Advance Optima

Advance OptimaModular Analyzer Product Linefor 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 8Limas 11 UV Analyzer Module 10Magnos 16 Oxygen Analyzer Module 12Magnos 17 Oxygen Analyzer Module 14Caldos 15 Thermal Conductivity Analyzer Module 16Caldos 17 Thermal Conductivity Analyzer Module 18Multi-FID 14 FID Analyzer Module 20Electrochemical Oxygen Sensor 22Gas Module 24

Chapter 3 The Central Unit: Housing and Power Supply 25

System Housing 25Display/Control Unit 27Power Supply 28

Chapter 4 Central Unit: Electronics Module 29

Electronics Module 29Hardware Concept 31I/O Boards 32Interfaces 33

Chapter 5 Multiple-Analyzer Systems 34

Multiple-Analyzer Systems 34

Chapter 6 Calibration 37

Calibration Concept 37Calibration Procedure 38

Chapter 7 Software 39

Software Concept 39Autodiagnostics 41Software Tools 42

Chapter 8 Operation 43

Operation via Display/Control Unit 43Remote Control / Remote Maintenance 44

Chapter 9 Explosion Protection 45

Chapter 10 Approvals 46

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

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 today’s analyzer technology.The demand is for systems that combine analyzers and system components intoefficient units.

All components in a sampling circuit, including sample gas collection, preparationand 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 costreduction.

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 preparationdevices.

• Integration in networks.

Measurementtechnology

Advance Optima is based on analyzer modules that are available for performingmeasurements using different techniques.

Performance is further increased by detailed solutions and the use of the latestmaterials based on the proven technology of previous analyzer modules.

Newly developed calibration techniques allow some operations to be performedwithout 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 asample gas.

• The Magnos 16 and Magnos 17 oxygen analyzer modules and an electrochemicaloxygen sensor to measure oxygen content in a sample gas.

• The Caldos 15 and Caldos 17 thermal conductivity analyzer modules to measurethermoconductive components in a sample gas.

• The Multi-FID 14 flame ionization detector to measure hydrocarbon content in asample gas.

Uniform devicedesign

All analyzer modules have uniform electrical, gas and mechanical interfaces. Thisallows a uniformly integrated analyzer system to be created.

The analyzer systems differ only in their selection of analyzer modules. This conceptis maintained in the various housing options, including a 19-inch version, wall-mountunit and explosion-protected housing.

Figure 1

Device arrangement

1 System Housing2 Analyzer Module3 Electronics Module

4 Power Supply5 Gas Module6 Display/Control Unit


3

2

1

4

5

6


Overview, continued

Multiple-analyzersystems

An essential principle of the Advance Optima integrated system concept is the abilityto connect several analyzer modules with one central unit and, in this manner,handle different sample components with a single analyzer system. Advance Optimacan 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 thecentral 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 samplesmust be collected at different measurement points. This is especially critical whenthe measurement points are located in explosion-hazard areas.

Short gas paths and lower costs for sample collection and preparation lead toadditional savings.

Incorporation ofexisting analyzers

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

Adaptation to localconditions

Advance Optima's integrated system concept allows analyzer modules to becombined 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-analyzersystem

Systembus

Zentraleinheit mit 1 x Analysatormodul

Analysator-odul

4 - 20 mAStatus

Hartmann & Braun

Advance Optima

IR-AnalyzerUras 14

IR-AnalyzerUras 14

bis zu 500 m

Vorhandenes Gerät

Hartmann & B raun

Advance Optima

Hartmann & BraunAdvance Optima

Analysatormodul

Existing Analyzer

Analyzer Module

Up to 350 m

System BusAnalyzer 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 anideal solution for applying analyzer modules in a explosion risk areas.

The Ex concept includes solution for operating analyzer systems in Zone 1 andZone 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 needfor consulting a manual since all messages are clear and online help is available formany phases of operation.

Further cost savings are achieved by reducing training costs for operation andmaintenance personnel.

System componentconnection

Some system components are directly incorporated in Advance Optima.

An example of this is the Advance SCC system cooler with an integrated SCM1 gassupply module. Here an I/O board connects the cooler directly to the AdvanceOptima system bus.

This makes information such as outlet dew point, cooler operation, peristaltic pumpstatus and sample gas flow available in the Advance Optima central unit from whichit can be processed or routed.

Connection of othersystem components

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

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

Control andmonitoring concept

Advance Optima's comprehensive control and monitoring concept is extended tosystem 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 programmablememory controller.

The simple integration of system components reduces costs of analyzer systemanalysis and design.



Overview, continued

Integration innetworks

The highest level of the Advance Optima system involves integration in themonitored facility's network (see Figure 3).

This makes all facility information available for Advance Optima operation andmaintenance.

Thus, for example, system component maintenance can take place when the facilityis shutdown for other reasons.

Figure 3

Integrating AdvanceOptima in themonitored facility’snetwork

Hartman n & Braun Advance Optima

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 analyzersystem.

The capability of setting limit values as necessary to trigger "maintenance needed"messages, the low service and maintenance burden and reduced spare partsinventories because of uniform device design make cost savings a reality whenoperating the analyzer system.

Communicationsconcept

The Advance Operation communications concept, based on PC and networkingindustry standards, is an ideal supplement to the Advance Optima system. If offerssavings in maintenance resources by providing remote control, maintenance anddiagnostics 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 servicecenter.


Chapter 2 Analyzer Modules

Uras 14 Infrared Analyzer Module

Application The Uras 14 infrared analyzer module is an NDIR photometer that can measure 1 to4 sample components simultaneously and continuously. The Uras 14 is chiefly usedin emissions monitoring, process monitoring/control and quality assurance, e.g.super-clean gases, for the energy, chemical, iron and steel, cement and otherindustries.

Typical sample components include CO, CO2, NO, SO2, N2O, CH4, C3H8, C2H4.

Analyzer modulestructure

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


1 2 3 4

56

7

8

9

10

1 Calibration unit 22 Sample cell 23 Main frame4 Modulator (covered)5 Calibration unit 1

6 Infrared detector 17 Sample cell 18 Infrared detector 29 Aperture disk10 Infrared detector 3



Uras 14 Infrared Analyzer Module, continued

Figure 5

Measurementprinciple

1 2 3 4 5 6

1 Emitter2 Aperture3 Chopper wheel

4 Sample cell5 Adjusting unit / Calibration cell6 Receiver


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

Description The photometer consists of a thermal emitter, the emissions of which reach asample cell via a chopper wheel. The sample cell is in the shape of a tube that isdivided by a land into sample and reference sides. The measurement effectproduced in the receiver is a pressure effect resulting from the chopper frequency,received by a diaphragm capacitor and converted into an electrical signal by anattached preamplifier.

The receiver is a two-layer device. The back of the receiver has an opticallytransparent window so that any residual radiation can reach a second receiver thatis sensitive to a second sample component.

By adding a second beam path with an emitter, sample cell and receivers thephotometer can measure 1 to 4 sample components simultaneously.

Calibration The infrared analyzer module's zero point is calibrated with a zero gas and a spangas 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 insertinga gas-filled calibration cell in the beam path; this means that test gas bottles are notrequired 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 monitoringof emissions. NOx reduction in engine exhaust gases. Quality control of H2S contentin natural gas and coke-oven gas, as well as emissions from waste and sewagefacilities. Monitoring and regulatory tasks in the production of paper, cellulose andplastics.

Typical sample components include NO, NO2, SO2, H2S, CS2, COS and Cl2.

Analyzer ModuleStructure

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 ModuleStructure

1 Reference Receiver2 Filter Wheels3 UV Lamp4 Calibration Wheel

5 Beam Splitter (covered)6 Sample Cell7 Measurement Receiver


1 2

6 75

3 4


Limas 11 UV Analyzer Module, continued

Figure 7

Measuring Principle

1 UV Lamp2 Filter Wheel with Interference Filter3 Filter Wheel with Gas Filter4 Beam Splitter

5 Reference Receiver6 Sample Cell7 Calibration Wheel with Calibration Cells8 Measurement Receiver

Measuring Principle The Limas 11 measurement principle uses the property of molecules to interact witha beam emitted at a certain wavelength and absorb radiation.

Sample component selectivity is achieved using gas filter or interference filtercorrelation.

Description The UV beam emitted by an electrodeless discharge lamp is split intopredetermined wavelengths by a filter wheel fitted with interference filters and/orgas filters.

The split beam is then separated by a beam splitter into measurement andreference signals and reaches the reference receiver without passing through anabsorption run while reaching the measurement receiver after absorption (samplecell).

Absorption of the emission in the sample cell causes a change in the intensity of themeasurement signal.

To identify sample component concentration a double-quotient evaluation process isapplied to the four time-multiplexed measurement signals thus formed.

876

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 inprocess 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-tightconnection on the bottom of the mounting flange.

The analyzer module's gas-tight design allows it to be purged separately from thecentral unit.

Figure 8


1 Permanent magnet2 Connection to sample chamber3 Flow regulator4 Optics tap5 Purge air port

6 Preamplifier board7 Pressure sensor8 Connection to Sensor-CPU board9 Pressure sensor gas port10 Sensor-CPU board


2

3

1

4

5

6

7

8

9

10


Magnos 16 Oxygen Analyzer Module, continued

Figure 9


N

S

N

S

60 °C

DumbbellCompensation

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 thesample chamber. The two cylindrical dumbbell halves are inserted in non-homogenous magnetic fields of a permanent magnet’s two pole shoe pairs.

Oxygen molecules are drawn into the magnetic field of the permanent magnet. Thepartial pressure drop thus produced applies a force to the dumbbell and generatestorque to move the dumbbell from its original position. The magnitude of this torqueis proportional to the oxygen concentration and can be converted into an electricalsignal.

The measurement unit is located in a thermostat chamber so that measured valuesare extensively free from variations in ambient temperature.

Measurementprinciplecharacteristics

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 andcorrosive 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:


• Sample chamber with sample and reference sides• Permanent magnet• Thermostat temperature sensor• Plug connection



Figure 10


1 Permanent magnet2 Sample chamber3 Purge air port

4 Support board5 Connection to Sensor-CPU board6 Sensor-CPU board


1

2

3

4

5

6


Magnos 17 Oxygen Analyzer Module, continued

Figure 11


Description The sample gas to be analyzed flows through the two-chamber system. Bothchambers have temperature-sensitive annular resistors.

On the sample side, oxygen molecules are drawn into the non-homogeneousmagnetic field of the permanent magnet. The "magnetic wind" thus generated coolsthe heated temperature-sensitive measuring resistors. The change in temperatureis proportionate to oxygen content and can be converted into an electrical signal.


Calibration is effected with oxygen-free process gas, process gas with a knownoxygen concentration or with a substitute gas.


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

Difference betweenMagnos 16 andMagnos 17

The Magnos 17 oxygen analyzer module is based on a thermomagnetic measure-ment principle. Thus, it is especially suitable for measuring oxygen content relativeto 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 magneticsusceptibility of oxygen.


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 followingassemblies:


• Sample chamber• Thermostat temperature sensor• Plug connection



Figure 12


1 Support board2 Connection to Sensor-CPU board3 temperature probe

4 Purge air port5 Sample chamber6 Sensor-CPU board


1

2

3

4

5

6


Caldos 15 Thermal Conductivity Analyzer Module, continued

Figure 13


60 °C

Measurement Side

GlassCoating

Bypass

Glass

Reference Side

Description The sample gas to be analyzed flows over two opposed temperature-sensitiveresistor wires in the sample chamber. With the sample chamber resistor wires, thetwo 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 wiresare at a specified temperature. The bridge circuit is in equilibrium when the samplegas has the same quantitative composition as the reference gas.

Even slight differences in the thermal conductivity of sample gas and reference gasdisrupt the temperature-dependent bridge balance and give rise to a bridgediagonal voltage that is proportional to the concentration of the sample component.



The measurement principle is primarily suited to measure a gas component in abinary 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 purityof hydrogen, to monitor turbine generators, to monitor protective gases and for LELmonitoring.

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 followingassemblies:

• Thermostat chamber• Mounting flange and sample chamber with

• Thermal conductivity sensor• Sensor electronics with temperature probe• Heater• Thermal link• Plug connections



Figure 14


1 Cover2 Pressure sensor3 Connection to Sensor-CPU board4 Thermal conductivity sensor

5 Thermal Link6 Heater element7 Preamplifier board8 Heater connection9 Sensor-CPU board


1

2

3

4

5

6

7

8

9


Caldos 17 Thermal Conductivity Analyzer Module, continued

Figure 15


Measurement Resistor60 °C

Bypass

Sample Gas

Description The sample gas to be analyzed is diffused in the sample chamber. The samplechamber has a thermal conductivity sensor consisting of three overlaid silicon chips.

The center chip contains a membrane with two thin-film resistors. The resistors areheated by an electrical current.

One resistor is exposed to the sample gas. The thermal conductivity of the samplegas is carried away by the membrane. The current that maintains the temperaturedifference between the resistors is the means for measuring the sample componentconcentration in the sample gas.



The micromechanical silicon sensor provides the smallest measurement ranges andquickest measurements.

Difference betweenCaldos 15 andCaldos 17

Caldos 15 is designed for highly corrosive applications. Its sample cell with glass-covered measurement resistors makes it especially resistant to corrosive samplemedia.

In contrast, because of its silicon sensor, the Caldos 17 provides very smallmeasurement ranges and rapid measurements.


Multi-FID 14 FID Analyzer Module

Application The Multi-FID 14 (FID = flame ionization detector) analyzer module is used foremissions monitoring, process measurements, purity measurement of H2 and O2 orwith 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 willprovide the flame with a constant volume of combustion gas, combustion air andsample gas per unit of time.

The sample gas line can be connected to a heated sample gas port. An upstreamcatalytic converter removes hydrocarbons from the combustion air.

Figure 16


1

1:2

2 3 4

5 6

1 Electronic pressure regulation2 Active charcoal filter3 Detector (covered by insulation)

4 Heated sample gas port5 Sensor electronics6 Gas ports



Multi-FID 14 FID Analyzer Module, continued

Figure 17


+ -

+

-

Cn Hm

+

-

H 2

Ampère

Combustion Air Combustion Gas

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 tothe burner nozzle. This mixture is burned while the hydrocarbon-free combustion airis metered.

The flame ionization detector measures the ionization of organically bound carbonatoms in a hydrogen flame.

Burning the hydrocarbons in the sample gas produces ionized particles causing aflow of ions between the electrode shells. This effect is directly proportional to theamount 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 oxygenin a sample gas.

The oxygen sensor is primarily used for emissions monitoring, for measurements infermentation facilities and fruit warehouses and for measurements of ambient airquality.

Oxygen sensorstructure

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 ananalyzer module (e.g. the Uras 14) and is controlled and monitored by the latter'ssensor electronics.

In contrast to the analyzer modules referenced earlier, the electrochemical oxygensensor cannot be installed by itself in a system housing.

Figure 18

Oxygen sensorstructure

1 Lead anode2 Gold-plated cathode3 Teflon membrane

4 Resistance5 Thermistor6 Acid electrolyte


1

2

3

4

5

6


Electrochemical Oxygen Sensor, continued

Figure 19


R I

DiffusionBarrier

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: O2 + 4 H+ + 4 e– → 2 H2OAnode: 2 Pb + 2 H2O → 2 PbO + 4 H+ + 4 e–

Total: O2 + 2 Pb → 2 PbO

The sensor’s temperature sensitivity is maintained by electrical compensationreferenced 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 oxygenconcentration of 20.96 vol-%.


Gas Module

Function The gas module supplies sample gas to the analyzer module and supplies a testgas 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 isconnected 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 andmonitored by the analyzer module's sensor electronics.

Two analyzermodules in onesystem housing

If two analyzer modules are installed in one system housing, a gas module cannotbe installed.

Figure 20

Gas module

1

2

3

4

5

1 Flow meter2 Solenoids3 Oxygen sensor

4 Fine filter5 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 andinstallation 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 analyzermodules to be physically separated (refer to the "Explosion Protection" chapter) andpermits the installation of an additional analyzer module in the system housing (referto the "Multiple Analyzer Systems" chapter).

Housing protectiontypes

The system housing is available in an IP 20 protection version (standard version) oran 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 ordisplay/control unit (see the example in Figure 23).

Housing purge The system housing can be flushed with a purge gas to protect against penetrationby 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 ifno analyzer module is installed, via a separate purge gas port.

Figure 23

Housing with twoanalyzers and nopower supply

Housing typeselection

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 protectionversion

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

• 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 (seethe "Operation" chapter). The menu can be switched between two languages.

Display/control unitstructure

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 display2 Menu bar3 Data field4 Softkey bar

5 Softkeys6 Status indication LEDs7 Numeric keypad8 Cancel keys


Power Supply

Input voltage The AC power supply is connected via a rubber plug to the electronics moduleconnection 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 isprovided by the power supply.

Two analyzermodules in onesystem 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 toconvert measurement values from the analyzer modules. The system controllerprocesses measurement values and makes them available in various forms, e.g. asexternal 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 inthe system housing. There are interfaces on the back and bottom of the systemhousing.

Figure 26

Electronics Module

1 System controller2 I/O boards (Optional)3 Electrical connections


2

3

1


Electronics Module, continued

System controllertasks

The system controller carries out the following functions:

• Processing and communicating the measurement values supplied by the analyzermodule 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 systemcontroller.

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


Hardware Concept

Figure 27

Hardware concept

I/O

HMIInterface

EthernetTCP/IP

I/O

I/O

I/O

I/O

10BASE2 / 10BASE-T RS232C RS485

Modbus

Output CurrentDigital I/OCAN-Bus

ControlFunctions

Function BlockProgramming

Calibration

SignalProcessing

Sensor CPUSignal A/DLinearizationThermostat...

Sensor CPUSignal A/DLinearizationThermostat...

System Bus

HMI ElectronicsDisplayStatus LEDs...

Field BusMaintenance-Bus

CPU

HMI interface The HMI interface (HMI = human-machine interface) is used to control thedisplay/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 interconnectedvia an internal system bus. If external functional units are added to the analyzersystem, 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 remotecontrol of analyzer systems.


I/O Boards

Expansion offunctionality

Functionality can be expanded by adding I/O boards with definable functions to theanalyzer system.

These I/O boards are controlled by the system controller.

Slots Control of associated Advance Optima systems should be implemented via optionalI/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 configuringfunction blocks.

The factory configuration of inputs and outputs is described in a separate documentsupplied 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 outputboard

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 Optimaand 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 moduleconnections

1 12

13 2410BASE-T

10BASE2

RS 485

RS 232C

BUS

1

22

1 2 3 4 5D 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 10BASE22 RS-485 port3 Power supply4 Inputs and outputs (System Controller)

5 Ethernet 10BASE-T6 I/O boards (per configuration)7 RS-232C Port8 System Bus


Chapter 5 Multiple-Analyzer Systems

Multiple-Analyzer Systems

The concept The uniform system component design allows individual analyzer modules to becombined into multiple-analyzer systems.

In addition to the purely financial aspect, centralized operation, monitoring andmaintenance of a multiple-analyzer system offers a decisive advantage over the useof 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 roundsout 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 16with 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 SCCsample gas cooler, and devices from other suppliers can be integrated. AdvanceOptima will then perform all system control functions which previously required aseparate 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 wiringsince the devices are already linked to the system bus.

Power supply inmultiple-analyzersystems

The integral power supply provides energy for the central unit. Any installedanalyzer module is powered by this power supply.

Physically separated analyzer modules should be powered by one or moreadequately dimensioned power supplies.



Multiple-Analyzer Systems, continued

Figure 29

Connection example:Physically separatedcentral unit andanalyzer module

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

Figure 30

Connection example:Central unit andanalyzer modulelinked to two analyzermodules in a separatesystem housing

Description Up to three analyzer modules can be connected to one central unit. The location ofthe analyzer modules is not important to the central unit.



Multiple-Analyzer Systems, continued

Figure 31

Connection example:Central unit linked tothree separateanalyzer modules

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

Figure 32

Connection example:Linking AdvanceOptima to a computernetwork

Description To perform various tasks Advance Optima can be incorporated in different types ofcomputer network structures.


Chapter 6 Calibration

Calibration Concept

Calibration control Depending on the analyzer system version and equipment, there are three methodsfor 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 theanalyzer system display/control unit keys.

The test gas supply can be started by means of the integral gas module's solenoidvalves 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'ssolenoid valves or via external solenoid valves.

Externally controlledcalibration

For externally controlled calibration, zero and span point alignment is triggered bycontrol signals from an external control unit.

The test gases should be started automatically by external solenoid valves alsocontrolled 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-pointshift and a loss of sensitivity. These changes in detector characteristics should becorrected by regular calibration of the zero- and end-points.

Simplified calibrationprocedure

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

Uras 14:Calibration withcalibration 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'ssample components and ranges. Ambient air free of the sample component can beused for zero calibration.

Caldos 17:Single-pointcalibration withstandard gas

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

Magnos 16:Single-pointcalibration withambient air

The long-term sensitivity drift of the Magnos 16 analyzer module is less than0.05 Vol.-% O2 per year. In this manner only a zero-point correction is needed forcalibration during each work shift. Since this causes a parallel shift of thecharacteristic 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 withambient 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.-%) isrequired 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 systemvia output tables.

Communication between analyzer modules, I/O modules and the database isrouted via the system bus.

The database communicates with the internal and integrated components, thedisplay/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 placesthe 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 taskconversion

Advance Optima is extremely versatile and can be converted to handle a widevariety of measurement tasks.

Advance Optima's standard software supports

• Adapting to various applications This can be done through function blockprogramming, additional devices and software are not required;

• Connection of an Advance SCC system cooler, additional devices for sample gaspreparation and software are not required;

• Incorporation of status signals in the system, no additional software is required forsignal evaluation;

• The field bus connection via the Modbus link and Ethernet port, additional networksoftware is not required.

Application program Additional application programs permit Advance Optima remote control, datastorage, 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 areimmediately displayed in clear messages on the display/control unit screen.

Status messages and measurement value indications can be displayed on a PC orin the control room using appropriate software (e.g. Optima Remote HMI).

Generating therequired information

Most measurement operation faults occur during sample preparation, e.g. due topump failure or filter plugging.

Thus, in addition to measurement values, Advance Optima measures and reports anumber of variables such as detector temperature, sample gas throughput, driftrates, etc.

Additionally, supplemental I/O boards allow access to all required information fromperipheral components, cooler temperatures, condensate trap contents, test gasbottle pressures, etc.

This allows problems with peripherals to be rapidly identified and eliminated.

Maintenance Maintenance requirements are displayed as clear text messages when applicable.

Preventivemaintenance

Operation and maintenance costs are held as low as possible by optimizing systemprocesses. Preventive maintenance can increase the reliability and availability ofanalyzers and systems.

This requires a comprehensive flow of information from all areas involved in samplegas analysis.

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

Integrating mainte-nance functions infacility status

User-defined limit values allow maintenance work to be performed when facilityoperation 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 oflinking and processing information in PC applications or control systems.

Optima Remote HMI Optima Remote HMI (Human Machine Interface) is a program that allows completeremote control of Advance Optima via a PC (see the "Remote Control/RemoteMaintenance" section).

The monitor display is identical to that of the display/control unit and permits accessto measurement values, clear text messages, calibration data and configurationdata.

Optima Plant Pilot Optima Plant Pilot is a display program for the monitoring of Advance Optima innetworks.

Optima Plant Pilot displays measurement values, permits the archiving of all valuesfrom Advance Optima, simplifies status monitoring and displays a trend graph ofselected measurement values.

Via the network, Optima Plant Pilot provides an overview with the capability toconfigure individual system and group frames.

Optima M-DDE Optima M-DDE is a software driver used to integrate information in Windowsapplications, based on an RS 232/RS 485 connection.

All signals can easily be incorporated and displayed in standard software such asMicrosoft Excel or Microsoft Visual Basic.

Optima ActiveX Optima ActiveX is a software driver used to create an application under Windows95/NT in standard programs such as Microsoft Excel, Access, Visual Basic orNational Instruments LabView, and is based on an Ethernet connection.

In addition to Optima M-DDE (see above), the driver includes the display ofmeasurement units, drift values, internal values and the number of samplecomponents.

Optima SMT Optima SMT is a software tool that simplifies Advance Optima system softwareupdates.

The individual configurations are stored as records and can be reloaded into thedevices.

Additionally, the device software can be adapted to meet national languagerequirements.


Chapter 8 Operation

Operation via Display/Control Unit

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

Language The menu can be switched between two languages. The change betweenlanguages can be done during operation.

German and English are the standard languages, other languages can beincorporated.

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 mainmenu items are shown.

Figure 34

Menu structure��

��

��

��

�� !�!��"��#�� $��


Remote Control / Remote Maintenance

Optima Remote HMI The Optima Remote HMI program transfers the Advance Optima display/control unitto a PC workstation. This allows remote control of the analyzer system via anEthernet 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/Pprotocol. 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 ofoperation

The mechanism for synchronizing operation via the display/control unit or via thePC is controlled by software.

The Advance Optima status message menu displays an appropriate message whenremote control via an Ethernet connection is in effect.


Chapter 9 Explosion Protection

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

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

Analyzer modules forZone 1

The Caldos 15-Ex, Caldos 17-Ex, Magnos 16-Ex and Uras 14-Ex analyzer modulesare capable of measuring combustible and non-combustible gases underatmospheric conditions which can form an explosive environment. Additionally, theanalyzer modules are suitable for measuring combustible and non-combustiblegases under positive pressure.

The analyzer modules are installed in a pressure-tight aluminum cylinder. To protectthe analyzer module sensor electronics against the entry of an aggressiveatmosphere or corrosive sample gas components, a purge gas can flow through thepressure-tight cylinder.

Central Unit forZone 1

The system housing is available as a wall-mount unit. The electrical and gasconnections are on the bottom of the housing.

The system housing is designed for "Positive Pressure Containment with Leak LossCompensation" ignition suppression. The required control unit is mounted on theoutside 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 Unitsand 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 systembus connection is designed for an Ex zone.

If the distance between the analyzer module and central unit is over 10 meters, thesystem bus cable must be routed through a connection box.

Peripheral devices, such as solenoid valves, are also connected to the central unitvia connection boxes.

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


Chapter 10 Approvals

TÜV PerformanceTesting

Advance Optima with analyzer modules Uras 14 and Magnos 16 satisfies theminimum requirements of the "Richtlinien für die Eignungsprüfung, den Einbau unddie Wartung kontinuierlich arbeitender Emissionsmeßgeräte“ [Directives forPerformance Testing, Installation and Maintenance of Continuously OperatingEmissions 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 andTA-Air.

Smallest measurement ranges tested:

Uras 14 0 to 75 mg/m3 CO0 to 75 mg/m3 SO2

0 to 200 mg/m3 NOO2 sensor 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 require-ments of the "Richtlinien über die Eignungsprüfung, den Einbau, die Kalibrierung,die Wartung von Meßeinrichtungen für kontinuierliche Emissionsmessungen unddie kontinuierliche Erfassung von Bezugs- bzw. Betriebsgrößen zur fortlaufendenÜberwachung der Emissionen besonderer Stoffe“ [Directives for PerformanceTesting, Installation, Calibration, Maintenance of Measuring Equipment forContinuous Emissions Monitoring and Continuous Determination of Reference andOperational Values for Continuous Monitoring of the Emissions of ParticularSubstances] – BMU Circulars, dated 1 September 1997; IG I-51134/3.

The analyzer module is suited for use in facilities per 13. BlmSchV, 17 BlmSchV andTA-Air, as well as in facilities with comparable exhaust gas matrices.

Smallest measurement range tested:

Multi-FID 14 0 to 15 mg/m3 C

Report No. 24016659

CSA approval The Advance Optima with housing, electronics module, gas module and theCaldos 15, Caldos 17, Magnos 16, Magnos 17 and Uras 14 analyzer modules isapproved for use in Class 1, Division 2, Gas Group A, B, C, and D, temperaturecode 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 cabinetwith 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 ProvisionsEN 50016:1977 + A1 "p" positive pressure containmentEN 50018:1977 + A1 – A3 "d" pressure-tight containmentEN 50019:1977 + A1 – A5 "e" elevated safetyEN 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 Europeanstandards:

EN 50014:1977 + A1 – A5 General ProvisionsEN 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 thefollowing standards:

DIN VDE 0165 / 2.91, Section 6.3prEN 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 XReduced positive pressure containment EEx nP II T4 XVapor-tight housing EEx nR II T4 X

Statement of expertise Pr. No. 97-09-203-Ex

CE ComplianceStatement

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 fullcompliance with European standard EN 61010-1:1993 (for Multi-FID 14 addEN 60335:1995).

Compliance with the provisions of 89/336/EEC is evidenced by full compliance withEuropean standards EN 55011:1991 and EN 50082-2:1995.

H&B registration No. CT001/97

Subject to technical changesPrinted in the Fed. Rep. of Germany

30/24-110-1 EN 03.00

Documents

Advance Optima