Advance Optima

Advance Optima
Modular Analyzer Product Line

for Process Gas Analysis
System Description 30/24-110-1 EN
2 Advance Optima System Description 30/24-110-1 EN
Contents
Page
Chapter 1 Advance Optima The Integrated System Concept 3
Overview 3
Chapter 2 Analyzer Modules 8
Uras 14 Infrared Analyzer Module 8
Limas 11 UV Analyzer Module 10
Magnos 16 Oxygen Analyzer Module 12
Magnos 17 Oxygen Analyzer Module 14
Caldos 15 Thermal Conductivity Analyzer Module 16
Caldos 17 Thermal Conductivity Analyzer Module 18
Multi-FID 14 FID Analyzer Module 20
Electrochemical Oxygen Sensor 22
Gas Module 24
Chapter 3 The Central Unit: Housing and Power Supply 25
System Housing 25
Display/Control Unit 27
Power Supply 28
Chapter 4 Central Unit: Electronics Module 29
Electronics Module 29
Hardware Concept 31
I/O Boards 32
Interfaces 33
Chapter 5 Multiple-Analyzer Systems 34
Multiple-Analyzer Systems 34
Chapter 6 Calibration 37
Calibration Concept 37
Calibration Procedure 38
Chapter 7 Software 39
Software Concept 39
Autodiagnostics 41
Software Tools 42
Chapter 8 Operation 43
Operation via Display/Control Unit 43
Remote Control / Remote Maintenance 44
Chapter 9 Explosion Protection 45
Chapter 10 Approvals 46
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30/24-110-1 EN Advance Optima System Description 3
Chapter 1 Advance Optima The Integrated System Concept
Overview
Analysis tasks Precise measurements are the only acceptable result in todays 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
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
1 System Housing
2 Analyzer Module
3 Electronics Module
4 Power Supply
5 Gas Module
6 Display/Control Unit
3
2
1
4
5
6
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
Systembus
Zentraleinheit mit
1 x Analysatormodul
Analysator-
odul
4 - 20 mA
Status
Hartmann & Braun
Advance Optima
IR-Analyzer
Uras 14
IR-Analyzer
Uras 14
bis zu 500 m
Vorhandenes Gert
Hartmann & Braun
Advance Optima
Hartmann & Braun
Advance Optima
Analysatormodul
Existing Analyzer
Analyzer Module
Up to 350 m
System Bus
Analyzer Module
Central Unit with
Analyzer Module
4-20 mA
Status
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 compo-
nents 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.
This makes all information from peripheral components available to the Advance
Optima system.
Control and
monitoring concept
Advance Optima's comprehensive control and monitoring concept is extended to
system components.
Fault messages are available in a central location.
Messages are in plain text.
Component feedback 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.
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 facilitys
network
Hartman n & Braun AdvanceOptima
Hartmann & Braun
Hartmann & Braun
Hartmann & Braun
Hartmann & Braun
Hartmann & Braun
Hartmann & Braun
Hartmann & Braun
Ease of service 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
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.
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, CO
2
, NO, SO
2
, N
2
O, CH
4
, C
3
H
8
, C
2
H
4
.
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
Analyzer module
structure
1 2 3 4
5
6
7
8
9
10
1 Calibration unit 2
2 Sample cell 2
3 Main frame
4 Modulator (covered)
5 Calibration unit 1
6 Infrared detector 1
7 Sample cell 1
9 Aperture disk
Uras 14 Infrared Analyzer Module, continued
Figure 5
Measurement
principle
1 2 3 4 5 6
1 Emitter
2 Aperture
3 Chopper wheel
4 Sample cell
5 Adjusting unit / Calibration cell
6 Receiver
Measurement
principle
The Uras 14 infrared analyzer module uses the NDIR (non-dispersive infrared
absorption) process. This process is based on resonance absorption at the charac-
teristic vibration rotation spectrum bands of non-elemental gases in the middle
infrared range between 2 m and 12 m. 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 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 passed 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.
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 H
2
S 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, NO
2
, SO
2
, H
2
S, CS
2
, COS and Cl
2
.
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
1 Reference Receiver
2 Filter Wheels
3 UV Lamp
4 Calibration Wheel
5 Beam Splitter (covered)
6 Sample Cell
7 Measurement Receiver
1
2
6 7 5
3
4
Limas 11 UV Analyzer Module, continued
Figure 7
Measuring Principle
1 UV Lamp
2 Filter Wheel with Interference Filter
3 Filter Wheel with Gas Filter
4 Beam Splitter
5 Reference Receiver
6 Sample Cell
7 Calibration Wheel with Calibration Cells
8 Measurement Receiver
Measuring Principle 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 passing 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.
8
7
6
4
5
3
2
1
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 (O
2
).
Analyzer module
structure
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
Analyzer module
structure
1 Permanent magnet
2 Connection to sample chamber
3 Flow regulator
4 Optics tap
5 Purge air port
6 Preamplifier board
7 Pressure sensor
8 Connection to Sensor-CPU board
9 Pressure sensor gas port
10 Sensor-CPU board
2
3
1
4
5
6
7
8
9
10
Magnos 16 Oxygen Analyzer Module, continued
Figure 9
Measurement
principle
N
S
N
S
60 C
Dumbbell
Compensation
Current
Si Photoelement
Difference
Bypass
IR Diode
Description The sample gas to be analyzed flows through the sample chamber. A dumbbell-
shaped cavity made of quartz glass is suspended on rotary tension bands in the
sample chamber. The two cylindrical dumbbell halves are inserted in non-
homogenous magnetic fields of a permanent magnets 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
Freely adjustable measurement ranges and the use of highly suppressed measure-
ment ranges allow the Magnos 16 to be easily adapted to special measuring tasks.
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 (O
2
) in flue gas or in nitrogen (N
2
).
Analyzer module
structure
The Magnos 17 oxygen analyzer module consists of the following assemblies:
Thermostat chamber
Thermal link
Sample chamber with sample and reference sides
Permanent magnet
Plug connection
central unit.
Figure 10
Analyzer module
structure
1 Permanent magnet
2 Sample chamber
3 Purge air port
4 Support board
6 Sensor-CPU board
1
2
3
4
5
6
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.
Calibration is effected with oxygen-free process gas, process gas with a known
oxygen concentration or with a substitute gas.
Measurement
principle
characteristics
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 measure-
ment 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 analy-
zer module offers very selective analysis techniques based on the high magnetic
susceptibility of oxygen.
Caldos 15 Thermal Conductivity Analyzer Module
Application The Caldos 15 thermal conductivity analyzer module is used to measure H
2
in Cl
2
,
SO
2
in corrosive gas or in NH
3
dissociation.
Typical sample components include H
2
in Cl
2
, SO
2
in N
2
or air, H
2
in N
2
or air.
Analyzer module
structure
The Caldos 15 thermal conductivity analyzer module consists of the following
assemblies:
Thermostat chamber
Thermal link
Sample chamber
Plug connection
central unit.
Figure 12
Analyzer module
structure
1 Support board
3 temperature probe
4 Purge air port
5 Sample chamber
6 Sensor-CPU board
1
2
3
4
5
6
Caldos 15 Thermal Conductivity Analyzer Module, continued
Figure 13
Measurement
principle
60 C
Measurement Side
Glass
Coating
Bypass
Glass
Reference Side
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.
Measurement
principle
characteristics
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.
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 O
2
, H
2
in Ar, H
2
in N
2
or air, CH
4
in N
2
or air,
Ar in N
2
, He in N
2
Analyzer module
structure
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
central unit.
Figure 14
Analyzer module
structure
1 Cover
2 Pressure sensor
4 Thermal conductivity sensor
5 Thermal Link
6 Heater element
7 Preamplifier board
8 Heater connection
9 Sensor-CPU board
1
2
3
4
5
6
7
8
9
Caldos 17 Thermal Conductivity Analyzer Module, continued
Figure 15
Measurement
principle
Measurement Resistor
60 C
Bypass
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.
Measurement
principle
characteristics
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 glass-
covered 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.
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 H
2
and O
2
or
with a stripper to monitor volatile hydrocarbons in water.
The sample components are hydrocarbons.
Analyzer module
structure
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
Analyzer module
structure
1
1:2
2 3
4
5 6
1 Electronic pressure regulation
2 Active charcoal filter
3 Detector (covered by insulation)
4 Heated sample gas port
5 Sensor electronics
6 Gas ports
Multi-FID 14 FID Analyzer Module, continued
Figure 17
Measurement
principle
+
-
+
-
C
n
H
m
+
-
H
2
Ampre
Combustion Air Combustion Gas
Sample Gas
Description The air injector causes a vacuum in the detector. This draws the sample gas,
combustion gas (H
2
) 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.
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
1 Lead anode
2 Gold-plated cathode
3 Teflon membrane
4 Resistance
5 Thermistor
6 Acid electrolyte
1
2
3
4
5
6
Electrochemical Oxygen Sensor, continued
Figure 19
Measurement
principle
R I
Diffusion
Barrier
Anode Cathode
Elektrolyte
Description 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: O
2
+ 4 H
+
+ 4 e
2 H
2
O
Anode: 2 Pb + 2 H
2
O 2 PbO + 4 H
+
+ 4 e
Total: O
2
+ 2 Pb 2 PbO
The sensors temperature sensitivity is maintained by electrical compensation
referenced to the measured temperature.
Calibration 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-%.
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 pneu-
matically 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
1
2
3
4
5
1 Flow meter
2 Solenoids
3 Oxygen sensor
4 Fine filter
5 Sample gas pump
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
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.
For more information see the design instructions and the specification sheet,
publication number 10/24-1.10 EN "Modular Process Analysis Product Line".
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".
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 user
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 panel.
Figure 24
Display/control unit
1
2
3
4
5
6
7
8
1 Graphic display
2 Menu bar
3 Data field
4 Softkey bar
5 Softkeys
6 Status indication LEDs
7 Numeric keypad
8 Cancel keys
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 Optima-
specification external power supply should be obtained.
Figure 25
Power Supply
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
1 System controller
2 I/O boards (Optional)
3 Electrical connections
2
3
1
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 To perform these tasks a concept was developed in order to assure that the
system's hardware was equipped with the required functionality.
Hardware Concept
Figure 27
Hardware concept
I/O
HMI
Interface
Ethernet
TCP/IP
I/O
I/O
I/O
I/O
10BASE2 / 10BASE-T RS232C RS485
Modbus
Output Current
Digital I/O
CAN-Bus
Control
Functions
Function
Block
Programming
Calibration
Signal
Processing
Sensor CPU
Signal A/D
Linearization
Thermostat
...
Sensor CPU
Signal A/D
Linearization
Thermostat
...
System Bus
HMI Electronics
Display
Status LEDs
...
Field Bus
Maintenance-Bus
CPU
HMI interface 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.
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:
Supply of external analyzer module power signals
Expansion of the number of power outputs
Measurement range switching and feedback
Limit-value signaling
Flow monitoring
Configuration The I/O board pin layout can be easily adapted to requirements by configuring
function blocks.
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 contacts
Analog I/O board The analog I/O board has:
Two analog inputs 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 contacts
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.
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
1 12
13 24
10BASE-T
10BASE2
RS 485
RS 232C
BUS
1
22
1 2 3 4 5
D I/O
L
PE
N
1
22
D I/O
1
22
D I/O
1
22
D I/O
1
22
D I/O
1
2
3
4
5
6
7
8
1 Ethernet 10BASE2
2 RS-485 port
3 Power supply
4 Inputs and outputs (System Controller)
5 Ethernet 10BASE-T
6 I/O boards (per configuration)
7 RS-232C Port
8 System Bus
Chapter 5 Multiple-Analyzer Systems
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-sensi-
tivity 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.
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.
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 To perform various tasks Advance Optima can be incorporated in different types of
computer network structures.
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.
Calibration Procedure
Zero-point and end-
point 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.-% O
2
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.
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.
TCP/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.
Software Concept, continued
The concept Optimum support of daily work requires consideration of the following points:
Data display and storage
Simplification of maintenance operations
Increased system availability
Administration of several tasks by the same personnel
Application of all Advance Optima capabilities
Sampling task
conversion
Advance Optima is extremely versatile and can be converted to handle a wide
variety of measurement tasks.
Advance Optima's standard software supports
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.
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 mainte-
nance functions in
facility status
User-defined limit values allow maintenance work to be performed when facility
operation is stopped for other reasons.
Software Tools
Advance Operation Advance Operation is designed to link analyzer technology and information techno-
logy 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.
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 Six sample components simultaneously
Digital (numerical values) and analog display (bar graphs) of measurement values
Current softkey layout
Status messages
Menu structure The overview shows the Advance Optima menu structure. For clarity only the main
menu items are shown.
Figure 34
Menu structure
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Logbook
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 TCP/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
System Bus
ISDN
Advance Optima
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.
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 non-
combustible gases.
In terms of explosion protection measures there are three types: "Nonarcing Units
and Components / Sealed (Arcing) Unit", "Simplified Positive Pressure Contain-
ment" 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 Design information can be found in publication No. 30/24-100 EN "Advance Optima -
Explosion-Protected Versions".
Chapter 10 Approvals
TV Performance
Testing
Advance Optima with analyzer modules Uras 14 and Magnos 16 satisfies the
minimum requirements of the "Richtlinien fr die Eignungsprfung, den Einbau und
die Wartung kontinuierlich arbeitender Emissionsmegerte [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:
Uras 14 0 to 75 mg/m
3
CO
0 to 75 mg/m
3
SO
2
0 to 200 mg/m
3
NO
O
2
sensor 0 to 10/25 Vol.-% O
2
Report No. 24016657
Magnos 16 0 to 10 Vol.-% O
2
0 to 25 Vol.-% O
2
Report No. 24016658
Advance Optima with analyzer module Multi-FID 14 satisfies the minimum require-
ments of the "Richtlinien ber die Eignungsprfung, den Einbau, die Kalibrierung,
die Wartung von Meeinrichtungen fr kontinuierliche Emissionsmessungen und
die kontinuierliche Erfassung von Bezugs- bzw. Betriebsgren zur fortlaufenden
berwachung 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 0 to 15 mg/m
3
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 +50C 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
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 General Provisions
EN 50016: 1977 + A1 "p" positive pressure containment
EN 50018: 1977 + A1 A3 "d" pressure-tight containment
EN 50019: 1977 + A1 A5 "e" elevated safety
EN 50020: 1977 + A1 A5 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 General Provisions
EN 50018: 1977 + A1 A3 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
Subject to technical changes
Printed in the Fed. Rep. of Germany
30/24-110-1EN 03.00

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