display and control unit contains A back lit graphics screen 320x240 pixel resolution Three status indication LED s A keypad with six softkeys tw...

Page 237: ...nge span at electronic T90 time 0 sec Detection limit 4 σ 1 of smallest measurement range span at electronic T90 time 0 sec Flow influence 1 to 5 of span at a flow change of 10 l h At the same sample and test gas flow rate the flow influence is automatically compensated Associated gas influence The knowledge of the sample gas composition is necessary for the analyzer configuration Measurement resu...

Page 238: ...e is automatically compensated Associated gas influence The knowledge of the sample gas composition is necessary for the analyzer configuration Temperature influence At each point in the measurement range 0 5 of span per 10 C based on temperature during calibration Ambient temperature in permissible range thermostat temperature 60 C Air pressure influence 0 25 of span per 10 hPa for the smallest p...

Page 239: ...ed gas effect optional Installation of filter cells or internal electronic cross sensitivity correction or carrier gas correction for a sample component by other sample components measured with the Limas11 Temperature influence At zero point 1 of span per 10 C for ranges smaller than Class 1 to Class 2 2 of span per 10 C On sensitivity 1 of measured value per 10 C Ambient temperature in permissibl...

Page 240: ...ne C2H6 0 46 Helium He 0 30 Ethylene C2H4 0 29 Neon Ne 0 13 Methane CH4 0 24 Nitrogen N2 0 00 Propane C3H8 0 98 Nitrogen oxide NO 43 00 Propylene C3H6 0 55 Nitrogen dioxide NO2 28 00 Trichloroethylene C2HCl3 2 17 Nitrous oxide N2O 0 20 Vinylchloride CH2CHCl 0 75 Carbon monoxide CO 0 01 For further associated gases refer to EN 61207 3 Temperature influence At zero point 0 02 Vol O2 per 10 C On sens...

Page 241: ...wn on the identification plate Temperature influence At zero point 2 of span per 10 C On sensitivity 0 5 of measured value per 10 C both based on temperature during calibration Ambient temperature in permissible range thermostat temperature 63 C Air pressure influence At zero point 0 05 Vol O2 per 1 air pressure change On sensitivity without pressure correction 1 5 of measured value per 1 air pres...

Page 242: ...r carrier gas correction for a sample component by other sample components measured with the Uras14 Temperature influence At zero point 1 of span per 10 C for ranges smaller than Class 1 to Class 2 2 of span per 10 C On sensitivity with temperature compensation 3 of measured value per 10 C On sensitivity with thermostat effect at 55 C option 1 of measured value per 10 C Ambient temperature in perm...

Page 243: ...ic T90 time static dynamic 5 0 sec Flow influence Flow rate in 20 to 100 l h range 2 of measurement range scale Temperature influence Ambient temperature in permissible range 0 2 Vol O2 per 10 C Air pressure influence At zero point No effect On sensitivity without pressure correction 1 of measured value per 1 air pressure change On sensitivity with pressure correction 0 2 of measured value per 1 a...

Page 244: ...puts II 2 Safe Isolation The electronics module power supply is galvanically isolated from other circuits by means of reinforced or double insulation Operational 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 I...

Page 245: ...and heavy metal dusts results in faster aging and or the destruction of the measuring cell The ingress of liquids into the analyzer module can lead to serious damage including the destruction of the measuring cell After disconnection of the power supply the case of the measuring cell has an excess temperature of approx 95 C which decreases only slowly Intended Application The trace oxygen analyzer...

Page 246: ...sure If the sample gas flow rate is too low contaminants from the gas lines leaks permeability desorption will adversely affect the measuring result If the sample gas flow rate is too high asymmetrical cooling of the sensor may cause measuring errors This can also cause faster aging or damage to the measuring cell Flammable and Corrosive Gases The analyzer must not be used for measurement of ignit...

Page 247: ...l O2 Factor 100 1 56 100 0 984 O2 concentration 20 93 Vol O2 0 984 20 6 Vol O2 Test Gases End point Test gas with oxygen concentration in the smallest measuring range e g 2 ppm O2 in N2 Note The pressure conditions at reference point and end point must be identical Connection Diagram Figure A 3 1 Connection Diagram 1 2 7 8 1 Sample gas inlet 3 mm Swagelok 2 Sample gas outlet 1 8 NPT female thread ...

Page 248: ... 2 NW2 O N 8 ppm 2 2 30 l h 8 0 2 l h Reference Air Referenzluft 1 2 11 12 13 4 5 7 8 9 6 Stainless Steel Tube Edelstahlrohr FPM Hose FPM Schlauch Figure A 3 3 ZO23 without Internal Pump and Flow Sensor Example of Sample Conditioning ZrO2 1 2 3 4 5 10 9 8 14 15 11 12 13 F F N2 O N 2 ppm 2 2 NW2 NW2 NW4 NW4 3 m 3 m O N 8 ppm 2 2 30 l h 8 0 2 l h Reference Air Referenzluft Stainless Steel Tube Edels...

Page 249: ...ch over valve should be 4 mm A bypass can be placed upstream of the first switch over valve to obtain a faster analysis With a nominal diameter of 4 mm the bypass should be longer than 3 m to prevent back diffusion from the ambient air The sample gas pressure must be reduced at the sampling point A heated adjust able pressure regulator is also to be provided if samples are taken from liquid gas li...

Page 250: ...n 3 m to prevent back diffusion from the ambient air On account of possible leaks the flow meters are always placed in the bypass feed path downstream of the branch to the gas analyzer respectively downstream of the gas analyzer they may on no account be installed in the sample gas supply line upstream of the measuring cell Exhaust Gas The sample gas and the bypass must be conducted to the atmosph...

Page 251: ... supply line with oxygen free gas e g with nitrogen from a loop feeder or with sample gas flow rate 5 to 10 l h 3 Set reference point to 20 6 Vol O2 Please refer to page A 3 3 for calculation of the oxygen concentration 4 Feed end point gas e g 2 ppm O2 in N2 and wait until the measured value has stabilized duration max 2 hrs 5 Set end point value in accordance with the certificate of analysis of ...

Page 252: ...t the change in the sample gas was too high during the test Test Factor The test result can be tailored to the required response time In this connection the test factor can be set by the user within the range 1 to 200 A test factor of 100 is set ex works Test factor 1 to 99 Test requirements lower T90 time 60 s Test factor 100 to 200 Test requirements higher T90 time 60 to 20 s If the test criteri...

Page 253: ...r 100 ppb O2 whichever is greater for a flow rate of 8 0 2 l h The flow rate must be kept constant to 0 2 l h in the permissible range The permissible range is 5 to 10 l h The flow rate is kept constant to 8 0 2 l h with integrated pump and flow control Associated Gas Influence Inert gases Ar CO2 N2 have no effect Flammable gases CO H2 CH4 in stoichiometric concentrations to the oxygen content Con...

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Page 255: ...A 8 Associated gas influence 8 C 1 Calibration Test gas 8 C 1 with substitute gas 8 C 1 8 C 4 Flow meter installation 3 13 Gas connections 3 4 3 5 Gas inlet conditions 1 3 Housing purge 3 12 Modifying range limits 7 A 2 Operating specifications A 2 1 Reference gas flow rate 5 5 Troubleshooting 10 20 Caldos27 Active component selection 7 A 8 Associated gas influence 8 C 2 Calibration Single point c...

Page 256: ...me Filter Date of next automatic calibration 8 B 3 Setting system 7 C 1 Decimal places Changing the number 7 A 4 Digital I O board I O boards Digital I O module I O modules Dimensional diagrams 2 4 Display and control unit 6 1 A 1 4 Cancel keys 6 6 Numeric keypad 6 5 Operating modes 6 1 Screen 6 2 Softkeys 6 7 Status LED s 6 4 10 4 Disposable filter in the gas module Replacing 9 24 Drift 9 29 E El...

Page 257: ...al needed 1 10 Interfaces A 1 1 I O modules A 1 3 Connection diagrams 2 way analog output module 4 4 4 way analog output module 4 5 4 way analog input module 4 6 Digital I O module 4 7 Modbus module 4 3 Profibus module 4 2 L Language of the user interface Selecting 7 C 2 LED s Status LED s Limas11 Amplification optimization 9 23 Calibration 8 C 5 Calibration cells 8 C 5 Cross sensitivity correctio...

Page 258: ...surement range switching 7 A 6 Modifying range limits 7 A 2 Switching 7 A 1 MENU key 6 7 Menu tree 6 16 Message display 6 3 Modbus configuration 7 C 13 Modbus module I O modules Module name changing 7 A 9 N Network configuration Bus I Os 7 C 15 Ethernet connection 7 C 12 Modbus connection 7 C 13 Profibus 7 C 14 Numeric keypad 6 5 O Operating specifications Caldos25 A 2 1 Caldos27 A 2 2 Limas11 A 2...

Page 259: ...configuration 7 D 6 Value entry 7 D 10 Configuring 7 D 11 Operating 6 10 Serial number of the system modules 7 C 6 Shipping 11 2 Shutdown 11 1 Signal line connection 4 15 Single calibration 8 A 10 Single point calibration Caldos27 with standard gas 8 C 2 8 C 3 Magnos206 8 C 7 8 C 8 Softkeys 6 7 Software version x Standard equipment 1 9 Standard function block applications Connections 4 8 Standard ...

Page 260: ... 10 18 Gas module 10 23 Caldos25 Caldos27 Magnos206 Magnos27 10 20 Limas11 10 21 Uras26 10 22 U Unpacking 2 1 Unstable readings in Caldos25 Caldos27 Magnos206 Magnos27 10 20 in Limas11 10 21 in Uras26 10 22 Uras26 Calibration 8 C 13 Calibration cells 8 C 13 Cross sensitivity correction 8 C 14 Test gas 8 C 13 Calibration cells 7 A 3 Measurement 9 7 Flow meter installation 3 13 Gas connections 3 9 G...

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Page 262: ...uct improvement and the right is reserved to modify the information contained herein without notice Printed in the Fed Rep of Germany 03 09 ABB 2009 42 24 10 EN Rev 9 ABB Automation GmbH Analytical Stierstaedter Strasse 5 60488 Frankfurt am Main Germany Phone 49 69 7930 40 Fax 49 69 7930 4566 E Mail analytical mkt deapr de abb com ...

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