Advance Optima 6b3311

Advance Optima Modular Analyzer Product Line for Process Gas Analysis

System Description

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Contents Page Chapter 1

Chapter 2

Advance Optima – The Integrated System Concept

3

Overview

3

Analyzer Modules

8

Uras 14 Infrared Analyzer Module Limas 11 UV Analyzer Module Magnos 16 Oxygen Analyzer Module Magnos 17 Oxygen Analyzer Module Caldos 15 Thermal Conductivity Analyzer Module Caldos 17 Thermal Conductivity Analyzer Module Multi-FID 14 FID Analyzer Module Electrochemical Oxygen Sensor Gas Module

8 10 12 14 16 18 20 22 24

The Central Unit: Housing and Power Supply

25

System Housing Display/Control Unit Power Supply

25 27 28

Central Unit: Electronics Module

29

Electronics Module Hardware Concept I/O Boards Interfaces

29 31 32 33

Multiple-Analyzer Systems

34


34

Calibration

37

Calibration Concept Calibration Procedure

37 38

Software

39

Software Concept Autodiagnostics Software Tools

39 41 42

Operation

43

Operation via Display/Control Unit Remote Control / Remote Maintenance

43 44

Chapter 9

Explosion Protection

45

Chapter 10

Approvals

46

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Chapter 7

Chapter 8

This system description is protected by copyright. The translation, duplication and distribution in any form, even in a revised edition or in extracts, in particular as a reprint, by photomechanical or electronic reproduction or in the form of storage in data processing systems or data networks are prohibited without the consent of the copyright holder and will be prosecuted under civil and criminal law. 2

Advance Optima – System Description

30/24-110-1 EN

Chapter 1

Advance Optima – The Integrated System Concept

Overview Analysis tasks

Precise measurements are the only acceptable result in today’s analyzer technology. The demand is for systems that combine analyzers and system components into efficient units. All components in a sampling circuit, including sample gas collection, preparation and transport to the analyzer, must interact perfectly and be matched to each other. This also includes integration in complex networks. Finally, implementation of this type of concept should lead to a significant cost reduction.

The concept

The Advance Optima integrated system concept consists of:

• Use of mature engineering methods. • Integration of the greatest possible number of components. • Ease of operation and maintenance. • Service-friendly design. • Capability of performing multiple component measurements easily. • Inclusion of all system components including sample collection and preparation devices. • Integration in networks.

Measurement technology

Advance Optima is based on analyzer modules that are available for performing measurements using different techniques. Performance is further increased by detailed solutions and the use of the latest materials based on the proven technology of previous analyzer modules. Newly developed calibration techniques allow some operations to be performed without test gases. Continued on next page

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3

Overview, continued Analyzer modules

The Advance Optima analyzer modules are:

• The Uras 14 infrared analyzer module to measure infrared-active components in a sample gas. • The Magnos 16 and Magnos 17 oxygen analyzer modules and an electrochemical oxygen sensor to measure oxygen content in a sample gas. • The Caldos 15 and Caldos 17 thermal conductivity analyzer modules to measure thermoconductive components in a sample gas. • The Multi-FID 14 flame ionization detector to measure hydrocarbon content in a sample gas.

Uniform device design

All analyzer modules have uniform electrical, gas and mechanical interfaces. This allows a uniformly integrated analyzer system to be created. The analyzer systems differ only in their selection of analyzer modules. This concept is maintained in the various housing options, including a 19-inch version, wall-mount unit and explosion-protected housing.

Figure 1 Device arrangement 4

3

5 2 6 1

1 System Housing 2 Analyzer Module 3 Electronics Module

4 Power Supply 5 Gas Module 6 Display/Control Unit Continued on next page

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Overview, continued Multiple-analyzer systems

An essential principle of the Advance Optima integrated system concept is the ability to connect several analyzer modules with one central unit and, in this manner, handle different sample components with a single analyzer system. Advance Optima can control up to three analyzer modules with a single central unit. The system bus allows analyzer modules to be installed up to 350 meters from the central unit. Use of a single central unit can considerably lower costs.

Separation

Separating the central unit from the analyzer modules is an ideal solution if samples must be collected at different measurement points. This is especially critical when the measurement points are located in explosion-hazard areas. Short gas paths and lower costs for sample collection and preparation lead to additional savings.

Incorporation of existing analyzers

Existing non-Advance Optima analyzers can be linked using I/O boards and controlled by the central unit.

Adaptation to local conditions

Advance Optima's integrated system concept allows analyzer modules to be combined to satisfy measurement tasking and existing conditions. Figure 2 shows a multiple-analyzer system consisting of: • A central unit with one analyzer module and • Two separate analyzer modules, one is an explosion-protected version, and • An existing analyzer, the current and status signals of which are linked to Advance Optima via an I/O board.

Figure 2 Multiple-analyzer system

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Zentraleinheit mit Central Unit with 1 x Analysatormodul Analyzer Module

4-20 4 - 20mA mA Status Status

Advance Optima

Vorhandenes Gerät Existing Analyzer

Hartmann & Braun

Analysatorodul

IR-Analyzer Uras 14

IR-Analyzer Uras 14

Advance Optima

Systembus System Bus Analyzer Module Up bis to zu350 500m m Hartmann & Braun Advance Optima

Analyzer Module Analysatormodul

Continued on next page

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5

Overview, continued Ex concept

The ability to install analyzer modules up to 350 meters from the central unit is an ideal solution for applying analyzer modules in a explosion risk areas. The Ex concept includes solution for operating analyzer systems in Zone 1 and Zone 2, as well as in aggressive atmospheres. Explosion protection is achieved by means of • A pressure-tight aluminum cylinder • Operation with a protective gas

Operation

The large screen on the display/control unit can display up to six sample components simultaneously. The system is completely menu-driven and allows work to be done without the need for consulting a manual since all messages are clear and online help is available for many phases of operation. Further cost savings are achieved by reducing training costs for operation and maintenance personnel.

System component connection

Some system components are directly incorporated in Advance Optima. An example of this is the Advance SCC system cooler with an integrated SCM1 gas supply module. Here an I/O board connects the cooler directly to the Advance Optima system bus. This makes information such as outlet dew point, cooler operation, peristaltic pump status and sample gas flow available in the Advance Optima central unit from which it can be processed or routed.

Connection of other system components

Other system components can be connected using variable I/O modules.

Control and monitoring concept

Advance Optima's comprehensive control and monitoring concept is extended to system components.

This makes all information from peripheral components available to the Advance Optima system.

• Fault messages are available in a central location. • Messages are in plain text. • Component and/or control is possible. Advance Optima takes on jobs that used to require a separate programmable memory controller. The simple integration of system components reduces costs of analyzer system analysis and design. Continued on next page

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Overview, continued Integration in networks

The highest level of the Advance Optima system involves integration in the monitored facility's network (see Figure 3). This makes all facility information available for Advance Optima operation and maintenance. Thus, for example, system component maintenance can take place when the facility is shutdown for other reasons.

Figure 3 Integrating Advance Optima in the monitored facility’s network

Hartmann & Braun

Hartmann & Braun

Hartmann & Braun

Hartmann & Braun

Hartmann & Braun

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Hartm an n & Braun

Ease of service

Advance Optim a

Advance Optima's ease of service is not limited to simply operating the analyzer system. The capability of setting limit values as necessary to trigger "maintenance needed" messages, the low service and maintenance burden and reduced spare parts inventories because of uniform device design make cost savings a reality when operating the analyzer system.

Communications concept

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The Advance Operation communications concept, based on PC and networking industry standards, is an ideal supplement to the Advance Optima system. If offers savings in maintenance resources by providing remote control, maintenance and diagnostics functions. Maintenance work does not need to be performed on site. Most of the tasks can be performed by telephone and data lines from a service center.


7

Chapter 2

Analyzer Modules

Uras 14 Infrared Analyzer Module Application

The Uras 14 infrared analyzer module is an NDIR photometer that can measure 1 to 4 sample components simultaneously and continuously. The Uras 14 is chiefly used in emissions monitoring, process monitoring/control and quality assurance, e.g. super-clean gases, for the energy, chemical, iron and steel, cement and other industries. Typical sample components include CO, CO2, NO, SO2, N2O, CH4, C3H8, C2H4.

Analyzer module structure

The Uras 14 infrared analyzer module consists of the following assemblies: • Emitter with modulator (chopper wheel) • Sample cell • Gas-filled transmissivity receiver with preamplifier

Figure 4

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3

Analyzer module structure 5 6

7

8 9 10

1 2 3 4 5

Calibration unit 2 Sample cell 2 Main frame Modulator (covered) Calibration unit 1

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Infrared detector 1 Sample cell 1 Infrared detector 2 Aperture disk Infrared detector 3 Continued on next page

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Uras 14 Infrared Analyzer Module, continued Figure 5

1 2 3

Measurement principle

1 Emitter 2 Aperture 3 Chopper wheel

4

5

6

4 Sample cell 5 Adjusting unit / Calibration cell 6 Receiver


The Uras 14 infrared analyzer module uses the NDIR (non-dispersive infrared absorption) process. This process is based on resonance absorption at the characteristic vibration rotation spectrum bands of non-elemental gases in the middle infrared range between 2 µm and 12 µm. Because of their bipolar moment, the gas molecules interact with infrared emissions. For selectivity, the receiver is filled with the applicable sample components to establish sensitivity to these components.

Description

The photometer consists of a thermal emitter, the emissions of which reach a sample cell via a chopper wheel. The sample cell is in the shape of a tube that is divided by a land into sample and reference sides. The measurement effect produced in the receiver is a pressure effect resulting from the chopper frequency, received by a diaphragm capacitor and converted into an electrical signal by an attached preamplifier. The receiver is a two-layer device. The back of the receiver has an optically transparent window so that any residual radiation can reach a second receiver that is sensitive to a second sample component. By adding a second beam path with an emitter, sample cell and receivers the photometer can measure 1 to 4 sample components simultaneously.

Calibration

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The infrared analyzer module's zero point is calibrated with a zero gas and a span gas is used to calibrate its span point. The zero gas is sample component-free, ambient air ed through the sample cell. Span calibration is achieved by inserting a gas-filled calibration cell in the beam path; this means that test gas bottles are not required for routine calibration.


9

Limas 11 UV Analyzer Module Application

The primary areas of Limas 11-UV operation are: NO measurement for burner optimization, regulation of DeNOx units and monitoring of emissions. NOx reduction in engine exhaust gases. Quality control of H2S content in natural gas and coke-oven gas, as well as emissions from waste and sewage facilities. Monitoring and regulatory tasks in the production of paper, cellulose and plastics. Typical sample components include NO, NO2, SO2, H2S, CS2, COS and Cl2.

Analyzer Module Structure

The Limas 11 analyzer module consists of the following assemblies:

• UV lamp • Filter wheels with • Interference filters and/or • gas filters • Sample cell • Calibration wheel with calibration cells • Measurement and reference receivers

Figure 6 Analyzer Module Structure

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1 2 3 4

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Reference Receiver Filter Wheels UV Lamp Calibration Wheel

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5 Beam Splitter (covered) 6 Sample Cell 7 Measurement Receiver


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Limas 11 UV Analyzer Module, continued Figure 7

6

1

Measuring Principle

7

8

2 3

4

5

1 2 3 4

Measuring Principle

UV Lamp Filter Wheel with Interference Filter Filter Wheel with Gas Filter Beam Splitter

5 6 7 8

Reference Receiver Sample Cell Calibration Wheel with Calibration Cells Measurement Receiver

The Limas 11 measurement principle uses the property of molecules to interact with a beam emitted at a certain wavelength and absorb radiation. Sample component selectivity is achieved using gas filter or interference filter correlation.

Description

The UV beam emitted by an electrodeless discharge lamp is split into predetermined wavelengths by a filter wheel fitted with interference filters and/or gas filters. The split beam is then separated by a beam splitter into measurement and reference signals and reaches the reference receiver without ing through an absorption run while reaching the measurement receiver after absorption (sample cell). Absorption of the emission in the sample cell causes a change in the intensity of the measurement signal. To identify sample component concentration a double-quotient evaluation process is applied to the four time-multiplexed measurement signals thus formed.

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Magnos 16 Oxygen Analyzer Module Application

The Magnos 16 oxygen analyzer module is used to measure the purity of oxygen in process gas measurement and during inertization. The sample component is oxygen (O2).


The Magnos 16 oxygen analyzer module consists of the following assemblies:

• Thermostat chamber • Thermal link • Mounting flange with • Sample chamber • Permanent magnet • Flow controller • Thermostat temperature sensor • Plug connection The thermostat chamber is a cylindrical polyester housing that makes a gas-tight connection on the bottom of the mounting flange. The analyzer module's gas-tight design allows it to be purged separately from the central unit.

Figure 8 1


6 2 7 3

8 9

4 10 5

1 2 3 4 5

Permanent magnet Connection to sample chamber Flow regulator Optics tap Purge air port

6 7 8 9 10

Preamplifier board Pressure sensor Connection to Sensor-U board Pressure sensor gas port Sensor-U board Continued on next page

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Magnos 16 Oxygen Analyzer Module, continued Figure 9 Measurement principle

Dumbbell Compensation Current

60 °C

IR Diode N

N

Si Photoelement

S

S

Difference

By

Description

The sample gas to be analyzed flows through the sample chamber. A dumbbellshaped cavity made of quartz glass is suspended on rotary tension bands in the sample chamber. The two cylindrical dumbbell halves are inserted in nonhomogenous magnetic fields of a permanent magnet’s two pole shoe pairs. Oxygen molecules are drawn into the magnetic field of the permanent magnet. The partial pressure drop thus produced applies a force to the dumbbell and generates torque to move the dumbbell from its original position. The magnitude of this torque is proportional to the oxygen concentration and can be converted into an electrical signal. The measurement unit is located in a thermostat chamber so that measured values are extensively free from variations in ambient temperature.

Measurement principle characteristics

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Freely adjustable measurement ranges and the use of highly suppressed measurement ranges allow the Magnos 16 to be easily adapted to special measuring tasks.


13

Magnos 17 Oxygen Analyzer Module Application

The Magnos 17 oxygen analyzer is used to analyze flue gases, cement flue gas and corrosive gases. The sample components are oxygen (O2) in flue gas or in nitrogen (N2).


The Magnos 17 oxygen analyzer module consists of the following assemblies:

• Thermostat chamber • Thermal link • Mounting flange with • Sample chamber with sample and reference sides • Permanent magnet • Thermostat temperature sensor • Plug connection The thermostat chamber is a cylindrical polyester housing that makes a gas-tight connection on the bottom of the mounting flange. The analyzer module's gas-tight design allows it to be purged separately from the central unit.

Figure 10 Analyzer module structure

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4

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3 6

1 Permanent magnet 2 Sample chamber 3 Purge air port

4 board 5 Connection to Sensor-U board 6 Sensor-U board Continued on next page

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Magnos 17 Oxygen Analyzer Module, continued Figure 11 Measurement principle

Description

The sample gas to be analyzed flows through the two-chamber system. Both chambers have temperature-sensitive annular resistors. On the sample side, oxygen molecules are drawn into the non-homogeneous magnetic field of the permanent magnet. The "magnetic wind" thus generated cools the heated temperature-sensitive measuring resistors. The change in temperature is proportionate to oxygen content and can be converted into an electrical signal. The measurement unit is located in a thermostat chamber so that measured values are extensively free from variations in ambient temperature. Calibration is effected with oxygen-free process gas, process gas with a known oxygen concentration or with a substitute gas.


The heavy-duty sample cell makes the Magnos 17 analyzer module especially insensitive to vibration and shock.

Difference between Magnos 16 and Magnos 17

The Magnos 17 oxygen analyzer module is based on a thermomagnetic measurement principle. Thus, it is especially suitable for measuring oxygen content relative to thermal conductivity in binary or quasibinary sample gas mixtures (in flue gases, for example). With its magnetomechanical measurement principle, the Magnos 16 oxygen analyzer module offers very selective analysis techniques based on the high magnetic susceptibility of oxygen.

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Caldos 15 Thermal Conductivity Analyzer Module Application

The Caldos 15 thermal conductivity analyzer module is used to measure H2 in Cl2, SO2 in corrosive gas or in NH3 dissociation. Typical sample components include H2 in Cl2, SO2 in N2 or air, H2 in N2 or air.


The Caldos 15 thermal conductivity analyzer module consists of the following assemblies:

• Thermostat chamber • Thermal link • Mounting flange with • Sample chamber • Thermostat temperature sensor • Plug connection The thermostat chamber is a cylindrical polyester housing that makes a gas-tight connection on the bottom of the mounting flange. The analyzer module's gas-tight design allows it to be purged separately from the central unit.

Figure 12 Analyzer module structure

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5

2 6

3

4

1 2 3

board Connection to Sensor-U board temperature probe

4 5 6

Purge air port Sample chamber Sensor-U board Continued on next page

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Caldos 15 Thermal Conductivity Analyzer Module, continued Figure 13 60 °C


Reference Side

Glass Coating

Measurement Side

Glass

By

Description

The sample gas to be analyzed flows over two opposed temperature-sensitive resistor wires in the sample chamber. With the sample chamber resistor wires, the two resistor wires exposed to the reference gas form a bridge circuit. The bridge circuit is powered by a constant current source to that the resistor wires are at a specified temperature. The bridge circuit is in equilibrium when the sample gas has the same quantitative composition as the reference gas. Even slight differences in the thermal conductivity of sample gas and reference gas disrupt the temperature-dependent bridge balance and give rise to a bridge diagonal voltage that is proportional to the concentration of the sample component. The measurement unit is located in a thermostat chamber so that measured values are extensively free from variations in ambient temperature.


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The measurement principle is primarily suited to measure a gas component in a binary or quasibinary gas mixture relative to thermal conductivity. The sample cell is made of glass to permit measurement of corrosive gases.


17

Caldos 17 Thermal Conductivity Analyzer Module Application

The Caldos 17 thermal conductivity analyzer module is used to measure the purity of hydrogen, to monitor turbine generators, to monitor protective gases and for LEL monitoring. Typical sample components include Ar in O2, H2 in Ar, H2 in N2 or air, CH4 in N2 or air, Ar in N2, He in N2


The Caldos 17 thermal conductivity analyzer module consists of the following assemblies:

• Thermostat chamber • Mounting flange and sample chamber with • Thermal conductivity sensor • Sensor electronics with temperature probe • Heater • Thermal link • Plug connections The thermostat chamber is a cylindrical polyester housing that makes a gas-tight connection on the bottom of the mounting flange. The analyzer module's gas-tight design allows it to be purged separately from the central unit.

Figure 14

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1

5 6

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8 3 9

1 2 3 4

Cover Pressure sensor Connection to Sensor-U board Thermal conductivity sensor

5 6 7 8 9

Thermal Link Heater element Preamplifier board Heater connection Sensor-U board Continued on next page

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Caldos 17 Thermal Conductivity Analyzer Module, continued Figure 15 60 °C


Measurement Resistor

By

Sample Gas

Description

The sample gas to be analyzed is diffused in the sample chamber. The sample chamber has a thermal conductivity sensor consisting of three overlaid silicon chips. The center chip contains a membrane with two thin-film resistors. The resistors are heated by an electrical current. One resistor is exposed to the sample gas. The thermal conductivity of the sample gas is carried away by the membrane. The current that maintains the temperature difference between the resistors is the means for measuring the sample component concentration in the sample gas. The measurement unit is located in a thermostat chamber so that measured values are extensively free from variations in ambient temperature.


The micromechanical silicon sensor provides the smallest measurement ranges and quickest measurements.

Difference between Caldos 15 and Caldos 17

Caldos 15 is designed for highly corrosive applications. Its sample cell with glasscovered measurement resistors makes it especially resistant to corrosive sample media. In contrast, because of its silicon sensor, the Caldos 17 provides very small measurement ranges and rapid measurements.

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19

Multi-FID 14 FID Analyzer Module Application

The Multi-FID 14 (FID = flame ionization detector) analyzer module is used for emissions monitoring, process measurements, purity measurement of H2 and O2 or with a stripper to monitor volatile hydrocarbons in water. The sample components are hydrocarbons.


The Multi-FID 14 analyzer module consists of the following assemblies:

• • • • • •

Detector Air injector Vacuum regulator Combustion air regulator Combustion gas regulator Sample gas inlet

The heated detector incorporates an air injector that produces a vacuum. This will provide the flame with a constant volume of combustion gas, combustion air and sample gas per unit of time. The sample gas line can be connected to a heated sample gas port. An upstream catalytic converter removes hydrocarbons from the combustion air.

Figure 16

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Electronic pressure regulation Active charcoal filter Detector (covered by insulation)

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Heated sample gas port Sensor electronics Gas ports Continued on next page

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Multi-FID 14 FID Analyzer Module, continued Figure 17 Measurement principle

+

-

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+

Ampère

+ H2

Combustion Air

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Combustion Gas

Cn Hm Sample Gas

Description

The air injector causes a vacuum in the detector. This draws the sample gas, combustion gas (H2) and combustion air into the combustion chamber. A constant volume of sample gas is mixed with the combustion gas and routed to the burner nozzle. This mixture is burned while the hydrocarbon-free combustion air is metered. The flame ionization detector measures the ionization of organically bound carbon atoms in a hydrogen flame. Burning the hydrocarbons in the sample gas produces ionized particles causing a flow of ions between the electrode shells. This effect is directly proportional to the amount of organically bound hydrocarbons in the sample gas. The ion flow is electrically amplified and converted to a voltage.

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Electrochemical Oxygen Sensor Application

The electrochemical oxygen sensor is used to measure the concentration of oxygen in a sample gas. The oxygen sensor is primarily used for emissions monitoring, for measurements in fermentation facilities and fruit warehouses and for measurements of ambient air quality.

Oxygen sensor structure

The oxygen sensor consists of the following components:

• Sensor • Housing body • Gas ports The oxygen sensor is mounted in the gas module; it is always associated with an analyzer module (e.g. the Uras 14) and is controlled and monitored by the latter's sensor electronics. In contrast to the analyzer modules referenced earlier, the electrochemical oxygen sensor cannot be installed by itself in a system housing.

Figure 18 Oxygen sensor structure 4

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Lead anode Gold-plated cathode Teflon membrane

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Resistance Thermistor Acid electrolyte Continued on next page

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Electrochemical Oxygen Sensor, continued Figure 19

R

I


Diffusion Barrier

Elektrolyte

Anode

Description

Cathode

The sensor works in the same manner as a fuel cell. The sample component (oxygen) is electrochemically converted at the cathode/electrolyte boundary layer. The resultant current at resistor R is proportional to the oxygen concentration. The following reactions occur between the anode and cathode: Cathode: Anode: Total:

O2 + 4 H + 4 e → 2 H2O + – 2 Pb + 2 H2O → 2 PbO + 4 H + 4 e O2 + 2 Pb → 2 PbO +

–

The sensor’s temperature sensitivity is maintained by electrical compensation referenced to the measured temperature.

Calibration

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Because of the principle involved, the oxygen sensor has an absolute zero point. Zero calibration is performed with ambient air containing a very stable oxygen concentration of 20.96 vol-%.


23

Gas Module Function

The gas module supplies sample gas to the analyzer module and supplies a test gas for calibrating the analyzer module.

Gas module structure

When fully equipped, the gas module consists of the following assemblies:

• • • • • • • •

Sample gas pump One or three solenoids One or two fine-particle filters Condensation sensor One or two flow meters Inlet pressure regulator Absorption and/or dryer cartridges (connected externally) Electrochemical oxygen sensor

The assemblies are attached to a common mounting plate. The gas module is connected to the sample gas inlet and analyzer module by means of Viton hoses. The gas module is assigned to an analyzer module and is electrically and pneumatically linked to that module. The gas module's assemblies are controlled and monitored by the analyzer module's sensor electronics.

Two analyzer modules in one system housing

If two analyzer modules are installed in one system housing, a gas module cannot be installed.

Figure 20 Gas module

4

5 1 2

3

1 2 3

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Flow meter Solenoids Oxygen sensor

4 5

Fine filter Sample gas pump


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Chapter 3

The Central Unit: Housing and Power Supply

System Housing Function

The system housing contains all of the analyzer system's functional units.

Two versions

There are two system housing versions available to meet different space and installation requirements (e.g. rack mounting).

• 19-inch housing • Wall-mount housing The analyzer system connections are on the back of the housing (19-inch housing) or on the bottom of the housing (wall-mount housing).

Figure 21 19-inch housing

Figure 22 Wall-mount housing


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System Housing, continued Housing concept

The housing concept allows the electronics module, power supply and analyzer modules to be physically separated (refer to the "Explosion Protection" chapter) and permits the installation of an additional analyzer module in the system housing (refer to the "Multiple Analyzer Systems" chapter).

Housing protection types

The system housing is available in an IP 20 protection version (standard version) or an IP 54 version (including display/control unit and connection box). IP 65 protection is possible if the system housing does not have a power supply or display/control unit (see the example in Figure 23).

Housing purge

The system housing can be flushed with a purge gas to protect against penetration by aggressive atmospheres or corrosive sample gas components. A housing purge is possible if the system housing is an IP 54 protection version (with display/control unit and connection box). The housing purge is accomplished via the analyzer module's purge gas port, or if no analyzer module is installed, via a separate purge gas port.

Figure 23 Housing with two analyzers and no power supply

Housing type selection

The choice of system housing depends on the site and system configuration.

Explosion protection version

For information on housing versions for Ex zones, see the "Explosion Protection" chapter in this system handbook and publication No. 30/24-100 EN "Explosion Protection Versions – Descriptions and Design Instructions".

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For more information see the design instructions and the specification sheet, publication number 10/24-1.10 EN "Modular Process Analysis Product Line".


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Display/Control Unit Function

The display/control unit displays measurement values and status signals. Advance Optima can be completely controlled via the display/control unit. The can

• • • •

Call up menu items for processing Start functions Confirm entries, e.g. parameter settings Configure the analyzer system

Operation

Analysis system operation is controlled from a menu using the keypad buttons (see the "Operation" chapter). The menu can be switched between two languages.

Display/control unit structure

The display/control unit consists of (see Figure 24):

• Backlit graphics display (320 x 240-pixel resolution) • Menu bar • Data field • Softkey bar • Three status indication LEDs • A keypad with • Six softkeys • Two cancel keys • Numeric keypad The control/display unit is located on the system housing front .

Figure 24 2

Display/control unit

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Graphic display Menu bar Data field Softkey bar

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Softkeys Status indication LEDs Numeric keypad Cancel keys


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Power Supply Input voltage

The AC power supply is connected via a rubber plug to the electronics module connection plate. The power supply input voltage can be switched from 230 VAC to 115 VAC.

Output voltage

A 24-VDC power supply is needed to power the analyzer modules. This voltage is provided by the power supply.

Two analyzer modules in one system housing

One power supply can only power one analyzer module. If two analyzer modules are installed in one system housing, an Advance Optimaspecification external power supply should be obtained.

Figure 25 Power Supply

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Chapter 4

Central Unit: Electronics Module

Electronics Module Function

The electronics module, at the heart of which is the system controller, is used to convert measurement values from the analyzer modules. The system controller processes measurement values and makes them available in various forms, e.g. as external device control commands.

Structure

The electronics module consists of the following components:

• • • • • •

Processor system with buffered real-time clock Non-volatile memory (EPROM) for firmware and device data Inputs and outputs Interfaces Display/control unit connector Up to five optional I/O boards

The system controller modules are centrally mounted on a common circuit board in the system housing. There are interfaces on the back and bottom of the system housing.

Figure 26 Electronics Module 3

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System controller I/O boards (Optional) Electrical connections Continued on next page

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Electronics Module, continued System controller tasks

The system controller carries out the following functions:

• Processing and communicating the measurement values supplied by the analyzer module sensor electronics • Measurement value calculation • System function control • Display and control • Control of associated systems • Communication with external systems The chart on the following page illustrates the tasks performed by the system controller.

The concept

30

To perform these tasks a concept was developed in order to assure that the system's hardware was equipped with the required functionality.


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Hardware Concept Figure 27 Field Bus

Hardware concept

Maintenance-Bus 10BASE2 / 10BASE-T

HMI Electronics Display Status LEDs ...

RS232C

Ethernet T/IP

RS485

Modbus

I/O I/O

HMI Interface

Calibration

I/O

U Output Current Digital I/O CAN-Bus Control Functions

Signal Processing

I/O I/O

Function Block Programming

System Bus Sensor U Signal A/D Linearization Thermostat ...

HMI interface

Sensor U Signal A/D Linearization Thermostat ...

The HMI interface (HMI = human-machine interface) is used to control the display/control unit. The HMI interface is responsible for

• Displaying status signals and measurement values • Operating the analyzer system

System bus

The system bus interconnects the following functional units

• • • •

Analyzer modules Sample preparation I/O boards System controller

The Advance Optima functional units within a system housing are interconnected via an internal system bus. If external functional units are added to the analyzer system, the connection is made via the external bus.

Field bus

The field bus transfers status signals and measurement values to the host system.

Maintenance bus

The maintenance bus connects Advance Optima to Ethernet networks. This allows Advance Optima to be used with other systems, including remote control of analyzer systems.

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I/O Boards Expansion of functionality

Functionality can be expanded by adding I/O boards with definable functions to the analyzer system. These I/O boards are controlled by the system controller.

Slots

Control of associated Advance Optima systems should be implemented via optional I/O boards. The electronics module has 5 slots for I/O boards.

Applications (examples)

I/O boards can be used to:

Configuration

The I/O board pin layout can be easily adapted to requirements by configuring function blocks.

• • • • •

Supply of external analyzer module power signals Expansion of the number of power outputs Measurement range switching and Limit-value signaling Flow monitoring

The factory configuration of inputs and outputs is described in a separate document supplied with the analyzer system. The configuration can be modified at any time to meet changing requirements.

Digital I/O board

The digital I/O board has: • Four digital inputs Optocouplers with internal power supply • Four digital outputs Floating double-throw s

Analog I/O board

The analog I/O board has: • Two anaputs –20 to +20 mA or –10 to +10 V • Two analog outputs 0/4 to 20 mA (configurable) • Two digital inputs Optocouplers with internal power supply • Two digital outputs Floating double-throw s

8-way analog output board

The 8-way analog output board has: • Eight analog outputs in two groups 0/4 to 20 mA (configurable)

System bus

The I/O boards are linked to the system controller via the system bus.

32


30/24-110-1 EN

Interfaces Ethernet interface

The Ethernet interface (10BASE2 or 10BASE-T) is used for

• Remote control of Advance Optima from a PC • Remote maintenance of Advance Optima

RS-485 port

The RS-485 port for the Modbus/Field bus is used to

• Transfer data to external devices (e.g. PC, monitor, printer) • Operate in a computer network • Display information in the control room

RS-232C port

The RS-232C port allows a point-to-point connection, e.g. between Advance Optima and a PC.

System bus

System bus functions:

• Internal transfer of signals from an analyzer module to the system controller • Internal transfer of signals from I/O boards to the system controller • External transfer of signals when the electronics module is physically separated from the analyzer module.

Figure 28 Electronics module connections

6

10BASE2 1

1

1

1

1

22

22

22

22

22

1 RS 485

2 L RS 232C

3

PE N BUS 1

12

13

24

10BASE-T

4

D I/O 1

D I/O 2

D I/O 3

D I/O 4

D I/O 5

7 5 1 2 3 4

30/24-110-1 EN

8

Ethernet 10BASE2 RS-485 port Power supply Inputs and outputs (System Controller)

5 6 7 8

Ethernet 10BASE-T I/O boards (per configuration) RS-232C Port System Bus


33

Chapter 5


Multiple-Analyzer Systems The concept

The uniform system component design allows individual analyzer modules to be combined into multiple-analyzer systems. In addition to the purely financial aspect, centralized operation, monitoring and maintenance of a multiple-analyzer system offers a decisive advantage over the use of individual analyzers.

Integration

The uniform design of electrical and gas ports allows: • Integration in networks via Modbus and Ethernet • Formation of compact systems by integrating system components for sample gas preparation (e.g. Advance SCC sample gas cooler), even in complex applications • Creation of an open system by connecting older models and third-party units via I/O interfaces.

Spare parts inventory

The uniform system concept's reduced spare parts inventory requirement rounds out the positive financial impact of multiple-analyzer systems.

Capabilities

• Up to 6 sample components can be collected and transmitted to a central unit (e.g. 2 Uras 14 analyzers with 3 sample components each). • Up to 3 analyzer modules can be connected to the central unit (e.g. 3 Magnos 16 with one sample component each).

Application example

Emission measurement with Uras 14 and Magnos 16. All system components used for sample gas preparation, such as the Advance SCC sample gas cooler, and devices from other suppliers can be integrated. Advance Optima will then perform all system control functions which previously required a separate SPS.

Application example

Stack gas analysis with Caldos 15/17 and Uras 14. Correction calculations required for interference component curves (cross-sensitivity correction) can be performed internally. There is no need for additional wiring since the devices are already linked to the system bus.

Power supply in multiple-analyzer systems

The integral power supply provides energy for the central unit. Any installed analyzer module is powered by this power supply. Physically separated analyzer modules should be powered by one or more adequately dimensioned power supplies. Continued on next page

34


30/24-110-1 EN

Multiple-Analyzer Systems, continued Figure 29 Connection example: Physically separated central unit and analyzer module

Description

The analyzer module can be located near the sampling site and the central unit can be in the control room.

Figure 30 Connection example: Central unit and analyzer module linked to two analyzer modules in a separate system housing

Description

Up to three analyzer modules can be connected to one central unit. The location of the analyzer modules is not important to the central unit. Continued on next page

30/24-110-1 EN


35

Multiple-Analyzer Systems, continued Figure 31 Connection example: Central unit linked to three separate analyzer modules

Description

If analyses are to be performed at different sites it is useful to located just the analyzer modules at the sampling sites.

Figure 32 Connection example: Linking Advance Optima to a computer network

Description

36

To perform various tasks Advance Optima can be incorporated in different types of computer network structures.


30/24-110-1 EN

Chapter 6

Calibration

Calibration Concept Calibration control

Depending on the analyzer system version and equipment, there are three methods for controlling calibration:

• Manual calibration • Automatic calibration • Externally controlled calibration All analyzer modules can be calibrated using any of the three methods.

Manual calibration

An individual manual zero and span calibration is performed by pressing the analyzer system display/control unit keys. The test gas supply can be started by means of the integral gas module's solenoid valves or via external solenoid valves.

Automatic calibration

Zero and span are calibrated automatically after starting. Automatic calibration is started • At time intervals determined by the internal clock (normal situation) • By an external control signal at a digital output • Manually via the analyzer system's display and control unit The test gas supply can be started automatically by means of the gas module's solenoid valves or via external solenoid valves.

Externally controlled calibration

For externally controlled calibration, zero and span point alignment is triggered by control signals from an external control unit. The test gases should be started automatically by external solenoid valves also controlled by the external control unit.

30/24-110-1 EN


37

Calibration Procedure Zero-point and endpoint calibration

Over time, contamination and aging effects in the detector can cause a zero-point shift and a loss of sensitivity. These changes in detector characteristics should be corrected by regular calibration of the zero- and end-points.

Simplified calibration procedure

The measurement principle and detector design of some analyzer modules allows the use of simplified calibration procedures. As a rule, this eliminates the need for stocking costly test gas bottles and for system components necessary for connecting test gas supplies.

Uras 14: Calibration with calibration cells

The Uras 14 analyzer module zero-point can be calibrated with calibration cells. Each calibration cell is filled with a test gas appropriate for the analyzer module's sample components and ranges. Ambient air free of the sample component can be used for zero calibration.

Caldos 17: Single-point calibration with standard gas

Under certain conditions single-point calibration can be performed with a standard gas on the Caldos 17. Normally, nitrogen is used as the standard gas. Standard gas calibration is only performed as span point calibration and causes an amplification correction. This eliminates the need for separate zero and span calibration with test gases.

Magnos 16: Single-point calibration with ambient air

The long-term sensitivity drift of the Magnos 16 analyzer module is less than 0.05 Vol.-% O2 per year. In this manner only a zero-point correction is needed for calibration during each work shift. Since this causes a parallel shift of the characteristic curve, it can be performed at each point on the characteristic curve. This single-point calibration is performed with dried ambient air.

Oxygen sensor: Calibration with ambient air

The oxygen sensor zero is not calibrated since it is fundamentally stable. Ambient (sample component-free) air with a constant oxygen content (e.g. 20.96 Vol.-%) is required for span calibration.

38


30/24-110-1 EN

Chapter 7

Software

Software Concept Figure 33 Software environment

Description

Measurement values are entered in the input table of a real-time database, processed or evaluated in function block tables and made available to the system via output tables. Communication between analyzer modules, I/O modules and the database is routed via the system bus. The database communicates with the internal and integrated components, the display/control unit and software utilities via internal bus lines. T/IP is used for outside communication.

Function blocks

A function block is a small entity with a precisely defined function. A function block reads its input value, calculates the underlying function and places the result and status information at its outputs. Individual function blocks can be linked into function block chains. Continued on next page

30/24-110-1 EN


39

Software Concept, continued The concept

Optimum of daily work requires consideration of the following points:

• • • • •

Sampling task conversion

Data display and storage Simplification of maintenance operations Increased system availability istration of several tasks by the same personnel Application of all Advance Optima capabilities

Advance Optima is extremely versatile and can be converted to handle a wide variety of measurement tasks. Advance Optima's standard software s

• Adapting to various applications This can be done through function block programming, additional devices and software are not required; • Connection of an Advance SCC system cooler, additional devices for sample gas preparation and software are not required; • Incorporation of status signals in the system, no additional software is required for signal evaluation; • The field bus connection via the Modbus link and Ethernet port, additional network software is not required.

Application program

Additional application programs permit Advance Optima remote control, data storage, display and remote diagnostics. For additional information see the "Software Tools" section.

Interface programs

Interface programs allow applications to be created in the Windows environment. For additional information see the "Software Tools" section.

40


30/24-110-1 EN

Autodiagnostics The concept

Advance Optima simplifies troubleshooting. The system controller can perform extensive diagnostics. Faults identified are immediately displayed in clear messages on the display/control unit screen. Status messages and measurement value indications can be displayed on a PC or in the control room using appropriate software (e.g. Optima Remote HMI).

Generating the required information

Most measurement operation faults occur during sample preparation, e.g. due to pump failure or filter plugging. Thus, in addition to measurement values, Advance Optima measures and reports a number of variables such as detector temperature, sample gas throughput, drift rates, etc. Additionally, supplemental I/O boards allow access to all required information from peripheral components, cooler temperatures, condensate trap contents, test gas bottle pressures, etc. This allows problems with peripherals to be rapidly identified and eliminated.

Maintenance

Maintenance requirements are displayed as clear text messages when applicable.

Preventive maintenance

Operation and maintenance costs are held as low as possible by optimizing system processes. Preventive maintenance can increase the reliability and availability of analyzers and systems. This requires a comprehensive flow of information from all areas involved in sample gas analysis.

Setting limit values

By setting limit values, information from components can be evaluated and converted to "Error" or "Maintenance Required" status signals.

Integrating maintenance functions in facility status

-defined limit values allow maintenance work to be performed when facility operation is stopped for other reasons.

30/24-110-1 EN


41

Software Tools Advance Operation

Advance Operation is designed to link analyzer technology and information technology in a single software concept. Based on widely distributed standards, Advance Operation simplifies the process of linking and processing information in PC applications or control systems.

Optima Remote HMI

Optima Remote HMI (Human Machine Interface) is a program that allows complete remote control of Advance Optima via a PC (see the "Remote Control/Remote Maintenance" section). The monitor display is identical to that of the display/control unit and permits access to measurement values, clear text messages, calibration data and configuration data.

Optima Plant Pilot

Optima Plant Pilot is a display program for the monitoring of Advance Optima in networks. Optima Plant Pilot displays measurement values, permits the archiving of all values from Advance Optima, simplifies status monitoring and displays a trend graph of selected measurement values. Via the network, Optima Plant Pilot provides an overview with the capability to configure individual system and group frames.

Optima M-DDE

Optima M-DDE is a software driver used to integrate information in Windows applications, based on an RS 232/RS 485 connection. All signals can easily be incorporated and displayed in standard software such as Microsoft Excel or Microsoft Visual Basic.

Optima ActiveX

Optima ActiveX is a software driver used to create an application under Windows 95/NT in standard programs such as Microsoft Excel, Access, Visual Basic or National Instruments LabView, and is based on an Ethernet connection. In addition to Optima M-DDE (see above), the driver includes the display of measurement units, drift values, internal values and the number of sample components.

Optima SMT

Optima SMT is a software tool that simplifies Advance Optima system software updates. The individual configurations are stored as records and can be reloaded into the devices. Additionally, the device software can be adapted to meet national language requirements.

42


30/24-110-1 EN

Chapter 8

Operation

Operation via Display/Control Unit The concept

The open software structure and uniform menu-driven operation simplify operation of the entire analyzer system.

Language

The menu can be switched between two languages. The change between languages can be done during operation. German and English are the standard languages, other languages can be incorporated.

Operational safety

Operational safety is achieved by means of

• The backlit graphic display is easy to read even under poor lighting conditions • Color LEDs are used to display status signals

Display

• • • •

Menu structure

The overview shows the Advance Optima menu structure. For clarity only the main menu items are shown.

Figure 34 Menu structure

30/24-110-1 EN

Six sample components simultaneously Digital (numerical values) and analog display (bar graphs) of measurement values Current softkey layout Status messages

0HQX

&DOLEUDWLRQ &RQILJXUDWLRQ &RPSRQHQW6SHFLILF &DOLEUDWLRQ'DWD )XQFWLRQ%ORFNV 6\VWHP 0DLQWHQDQFH7HVW 6\VWHP $QDO\]HUVSHFLILFDOLJQPHQW 'LDJQRVWLFV,QIR 6\VWHP2YHUYLHZ 0RGXOH6SHFLILF /RJERRN


43

Remote Control / Remote Maintenance Optima Remote HMI

The Optima Remote HMI program transfers the Advance Optima display/control unit to a PC workstation. This allows remote control of the analyzer system via an Ethernet connection. Functionality is identical to direct operation on the device itself.

Types of connection

The connection is implemented over an Ethernet interface using the T/P protocol. There are some possible variations in the technology

• Peer-to-Peer Connection • Ethernet network connection as outlined below (expanded by a client system bus connection and an ISDN link).

Figure 35 Remote control / remote maintenance

ISDN Advance Optima System Bus

Advance Optima

Synchronization of operation

The mechanism for synchronizing operation via the display/control unit or via the PC is controlled by software. The Advance Optima status message menu displays an appropriate message when remote control via an Ethernet connection is in effect.

44


30/24-110-1 EN

Chapter 9

Explosion Protection

The concept

The Advance Optima modular product line offers explosion protected analyzers and multiple analyzer systems for use in Zones 1 and 2 to measure combustible and non-combustible gases.

Separation

Advance Optima's modular design allows physical separation of the central unit and analyzer modules for use in Zones 1 and 2.

Analyzer modules for Zone 1

The Caldos 15-Ex, Caldos 17-Ex, Magnos 16-Ex and Uras 14-Ex analyzer modules are capable of measuring combustible and non-combustible gases under atmospheric conditions which can form an explosive environment. Additionally, the analyzer modules are suitable for measuring combustible and non-combustible gases under positive pressure. The analyzer modules are installed in a pressure-tight aluminum cylinder. To protect the analyzer module sensor electronics against the entry of an aggressive atmosphere or corrosive sample gas components, a purge gas can flow through the pressure-tight cylinder.

Central Unit for Zone 1

The system housing is available as a wall-mount unit. The electrical and gas connections are on the bottom of the housing. The system housing is designed for "Positive Pressure Containment with Leak Loss Compensation" ignition suppression. The required control unit is mounted on the outside right sidewall of the system housing.

Zone 2 version

In the Zone 2 version all analyzer modules are capable of measuring noncombustible gases. In of explosion protection measures there are three types: "Nonarcing Units and Components / Sealed (Arcing) Unit", "Simplified Positive Pressure Containment" and "Vapor-Tight Housing". The central unit can be installed up to 350 meters away in an ex-free zone.

Cabling

The system bus cable connects the analyzer module to the central unit. The system bus connection is designed for an Ex zone. If the distance between the analyzer module and central unit is over 10 meters, the system bus cable must be routed through a connection box. Peripheral devices, such as solenoid valves, are also connected to the central unit via connection boxes.

Design

30/24-110-1 EN

Design information can be found in publication No. 30/24-100 EN "Advance Optima Explosion-Protected Versions".


45

Chapter 10

Approvals

TÜV Performance Testing

Advance Optima with analyzer modules Uras 14 and Magnos 16 satisfies the minimum requirements of the "Richtlinien für die Eignungsprüfung, den Einbau und die Wartung kontinuierlich arbeitender Emissionsmeßgeräte“ [Directives for Performance Testing, Installation and Maintenance of Continuously Operating Emissions Measurement Equipment] – BMU Circulars, dated 1 March 1990; IG I-556134/4. The analyzer system is suited for use in facilities per 13. BlmSchV, 17 BlmSchV and TA-Air. Smallest measurement ranges tested: 3

Uras 14

O2 sensor

0 to 75 mg/m CO 3 0 to 75 mg/m SO2 3 0 to 200 mg/m NO 0 to 10/25 Vol.-% O2

Report No. 24016657 Magnos 16

0 to 10 Vol.-% O2 0 to 25 Vol.-% O2

Report No. 24016658 Advance Optima with analyzer module Multi-FID 14 satisfies the minimum requirements of the "Richtlinien über die Eignungsprüfung, den Einbau, die Kalibrierung, die Wartung von Meßeinrichtungen für kontinuierliche Emissionsmessungen und die kontinuierliche Erfassung von Bezugs- bzw. Betriebsgrößen zur fortlaufenden Überwachung der Emissionen besonderer Stoffe“ [Directives for Performance Testing, Installation, Calibration, Maintenance of Measuring Equipment for Continuous Emissions Monitoring and Continuous Determination of Reference and Operational Values for Continuous Monitoring of the Emissions of Particular Substances] – BMU Circulars, dated 1 September 1997; IG I-51134/3. The analyzer module is suited for use in facilities per 13. BlmSchV, 17 BlmSchV and TA-Air, as well as in facilities with comparable exhaust gas matrices. Smallest measurement range tested: Multi-FID 14

3

0 to 15 mg/m C

Report No. 24016659

CSA approval

The Advance Optima with housing, electronics module, gas module and the Caldos 15, Caldos 17, Magnos 16, Magnos 17 and Uras 14 analyzer modules is approved for use in Class 1, Division 2, Gas Group A, B, C, and D, temperature code T4, max. ambient temperature +50°C explosion hazard areas. Approval includes testing per applicable Canadian (CSA) and US directives. If the housing has IP 20 protection it must be installed in a suitable IP 54 cabinet with electrical connections implemented by means of rigid metal conduits. Certificate No. LR 27974-134 Continued on next page

46


30/24-110-1 EN

Approvals, continued Explosion protection

Zone 1 and Zone 2 (combustible sample gas): The Advance Optima Ex central unit satisfies the following European standards: EN 50014:1977 + A1 – A5 EN 50016:1977 + A1 EN 50018:1977 + A1 – A3 EN 50019:1977 + A1 – A5 EN 50020:1977 + A1 – A5

General Provisions "p" positive pressure containment "d" pressure-tight containment "e" elevated safety Intrinsic safety "i"

The identification is EEx ped [ib] IIC T4 Compliance certification No. BVS 97.D.2020 The Advance Optima Ex analyzer modules satisfy the following European standards: EN 50014:1977 + A1 – A5 EN 50018:1977 + A1 – A3

General Provisions Pressure-tight containment "d"

The identification is EEx d IIC T4 Compliance certification No. BVS 97.D.2021 X Zone 2 (non-combustible sample gas): The Advance Optima Zone 2 (non-combustible sample gas) version satisfies the following standards: DIN VDE 0165 / 2.91, Section 6.3 prEN 50021:1998 Ignition prevention type "n" There are three operating modes. The identifiers are: Non-arcing assemblies and components/ Sealed (arcing) devices EEx nVW II T4 X Reduced positive pressure containment EEx nP II T4 X Vapor-tight housing EEx nR II T4 X Statement of expertise Pr. No. 97-09-203-Ex

CE Compliance Statement

Advance Optima satisfies the provisions of the following European directives: 73/23/EEC (Low Voltage Directive) 89/336/EEC (EMC Directive) Compliance with the provisions of directive 73/23/EEC has been evidenced by full compliance with European standard EN 61010-1:1993 (for Multi-FID 14 add EN 60335:1995). Compliance with the provisions of 89/336/EEC is evidenced by full compliance with European standards EN 55011:1991 and EN 50082-2:1995. H&B registration No. CT001/97

30/24-110-1 EN


47

Subject to technical changes Printed in the Fed. Rep. of 30/24-110-1 EN 03.00

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