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ABB AO2000 Series, Operating Instructions Manual

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ABB AO2000 Series Operating Instructions Manual Download Page 341

 

AO2000

 CONTINUOUS GAS ANALYZERS  |  OI/AO2000-EN REV. B 

341

 
 

 

Pneumatic module: Troubleshooting 

Flow error 

Condensation in the flowmeter 

•

 

Disconnect gas analyzer from the gas conditioning system. 

•

 

Dry the flow meter by heating 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 if necessary. 

•

 

Check the disposable filter and replace (see page 314) if necessary. 

•

 

Check the solenoid valve(s) and replace if necessary. 

 

Summary of Contents for AO2000 Series

Page 1: ... ABB MEASUREMENT ANALYTICS OPERATING INSTRUCTION AO2000 Continuous gas analyzers Integrated analyzer system Measurement made easy ...

Page 2: ......

Page 3: ...tion 27 Limas11 IR Uras26 Version for the Safety Concept 28 Caldos25 Caldos27 Magnos206 Version for the Safety Concept 30 Purge gas flow monitoring 32 Version for use in Class I Div 2 explosion hazard areas 33 Preparation for installation 34 Scope of supply and delivery 34 Material required for the installation not supplied 35 Installation location 37 Pressure sensor 39 Housing purge 40 Power supp...

Page 4: ... heated sample gas connection 101 Fidas24 Connecting the sample gas line unheated sample gas connection 105 Connecting the electrical leads 107 Electronics module connection diagram 107 Profibus module Electrical connections 108 Modbus module Electrical connections 109 Analog output module Electrical connections 110 Analog input module Electrical connections 111 Digital I O module Electrical conne...

Page 5: ...ent selection 164 Configuring a component 165 Changing module name 179 Gas analyzer configuration Function blocks 180 The Function blocks concept 180 Standard configuration 181 The Function blocks sub menu 182 Gas analyzer configuration System functions 183 Setting the time zone date and time 183 Selecting user interface language 184 Changing the password 185 Inhibit operation 186 Setting up syste...

Page 6: ...tion data for externally controlled calibration 231 Output current response 232 Notes for calibrating analyzer modules 233 Caldos25 Notes for calibrating 233 Caldos27 Notes for calibrating 234 Caldos27 Single point calibration with standard gas 235 Caldos25 Caldos27 Substitute gas calibration 237 Fidas24 Notes for calibrating 238 Fidas24 NMHC Notes for calibrating 241 Fidas24 Substitute gas calibr...

Page 7: ...er effectiveness testing 286 Uras26 Optical alignment 287 Uras26 Phase alignment 290 Limas11 IR Limas21 UV Limas21 HW Uras26 Measurement of calibration cells 291 Limas11 IR Limas21 UV Limas21 HW Uras26 Relinearization 292 Limas11 IR Limas21 UV Limas21 HW Thermal link replacement 293 Limas11 IR Limas21 UV Aluminum sample cell cleaning 294 Limas11 IR Limas21 UV Limas21 HW Quartz sample cell cleaning...

Page 8: ...346 Caldos25 Operating specifications 346 Caldos27 Operating specifications 347 Fidas24 Fidas24 NMHC Operating specifications 348 Limas11 IR Limas21 UV Operating specifications 349 Limas21 HW Operating specifications 350 Magnos206 Operating specifications 351 Magnos28 Operating specifications 352 Magnos27 Operating specifications 353 Uras26 Operating specifications 354 ZO23 Operating specification...

Page 9: ...idas24 NMHC analyzer module Divergent and supplementary descriptions and instructions for the Fidas24 NMHC analyzer module are added if applicable Additional documentation Title Publication No AO2000 Series Continuous gas analyzers Data sheet DS AO2000 EN Function blocks Descriptions and configuration Technical information 30 24 200 EN AO HMI Remote control interface Technical information 30 24 31...

Page 10: ...ased to supply additional information as required Please contact your local service representative For emergencies please contact ABB Service Telephone 49 0 180 5 222 580 Telefax 49 0 621 381 931 29031 E mail automation service de abb com Symbols and typefaces in this instruction ATTENTION identifies safety information to be heeded during gas analyz er operation in order to avoid risks to the user...

Page 11: ...cation see page 12 2 Follow safety precautions see page 13 3 Prepare for the installation provide the requisite material see page 34 4 Unpack the gas analyzer see page 73 5 Check gas path seal integrity see page 268 6 Install the gas analyzer see page 79 7 Connect the gas lines see page 80 8 Connect the electrical leads see page 107 9 Check the Installation see page 126 10 Purge the gas paths and ...

Page 12: ...e note the information on intended application for versions with type of protection II 3G for measurement of non flammable gases and vapors see page 18 with type of protection II 3G for measurement of flammable and non flammable gases see page 20 and for use in Class I Div 2 explosion hazard areas see page 33 Special requirements for the operator Special requirements for the operator The operator ...

Page 13: ...when the device is used in other countries Device safety and safe operation The device is designed and tested in accordance with the relevant safety standards and has been shipped ready for safe operation To maintain this condition and to assure safe operation read and follow the safety infor mation in this operating instruction Failure to do so can put persons at risk and can lead to device damag...

Page 14: ...t that safe operation is no longer possible the device should be taken out of operation and secured against unauthorized use The possibility of safe operation is excluded If the device is visibly damaged If the device no longer operates After prolonged storage under adverse conditions After severe transport stresses ...

Page 15: ...gnition attempts are unsuccessful The interior of the gas analyzer is not assigned to an explosion protection zone no explosive gas mixture can escape from it to the outside Conditions to be complied with by the end user The end user must comply with the following prerequisites and conditions to ensure safe operation of the gas analyzer The gas analyzer may be used for the measurement of flammable...

Page 16: ...ic shut off of the combustion gas supply to the gas analyzer in case of an instrument supply failure a visible or audible alarm must be triggered see page 335 When measuring flammable gases it must be made sure that in case of a failure of the instrument air supply or of the analyzer module itself the sample gas supply to the analyzer module is shut off and the sample gas path is purged with nitro...

Page 17: ... thorized access interference intrusion leakage and or theft of data or in formation ABB Ltd and its affiliates are not liable for damages and or losses related to such security breaches any unauthorized access interference intrusion leakage and or theft of data or information Active services and open ports on the Ethernet interface 22 tcp Used for software update only No direct access to the devi...

Page 18: ...nless specified otherwise in our certificates Atmospheric conditions are defined as follows Temperature range 20 to 60 C Pressure range pabs 80 to 110 kPa 0 8 to 1 1 bar Ambient air with normal oxygen content typically 21 v v If the atmospheric conditions are not met the operator is obliged to ensure the safe operation of our equipment outside the atmospheric conditions by means of further measure...

Page 19: ...le the power is on In order to comply with degree of case protection IP54 Cables have to be properly inserted in the screwed cable glands and sealed by screwing the nut firmly Cable connectors not in use have to be closed with suitable vent plugs System bus and 24 VDC power supply terminals not in use have to be closed with the provided seals Only the original battery types Varta CR2032 type no 60...

Page 20: ...king note of this operating instruction Important safety note According to EU Directive 2014 34 EU and the general requirements for equipment installed in explosive atmospheres stated in IEC 60079 0 the scope of the certification of our equipment is limited to atmospheric condi tions unless specified otherwise in our certificates Atmospheric conditions are defined as follows Temperature range 20 t...

Page 21: ...ith an ignition protective gas is provided for example in order to continue oper ating the gas analyzer each supply point must be able to maintain the re quired pressure level or the required amount of ignition protection gas in dependently of each other The two supply points may have common pipes or lines Installation of the gas analyzer and the supply lines When installing the gas analyzer as we...

Page 22: ... the pressurized equipment for normal operation Sample gas supply 3 hPa 1 5 4 5 hPa purge gas supply 50 hPa 1 5 75 hPa The materials used for the ducts and connecting parts shall not be ad versely affected by the specified protective gas nor by the flammable gas or vapors in which they are to be used Ducting should be located in a non hazardous area as far as is reasona bly practicable Ducts for e...

Page 23: ...it system housing with display and operator control unit power supply unit and electronics module and the analyzer module The analyzer module is installed in the central unit or in a separate housing The version satisfies the provisions of the European Directive 2014 34 EU ATEX Directive It is designed to EN 60079 15 and EN 60079 2 NOTE The Declaration of Conformity can be found on the DVD ROM Sof...

Page 24: ...Pa above sample gas pressure In this way the sample gas path meets the basic requirements for no release as specified in EN 60079 2 2005 Section 11 1 At appropriate intervals the sample gas pressure and function of the pressurized enclosure are checked At appropriate intervals the sample gas path and purge gas path are checked for leak tightness Remark The term purging gas is used in the sense of ...

Page 25: ...s pabs 1 1 bar oxygen content 21 vol Temperature Class T4 for Limas11 IR T6 not potentially explosive under normal conditions if poten tially explosive in the event of a fault then only seldom and briefly in ac cordance with Zone 2 only for Limas11 IR occasionally potentially explosive under normal conditions in accordance with Zone 1 Temperature Class T4 Mixtures of flammable gases and vapors and...

Page 26: ... min 40 l h An initial purge is not necessary if it has been proved that no flammable sample gas is present in the sample gas path or purge gas path Operation A capillary located in the purge gas path monitors that the required positive pressure of the purge curtain is 0 5 hPa above that of the sample gas at the above purge gas flow rates Monitoring Compliance with the above purge gas flow rate is...

Page 27: ...st be corrected quickly The gas analyzer can remain in operation If the fault cannot be eliminated quickly supply of the sample gas must be cut off If the gas analyzer is not in operation then the supply gases must be cut off Tests At start up after failure of the pressurized enclosure and at regular intervals a test for proper functioning of the pressurized enclosure must be conducted by a techni...

Page 28: ...of 15 to 20 l h and at a positive pressure of pe 50 hPa As a result of the capillary a posi tive pressure of pe 7 to 20 hPa is established The purge gas flow is meas ured by a flow meter located downstream from a capillary in the sample gas path The outlet pressure should be open to atmospheric pressure The signal from the flow sensor is monitored and evaluated by a function block application see ...

Page 29: ...ring Analyzer Purge Out 6 Purge gas inlet for housing 7 Pressure sensor option Uras26 1 Sample gas inlet optical beam path 1 2 Sample gas outlet optical beam path 1 3 Purge gas inlet sample cell windows Analyzer Purge In Connect needle valve upstream to adjust the purge gas flow rate to 15 to 20 l h 4 Purge gas inlet for housing 5 Purge gas inlet for housing 6 Purge gas outlet flow monitoring Anal...

Page 30: ... flow rate of 15 to 20 l h and a positive pressure of pe 50 hPa to the thermostat chamber As a result of the capil lary a positive pressure of pe 7 to 20 hPa is established The purge gas flow is measured by a flow meter located downstream from a capillary in the sample gas path The outlet pressure should be open to atmospheric pres sure The signal from the flow sensor is monitored and evaluated by...

Page 31: ...et 2 Sample gas outlet 3 Purge gas inlet thermostat chamber Analyzer Purge In Connect needle valve upstream to adjust the purge gas flow rate to 15 to 20 l h 4 Purge gas outlet thermostat chamber ex works tubed with 13 7 Purge gas inlet for housing 8 Purge gas inlet for housing 9 Pressure sensor 10 Pressure sensor 11 unused closed off 12 unused closed off 13 Purge gas inlet flow monitoring 14 Purg...

Page 32: ...as flow monitoring Detektor messwert Flow Einh l h Fan Flow Spuelgas Grenzwert wächter Flow Spuelgas 1 Schwellwert 50 l Hysterese 3 l Meld Nr xxxxx Meldungs generator Flow Spuelgas 1 Grenzwert wächter Flow Spuelgas 2 Schwellwert 15 l Hysterese 3 l Meld Nr xxxxx Meldungs generator Flow Spuelgas 2 Meldungs eingang Flow error Meld Nr xxxxx Negierer Flow error Digital ausgang Flow error DOx Output of ...

Page 33: ...on for connection of Div 2 wiring methods acceptable to the local inspection authority having jurisdic tion Certificate Certificate No 1105720 Warnings WARNING EXPLOSION HAZARD Substitution of components may impair suitability for Class I Division 2 Secure all connectors with fasteners provided Relay contacts rated 30 V 1 A I O connectors must only be connected to Class 2 circuits Ratings and ambi...

Page 34: ...ing resistor DVD ROM Software tools and technical documentation with software tools and technical documentation Commissioning instruction Analyzer Data Sheet Also in the scope of supply and delivery depending on version Connecting cable for the 24 V DC supply to analyzer modules which are not installed in the central unit Connecting cable T pieces and terminating resistors for the system bus accor...

Page 35: ...ply line see page 48 Sample gas Heated sample gas line recommended TBL 01 or unheated sample gas line PTFE or stainless steel tube with inside outside diameter 4 6 mm The fittings and O rings required for the connection are included in the scope of supply and delivery of the gas analyzer Flowmeter In the Caldos25 and Uras26 analyzer modules with flowing reference gas a flowmeter with a needle valv...

Page 36: ...tool of Weidmüller Co must be used for crimping the ferrules Max length of the RS485 leads 1200 m max transmission rate 19200 bit s Max length of the RS232 leads 15 m 24V supply to the analyzer modules Extension cable Min cable cross section 2 5 mm2 Max length 30 m Power supply unit If 2 analyzer modules are installed in a system housing a separate power supply be provided for their power supply T...

Page 37: ...er as close as possible to the sampling location Install the gas conditioning and calibration modules as close as possible to the gas analyzer Adequate air circulation Provide for adequate natural air circulation around the gas analyzer Avoid heat build up When installing several system housings in a 19 inch housing maintain a minimum spacing of 1 height unit between housings The complete surface ...

Page 38: ...ng without electronics module or Uras26 Vibrations shocks If the gas analyzer is installed in a cabinet the maximum acceleration am plitude may not exceed 0 01 ms 2 in a frequency range of 0 1 to 200 Hz If the gas analyzer is not installed in a cabinet the following data for the individual analyzer modules apply Analyzer module Vibrations shocks Caldos25 max 0 04 mm for 5 to 30 Hz Caldos27 max 0 0...

Page 39: ...ion of the pressure sensor Prior to the commissioning of the analyzer module the screw cap has to be screwed out of the connectors of the pressure sensor For a precise pressure correction the connection of the pressure sensor and sample gas outlet have to be connected to each other via a T piece and short lines The lines must be as short as possible or in the case of a greater length have a suffic...

Page 40: ...das24 and Fidas24 NMHC analyzer modules In gas analyzers with the Fidas24 and Fidas24 NMHC analyzer modules the housing purge is provided in such a way that a part approx 600 to 700 l h of the instrument air is conducted continuously through the housing as purge air Thus it is made sure that no ignitable gas mixture can form within the housing in case of a leak in the combustion gas path NOTE The ...

Page 41: ... analyzer module 200 l h max approx 1 h Analyzer separately Caldos25 Caldos27 Magnos206 Magnos28 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 For a purge gas flow rate at the device inlet of 20 l h the purge gas flow rate at the device outlet is approx 5 to 10 l h Information...

Page 42: ...d in the central unit If only one analyzer module is installed in the system housing an AO2000 power supply can be installed in the same system housing If two analyzer modules are installed in the separate system housing a power supply outside the system housing must be provided This power supply unit must comply with the specifications of the AO2000 power supply unit NOTE Only 1 analyzer module m...

Page 43: ...ox 200 VA for detector Fidas24 NMHC 125 VA for sample gas inlet option Connection 4 pin connector connecting cable supplied Safety Test to EN 61010 1 2010 Class of protection Central unit with electronics module power sup ply I Analyzer module without electronics mod ule power supply III Overvoltage category degree of pollution Power supply II 2 Safe isolation The electronics module power supply i...

Page 44: ...10 to 90 l h max 90 to 200 l h for option T90 6 s Remark Sample gas temperature pressure and flow rate should be main tained constant to such a degree that the fluctuation influence on the accu racy of measurement is acceptable see also chapter Analyzer module oper ating data see page 346 Flammable gases The analyzer module is suitable for the measurement of flammable gases and vapors under atmosp...

Page 45: ...ent free process gas or substitute gas End point calibration Process gas with a known sample gas concentration or substitute gas Dew point The dew point of the test gases must be approximately the same as the dew point of the sample gas NOTE The notes for calibrating see page 233 must be considered Gas connections see section Caldos25 Gas connections see page 80 ...

Page 46: ...udes above 2000 m on request Overpressure in the sample chamber max 100 hPa Flow 10 to 90 l h min 1 l h Remark Sample gas temperature pressure and flow rate should be main tained constant to such a degree that the fluctuation influence on the accu racy of measurement is acceptable see also chapter Analyzer module oper ating data see page 346 Corrosive gases If the sample gas contains Cl2 HCl HF SO...

Page 47: ...ust be tested Test gases Zero point calibration Test gas sample component free process gas or substitute gas End point calibration Test gas process gas with a known sample gas concentration or substitute gas Caldos27 with standard gas calibration Standard gas with a defined relative thermal conductivity rTC Dew point The dew point of the test gases must be approximately the same as the dew point o...

Page 48: ...re set ex works to 180 C Inlet pressure pabs 800 to 1100 hPa Flow Approx 80 to 100 l h at atmospheric pressure 1000 hPa Humidity 40 H2O Remark Sample gas temperature pressure and flow rate should be main tained constant to such a degree that the fluctuation influence on the accu racy of measurement is acceptable see also chapter Analyzer module oper ating data see page 346 Sample gas outlet condit...

Page 49: ...yzer has been ordered and supplied in the execution specified for this If the gas analyzer has been sup plied in the execution for H2 He mixture H2 may not be used as a combus tion gas under any circumstances This would cause overheating and there fore the destruction of the detector ATTENTION A flow restriction and a shut off valve must be installed in the combustion gas supply line by the end us...

Page 50: ...can be purchased from ABB Part number 0769440 If a pneumatic shut off valve of this kind cannot be installed precautionary measures must be taken so that the overall status or the failure status of the gas analyzer is monitored see section Fidas24 Troubleshooting see page 335 Test gases Zero point calibration Quality Nitrogen Quality 5 0 synthetic air or catalytically cleaned air with an organic C...

Page 51: ...x works to 180 C Inlet pressure pabs 850 to 1100 hPa Flow Approx 80 to 100 l h at atmospheric pressure 1000 hPa Humidity 40 H2O Remark Sample gas temperature pressure and flow rate should be main tained constant to such a degree that the fluctuation influence on the accu racy of measurement is acceptable see also chapter Analyzer module oper ating data see page 346 Sample gas outlet conditions The...

Page 52: ...lyzer has been ordered and supplied in the execution specified for this If the gas analyzer has been sup plied in the execution for H2 He mixture H2 may not be used as a combus tion gas under any circumstances This would cause overheating and there fore the destruction of the detector CAUTION A flow restriction and a shut off valve must be installed in the combustion gas supply line by the end use...

Page 53: ...kind cannot be installed precautionary measures must be taken so that the overall status or the failure status of the gas analyzer is monitored see section Fidas24 Troubleshooting see page 335 Test gases Zero calibration Quality Synthetic air or catalytically purified air with an org C content of 1 span Inlet pressure pe 1000 100 hPa Flow rate 130 to 250 l h Span calibration Components Sample comp...

Page 54: ...t least 5 C lower than the lowest ambient temperature in the overall sample gas path Otherwise a sample gas cooler or con densate trap is required Pressure The analyzer module is operated under atmospheric pres sure the sample gas outlet is open to atmosphere Inter nal pressure drop 5 hPa with standard flow rate 60 l h Permissible absolute pressure range 800 to 1250 hPa Operation under lower absol...

Page 55: ...ple component free air or with N2 Sample cell purge 1 with N2 or with sample compo nent free air under positive pressure 2 with flow mon itoring Flammable gases 4 Gas lines of stainless steel housing purge 3 with N2 Housing purge 3 with N2 Sample cell purge 1 with N2 1 Purge curtain 2 pe 7 to 20 hPa 15 to 20 l h 3 20 l h 4 See the following section for further information Flammable gases The analy...

Page 56: ...ee page 249 must be considered Pressure sensor The pressure sensor is installed in the gas analyzer ex works The pressure sensor is located in the sample gas feed path if the internal gas lines are executed as FPM flexible tubes The connection of the pressure sensor is led to the outside via an FPM hose if the internal gas lines are exe cuted as tubes The connection of the pressure sensor is docum...

Page 57: ...ll max 500 hPa Flow 20 to 90 l h Remark Sample gas temperature pressure and flow rate should be main tained constant to such a degree that the fluctuation influence on the accu racy of measurement is acceptable see also chapter Analyzer module oper ating data see page 346 Test gases Zero point calibration Nitrogen or air or UV sample component free gas End point calibration Calibration cells or te...

Page 58: ...e in water or can cause salt formation In addition any low boiling hydrocarbons present must be prevented from precipitating Sample gas inlet temperature from the process 150 to 190 C Sample gas filter for the measurement of NO and NO2 sintered metal for the measurement of NH3 ceramic pore size 0 5 µm Materials of the gas bearing components PTFE PVDF or silicosteel Installation note Route the exha...

Page 59: ...ove 2000 m on request Operation under elevated pressure A pressure sensor is required for pressure influence compensation Absolute pressure 1250 hPa An optional internal pressure sensor can be connected to the sample gas path Absolute pres sure 1250 hPa An external pressure sensor must be connected to the sample gas path The analyzer module is function tested for 5000 hPa in ternal pressure withou...

Page 60: ...n or a substitute gas e g dried air Magnos206 with a suppressed measuring range Test gas with an oxygen concentration in the selected measuring range Magnos206 with single point calibration Test gas with an oxygen concentration in an existing measuring range or nitrogen or ambient air Same moisture content as process gas ATTENTION In order to avoid accumulations of explosive gas mixtures do not us...

Page 61: ...sure sensor is required for pressure influence compensation Absolute pressure 1250 hPa An optional internal pressure sensor can be connected to the sample gas path Absolute pres sure 1250 hPa An external pressure sensor must be connected to the sample gas path Flow 30 to 90 l h Abrupt changes in the sample gas flow rate should be avoided when using highly suppressed measurement ranges Remark Sampl...

Page 62: ...concentration in the selected measuring range Magnos28 with single point calibration Test gas with an oxygen concentration in an existing measuring range or nitrogen or ambient air Same moisture content as process gas ATTENTION In order to avoid accumulations of explosive gas mixtures do not use air as a test gas for single point calibration when measuring flammable gas es Dew point The dew point ...

Page 63: ...he analyzer module is operated under atmospheric pres sure the sample gas outlet is open to atmosphere Inter nal pressure drop 5 hPa with standard flow rate 60 l h Permissible absolute pressure range 800 to 1250 hPa Operation under lower absolute pressure e g at altitudes above 2000 m on request Overpressure in the sample chamber max 100 hPa Flow 20 to 90 l h Remark Sample gas temperature pressure...

Page 64: ...NALYZERS OI AO2000 EN REV B Pressure sensor The pressure sensor is installed in the gas analyzer as an option It is con nected to a connection port via an FPM tube Gas connections see section Magnos27 Gas connections see page 91 ...

Page 65: ...perature pressure and flow rate should be main tained constant to such a degree that the fluctuation influence on the accu racy of measurement is acceptable see also chapter Analyzer module oper ating data see page 346 Corrosive gases Highly corrosive associated gas components such as chlorine Cl2 or hydro gen chlorides e g wet HCl as well as gases or aerosols containing chlorine must be cooled or...

Page 66: ...pressed measurement range if possible equal to the final value Dew point The dew point of the test gases must be approximately the same as the dew point of the sample gas NOTE The notes for calibrating see page 261 must be considered Pressure sensor The pressure sensor is installed in the gas analyzer ex works The pressure sensor is located in the sample gas feed path if the internal gas lines are...

Page 67: ...ified range The sample gas must be taken from a bypass at zero pressure If the sample gas flow rate is too low the effects of contaminants from the gas lines leaks permeabilities desorptions have an adverse effect on the measurement result If the sample gas flow rate is too high asymmetrical cooling of the sensor can cause measuring errors This can also cause faster aging of or damage to the sampl...

Page 68: ...t Test gas with oxygen concentration in the smallest measurement range e g 2 ppm O2 in N2 NOTES The pressure conditions at reference point and end point must be identical Notes for checking the reference point and end point see page 263 must be considered Purge gas If a housing purge is selected only in IP54 version purging may only be carried out with air not with nitrogen as the ambient air serv...

Page 69: ...act 6 2 way ball valve 1 7 2 way ball valve 1 8 Air filter 1 9 Gas analyzer 10 Flowmeter without needle valve with alarm contact 11 Purge gas cylinder with N2 1 12 Test gas cylinder with e g 2 ppm of O2 in N2 2 13 Test gas cylinder with 8 ppm O2 in N2 1 14 Pump 1 15 Needle valve 1 1 Option 2 A hard mounted test gas cylinder is normally adequate The annual check of the reference point can also be c...

Page 70: ...bient air Bypass The gas analyzer is connected to a gas flow in the bypass at a constant flow rate approx 30 l h The needle valve is installed upstream of the branch to the gas analyzer and the bypass flowmeter downstream of the branch to the gas analyzer The gas analyzer takes 8 l h from the gas flow A surplus of approx 20 l h remains If several ZO23 analyzer modules are supplied with gas in para...

Page 71: ... sample gas path Otherwise a sample gas cooler or con densate trap is required Inlet pressure pe 2 to 500 hPa Flow 20 to 100 l h Remark Sample gas temperature pressure and flow rate should be main tained constant to such a degree that the fluctuation influence on the accu racy of measurement is acceptable see also chapter Analyzer module oper ating data see page 346 Moisture content H2O dew point ...

Page 72: ...ted since it is fundamentally stable End point calibration Ambient non process air with constant oxygen content 20 96 vol or synthetic air Dew point The dew point of the test gases must be approximately the same as the dew point of the sample gas NOTE The notes for calibrating see page 264 must be considered ...

Page 73: ...eri als from the shipping box 2 Take off the foam packing and other packaging and place the gas ana lyzer in a clean area 3 Clean the adhesive packaging residue from the gas analyzer NOTES If there is shipping damage which points to improper handling file a dam age claim with the shipper railway mail or freight carrier within seven days Make sure that none of the enclosed accessories are lost duri...

Page 74: ...entification plate is located externally on the connection board except for analyzer modules with direct connection to the sample chamber The electronics module identification plate is located externally on the connection board The pneumatic module identification plate is located at the rear behind the back plate behind the flow sensors Contents of the identification plate The gas analyzer identif...

Page 75: ...ditionally the maintenance work or any modifications performed on the gas analyzer can be documented on the analyzer data sheet Storage of the analyzer data sheet The analyzer data sheet is located in a sleeve which is affixed on the left hand side panel inside the 19 inch housing model AO2020 and on the inside of the door of the wall mounting case model AO2040 NOTES The analyzer data sheet should...

Page 76: ...76 AO2000 CONTINUOUS GAS ANALYZERS OI AO2000 EN REV B Dimensional diagrams 19 inch housing model AO2020 Dimensions in mm in Wall mount housing model AO2040 Dimensions in mm in ...

Page 77: ...is required for the heated sample gas line comply with minimum bending radius in ac cordance with manufacturer s instructions When installing the wall mount housing note that clearance is required on the left side to allow the door to swing open approx 60 mm 2 36 in When installing the wall mount housing note that additional clearance is required above the housing since some modules are only acces...

Page 78: ...e metal tubing connectors or threaded connectors Caldos25 The analyzer module gas connection ports in the version for flowing reference gas or for corrosive sample gas are made of plastic PVC C Do not use metal tubing connectors or threaded connectors Fidas24 Only use threaded connections of metal Gas connection installation 1 Screw out the yellow plastic screwing caps 5 mm hexagon socket from the...

Page 79: ...e 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 Requisite material 19 inch housing 4 oval head screws Recommendation M6 this depends on the cabi net rack system 1 pair of mounting rails execution depends on the cabinet rack system Wall mount housing 4 screws M8 or M10 Installation Instal...

Page 80: ...ne connection Caldos25 Gas connections Gas connections Standard version The sample chamber is connected directly to the gas connections Versions for corrosive sample gas or for flowing reference gas The sample chamber is connected directly to the gas connections ...

Page 81: ... with 3 solenoid valves 13 Test gas zero point gas inlet with 1 or 3 solenoid valves 14 Sample gas outlet to be connected to sample gas inlet 1 1 Option 2 Not in the version for corrosive sample gas Design of the gas connections unless stated otherwise NPT female thread for threaded connections not supplied NOTE The gas connections 1 to 6 in the versions for corrosive sample gas or for flowing ref...

Page 82: ...for housing 1 also with flow sensor 9 Pressure sensor 1 10 Pressure sensor 2 Pneumatic module 1 11 Sample gas inlet 12 Span gas inlet with 3 solenoid valves 13 Test gas zero point gas inlet with 1 or 3 solenoid valves 14 Sample gas outlet to be connected to sample gas inlet 1 1 Option Design of the gas connections unless stated otherwise NPT female thread for threaded connections not supplied Addi...

Page 83: ...nt air inlet 38 Exhaust air outlet screw joint for PTFE or stainless steel tube with outside diameter 6 mm The inside diameter of the exhaust air line must be widened to max 30 cm downstream of the exhaust air outlet to 10 mm 39 Sample gas inlet heated or unheated screw joint for PTFE or stain less steel tube with outside diameter 6 mm 40 Pressure equalizing opening with protective filter the prot...

Page 84: ...on cell made of quartz with PTFE FPM or PTFE Cr hoses 60 C 1 Sample gas inlet 3 Housing purge gas inlet 1 4 Sample gas outlet 6 Purge gas outlet for housing 1 7 Pressure sensor 2 8 Span gas inlet with 3 solenoid valves 1 3 9 Zero gas inlet with 1 or 3 solenoid valves 1 3 1 Option 2 External connection not for the standard cell with FPM hoses 3 not for version with PTFE hoses Design of the gas conn...

Page 85: ...ell with PFA tubes 1 Sample gas inlet PFA tube 6 4 mm 3 Housing purge gas inlet 1 4 Sample gas outlet PFA tube 6 4 mm 6 Purge gas inlet for housing 1 7 Pressure sensor 1 Option Design of the gas connections unless stated otherwise NPT female thread for threaded connections not supplied ...

Page 86: ...r 2 Sample gas outlet stainless steel tube with 4 mm outside diameter 3 Housing purge gas inlet 1 4 Purge gas inlet sample cell FPM tube 4x1 5 5 Purge gas outlet sample cell FPM tube 4x1 5 6 Housing purge gas outlet 1 7 Pressure sensor 1 Option Design of the gas connections unless stated otherwise NPT female thread for threaded connections not supplied ...

Page 87: ...87 Limas21 HW Quartz cell 1 Sample gas inlet 3 Purge gas inlet for housing 4 Sample gas outlet 6 Purge gas outlet for housing 7 Pressure sensor Design of the gas connections unless stated otherwise NPT female thread for threaded connections not supplied ...

Page 88: ...gas inlet 12 Span gas inlet with 3 solenoid valves 13 Test gas zero point gas inlet with 1 or 3 solenoid valves 14 Sample gas outlet to be connected to inlet 1 1 Option With measurements in suppressed measuring ranges the con nection of the pressure sensor and the sample gas outlet are to be connected to each other via a T joint and short lines 2 not in version with performance test for emission m...

Page 89: ... EN REV B 89 Magnos28 Gas connections Gas connections 19 inch housing Model AO2020 The sample chamber is connected directly to the gas connections Wall mount housing Model AO2040 The sample chamber is connected directly to the gas connections ...

Page 90: ...e gas inlet 12 Span gas inlet with 3 solenoid valves 13 Test gas zero point gas inlet with 1 or 3 solenoid valves 14 Sample gas outlet to be connected to inlet 1 1 Option With measurements in suppressed measuring ranges the con nection of the pressure sensor and the sample gas outlet are to be connected to each other via a T joint and short lines 2 not in version with performance test for emission...

Page 91: ...nections Gas connections Sample chamber connection to FPM hoses Sample chamber direct connection The sample chamber is directly connected to the gas connections only in the wall mount housing Application e g for connection of an external gas feed and for a short T90 time ...

Page 92: ... outlet 8 9 Pressure sensor 1 1 10 Pressure sensor 2 1 Pneumatic module 2 11 Sample gas inlet 12 Span gas Inlet with 3 solenoid valves 13 Test gas zero point gas inlet with 1 or 3 solenoid valves 14 Sample gas outlet to be connected to sample gas inlet 4 1 Option 2 Option not in the version with sample chamber direct connection Design of the gas connections unless stated otherwise NPT female threa...

Page 93: ...signment of the gas connections as an example for the three variants A 1 gas path with 1 sample cell B 1 gas path with 2 sample cells in series and C 2 separate gas paths with 1 sample cell each The assignment of the gas connections of a supplied analyzer module is documented in the analyzer data sheet enclosed with the gas analyzer ...

Page 94: ...e cell 1 1 Pneumatics module 1 11 Sample gas inlet A or B or C gas path 1 12 Span gas inlet with 3 solenoid valves or sample gas inlet C gas path 2 only with flow sensor 13 Test gas zero point gas inlet with 1 or 3 solenoid valves or sample gas outlet C gas path 2 only with flow sensor in this case to be connected to sample gas inlet 7 14 Sample gas outlet A or B or C gas path 1 to be connected to...

Page 95: ...tube on the inlet side and to the sample gas outlet connection via an FPM hose on the outlet side 1 Sample gas inlet 3 mm Swagelok 2 Sample gas outlet NPT female thread 7 Purge gas inlet for housing only in IP54 version 8 Purge gas outlet for housing only in IP54 version Design of the gas connections unless stated otherwise NPT female thread for threaded connections not supplied ...

Page 96: ...nal diameter which is as short as possible or into a gas discharge line Do not conduct exhaust gases via restrictions or shut off valves NOTE Dispose of corrosive toxic or combustible exhaust gases according to the regulations Provide for sample gas line purging Install a shut off valve in the sample gas line definitely recommended with pressurized sample gas in order to provide a means for purgin...

Page 97: ...rough leak points in the gas paths in the instrument can cause fires and explosions also outside the gas ana lyzer The lines and fittings must be clean and free of any residues e g particles left over from manufacturing Contaminants can enter the analyzer and damage it or lead to false measurement results NOTES The installation of gas connections is described in section Installing the gas connecti...

Page 98: ...urging air for the housing purge see page 40 Connect see page 83 the instrument air line to the instrument air inlet of the analyzer module via a pressure regulator 0 to 6 bar Combustion air connection Connect see page 83 the combustion air line to the combustion air inlet of the analyzer module via a pressure regulator 0 to 1 6 bar Combustion gas connection See section Fidas24 Connecting the comb...

Page 99: ... the medium can be up to 200 C Lay the exhaust air line with a downward gra dient The inside diameter of the exhaust line should be increased to 10 mm within no more than 30 cm from the exhaust outlet If a very long exhaust air line is used it s inside diameter must be much larger than 10 mm otherwise the pressure regulation in the gas analyzer may not work properly Do not conduct waste air via re...

Page 100: ... Install a flow restrictor in the combustion gas supply line which restricts the combustion gas flow to 10 l h of H2 or 25 l h of H2 He mixture This means that operation of the gas analyzer is safe even with a defect in the combustion gas feed path e g leaks 8 Install a shut off valve in the combustion gas supply line It is recom mended that a pneumatic valve is installed this valve must be contro...

Page 101: ...eated sample gas line is connected directly to the sample gas inlet In this respect the correct seat of the O rings must be ensured and also that the sample gas tube is inserted all the way in into the sample gas connec tion Unused sample gas inlets If the analyzer module draws in the sample gas through the sample gas line the unused sample gas inlets must be sealed with the screw plugs screwed in...

Page 102: ...5 1 Test gas outlet 2 Connection of test gas outlet sample gas connection 3 Electrical connection to the heated sample gas connection 4 Heated sample gas connection 5 Heated sample gas line example Remark One half of the cover of the heated sample gas connection has been removed in the picture ...

Page 103: ...I AO2000 EN REV B 103 Connection of the sample gas line to the heated sample gas connection Wall mount housing view from bottom right III 1 2 3 4 5 6 7 8 9 10 11 I II 19 inch housing view from top left 5 6 7 8 II III 9 10 11 1 2 3 4 I ...

Page 104: ...aust gas tube Sample gas Connection of the sample gas line inlets on 19 inch housing on wall mount housing I from the rear from below II from above from the right III from below not possible the sample gas inlet must always be closed Maximum length of the sample gas line The maximum length of the heated sample gas line inside diameter 4 mm is 60 m Provide for sample gas line purging Install a shut...

Page 105: ...tion of the sample gas line The unheated sample gas connection has only one sample gas inlet If the sample gas is under positive pressure a T piece must be connected between the sample gas line and the sample gas inlet The free connection of the T piece must be connected to an exhaust gas discharge line so that no positive pressure builds up in the analyzer module Connection of the sample gas line...

Page 106: ...cket 7 Tapered ring 8 Compression fitting 9 Exhaust gas tube for 19 inch housing 10 Exhaust gas tube for wall mount housing Maximum length of the sample gas line The maximum length of the unheated sample gas line inside diameter 4 mm is 50 m Provide for sample gas line purging Install a shut off valve in the sample gas line definitely recommended with pressurized sample gas in order to provide a m...

Page 107: ...8 X08 X09 Ethernet 10 100 1000BASE T connection X20 to X29 I O Modules 5 slots options Profibus module see page 108 Modbus module see page 109 2 way analog output module see page 110 4 way analog output module see page 110 4 way analog input module see page 111 Digital I O module see page 112 Potential compensation connection see page 124 The connection diagram shows an example for the equipment o...

Page 108: ...erence 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 send data N A line 9 not assigned Design 9 pole female Sub D plug MBP interface not intrinsically safe Pin Signal 1 2 Shield 3 4 not assigned Design 4 pole plug in terminal strip Please refer to the information about the requisite material see page 116 NOTE For additional information o...

Page 109: ...trical connections RS232 interface Pin Signal 2 RxD 3 TxD 5 GND Design 9 pole male Sub D plug RS485 interface Pin Signal 2 RTxD 3 RTxD 5 GND Design 9 pole female Sub D plug NOTE For additional information on Modbus refer to the Technical Information AO2000 Modbus and AO MDDE ...

Page 110: ... regard max gain compared to local protective ground potential 50 V work ing resistance max 750 Ω Resolution 16 bit The output signal may not be less than 0 mA Design 4 pole or 8 pole plug in terminal strip Please refer to the information about the requisite material see page 116 Terminal layout An analog output is allocated in the sequence of the sample components for each sample component The se...

Page 111: ...le Electrical connections Analog inputs AI1 to AI4 0 to 20 mA load 50 Ω Current output 24 V 24 V DC for supply of an external sensor fused with 100 mA self resetting fuse Design 2x5 pin terminal strip Please refer to the information about the requisite material see page 116 ...

Page 112: ...Floating double throw contacts max contact load rating 30 V 1 A The relays must always be operated within the specified data Inductive or capacitive loads are to be connected with appropriate protective measures freewheeling diodes for inductive and series resistors with capacitive loads Relays are shown in the unpowered state The unpowered state corresponds to the state in the event of a fault fa...

Page 113: ...int DI4 Adjust end point 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 switch over DI2 Measuring range switch over DI3 Measuring range switch over DI4 Measuring range switch over Limit values DO1 Limit value DO2 Limit value DO3 Limit value DO4 Limit value DI1 Calibrati...

Page 114: ...ptional Profibus module see page 108 is always X20 The slot of the optional Modbus module see page 109 is X20 or X22 if a Profibus module is present Analog outputs Analog outputs are available at the 2 way analog output module or the 4 way analog output module see page 110 Analog output is allocated for each sample component in the order of the sample components Alarm values Alarm values are avail...

Page 115: ... meas range 4 measuring ranges 4 DI and 4 DO NO closed Active meas range The measuring range control is not installed across I O modules Example A gas analyzer contains 4 sample components with the following number of measuring ranges Sample components Number of measuring ranges Sample component 1 SC1 3 measuring ranges MR1 MR2 MR3 Sample component 2 SC2 3 measuring ranges MR1 MR2 MR3 Sample compo...

Page 116: ... The PZ 6 5 crimping tool of Weidmüller Co must be used for crimping the ferrules Max length of the RS485 leads 1200 m max transmission rate 19200 bit s Cable type 3 core twisted pair cable cable cross section 0 25 mm2 e g Thomas Betts Type LiYCY Max length of the RS232 leads 15 m The mating plugs socket housing for the plug in terminal strips on the I O modules are supplied Connection box In the ...

Page 117: ... leave the ring in the screwed cable glands for sealing and strain relief M32 Remove the plugs from the screwed cable glands If required slit open the insert with drill holes from the accessories pack and press over the cable seal any open drill holes with dowel pins from the accessories pack 2 Connect the lines to the mating plugs as shown in the connection dia grams of the I O modules 3 Attach t...

Page 118: ...e a terminating resistor should be installed in the system bus connector of the electronics module supplied with the unit PS AM EM BUS AM Analyzer module EM Electronics module PS Power supply BUS System bus internal Terminating resistor Multiple system housings If the electronics module and the analyzer module are accommodated in several system housings they must be interconnected externally via t...

Page 119: ...on of the system bus cable Note the following information if using other than the standard system bus cables and plugs to extend the system bus A shielded cable with twisted pairs and the following specifications is to be used as an extension cable 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 capac...

Page 120: ... a T joint on the system bus connection designated BUS of each module electronics and analyzer modules 3 Connect the T joints with the system bus cables 4 Place a terminating resistor on the open ends of each T piece 5 Set up the added analyzer module Several analyzer modules Connection via the system bus BUS PS PS EM AM AM BUS AM Analyzer modules EM Electronics module PS Power supply BUS System b...

Page 121: ...ted current should be used as re placements Never use patched fuses Do not short circuit the fuse holder contacts If the power supply fuse fails some power supply switch components can still carry current Never connect line voltage to a 24 VDC analyzer module input This will destroy the analyzer module electronics An easily accessible mains isolator must be installed near the gas analyzer in order...

Page 122: ...ing cable length 5 m 16 4 feet cross section 2 x 0 5 mm2 will be supplied The receptacle on one cable end is designed to connect to the 24 VDC male plug on the analyzer module 1 4 2 3 The illustration shows the pin side of the analyzer module plug and thus the solder side of the matching female jack The wires on the free end of the connecting cable are intended for connec tion to the power supply ...

Page 123: ...4 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 100 ft long The extension cable should be connected as close as possible to the ...

Page 124: ...or in the power supply feeder near the gas analyzer or a switched socket outlet in order to be able to completely disconnect the gas analyzer from the power supply if re quired Mark the mains isolator in such a way that the assignment of the devices to be disconnected can be clearly recognized 3 Connect the power cord supplied to the X01 with grounded instrument connector on the power supply conne...

Page 125: ...ating is automatically detected and switched The set voltage can be identified through two LEDs on the mains distribution card 115 230 V AC connection to the analyzer module 1 Ensure that the power supply feeder has an adequately dimensioned protective device circuit breaker 2 Install an easily accessible mains isolator in the power supply feeder near the gas analyzer or a switched socket outlet i...

Page 126: ...s the gas analyzer securely fastened see page 79 Are all gas lines including that of the pressure sensor correctly con nected see page 80 Have all the signal control and interface lines the power supply lines and if applicable the system bus been correctly laid and connected see page 107 Are all devices needed for gas conditioning calibration and waste gas disposal correctly connected and ready fo...

Page 127: ...e following table If the purge gas flow is lower than specified the duration of the purging must be extended accordingly Volume to be purged Purge gas flow rate Duration Gas path 100 l h max approx 20 s Central unit with or without analyzer module 200 l h max approx 1 h Analyzer separately Caldos25 Caldos27 Magnos206 Magnos28 Magnos27 200 l h max approx 3 min NOTE The purge gas flow rates given in...

Page 128: ...nalyzer module 3 The following events will occur after the power supply is turned on 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 softkey STATUS MESSAGE appears on the screen This indicates the possibil ity of a temperature or flow ...

Page 129: ...layed in this menu option T Re D Detector temperature T Re E Temperature of the heated gas connection T Re K Temperature of the internal combustion air preparation TR VV1 Temperature of the preamplifier The temperature values slowly increase after the power supply is switched on 4 Feed in instrument air combustion air and combustion gas H2 or H2 He mixture Adjust the pressure to the value specifie...

Page 130: ...e respective solenoid valve in the analyzer module automatically connects the combustion gas The combustion gas regulation attempts to adjust the pressure to the set point Adjustment of the controlled variables of the internal pressure regula tors If the analyzer module is not automatically put into service with the pressure values specified in the analyzer data sheet the controlled vari ables of ...

Page 131: ...30 C Combustion air ramp height reached Number of ignition attempts 10 Fidas24 is ready to measure after warm up phase Temperature of detector and sample gas connection 150 C yes yes yes yes yes no no no no no Depending on the number of ignition attempts the flame can take up to 10 minutes to ignite Depending on the length of the combustion gas supply line it is possi ble that not enough combustio...

Page 132: ...as pressure 4 Carry out a seal integrity test on the combustion gas line see page 283 5 Turn on the sample gas supply ATTENTION The gas analyzer and the analyzer module must be de energized before the connector of the 115 230 V AC power supply for heating the detector and the heated sample gas connection is connected or disconnected Otherwise the heating may be damaged The cover of the heated samp...

Page 133: ...e gas analyzer power supply 2 Wait for the warm up phase to end Wait at least 2 hours until the tem perature of the heated sample gas line has stabilized at 180 C 3 Purge the complete sample gas feed path sample gas line and gas ana lyzer for at least 1 h with clean and dust free ambient air 4 Turn on the sample gas supply ...

Page 134: ...cal zero feed ambient air wait and until the measured value has stabilized duration approx 2 hrs Meanwhile purge the test gas valves and the gas supply line with oxy gen 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 of O2 4 Feed span gas and wait until the measured value has stabilized dura tion max 2 hrs 5 Set end point va...

Page 135: ...rox 0 5 2 hours without with thermostat ZO23 Approx 15 minutes 1 See AO2000 Series data sheet for class details NOTES The warm up phase can take longer if the gas analyzer was not brought to room During the warm up phase measurement values can be outside the ranges specified in the data sheet Warm up phase duration The warm up phase is deemed to be over when the measured value drift indication is ...

Page 136: ...Caldos25 10 to 90 l h for option T90 6 s max 90 to 200 l h Caldos27 10 to 90 l h min 1 l h Fidas24 80 to 100 l h with atmospheric pressure 1000 hPa Fidas24 NMHC 80 to 100 l h with atmospheric pressure 1000 hPa Limas11 IR 20 to 100 l h Limas21 UV 20 to 100 l h Limas21 HW 20 to 90 l h Magnos206 30 to 90 l h Magnos28 30 to 90 l h Magnos27 20 to 90 l h Uras26 20 to 100 l h ZO23 5 to 10 l h The flow ra...

Page 137: ...at the device outlet is approx 5 to 10 l h Fidas24 Housing purge during operation A part approx 600 to 700 l h of the instrument air for the air jet injector is conducted continuously through the housing as purge air Date and time check A correct date and time setting see page 183 is required for proper opera tion of functions such as automatic calibration and logging of error mes sages 1 Select t...

Page 138: ...e 139 with Menu line Information field Softkey line Status LEDs see page 141 Numeric keypad see page 142 Cancel keys see page 143 and Softkeys see page 144 In both system housing versions the display and control unit is located on the front face Display and control unit operating modes The display and control unit operating modes are Measurement and Menu The display and control unit operating mode...

Page 139: ...rement component designation The measurement range lower and upper limit values on the horizontal 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 configure di...

Page 140: ...ive It shows that the gas analyzer is being controlled from a remote HMI It shows that an automatic calibration process is running in the gas analyzer Display of status messages When a status message is generated by the Message Generator function block its short text is displayed on the message display as configured in the function block The Technical Information Function Blocks Descriptions and c...

Page 141: ...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 Error The red Error LED lights when the Failure status signal or the overall sta tus signal is active The STATUS MESSAGE softkey appears on the screen at the same time NOTE Chapter Status messages troubleshooting see page 315 contains de tailed...

Page 142: ... with the numeric keys 0 through 9 decimal point and minus sign Examples Test gas concentration Date and time Air pressure Password NOTE Any digits displayed cannot be overwritten directly 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 see page 146 section explains how to enter information such as sample co...

Page 143: ...th 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 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 NOTE The gas analyzer automatically...

Page 144: ...alled keys in this manual The softkeys in measurement mode In the measurement mode the softkey line contains the softkeys MENU and The softkey Status message also appears if an error occurs The MENU key is used to call up 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 The Back key ...

Page 145: ...ters on a dark background The operator can use the BACKSPACE key to delete characters to the left of the cursor as in a PC keyboard The operator can use the CLEAR key to delete all characters in a selected field 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 of the softkey li...

Page 146: ...t is entered and modified in two ways The operator 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 The PREV PAGE and NEXT PAGE keys allow the operator to move to the previous or next keypad page The CAPS key allows the operator to switch between upper and lowercase lette...

Page 147: ...e number key that corresponds to the position of the display element in the display and that is indicated above the display element In the example this is key 4 A field then appears for entering the value Description and configuration Further information can be found in sections Value entry see page 207 and Configuring value entry see page 208 ...

Page 148: ...e number key that corresponds to the position of the display element on the display and that is indicated over the display element In the example this is key 4 A softkey line then appears with the configured keys Description and configuration Further information can be found in sections Key entry see page 209 and Configuring key entry see page 210 ...

Page 149: ...sers Password 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 Factory setting User group Access to password levels Default password Every user 0 None Maintenance team 0 1 471100 Specialist team 0 1 2 081500 Function block specialist 0 1 2 3 325465 Field se...

Page 150: ...el 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 by the ...

Page 151: ...th the level n 1 pass word 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 receives Local HMI receives Remote HMI level n Priority with level n 1 Priority with level n Local HMI level n Priority with level n 1 NOTE If a second user with an HMI receives pr...

Page 152: ...Technical Information Function Blocks Descriptions and configuration contains complete information on the individual function blocks 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 currently locked Cancel BACK Access lock via password protection As an alternative to ...

Page 153: ...AO2000 CONTINUOUS GAS ANALYZERS OI AO2000 EN REV B 153 Menu tree Menu tree ...

Page 154: ...nalyzer modules are integrated into the gas analyzer Function blocks sub menu see page 182 Calibration data sub menu see page 225 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 apply especially to those sub menu items which allow access to function block applications Remark The C...

Page 155: ...nge switch over 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 NOTE The measurement range selected is shown on the screen after switching to measurement mode ...

Page 156: ...the old to the new meas urement range is 1 10 we recommend manually calibrating see page 265 the end point Parameters of the auto range switching see page 161 should be verified after the range limits have been changed Notes for individual analyzer modules Caldos25 Magnos27 Measurement ranges are factory set and cannot be modified Caldos27 Measurement ranges are freely selectable for binary gas mi...

Page 157: ...e maximum ratio of the spans is 1 20 The measurement ranges can be starting meas urement ranges or suppressed measurement ranges If a calibration cell is provided for the measurement component its set point will always be at the upper end of the largest measurement range When the new measurement range is smaller than the old one the associated calibra tion cell may continue to be used In addition ...

Page 158: ...dicated 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 measurement range Span Places after the decimal point 0 05 5 0...

Page 159: ...ges can be locked when configuring the gas analyzer by means of the test and calibration software TCT In this case the entry Free is not shown even if fewer than the 4 maximum possible measurement ranges are displayed Procedure 1 Press NEW MEASURING RANGE 2 Confirm safety interrogation by pressing NEW MEASURING RANGE if necessary enter password level 1 In the list a new measurement range is displa...

Page 160: ...guration of the sample component then the softkey DELETE MEASURING RANGE is displayed NOTES The deletion of measurement ranges can be locked when configuring the gas analyzer by means of the test and calibration software TCT The active measurement range in which measurements are currently taken and measurement ranges of the currently active calibration method cannot be deleted Procedure 1 Press DE...

Page 161: ...r and upper threshold values should be selected so that the gas analyzer is not constantly switching between two measurement ranges see the example below Assigned ranges Parameters can be set for measurement ranges to be included for auto ranging can be initialized The number of measurement ranges available depends on the analyzer module NOTE The parameter cannot be selected if the analyzer module...

Page 162: ...d value Select Threshold in physical units Set 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 functi...

Page 163: ...6 T90 1 Low pass time constant for constant measured value Set T90 2 Low pass time constant for measured value changes Set Threshold Threshold T90 2 applies for overshoot Set Non linear filter T90 2 should be adjusted T90 2 T90 1 for the non linear filter The switching threshold in is generally based on the largest measure ment range selected reference measurement range Recommendation for Fidas24 ...

Page 164: ...os27 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 con firm Subsequently use the Measurement range menu item to select the range for the desired active component NOTE The selected active component and measurement ran...

Page 165: ...stem component a component configured at the factory S A Active i e system component currently being measured S K System component used for calibration B User component a component configured by the user B A Active i e user component currently being measured B K User component used for calibration Name above Name of the component in the measured value display e g total formula below Full name of t...

Page 166: ...a separate window with a detailed list of the com ponent data is opened see below OVERVIEW The detailed display is closed Detailed display The following component data are listed in the detailed display Display Name of the component in the measured value display e g structure formula Name Full name of the component Molar mass g mol Molar mass in g mol Response Factor Detector reply related to prop...

Page 167: ...tory configured system components if applicable the user components already configured and an entry with the name Free The following information is displayed for each component Type S System component or B User component Display Name of the component in the measured value display e g total formula Name Full name of the component ...

Page 168: ...ey NEW COMP in succession If applicable enter password level 3 A window appears with the component data If a component was not yet configured at the point of the free entry no component data is dis played If a component was already configured at the point of the free entry its component data is displayed If this component is included in the com ponent list press the Back key and by pressing the Me...

Page 169: ...try Free in the component selection list and confirm with ENTER 2 Enter the display name of the new component This input is required as a minimum for the new component to be saved in the component list Enter the additional parameters for the new component and save the configuration with CONFIRM ...

Page 170: ...it the menu with Back or Meas Adding a system component 1 Select a factory configured system component in the component se lection list and confirm with ENTER 2 If necessary change the unit and save the configuration with CONFIRM Note The other parameters of a system component cannot be changed ...

Page 171: ...AO2000 CONTINUOUS GAS ANALYZERS OI AO2000 EN REV B 171 3 The component list is displayed 4 Quit the menu with Back or Meas ...

Page 172: ... In the case of a system component Type S only the parameter Unit can be changed in the case of a user component Type B all the parameters can be changed with the exception of the parameter Type The parameters of the active component Type SA or BA and the compo nent used for calibration Type SK or BK cannot be changed 1 Press softkey COMP CONFIG The Configure Component menu is displayed with the c...

Page 173: ...enu with Back or Meas Replace one component with another component 1 Press softkey COMP CONFIG The Configure Component menu is displayed with the component list 2 Select the modules in the component list which is to be replaced by another component 3 Press softkey COMP CHANGE Enter password level 3 as applicable The parameters of the component to be replaced are displayed ...

Page 174: ...EN REV B 4 Press softkey COMP LIST Select the new component in the component selection list and press the softkey ENTER 5 Confirm the overwriting of the component with ENTER and save the configuration with CONFIRM 6 Quit the menu with Back or Meas ...

Page 175: ...e 168 to the component list again later on A user component which is no longer required can be finally deleted from the component selection list see page 167 The system components cannot be deleted Menu path MENU Configure Component specific Active Component Select component and confirm with ENTER Delete component from the component list 1 Press COMP CONFIG softkey The Configure Component menu is ...

Page 176: ... component from the component selection list 1 Press COMP CONFIG softkey The Configure Component menu is displayed with the component list 2 Select any component in the component list 3 Press CHANGE COMP softkey enter password level 3 as applicable and then press COMP LIST softkey The component selection list is dis played 4 Select the user component to be deleted in the component selection list 5...

Page 177: ... calculation have been entered during configura tion see page 168 of the component Changing a unit of component is possible for the following analyzer mod ules Analyzer module Unit Caldos27 ppm vol Fidas24 ppmC1 ppm vol mgC m3 gC m3 mg m3 g m3 LEL mgC l gC l mg l g l Magnos206 ppm vol Magnos28 ppm vol Magnos27 ppm vol Uras26 ppm vol mg m3 g m3 ZO23 ppm vol Prerequisites for this are AMC Software v...

Page 178: ... Enter password level 3 as applicable A list of the units available is displayed 4 Select the desired unit and confirm with ENTER 5 A security prompt appears with the information that when switching the unit the range limits of the component are automatically adjusted 6 Confirm the switching of the unit with ENTER or cancel with Back 7 Quit the menu with Back or Meas 8 Check the range limits see p...

Page 179: ...e user interface see page 184 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 146 NOTES The changed module name is shown in the display after s...

Page 180: ... total at its output A Component measurement 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 Various function blocks are factory linked to other function blocks to make applications see the Standard configuration see page ...

Page 181: ...surement value Hold Limit monitor and Digital output function blocks Grenzwert waechter Komp Messw Digital ausgang Halteglied Auto kalibrierung Example Measuring range switch over feedback signal The measurement range switch over feedback application consists of a factory configured linkage between a Measuring range switch over function block with several Digital input function blocks and Componen...

Page 182: ...182 AO2000 CONTINUOUS GAS ANALYZERS OI AO2000 EN REV B The Function blocks sub menu ...

Page 183: ...ar with 4 digits Time Time must be entered in hour minute second format Enter seconds too Definitions GMT Greenwich Mean Time CET Central European Time GMT 1 hour CEST Central European Daylight saving Time GMT 2 hours Daylight saving time The gas analyzer is automatically set to daylight saving time Note This applies only when the time zone has been selected from the conti nent country city list a...

Page 184: ...Language the user can switch between these two languages Other languages Other user interface languages can be loaded into the gas analyzer using the SMT Software Migration Tool SMT can be found on the DVD ROM Software tools and technical documentation which is delivered with the gas analyzer These language pairs are available English German English French English Italian English Dutch English Spa...

Page 185: ...cialist 0 1 2 3 325465 Field service 0 1 2 3 4 S 737842 It is recommended to change the default passwords Procedure 1 Select the menu item Change password 2 Select the user group 3 Enter the old password 4 Enter the new password 6 digits 5 Re enter the new password 6 Leave the menu item with Back NOTE Password level 0 is not displayed in the Change password menu item CAUTION After entering the pas...

Page 186: ...main menu and thus switch ing 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 protec tion The level 3 password must be entered Procedure Press the MENU ACCESS softkey in the Change password menu item and set the password protection ...

Page 187: ...s Modbus 2 way analog output 4 way analog output 4 way analog input digital input output 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 The I O modu...

Page 188: ...dule during operation The standard function block applica tions with the respective connection layouts of the module are listed in the Electrical connections Digital I O module see page 112 section Unknown system module There are several reasons for a system module to have an Unknown status in the Setup system modules menu item Cause The system module was not found after the power supply was turne...

Page 189: ...ey 3 Enter the 14 digit serial number for the new system module 4 In the list the added system module will be shown with New status 5 Save the configuration change by pressing ENTER or discard it by pressing Back Adding a new I O module 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 au...

Page 190: ...tion Change must be used NOTES The type and configuration of the new system module must match the con figuration 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 ana lyzer and its configuration is not necessary Replacing an existing system module analyzer module or I O device with an...

Page 191: ...the gas analyzer Removing an installed system module without a replacement 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 3 Press the DELETE softkey This will irretrievably remove the system module s parameter settings and function block configuration 4 In the list the deleted...

Page 192: ... out When the gas analyzer is booting the last saved valid configuration file is loaded Manual saving of the configuration The database can also be saved manually This is useful e g for buffering a large function block configuration Backup In addition to automatic or manual saving of the configuration a backup of the current configuration can be created This backup can be saved in a sep arate memo...

Page 193: ...idual status signals i e Error Maintenance request and Maintenance mode Overall status signal NOTES If the status signal configuration is changed from overall status signal to individual status signal the digital outputs DO2 and DO3 of the standard function block application Status signals externally controlled calibration see page 112 which possibly are assigned to limit value signals will be ove...

Page 194: ...and special charac ters DHCP off IP address IP address mask and IP gateway address Addresses The IP address IP address mask and IP gateway address must be obtained from the system administrator NOTES Addresses of TCP IP classes D and E are not supported The address bits that can be varied in the address mask may not all be set to 0 or 1 broadcast addresses The IP address must not be mistaken for t...

Page 195: ...s module see page 109 is installed in the gas analyzer 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 to 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 shown ...

Page 196: ... Warm start With Warm start the Profibus stack is reset compara ble with a power off on Cold start With Cold start all the parameters which are stored in the Profibus stack as store parameters are reset to the default value Profibus fail safe Measured value The value of the Profibus function block comes after the output value of the AO2000 function block Hold value The Profibus function block hold...

Page 197: ...re not matched This may also cause damage in the function block applications Parameters 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 calibra tion measurement range...

Page 198: ...ig ured A value can only be displayed on a single page System pages standard layout The gas analyzer normally displays its measured values in a fixed sequence on the various screen pages This holds true for the measured quantities of system modules see page 187 that were added by the user Since up to six values can be displayed on a page the number of system pages depends on the number of values T...

Page 199: ...f these measured quantities are displays of function blocks in the system Technical Bulletin Function Blocks Descriptions and configuration contains complete infor mation on the Function block concept as well as detailed descriptions of the individual function blocks Display element positioning on the screen The display elements can be represented in two sizes A maximum of three large and six smal...

Page 200: ...me of the value Softkeys in the screen overview The screen overview softkeys have the following functions The PAGE LIST softkey calls up the page overview see page 201 The NEW softkey starts the configuration of a new value e g Configuring the bar display or point display see page 206 Value entry see page 208 Key entry see page 210 The DELETE softkey deletes the value selected by the user The ENTE...

Page 201: ...onfigured by the user Page overview softkeys The page overview softkeys have the following functions The operator toggles the selected screen page on or off with the PAGE ON OFF softkey The NEW softkey starts the configuration of a new user page see page 203 The DELETE softkey deletes the page selected by the user Only empty user pages can be deleted The ENTER softkey allows the user to input text...

Page 202: ...element can be moved to any system 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 see page 207 ...

Page 203: ...rview 3 Start configuring a new page with NEW 4 Either Enter the page name The page overview is displayed Or Go directly to the page overview In this case the system assigns the name Page where page number 5 The new page will appear in the page overview No Assigned by the system status on Name As entered in step 4 Usage 0 no measured quantity Type User ...

Page 204: ...tion are displayed If the new page is a system page the display element is located in the first free position If the new page is a 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 also 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 d...

Page 205: ...play element is on system page its position can only be ex changed with that of another display element the softkey Swap Dis play is pressed If the display element is on user page its position can either be ex changed with that of another display element the softkey Swap Dis play is pressed or it can be moved to a free position the softkey Swap Display is not pressed Select the desired position wi...

Page 206: ...selected page is a system page the position of the display ele ment is set by the system it can only be changed using Swap Display see page 205 If the selected page is a user page the position must be configured 8 Select the parameter Position The nine possible positions are graphically represented free positions are identified by the position number 9 Select the position with the corresponding nu...

Page 207: ...ion Configuration The following are to be configured for the display element Value Entry 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 measurement by pressing the number key that corresponds to the posi...

Page 208: ...ter 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 func tion block see step 11 9 Select the parameter Config entry and configure the other parame ters entry range decimal places text and password level The config...

Page 209: ...llowing are to be configured for the display element Key Entry 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 level on which the keys can be used Use Key entries are made during me...

Page 210: ...umber key 7 Select the parameter Type 8 Select the display type Key entry This creates a single function block Constant 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 numbe...

Page 211: ...nfiguration that results from the configuration of the example It consists of the function block FB Const Pump that is created when configuring the display element Input Pump and the function block Pump that is the system default I1 I2 FB FB Pumpe Pumpe Konstante Konst Pumpe Configuring value entry 1 Configure the display element for the pump output value entry The source is the function block FB ...

Page 212: ... the function block FB Pump Results of the configuration example The following diagram shows the display with the display elements Value entry and Bar display The following diagram shows the field for entry of the value this is select ed by pressing key 4 during measurement mode see section Operating by value entry see page 147 ...

Page 213: ...gered by an external control signal Wait until the warm up phase has ended Calibration should only be started after the warm up phase Analyzer module Duration of the warm up phase Caldos25 1 5 hours Caldos27 30 60 minutes for class 1 2 measurement ranges 1 Fidas24 2 hours Fidas24 NMHC 2 hours Limas11 IR Approx 2 5 hours Limas21 UV Approx 2 5 hours Limas21 HW Approx 4 hours Magnos206 1 hour Magnos2...

Page 214: ...on off during manual calibration matches the setting for automatic calibration see page 227 Example Test gas connection for Caldos27 with single point calibration Magnos206 with single point calibration Magnos28 with single point calibration Limas11 IR Limas21 UV and Limas21 HW with calibration cells Uras26 with calibration cells with flow monitoring as option e g for flowing reference gas or purg...

Page 215: ...ing manual calibration If the Output Current Response parameter is set to Hold current output is halted for a specific time to allow the measurement value to stabilize after automatic calibration is ended 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 page 216 C...

Page 216: ... calibrated simultaneously Starting the automatic calibration Automatic calibration is started at time intervals determined by the internal clock by an external control signal or manually via the gas analyzer s display and control unit Internal start Automatic calibration is normally started cyclically on a time controlled ba sis by the internal clock of the gas analyzer The cycle time is provided...

Page 217: ...the parame terized cycle time Input Digital input DI2 on Digital I O module Status signals Exter nally controlled calibration see page 112 standard function block application Automatic calibration start block and cancel Start Block Cancel Controlled by interval lf Activation parameter is set to on if Activation parameter is set to off or with the Block Auto matic Calibration con trol signal by app...

Page 218: ... allow the measurement value to stabilize after automatic calibration is ended 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 Calibration data Setting the calibration data is described in section Calibration data for automatic calibration see page 227 Setting the T90 time constants is described in section Filter parameteriza tion see p...

Page 219: ...stalled there are several layout possibilities for the test gas supply 1 analyzer module integral pneumatic module with 1 solenoid valve To calibrate analyzer modules with simplified calibration procedures Caldos27 with single point calibration Magnos206 and Magnos28 with single point calibration Limas11 IR Limas21 UV Limas21 HW with calibration cells Uras26 with calibration cells Oxygen sensor 1 ...

Page 220: ...al solenoid is controlled via a digital output on the electronics module Digital output DO4 on Digital I O module Status signals Exter nally controlled calibration see page 112 standard function block applica tion 1 analyzer module external gas supply with 3 solenoid valves To calibrate all analyzer modules with zero and span gas even without an integral pneumatic module The external solenoid valv...

Page 221: ...rnal solenoid valve is as standard controlled via a digital output on the electronics module via a digital output Digital output DO4 on Digital I O module Status signals Externally controlled calibration see page 112 standard function block application If the sample components of the individual analyzer modules show cross sensitivities among each other it must be made sure by appropriate ar rangem...

Page 222: ... must be present for at least 1 s 3 Standard function block applications see page 112 4 Uras26 analyzer module only Requirements for the external control set up For the Caldos25 Caldos27 Magnos206 Magnos28 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 produce th...

Page 223: ...f 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 gas is available Substitute gas calibration If test gases are not available for calibration e g be...

Page 224: ...each sample component 1 1 Substitute gas components and measur ing ranges for zero and span calibration zero in one component measurement range and span in one range for an other component all detector components and measurement ranges SC Sample and substitute gas components MR Measurement ranges per component Setting the calibration method The calibration method can be set separately for the thre...

Page 225: ...AO2000 CONTINUOUS GAS ANALYZERS OI AO2000 EN REV B 225 Gas analyzer configuration Calibration data The Calibration data sub menu ...

Page 226: ...or the se lected component Substitute gas calibra tion The substitute gas components for zero and span calibration and the measurement range for the selected component NOTE The components and measurement ranges settings apply to manual auto matic and externally controlled calibration Drift calculation In MENU Configure Calibration data Drift calculation it can be set if the relative drift between ...

Page 227: ...time Operating mode Automatic calibration is based on the function block Autocalibration This function block operates either as calibration or as validation see page 230 The Technical Information Function Blocks Descriptions and configura tion contains complete information on the individual function blocks Test gas concentration for the calibration The zero and span test gas concentrations to be u...

Page 228: ...l of the Autocalibration function block Pump Setting should be made whether the pump is on or off during automatic calibration on or off This setting also applies to manual calibration Purge time Setting should be made for the length of the interval between turning on the zero gas flow and starting zero calibration between turning on the test gas flow and starting span calibration between restarti...

Page 229: ...ibration method see page 223 for automatic calibration needs to be set for the selected sample component The zero and span calibration measurement ranges for common and sub stitute gas calibration are chosen in the Manual Cal Calibration method parameter The calibration method parameter is not available in the analyzer modules Limas11 IR Limas21 UV Limas21 HW and Uras26 since automatic calibration...

Page 230: ...point are outside the parameterized 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 see page 227 also apply to validation After selecting validation in the Operating Mode parameter it must be set If the valid...

Page 231: ...pan calibration measuring ranges for common and substi tute gas calibration are chosen in the Manual Cal Calibration method parameter The calibration method parameter is not available in the analyzer modules Limas11 IR Limas21 UV Limas21 HW and Uras26 since externally controlled calibration is always run as common calibration Calculation method Select whether the calibration is to be calculated as...

Page 232: ... response Menu path MENU Configure Calibration data Output current response Output current response Signals at the current outputs analog outputs Are held at the last measured value prior to starting calibration or Can follow measurement value changes during calibration ...

Page 233: ...le gas con centration or substitute gas Test gas for corrected sample components During calibration possible electronic cross sensitivity and or carrier gas corrections by other measurement components are switched off Therefore corrected measurement components should be calibrated only using a test gas consisting of the measurement component and an inert gas like Nitro gen Calibration with substit...

Page 234: ...as corrections by other measurement components are switched off Therefore corrected measurement components should be calibrated only using a test gas consisting of the measurement component and an inert gas like Nitro gen Calibration with substitute gas If test gases are not available for calibration the analyzer module can be factory set for calibration with a substitute gas see also section Cali...

Page 235: ...ss 2 is specified in Advance Optima AO2000 Series Continuous gas analyzers data sheet Measurement range for standard gas When the Caldos27 analyzer module is ordered with standard gas calibra tion the factory set measurement range for the standard gas is 0 to 60 000 rTC rTC relative thermal conductivity During basic calibra tion in the factory one standard gas is calibrated in this measurement ran...

Page 236: ...ion Never Single span calibration Always Zero point and span calibration together Never Test gas concentration Value depending on standard gas 3 1 Though standard gas calibration is carried out exclusively as span cali bration standard gas must also be chosen as zero component 2 Settings of sample components and measurement ranges for zero and span calibration are taken over from the calibration d...

Page 237: ... 20 79 1 Coal Air 10 10 79 1 20 79 1 Calibration with substitute gas 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 to 20 vol of CO2 in N2 N2 and CO2 N2 mixtures are available practically everywhere Measurement ranges Component 1 CO2 in flue...

Page 238: ...llest measurement range is 0 to 5 mg org C m3 equivalent to 0 to 10 ppm CH4 NOTE The associated amplification levels are set at the factory during calibration They can only be changed using the TCT test and calibration software Setting the calibration method For detailed information on the calibration methods see the Calibration methods see page 223 section Analyzer module with 1 sample component ...

Page 239: ...ring range Inlet pressure pe 1000 100 hPa Flow 130 to 250 l h Zero offset If the zero reference gas is not completely free of hydrocarbons even puri fied nitrogen contains fractions of hydrocarbons negative measured values may be displayed in small measuring ranges the process gas is cleaner than the zero reference gas Test gas infeed The test gases for the zero and span calibration must be fed in...

Page 240: ...ases are connected at the separate test gas inlets the built in pressure switch can be activated during automatic calibration to monitor the flow of the test gases If the flow is insufficient calibration is stopped The pressure switch can be activated for zero gas span gas and zero and span gas Menu path MENU Configure Calibration Parameters Automatic Calibration Advanced settings Pressure switch ...

Page 241: ...lation Hence it is recommended to calibrate all sample components with methane as test gas For the calibration of the sample component THC a second substitute gas component CH4 can be configured in the factory per customer order Sub stitute gas calibration and test gas calibration are then configured as cali bration methods Substitute gas calibration must always be selected as calibration method i...

Page 242: ...n calibration Sample component CH4 Set point CH4 Test gas concentration CH4 Sample component THC calibration method Test gas calibration Set point THC Test gas concentration C3H8 Set point THC Test gas concentration CH4 Response factor CH4 Sample component THC calibration method Substitute gas cali bration Set point CH4 Test gas concentration CH4 Zero offset If the zero reference gas is not comple...

Page 243: ...ases are connected at the separate test gas inlets the built in pressure switch can be activated during automatic calibration to monitor the flow of the test gases If the flow is insufficient calibration is stopped The pressure switch can be activated for zero gas span gas and zero and span gas Menu path MENU Configure Calibration Parameters Automatic Calibration Advanced settings Pressure switch ...

Page 244: ...omponent 1 C3H6O in room air Meas range 1 0 to 10 000 ppm Component 2 C3H8 in N2 substitute gas Meas range 1 0 to 10 000 ppm Calibration parameters Calibration method Substitute gas calibration Zero component Component 1 C3H6O Measuring range 1 or Component 2 C3H8 Measuring range 1 Span component Component 1 C3H6O Measuring range 1 or Component 2 C3H8 Measuring range 1 Calibration Calibrate zero w...

Page 245: ...t Response factor 1 Toluol C7H8 0 95 Chlorbenzene C6H5Cl 0 95 p Xylol C8H10 0 92 Benzol C6H6 0 99 Ethylbenzene C8H10 0 92 Propane C3H8 1 00 n Hexane C6H14 0 97 n Octane C8H18 0 93 iso Octane C8H18 1 04 Trichlorethylene C2HCl3 0 96 Tetrachlorethylene C2Cl4 1 00 Ethane C2H6 1 01 Butane C4H10 0 97 Methanol CH3OH 0 74 Butanol C4H9OH 0 83 Acetic acid C2H4O2 0 52 Dichlormethane CH2Cl2 1 00 Methane CH4 1...

Page 246: ...the calibra tion of the zero point with the measured value display The response factors of a gas in nitrogen and in synthetic air may differ considerably from each other The measurements should always be performed with a sample compo nent and a measuring range e g TOC in ppm C1 When calculating the test gas concentration the number of C atoms must be considered Test gas cylinders with high accurac...

Page 247: ...or methane CH4 Examples for the conversion of units and concentration data Conversion ppm to mg CnHm m3 m 3 m n V weight Molecular ppm m H C mg Conversion ppm to mg C m3 m 3 V 12 011 atoms C of Number ppm m C mg Conversion ppm to ppm C1 atoms C of Number ppm C1 ppm Example 1 The analyzer module has a measuring range of 0 to 50 mg C m3 As a test gas propane C3H8 in N2 or in air is used What is the ...

Page 248: ... too great by this factor In order to determine the maximum test gas concentration to avoid exceeding the measuring range the measured value display must be divided by the response factor 4 CH CH maxCH CH ppm 82 572 1 13 93 306 Rf ppm c ppm c 4 4 4 3 4 CH 3 CH 3 maxCH m CH mg 59 102 1 13 66 785 Rf mg m c mg m c 4 4 4 A test gas cylinder with approx 80 ppm CH4 is ordered The test gas con centration...

Page 249: ...suitable absorber Test gases for end point calibration without calibration cells A test gas is required for each sample component for span calibration with out calibration cells Observe the notes in the Analyzer Data Sheet when preparing the test gas mixtures The concentration of the span gas should be 70 to 80 of the end value of the measurement range Test gases for span calibration of suppressed...

Page 250: ...ed using a test gas contain no components which cause cross sensitivity i e which only consists of the sample component and an inert gas e g N2 Wait until the warm up phase has ended The analyzer module should only be calibrated after the warm up phase see page 135 Limas21 HW Special notes for calibrating NO2 and NH3 Calibration with calibration cells We recommend using the calibrating cells insta...

Page 251: ...tion with substitute gas If test gases are not available for calibration the analyzer module can be factory set for calibration with a substitute gas see also section Calibra tion methods see page 223 This setting is documented in the analyzer data sheet Substitute gas calibration of the Magnos206 analyzer module is described using the example of Purity measurement of CO2 see page 254 Single point...

Page 252: ... content 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 flammable gas es Suppressed measuring range The single point calibration can also be carried out in a measuring range with a suppressed zero point provided that the suppression ratio is 1 5 In this case as well the O2 concentration o...

Page 253: ...n span gas n a Calibration data for an analyzer module with 1 sample component Example Test gas air Calibration data for manual calibration Calibration method Substitute gas calibration Zero component O2 in N2 Zero range 0 to 25 vol of O2 Span component n a Span range n a Test gas concentration zero gas 20 96 vol of O2 Test gas concentration span gas n a Calibration data for automatic calibration ...

Page 254: ...nt range for 0 to 25 vol of O2 in N2 is calibrated in addition N2 and O2 N2 mixtures are available practically everywhere Measuring ranges Component 1 O2 in CO2 Meas range 1 0 to 1 vol Meas range 2 0 to 15 vol Meas range 3 0 to 25 vol Meas range 4 0 to 100 vol Component 2 O2 in N2 substitute gas Meas range 1 0 to 25 vol Calibration parameters Calibration method Substitute gas calibration Zero comp...

Page 255: ...tion with substitute gas If test gases are not available for calibration the analyzer module can be factory set for calibration with a substitute gas see also section Calibra tion methods see page 223 This setting is documented in the analyzer data sheet Substitute gas calibration of the Magnos28 analyzer module is described using the example of Purity measurement of CO2 see page 258 Single point ...

Page 256: ...n also be used as the test gas The test gas must have the same moisture content 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 flammable gas es Suppressed measuring range The single point calibration can also be carried out in a measuring range with a suppressed zero point provided that t...

Page 257: ... span gas n a Calibration data for an analyzer module with 1 sample component Example Test gas air Calibration data for manual calibration Calibration method Substitute gas calibration Zero component O2 in N2 Zero range 0 to 25 vol of O2 Span component n a Span range n a Test gas concentration zero gas 20 96 vol of O2 Test gas concentration span gas n a Calibration data for automatic calibration C...

Page 258: ...t range for 0 to 25 vol of O2 in N2 is calibrated in addition N2 and O2 N2 mixtures are available practically everywhere Measuring ranges Component 1 O2 in CO2 Meas range 1 0 to 1 vol Meas range 2 0 to 15 vol Meas range 3 0 to 25 vol Meas range 4 0 to 100 vol Component 2 O2 in N2 substitute gas Meas range 1 0 to 25 vol Calibration parameters Calibration method Substitute gas calibration Zero compo...

Page 259: ...for corrected sample components During calibration possible electronic cross sensitivity and or carrier gas corrections by other measurement components are switched off Therefore corrected measurement components should be calibrated only using a test gas consisting of the measurement component and an inert gas like Nitro gen Calibration with substitute gas If test gases are not available for calib...

Page 260: ... a substitute gas In this case an additional measurement range is calibrated for 0 to 25 vol of O2 in N2 N2 and O2 N2 mixtures are available practically everywhere Measuring ranges Component 1 O2 in flue gas Meas range 1 0 to 5 vol Meas range 2 0 to 10 vol Component 2 O2 in N2 substitute gas Meas range 1 0 to 25 vol Calibration parameters Calibration method Substitute gas calibration Zero componen...

Page 261: ...r for CO HOPCALIT for CO2 Sodium hydroxide on substrate Test gases for end point calibration without calibration cells A test gas is required for each detector for span calibration without calibra tion cells In the case of automatic and externally controlled calibration a test gas mixture is required for all detectors since all are calibrated simulta neously The span gas concentration should be 70...

Page 262: ...nent which is affected by the smallest number of corrections Up to that sample component which is affected by the largest number of corrections Example Sample components CO2 CH4 C3H6 Cross sensitivity correction CO2 by CH4 CO2 by C3H6 C3H6 is not corrected Sequence for zero point calibration 1 C3H6 2 CH4 3 CO2 All the sample components must also always be calibrated in the end point calibration He...

Page 263: ...found in the section ZO23 Preparation for installation see page 67 Check of the end point It is recommended that the end point is checked approx 4 weeks after start up Further checks of the end point should be carried out as required Check of the reference point It is recommended that the reference point is checked once a year or as required ...

Page 264: ...e calibrated with the following analyzer Magnos206 and Magnos28 with single point calibration Limas11 IR Limas21 UV Limas21 HW with calibration cells Uras26 with calibration cells 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 control of cali...

Page 265: ...hange the test gas concentration3 shown ENTER 11 When the sample value indication stabilizes initiate span calibration with ENTER 12 Accept the calibration result with ENTER or REPEAT4 calibration back to step 10 or reject calibration with Back back to step 11 or reject calibration with Meas back to measurement value readout 13 For single calibration repeat steps 2 to 12 for other components and m...

Page 266: ...nu MENU Calibrate Automatic calibration 2 Only zero point calibration ZERO AUTOCAL Only span calibration SPAN AUTOCAL 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 stopped the analyzer module is in an indefi nite state For example the zero poin...

Page 267: ...lyzer mod ules are shown on the display screen and the green Power LED is lit Periodic checks Module assembly Function Interval Sample gas flowmeter Caldos25 10 to 90 l h max 200 l h Regularly Caldos27 10 to 90 l h Fidas24 80 to 100 l h Fidas24 NMHC 80 to 100 l h Limas11 IR 20 to 100 l h Limas21 UV 20 to 100 l h Limas21 HW 20 to 90 l h Magnos206 30 to 90 l h Magnos28 30 to 90 l h Magnos27 20 to 90...

Page 268: ...n the Caldos25 and Uras26 analyzer mod ules to the reference gas path Checking gas path seal integrity Example Sample gas path in Magnos27 1 2 3 4 5 6 7 8 9 10 11 12 14 13 Luft Air 50 hPa 1 Seal the outlet of the gas path to be tested 7 in the example so it is gas tight 2 Connect plastic tubing with the T piece fitted with a shut off valve to the inlet of the gas path to be tested 4 in the example...

Page 269: ... be activated and deactivated manually for instance in emergency situations The emergency shutdown cannot be overridden by the automatic calibration Setting the pump output 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 pneumatic module its reading is shown when adjusting the pump output Menu ...

Page 270: ...n on the individual function blocks Menu path MENU Configure Function blocks Outputs Analog output Changing current range The current range is changed using the Output current range parameter Selection The current range choices are 0 to 20 mA 2 to 20 mA and 4 to 20 mA NOTE The output signal may not be less than 0 mA and larger than 22 mA Current range limitation The output signal is limited to the...

Page 271: ... Caldos25 Fidas24 ZO23 not required The information as to whether a pressure sensor has been installed in an analyzer module can be found in the MENU Diagnosis Information System Overview menu item after selecting the respective analyzer module Air pressure values 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 ...

Page 272: ...sure 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 steps 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 correctio...

Page 273: ...he relative offset and ampli fication 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 no longer be calibrat...

Page 274: ...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 calibra tion Performing the basic calibration The basic cali...

Page 275: ...centration can be measured in two ways Using the analyzer module with which the sample component is meas ured internal cross sensitivity correction possible only with the Limas11 IR Limas21 UV Limas21 HW 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 compon...

Page 276: ...ld 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 interfer ence components is required as the test gas Prior to the carrier gas a...

Page 277: ...easuring mode The analyzer module is operational meas urement is in progress Standby The analyzer module is in standby mode the measured values are invalid Flame error The flame is out the analyzer module must be restarted Fail safe The analyzer module is turned off because of a serious error Air Pr Combustion air pressure H2 Combustion gas pressure Definitions Standby mode heater on combustion ga...

Page 278: ... also continue to be observed in the menu The current values for the flame temperature combustion air pressure and combustion gas pressure as well as the number of ignition attempts are displayed If ignition of the flame has failed after 10 attempts for the parameter Ignition attempts 10 failed is displayed By pressing the softkey RESTART another restart can be initiated Fidas24 in fail safe statu...

Page 279: ...he replacement of the sample gas filter in the heated sample gas connec tion is necessary if it is contaminated and the sample gas flow is too low as a result Requisite material Sample gas filter with O rings Part Number 0768649 Allen key key size 4 mm Replace sample gas filter 1 2 3 4 5 2 1 Mounting screws 2 Sample gas filter holder 3 O ring 4 O ring 5 Sample gas filter ...

Page 280: ... gas filter 5 and new O rings 3 and 4 into the sample gas filter holder 2 NOTE Always replace O rings in conjunction with sample gas filter Contaminated or damaged O rings impair the seal integrity of sample gas path this leads to erroneous measurement values 5 Put sample gas filter holder 2 on the sample gas terminal section and secure with the three mounting screws 1 Only tighten mounting studs ...

Page 281: ...ure is too high i e if the negative pressure can no longer be adjusted to pabs 600 hPa Requisite material Open end wrench key size 12 mm and 14 mm O Ring set for the detector Part Number 0769343 Ultrasonic bath with aqueous cleaning agent e g Extran Cleaning the air jet injector 1 2 3 4 5 6 1 Exhaust air outlet with screwed in air jet injector 2 Exhaust pipe 3 O ring 4 O ring 5 O ring 6 Air jet in...

Page 282: ... e g Extran 5 Replace O rings 3 4 and 5 with new O rings NOTE When cleaning the air jet injector always replace all three O rings Contaminated or damaged O rings impair the suction performance of the air jet injector this may result in the failure of the Fidas24 Slightly lubricate all three O rings with high temperature grease part no 772341 before mounting them 6 Screw air jet injector 6 into the...

Page 283: ... pressure of the combustion gas i e approx 1 4 bar 3 Mark cylinder pressure indication on the high pressure gauge 4 Close the valve of the combustion gas cylinder 5 The display on the high pressure gauge it should not change measura bly in 10 minutes A measurable change in the display is an indication of a leak in the combustion gas feed path between the cylinder pressure reducer and the combustio...

Page 284: ...ication of a leak in the combustion gas path between the pressure reducer and the combustion gas inlet valve of the gas analyzer In this case the following measures are to be taken 1 Check the combustion gas line between the pressure reducer and gas analyzer with a leak detection spray A leak in this area must be remedied and another leak test must be performed before the gas analyzer is put into ...

Page 285: ...om bustion gas inlet to combustion gas nozzle With a leak detector measurement principle thermal conductivity sniff all the connection points 2 Inspection of the combustion gas feed path with negative pressure in the detector after the combustion gas nozzle Connect zero gas at the sample gas inlet Envelope all the connection points one after the other with a small gas cloud containing hydrocarbons...

Page 286: ...ation prior to effectiveness testing Before the effectiveness test the zero and span points of the sample com ponents CH4 and THC must be calibrated Perform effectiveness testing Determine methane loss 1 Connect test gas methane 2 Press key Conv Test Test gas flows through the converter 3 Write down THC converter reading 4 Press key THC Test gas flows through the bypass 5 Write down THC bypass rea...

Page 287: ... beam path in the analyzer module must be optically aligned separately If there are two detectors in a beam path the optical alignment should be performed in the rearmost detector as seen from the emitter During an optical alignment beam path intensity is varied by means of mechanical apertures and if necessary by turning the emitter case For this the system housing must be opened Detector arrange...

Page 288: ...EV B Uras26 analyzer module emitter 1 2 3 4 5 6 1 Beam path 1 aperture adjustment wheel 2 Beam path 2 aperture adjustment wheel 3 Two emitter case mounting screws beam path 2 here 4 Openings for emitter wrench insertion 5 Emitter case 6 Emitter wrench ...

Page 289: ... 5 Minimize the zero gas value displayed by turning the applicable beam path aperture adjustment wheel 1 and 2 If the measurement value is much smaller than 1 000 000 then go to Step 10 If the measurement value is still greater than 1 000 000 then go to Step 6 6 Loosen the two emitter case mounting screws 3 and insert the emitter wrench 6 in openings 4 7 Turn the emitter case 5 until the displayed...

Page 290: ...onent 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 Phase alignment procedure 1 Select the Phase adjustm menu item 2 Select the Sample component 3 Turn on the zero gas supply 4 Wait until the me...

Page 291: ...n should calibration cells be measured We recommend measuring the calibration cells once 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 or after a relinearization see page 292 Before measuring the calibration cells Prior to measuring the calibration cells the zero and end points of ...

Page 292: ... and type of measurement ranges test gases with varying concentrations are required for relinearization Number and type of meas ranges Test gas concentration 1 measurement range Approx 40 to 60 measurement range end value center point gas 2 measurement ranges End value of the smaller measure ment range 2 measurement ranges 1 of which is suppressed Start value of the suppressed measurement range Me...

Page 293: ...ching off the power supply ap prox 30 minutes 1 Switch off the gas analyzer power supply 2 Open the wall housing door or the 19 inch housing cover 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 ther mal link part number 0...

Page 294: ...w lamp intensity see section Limas11 IR Limas21 UV Limas21 HW Trou bleshooting see page 339 Status messages When beam intensity becomes too low the appropriate status messages see page 322 will be displayed Requisite material For cleaning Neutral detergent deionized water ethanol For drying Oil and dust free instrument air or nitrogen Spray bottle 2 plugs for sealing the sample cell 2 Pieces of FP...

Page 295: ...sen 4 screws 1 socket head wrench opening 3 mm and remove 2 mounting brackets 2 5 Remove the sample cell from its housing Sample cell cleaning 6 Clean the sample cell with a warm detergent water mixture Do not use other cleaners as they can damage the sample cell 7 Thoroughly rinse the sample cell with deionized water and then with ethanol 8 Dry the sample cell with oil and dust free air 30 to 100...

Page 296: ...s analyzer power supply 16 Wait for the warm up phase to end Turn on the sample gas supply 17 Check linearity Aluminum sample cell with center connection An aluminum sample cell with center connection is built in in the Limas21 UV analyzer module with Class 2 NO measurement ranges In this version the sample gas inlet is in the center and the sample gas outlets are at the ends of the sample cell Th...

Page 297: ...ing see page 339 Status messages When beam intensity becomes too low the appropriate status messages see page 322 will be displayed Requisite material For cleaning Neutral detergent deionized water ethanol For drying Oil and dust free instrument air or nitrogen Spray bottle 2 plugs for sealing the sample cell Spare parts kit Part Number 0768823 ATTENTION The quartz sample cell should be handled wi...

Page 298: ...ng door or the 19 inch housing cover Sample cell removal 3 Loosen the sample gas pipes 2 from the connections on the sample cell 5 and from the housing rear wall 1 and pull them from the housing When removing the sample gas pipes make sure no contaminants con tained in the pipes fall into the housing The sample gas pipes removed should not be reused since they are contaminated follow the appropria...

Page 299: ...nnections may not be securely sealed 13 Place the sample cell 6 in its holder with the gas ports pointing to the left housing wall as seen from the front above 14 Install 2 mounting brackets 4 making sure that the notches for the sample cell gas lines also face the left wall and secure with 4 screws 3 Connect the sample gas lines to the sample cell 15 Push the sample gas tubes 2 through fittings 1...

Page 300: ...ing to the measuring de tector The beam guide tubes are screwed into the sample cell and press the cell window against the clamped 22 1x1 6 FFKM70 O ring seals In 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 b...

Page 301: ...nting bracket 7 Purge gas hose 8 Fixing device 9 Sample cell 10 Beam guide 11 Beam guide When should the sample cell be cleaned Sample cell contamination can result in unstable measurement values due to low lamp intensity see section Limas11 IR Limas21 UV Limas21 HW Trou bleshooting see page 339 Status messages When beam intensity becomes too low the appropriate status messages see page 322 will b...

Page 302: ...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 Oil and dust free instrument air or nitrogen For the seal integrity test positive pressure method 1 Pressure gauge measuring range pe 0 to 400 hPa 1 T piece with shut off valve 1 ...

Page 303: ... power supply approx 30 minutes Preparation for sample cell removal 1 Turn off the sample gas and purge gas supply to the analyzer 2 Purge the sample gas feed path with dry nitrogen flow approx 60 l h duration approx 30 minutes 3 Seal the sample gas inlet and outlet of the sample cell tubing with one plug each so that no fluid can escape during the removal of the sample cell 4 Switch off the gas a...

Page 304: ...ain The other cell window is thereby removed from the seal Collect the cell window in the paper towel 14 Remove the 2 O ring seals 22 1x1 6 FFKM70 dispose with a pair of twee zers Also remove and dispose of the 2 O ring seals 28x2 FKM80 The O ring seals may not be used again Always replace them with new seals Cleaning the sample cell and sample gas tubing 15 Clean the sample cell with a warm deter...

Page 305: ...e apertures of the sample gas tubing are located 23 Hold the sample cell with 2 open end wrenches clamp one open end wrench in the vise in order to fix the sample cell in position and screw in the beam guide tubes 10 and 11 as far as they will go Checking the sample cell for tightness For the assembly of the sample cell as prescribed a leakage rate of 1 x 10 4 mbar l s must be safely reached This ...

Page 306: ...ocket head wrench opening 3 mm 35 Press the 2 plugs 2 into the leadthroughs Fix the retaining board 3 in position with the screw 4 36 If applicable push the purge gas line onto the input of the flow sensor option and fasten by means of the spring 37 Lay the purge gas lines in the housing in such a way that no movable parts e g the chopper wheel are obstructed feed through the 2 cou plings 1 and fi...

Page 307: ...ed The Electrodeless Discharge Lamp EDL has a limited lifetime Lamp re placement operations shall be accounted for maintaining analyzer function ality over the time The analyzer notifies the user about reduced source intensity through a dedicated analyzer status message see page 322 No 358 Upon notifica tion of such message an investigation of root cause has to be planned and in case of lamp inten...

Page 308: ...11 3 1 Light barrier circuit board 1 2 Light barrier circuit board 2 3 Lamp EDL 4 Fastening screws of the support 5 Fastening screws of the lamp 6 Support 7 Temperature sensor block 8 Fastening screw of the temperature sensor 9 Temperature sensor 10 12 V supply connector 11 Fastening screws of the heater block ...

Page 309: ... Remove the mounting screw 8 with washer and mounting bracket for the temperature sensor 9 These parts are needed to mount the temperature sensor to the new lamp 11 Remove the temperature sensor 9 from the cavity of the temperature sensor block 7 12 Loosen the 2 mounting screws 11 of the heater block and remove the complete heater block from the lamp 3 Install the new lamp 13 Before installing the...

Page 310: ...sages No 358 and 359 Lamp intensity above or below middle of per missible range How should amplification optimization be performed When the lamp has been replaced Write down the serial number of 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 pat...

Page 311: ...supply will be acti vated automatically 2 Select the Amplification optimization menu item 3 Select the first sample component for which status message No 301 is present 4 Press the New Lamp or Optimize or Optimize All softkey After pressing New Lamp a window will appear for entering the serial number of the new lamp After this the amplification optimization pro cedure will run automatically for al...

Page 312: ...tively fast response time of the measuring cell In this case the result of the function test is Test Passed If the value deviates from the value before the completion of the test by more than 10 of the value before the beginning of the test the result is rejected since it is assumed that the change in the sample gas was too high during the test Test factor The test result can be tailored to the re...

Page 313: ...me when the process control is not adversely af fected thereby The function test is executed in 2 phases 1 Test current on After start up the test current is applied to the meas uring cell for approx 400 s 2 Test current off The test current is then switched off and the function test is ended after a further 400 s Menu path MENU Maintenance Test Analyzer spec adjustm ZO23 function test ...

Page 314: ... gas analyzer power supply 2 Open the wall housing door or the 19 inch housing front plate 3 Remove the disposable filter 1 from the bracket in the pneumatics mod ule 4 Remove the hose clamps from both sides of the disposable filter and disconnect the hoses Properly dispose of the contaminated filter 5 Attach the hoses to the new disposable filter and fasten them with the hose clamps Pay attention...

Page 315: ...flow values Drift values Analyzer specific values In combination with mobile devices smartphone tablet etc Dynamic QR Code represents an innovative way of customer s communication which allows for instance improved case specific support by ABB resulting in an increased availability of analyzer assets Dynamic QR Code is compatible with the ABB application my Installed Base as well as with standard ...

Page 316: ...he diagnosis menu can be selected directly from the status messages overview The QR code can also be selected in Remote HMI and scanned from the computer screen Recommended QR code scanner applications ABB recommends the use of the following QR code scanner applications available free of charge for iOS and Android my Installed Base by ABB Download in App Store Download in Google Play QR Scanner by...

Page 317: ... meas ured value in the display flashes A status message is also generated in each case these messages will not be entered into the logbook The thresholds established cannot be changed Transgression of limit values If a measured value is above or below a limit value this status is output as a binary signal at one of the digital outputs Two prerequisites must be met to this effect The limit value m...

Page 318: ...contains complete information on the indi vidual function blocks Status message processing generates Peripheral Status Message Component Module Status Signal System generates sets Screen Log LEDs Digital Outputs Display Entry generates generates Output Display Status messages are shown on the screen and recorded in the log Status messages set a corresponding status signal overall status or individ...

Page 319: ...asured value is invalid Maintenance request The analyzer is in a state that will soon require user intervention The measured value is valid Maintenance mode The gas analyzer is being calibrated or serviced The measured value is not a process measured value and is to be dis carded Individual status by analyzer module or sample component In principle the individual status signals apply to the entire...

Page 320: ...operates normally after the status has been cleared howev er the operator must be informed of the status When the status is cleared the status signal is reset The status message disappears as soon as the operator has acknowledged it The operator is thus informed about the malfunction of the instrument Example No new measurement values from the analog digital converter Status messages requiring ack...

Page 321: ...wledge LED lights up LED goes out Status signal set Status signal reset Message appears q Message remains I Message canceled Status begins Acknowledge Status ends LED lights up LED goes out Status signal set Status signal reset Message appears q Message remains Q Message canceled Status messages requiring acknowledgment and intervention Status begins Status ends Acknowledge correct LED lights up L...

Page 322: ...ssages occur repeatedly System controller 101 System controller shut down at For information shows date and time 102 System controller starts up at For information shows date and time as well as warm or cold start 103 Install Module For information 104 Remove Module For information 105 Reactivate Module For information 106 A user installed module For information 107 A user removed module For infor...

Page 323: ... system bus was not able to transfer data into the data base x x The system bus module software version is not com patible with that of the system controller update the system controller software 209 The system bus connection to this module is interrupted x x Check the system bus connection to the indicated sys tem bus module Check the power supply system of the indicated system bus module 210 The...

Page 324: ... plausibility Fix possible cause of implausibility Manually calibrate the indicated detector at zero No 306 and end point No 307 Permissible range 15 of the smallest installed meas uring range 6 of the smallest installed measuring range for measurements on plants subject to approval and pursuant to the 27th and 30th BImSchV Federal Regulation on Immissions 307 The amplification drift between two c...

Page 325: ...00 C hardware fault Pt 100 line break or short circuit Switch power supply off and back on after 3 seconds If this status message appears again notify Service Remark Fail safe state means Heater off combustion gas valve closed instrument air valve closed case purging on zero gas valve open Temperature regulator 324 Temperature is above or below upper and or lower limit value 1 x Status messages du...

Page 326: ... 339 Line break or short circuit in the analog input x x Check system cooler temperature 340 Analog input value exceeds upper or lower limit value 1 x Check system cooler temperature 341 Analog input value exceeds upper or lower limit value 2 x Check system cooler temperature Flow monitor pneumatic module 342 The flow rate undershoots limit value 1 x Check sample preparation Alarm value 1 25 of MR...

Page 327: ...The calibration filter wheel cannot be initialized x x Notify Service 363 The Limas analyzer board can not be initialized x x Notify Service 364 A new lamp has been installed The amplifiers settings are optimized For information 365 The Limas amplifiers settings are optimized For information LS25 366 The LS25 analyzer has an overall error x x 367 The LS25 analyzer has a maintenance request x x 368...

Page 328: ...e preamplifier defective x x Notify Service 382 Meas value is influenced by shock x x Flow controller 398 No new measured values from the analog digital converter x x Notify Service 399 The measured value overshoots the range of the analog digital converter x x Check the sample gas concentration Check connectors in the gas analyzer Notify Service 400 A calculation error occurred during calculation...

Page 329: ...502 A system error occurred in the system module concerned The calibration is interrupted Notify Service 503 Amplification error during cali bration Calibration impossible x The calibration is interrupted Span gas concentration too low check 507 A combination of the following errors occurred Half Drift Lim it Drift Limit Amplification or Delta Drift 508 Unknown error number Check software versions...

Page 330: ...or information 528 Autocalibration not started i e manual calibration was run ning For information 529 Calibration was stopped be cause no raw measured values were recorded x x 530 Calibration stopped because the pressure switch did not detect any calibration gas x x 531 Automatic validation started For information 532 Automatic validation ended For information 533 Automatic validation externally ...

Page 331: ...used 1003 Flow rate too low at this point x x Currently not used System Cooler 1100 Cooler temperature too high x x Sample gas feed module pump is automatically turned off Check the system cooler and sample gas prepara tion system 1101 Cooler temperature too low x x 1102 Condensate penetration in cooler x x 1103 Flow rate too low in cooler x Check the system cooler and sample gas preparation syste...

Page 332: ...s lines for seal integrity Gas feed paths in the gas analyzer kinked or leaky Disconnect gas analyzer from the gas conditioning system Check whether the gas lines in the analyzer module or to the pneumatic module are kinked or have become detached from the connections Check the seal integrity see page 268 of the analyzer module gas paths and if applicable of the lines to the pneumatics module Samp...

Page 333: ...cold and heat sources such as the sun ovens and Observe climatic conditions Relative humidity max 75 no condensation Ambient temperature for storage and transport with integrated oxygen sensor 25 to 65 C 25 to 60 C Ambient temperature range during operation with Analyzer module installed in a housing without electronics module installed in a housing with electronics module or with power supply onl...

Page 334: ... continuity and replace if necessary 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 and reduce as needed in operation max 20 l h positive pressure pe 2 to 4 hPa Unstable reading...

Page 335: ...re end ferrules Inspect power supply of the heater Unstable readings Vibrations Reduce vibration at the installation site Sample gas path leaky Check gas path in the analyzer module and in the sampling modules for seal integrity Loss of sensitivity Have sample gas nozzle replaced by Service Sample gas outlet pressure too high Check air jet injector for congestion if necessary clean see page 281 In...

Page 336: ... variable 90 Increase combustion air primary pressure H2 Output variable 40 Reduce combustion gas primary pressure Output variable 90 Increase combustion gas primary pressure Input Output variable 50 Reduce sample gas inlet pressure Output Output variable 50 Increase the instrument air pressure Clean air jet injector see page 281 Reduce length of the gas discharge line or increase cross section Ou...

Page 337: ...e Test Analyzer spec adjustm Standby Restart FID Remark The operating status Wait for restart means Heater on Combus tion gas valve closed Instrument air valve open Housing purge on Combustion air pressure too high Reduce combustion air pressure note details in Analyzer Data Sheet Fidas24 in fail safe status If a serious fault has occurred in the analyzer module the analyzer module is put in fail ...

Page 338: ...er must be monitored If the status appears the cause must be verified in the gas analyzer on site If the gas analyzer is not in operation e g as a result of a supply voltage failure the supply gases must be shut off see section Gas analyzer shutdown see page 343 If the gas analyzer is in operation an adequate instrument air supply must be verified If this is the case the status messages must be ve...

Page 339: ...factor of 10 or more is the probable cause of unstable measurement value readings Three different cases can be identified 1 If only the two measurement detector values have dropped there is probably a contaminated sample cell Clean the sample cell 2 If all four values are have dropped by similar amounts then lamp in tensity has probably decreased Perform an amplification optimiza tion see page 310...

Page 340: ...e the vibrations Permissible vibration levels for analyzer max 0 04 mm at 5 to 55 Hz 0 5 g at 55 to 150 Hz when in stalled in cabinet max 0 01 ms 2 at 0 1 to 200 Hz Increase T90 increase switching threshold for non linear filter see page 163 Loss of sensitivity Check the sensitivity variation Indication 75 Maintenance request status signal appears The de tector concerned will need to be changed so...

Page 341: ...eating 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 if necessary Check the disposable filter and replace see page 314 if necessary Check the solenoid valve s and replace i...

Page 342: ...ed It is located on the sys tem housing identification plate inside the right wall of the 19 inch housing 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 item MENU Diagnostics Information System overview An exact description of the problem or status as well as the status mes sag...

Page 343: ...s line with nitrogen for at least 5 minutes from the sampling point 3 Set the gas analyzer to standby operation see page 277 In case of corrosive and flammable gases set the gas analyzer to standby opera tion with detector purging 4 Shut off combustion air supply and combustion gas supply In the case of a long term shutdown carry out the following in addi tion 5 Shut off instrument air supply 6 Sw...

Page 344: ...le wrap or corrugated cardboard When shipping overseas additionally shrink wrap the gas analyzer air tight in 0 2 mm thick polyethylene film adding a drying agent such as silica gel The amount of drying agent should be appropriate for the package volume and the expected ship ping duration at least 3 months 5 Pack the gas analyzer in an adequately sized box lined with shock absorbing material foam ...

Page 345: ...r the following in mind when disposing of this product and its packaging As of 8 15 2018 this product will be under the open scope of the WEEE Directive 2012 19 EU and relevant national laws The product must be supplied to a specialist recycling company Do not use municipal waste collection points These may be used for privately used products only in accordance with WEEE Directive 2012 19 EU If th...

Page 346: ...k Output fluctuation 2 σ 0 5 of smallest measurement range span at electronic T90 time 0 s Detection limit 4 σ 1 of smallest measurement range span at electronic T90 time 0 s 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 effect Knowledge of the sample gas composition is required for ...

Page 347: ...l ly compensated Associated gas effect 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 with re spect to the temperature during calibration Thermostat temperature 60 C Ambient temperature in permissible range Air pressure effect 0 25 of span per 10 hPa for the smallest possible ...

Page 348: ...tion 2 σ 0 5 of span at electronic T90 time 20 s not smaller than 10 µg org C m3 Detection limit 4 σ 1 of span at electronic T90 time 20 s not smaller than 20 µg org C m3 Oxygen dependence 2 of measured value for 0 to 21 vol O2 or 0 3 mg org C m3 whichever is greater Temperature influence Ambient temperature in permissible range on zero point and on sensitivity 2 per 10 C in the measurement range ...

Page 349: ...allation of filter cells or internal electronic cross sensitivity correction or carrier gas correction for a sample component by other sample compo nents measured with the Limas11 IR or Limas21 UV Temperature influence At zero point 1 of span per 10 C for measurement ranges smaller than Class 1 to Class 2 2 of span per 10 C On sensitivity 1 of the measured value per 10 C Sample cell temperature re...

Page 350: ... of span NO2 120 ppb or 1 of span at electronic T90 time 15 s Process measurement 300 ppb or 0 3 of span at electronic T90 time 30 sec Flow influence Flow rate in the 20 to 90 l h range within the detection limit Associated gas effect cross sensitivity The knowledge of the sample gas composition is necessary for the analyzer configuration Selectivity measures to reduce associated gas effect option...

Page 351: ...ormance Part 3 Paramagnetic oxygen analyzers Temperature influence At zero point 0 02 vol O2 per 10 C On sensitivity 0 1 of the measured value per 10 C Thermostat temperature 64 C ambient temperature in permissible range Air pressure effect At zero point no influence effect On sensitivity without pressure correction 1 of the measured value per 1 air pressure change On sensitivity with pressure cor...

Page 352: ...002 Gas analyzers Expression of performance Part 3 Paramagnetic oxygen analyzers Temperature influence At zero point 0 02 vol O2 per 10 C On sensitivity 0 3 vol O2 per 10 C Thermostat temperature 60 C ambient temperature in permissible range Air pressure effect At zero point no influence effect On sensitivity without pressure correction 1 of the measured value per 1 air pressure change On sensitiv...

Page 353: ...rature influence At zero point 2 of span per 10 C On sensitivity 0 5 of measured value per 10 C each with respect to the temperature during calibration Thermostat temperature 63 C Ambient temperature in permissible range Air pressure effect At zero point 0 05 vol of O2 per 1 air pressure change On sensitivity without pressure correction 1 5 of the measured value per 1 air pressure change On sensit...

Page 354: ...rection for a sample component by other sample components measured with the Uras26 Temperature influence At zero point 1 of span per 10 C for measurement ranges smaller than Class 1 to Class 2 2 of span per 10 C On sensitivity with temperature compensation 3 of the measured value per 10 C On sensitivity with thermostat effect at 55 C Option 1 of the measured value per 10 C Ambient temperature in p...

Page 355: ... The flow rate is kept constant to 0 2 l h in the permissible range The per missible range is 5 to 10 l h Associated gas effect Inert gases Ar CO2 N2 have no effect Flammable gases CO H2 CH4 in stoichiometric concentrations to the oxygen content Conversion of O2 20 of the stoichiometric conversion If higher concentrations of flamma ble gases are present higher O2 conversions must be expected The c...

Page 356: ...amic 5 0 s Flow influence Flow rate in 20 to 100 l h 2 of the span Temperature influence Ambient temperature in permissible range 0 2 vol of O2 per 10 C Air pressure effect At zero point no influence effect On sensitivity without pressure correction 1 of the measured value per 1 air pressure change On sensitivity with pressure correction 0 2 of the measured value per 1 air pressure change Pressure...

Page 357: ...56 259 Calibration reset 273 274 Cancel keys 138 143 Carrier gas alignment 276 Changing a component 166 172 Changing analog output current range 270 Changing module name 179 Changing the number of decimal places 158 159 178 202 Changing the password 150 185 Changing the unit of a component 177 Checking gas path seal integrity 11 78 268 295 299 314 332 334 339 340 Component selection list 167 168 1...

Page 358: ...8 Gas analyzer shutdown 58 338 343 Gas analyzer shutdown and packing 343 Gas analyzer start up 126 Gas connection installation 78 96 97 Gas line connection 11 39 78 80 96 126 Gas path and housing initial purge 11 127 Guideline for installation and commissioning 11 H Housing purge 40 98 338 I Identification plate 74 110 Important information for the operator 21 Inhibit operation 150 152 186 Inspect...

Page 359: ...e connection Safety notes 121 Power supply line connection to an analyzer module 122 Preface 9 Preparation for installation 11 34 Pressure sensor 39 Process status 317 Profibus module Electrical connections 107 108 114 Pump activation pump output adjustment 269 Purge gas flow monitoring 23 28 30 32 R Removing a system module 191 Replacing a system module 190 S Safety information 11 12 13 Saving th...

Page 360: ...asurement of flammable gases Safety Concept and non flammable gases 20 Version with type of protection II 3G for measurement of non flammable gases and vapors 18 W Warm up phase 135 233 234 240 243 250 251 255 259 262 Z ZO23 Check of the end point and reference point 68 263 Function test 312 Gas analyzer start up 134 Gas connections 68 95 Operating specifications 355 Preparation for installation 6...

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Page 362: ...t without prior notice With regard to purchase orders the agreed particulars shall prevail ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document We reserve all rights in this document and in the subject matter and illustrations contained therein Any reproduction disclosure to third parties or utilization of its contents in whole or ...

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