Manual Analizadores URAS CALDOS PDF

Advance Optima Continuous Gas Analyzers
AO2000 Series
Instructions for Installation,

Start-Up and Operation 41/24100 EN Rev. 6
Page 277 of 3829

Page 278 of 3829
Advance Optima Continuous Gas Analyzers
AO2000 Series
Instructions for Installation,

Start-Up and Operation
Publication No. 41/24100 EN Rev. 6

Edition March 2009
This condensed operator’s manual is protected by copyright. The translation, duplication and distribution in any
form, even in a revised edition or in extracts, in particular as a reprint, by photomechanical or electronic repro-
duction or in the form of storage in data processing systems or data networks are prohibited without the consent
of the copyright holder and will be prosecuted under civil and criminal law.
Page 279 of 3829

Table of Contents
Page
Preface 6
Important Safety Information 7
Safety Tips for Handling Electronic Measurement Devices 8
Safety Tips for Handling the Gas Analyzers 9
Explosion-protected Version with Type of Protection II 3G for Measurement of
Non-flammable Gases and Vapors: Description and Special Conditions for
Operation 10
Guideline for Installation and Start-Up 11
Chapter 1 Preparing the Installation 12

Installation Location Requirements 12
Sample Gas Inlet and Outlet Conditions 14
Test Gases for Calibration 16
Purge Gas for Housing Purge 17
Power Supply Information 18
Scope of Delivery 19
Material Needed for Installation (not delivered) 20
Chapter 2 Gas Analyzer Unpacking and Installation 21

Gas Analyzer Unpacking 21
Gas Connections Installation 22
Checking Gas Path Seal Integrity 23
Dimensional Diagrams 24
Gas Analyzer Installation 25
Chapter 3 Gas Line Connection 26

Magnos206: Gas Connections 26
Caldos25, Caldos27: Gas Connections 29
Caldos25: Gas Connections 30
Limas11: Gas Connections 31
Uras26: Gas Connections 34
Housing Purge 35
Gas Line Connection 36
Pressure Sensor 37
4 Advance Optima AO2000 Series Condensed Operator’s Manual 41/24-100 EN Rev. 6
Page 280 of 3829

Table of Contents
Page
Chapter 4 Electrical Connection 38

Electronics Module Connections 38
Profibus Module: Electrical Connections 39
Modbus Module: Electrical Connections 40
2-Way Analog Output Module: Electrical Connections 41
4-Way Analog Output Module: Electrical Connections 42
4-Way Analog Input Module: Electrical Connections 43
Digital I/O Module: Electrical Connections 44
Standard Terminal Connections 46
System Bus Connection 47
Signal, Control and Interface Line Connection 50
Power Supply Line Connection – Safety Notes 52
Power Supply Line Connection to the Analyzer Module 53
Power Supply Line Connection 55
Chapter 5 Gas Analyzer Start-Up 56

Installation Check 56
Gas Path and Housing Initial Purge 57
Power Supply Activation 58
Warm-Up Phase 59
Operation 60
Chapter 6 Gas Analyzer Operation 61

Display and Control Unit 61
Softkeys 62
Changing the Password 63
Menu Tree 64
Chapter 7 Gas Analyzer Calibration 65

Manual Calibration 65
Automatic Calibration 67
Chapter 8 Status Messages 68

Status Messages 68
Appendix ZO23 Trace Oxygen Analyzer Module 79

Safety Information 79
Requirements at the Installation Site 80
Sample Gas Inlet Conditions 80
Test Gases 81
Connection Diagram 81
Information for the Installation and Sample Conditioning 82
Start-Up 84
41/24-100 EN Rev. 6 Advance Optima AO2000 Series Condensed Operator’s Manual 5
Page 281 of 3829

Preface
Content of this This operator’s manual is an extract from the comprehensive operator’s manual for
Operator’s Manual the AO2000 Series Gas Analyzers. It contains the essential information you will
need to install, start-up and operate the gas analyzers. It does not contain any
information on configuration and maintenance.
The comprehensive operator’s manual is included as PDF file on the CD-ROM
which is delivered together with the gas analyzer.
Which information is This operator’s manual does not contain any information on installation, start-up
not included in this and operation of
operator’s manual? • the MultiFID14 and MultiFID14 NMHC analyzer modules,
• the LS25 analyzer module and
• the gas analyzers in explosion protected version.
The operator’s manuals for these instrument versions are included as PDF files on
the CD-ROM which is delivered together with the gas analyzer.
Symbols and Indicates safety information to be heeded during gas analyzer

Typefaces operation in order to avoid risks to the operator.
Identifies specific information on operation of the gas analyzer

as well as on the use of this manual.
Module Name Indicates specific information for individual analyzer modules.
1, 2, 3, … Identifies reference numbers in the figures.
Display Identifies a message in the display.
Input Identifies a user entry.
Page 282 of 3829

Important Safety Information
Intended Application The AO2000 Series Gas Analyzers are designed for continuous measurement of
the concentration of individual components in gases or vapors.
The non-explosion protected models of the AO2000 Series Gas Analyzers as well
as the models with type of protection II 3G for measurement of non-flammable
gases and vapors must not be used for measurement of explosive gas/air or
gas/oxygen mixtures. For this application explosion protected models of the gas
analyzers are available.
Requirements for In order to operate in a safe and efficient manner the gas analyzers should be
Safe Operation properly handled and stored, correctly installed and set-up, properly operated and
correctly maintained.
Personnel Only persons familiar with the installation, set-up, operation and maintenance of
Qualifications comparable devices and certified as being capable of such work should work on
the gas analyzer.
Special Information These include

and Precautions • The content of this operator’s manual.
• The safety information affixed to the gas analyzer.
• The applicable safety precautions for installing and operating electrical devices
• Safety precautions for working with gases, acids, condensates, etc.
National Regulations The regulations, standards and guidelines cited in this operator’s manual are
applicable in the Federal Republic of Germany. The applicable national regulations
should be followed when the gas analyzer is used in other countries.
Gas Analyzer Safety The gas analyzer is designed and tested in accordance with EN 61010 Part 1,
and Safe Operation “Safety Provisions for Electrical Measuring, Control, Regulation and Laboratory
Instruments” and has been shipped ready for safe operation.
To maintain this condition and to assure safe operation, read and follow the safety
information identified with the symbol in this manual. Failure to do so can put
persons at risk and can lead to gas analyzer damage as well as damage to other
systems and instruments.
Additional If the information in this operator’s manual does not cover a particular situation,
Information ABB Service is prepared to supply additional information as needed.
Contact your local ABB Service representative. For emergencies, please contact:
ABB Service, Telephone: +49-(0)180-5-222580, Telefax: +49-(0)621-38193129031,
E-Mail: automation.service@de.abb.com
Page 283 of 3829

Safety Tips for Handling Electronic Measurement Devices
Protective Lead The protective lead (ground) should be attached to the protective lead connector
Connection before any other connection is made.
Risks of a Disconnect- The gas analyzer can be hazardous if the protective lead is interrupted inside or
ed Protective Lead outside the gas analyzer or if the protective lead is disconnected.
Proper Operating Be sure the gas analyzer voltage setting matches the line voltage before connect-
Voltage ing the power supply.
Risks Involved in Current-bearing components can be exposed when the covers or parts are
Opening the Covers removed, even if this can be done without tools. Current can be present at some
connection points.
Risks Involved in The gas analyzer must be disconnected from all power sources before being
Working with an opened for any work. All work on a gas analyzer that is open and connected to
Open Gas Analyzer power should only be performed by trained personnel who are familiar with the
risks involved.
Charged Capacitors The capacitors in the gas analyzer power supply discharge after 10 minutes when
the gas analyzer is disconnected from all power sources.
Use of Proper Fuses Only fuses of the specified type and rated current should be used as replacements.
Never use patched fuses. Do not short-circuit the fuse holder contacts.
When Safe Operation If it is apparent that safe operation is no longer possible, the gas analyzer should
can no Longer be be taken out of operation and secured against unauthorized use.
Assured
The possibility of safe operation is excluded:
• If the gas analyzer is visibly damaged
• If the gas analyzer no longer operates
• After prolonged storage under adverse conditions
• After severe transport stresses
Page 284 of 3829

Safety Tips for Handling the Gas Analyzers
Unpacking, Transport A system housing with an electronics module and an analyzer module weighs from
and Installation 18 to 23 kg (40 to 50 pounds). Two persons are needed for unpacking, carrying and
installation.
The location must be capable of supporting the gas analyzer’s weight. The 19-inch
housing must be supported with rails in the bay or rack.
Neither the 19-inch nor the wall-mount housings use hinges to secure the housing
cover. The cover can drop when opened.
Gas Lines and The fittings must be clean and free of residue. Contaminants can enter the analyzer
Gas Connections and damage it or lead to false measurement results.
Do not use sealing compounds to seal the gas connections. Sealing compound
components can lead to false measurement results.
The gas connections on the gas module are made of plastic (PVDF). Do not use
metal tubing connectors or threaded connectors.
The gas connection ports on the Caldos25 versions for flowing reference gas and
for corrosive sample gas are made of plastic (PVC-C). Do not use metal tubing
connectors or threaded connectors.
Seal Integrity Test If the seal integrity test is to be carried out with air and there is the possibility of a
combustible gas being present in the gas paths or if a combustible gas is to be
introduced later, the gas paths should first be purged with nitrogen. Otherwise the
seal integrity test can be performed with nitrogen.
Housing Purge For joint purging of the analyzer and central unit, the purge gas must first be routed
through the central unit and then through the analyzer. Flow direction inversion and
leaks in the sample gas path can result in damage to electronics by corrosive
sample gas components. An analyzer module used to measure corrosive sample
gas components should be the last unit connected in a series.
Purge gas can escape from the housing if there are any leak points. When using
nitrogen as the purge gas, take all required precautions against suffocation.
Purge gas flow must always be restricted ahead of the purge gas inlet! If the purge
gas flow is restricted after the purge gas outlet, the housing seals are subjected to
full purge gas pressure which can result in damage to the keypad!
Electrical Line Follow all applicable national safety regulations for the preparation and operation
Connection of electrical devices as well as the following safety precautions.
Only one analyzer module should be supplied with 24 VDC from the central unit
power supply. A separate 24-VDC supply is required for additional analyzer
modules.
Never connect the line voltage to the 24-VDC analyzer module input. This will
destroy the analyzer module electronics.
Install a breaker near the gas analyzer in order to completely disconnect it from the
power supply. Mark the breaker so that its relationship to the protected device is
clear.
Page 285 of 3829

Explosion-protected Version with Type of Protection II 3G
for Measurement of Non-flammable Gases and Vapors:
Description and Special Conditions for Operation
Intended Application The AO2000 Series gas analyzers with type of protection II 3G are tested for
explosion protection. They are suitable for use in hazardous areas in compliance
with the technical data (see “Installation Location Requirements” section, page 12)
and the special conditions (see below). They may be used for the measurement of
non-flammable gases and vapors.
Special Version The explosion-protected version with type of protection II 3G for the measurement
of non-flammable gases and vapors is a special version of the AO2000 Series gas
analyzers. This version is different from other versions by the following designation
on the identification plate.
Designation II 3G EEx nAC II T4 X
Description In undisturbed operation there cannot be any sparking, arcing or impermissible

temperatures inside the device.
For further information please refer to the Declaration of Conformity which can be
found on the CD-ROM delivered with the gas analyzer.
Special Conditions • The device must be switched off when it is observably disturbed (i.e. when it is
for Operation in not in undisturbed operation).
Hazardous Areas
• The connectors may not be plugged in or unplugged while the power is on.
• The analyzer housing may not be opened while the power is on.
• All cables must enter via the specified cable fittings and be sealed by tightening
the nuts in accordance with IP54.
• Unused cable fittings must be closed off with plugs in accordance with IP54.
• Measures must be taken outside the device against intermittent noise on the
data lines (transients) exceeding 84 VAC/ 105 VDC.
• Only the original battery types Varta CR2032 (type no. 6032) or Renata CR2032
may be used as replacement for the battery on the system controller.
Page 286 of 3829

Guideline for Installation and Start-Up
Basic Steps The following basic steps should be followed when installing and starting up the
gas analyzer.
Step Action see Page

Follow safety precautions 7, 8, 9, 10
1 Prepare the installation 12
Installation location 12
Sample gas inlet and outlet conditions 14
Test gases for calibration 16
Purge gas for housing purge 17
Power supply 18
2 Unpack the gas analyzer 21
3 Install the gas connections ports 22
4 Check gas path seal integrity 23
5 Install the gas analyzer 25
6 Connect the gas lines 26
7 Connect the electrical leads 38
System bus 47
Signal, control and interface lines 50
Analyzer module power supply lines 53
Power supply lines 55
8 Start-up the gas analyzer 56
Check the installation 56
Purge the gas paths and housing 57
Activate the power supply 58
Verify the calibration 60
Page 287 of 3829

Chapter 1 Preparing the Installation
Installation Location Requirements
Short Gas Paths Install the gas analyzer as close as possible to the sampling location.
Locate the gas preparation and calibration assemblies as close as possible to the
gas analyzer.
Adequate Air Provide for adequate natural air circulation around the gas analyzer. Avoid heat
Circulation buildup.
When installing several system housings in a 19-inch rack, maintain a minimum
spacing of 1 rack unit between housings.
The entire surface of the system housing is used to dissipate heat.
Protection from Protect the gas analyzer from:

Adverse Conditions • Cold
• Direct sunlight and heat
• Large temperature variations
• Strong air currents
• Accumulations of dust and dust infiltration
• Corrosive atmospheres
• Vibration (see “Vibrations”, page 13)
Environmental Air pressure range 600 to 1250 hPa

Conditions Relative humidity max. 75 %
Ambient temperature range at storage and transport –25 to +65 °C
Ambient temperature range during operation with
analyzer module installed in a system housing installed in a system housing
without electronics module with electronics module or
with power supply only
Caldos25 +5 to +45°C +5 to +45°C
Caldos27 +5 to +50°C +5 to +45°C
Limas11 +5 to +45°C +5 to +45°C 1)
Magnos206 +5 to +50°C +5 to +45°C
2)
Magnos27 +5 to +45°C +5 to +45°C
Uras26 +5 to +45°C +5 to +40°C
Oxygen Sensor +5 to +40°C +5 to +40°C
1) +5 to +40°C when I/O modules are installed

2) +5 to +50°C for measurement chamber direct connection and installation in
system housing without electronics module or Uras26
Continued on next page
Page 288 of 3829

Installation Location Requirements, continued
Installation Location The maximum installation location altitude is 2000 m.

Altitude
Vibrations If the gas analyzer is installed in a cabinet the maximum acceleration amplitude is
0.01 ms–2 in a frequency range of 0.1 to 200 Hz.
If the gas analyzer is not installed in a cabinet the following data for the individual
analyzer modules apply.
Analyzer Module Vibrations

Caldos25 max. ±0.04 mm at 5 to 30 Hz
Caldos27 max. ±0.04 mm at 5 to 55 Hz, 0.5 g at 55 to 150 Hz
Limas11 max. ±0.04 mm at 5 to 55 Hz, 0.5 g at 55 to 150 Hz
Magnos206 max. ±0.04 mm at 5 to 20 Hz
Magnos27 max. ±0.04 mm at 5 to 60 Hz
Uras26 max. ±0.04 mm at 5 to 55 Hz, 0.5 g at 55 to 150 Hz,
slight transient effect on sample value in the region
of the beam modulation frequency
Page 289 of 3829

Sample Gas Inlet and Outlet Conditions
Gas Inlet Conditions Module Temperature Pressure pe 3) Flow Rate

1)2) 6)
Caldos25 +5 to +50°C 2 to 100 hPa 10 to 90 l/h
max. 90 to 200 l/h 4)
Caldos27 +5 to +50°C 1)2) 2 to 100 hPa 6) 10 to 90 l/h
min. 1 l/h
Limas11 +5 to +45°C 1) 2 to 500 hPa 20 to 100 l/h
Magnos206 +5 to +50°C 1)2) 2 to 100 hPa 6) 30 to 90 l/h 5)
Magnos27 +5 to +50°C 1)2) 2 to 100 hPa 7) 20 to 90 l/h
1)
Uras26 +5 to +45°C 2 to 500 hPa 20 to 100 l/h
Oxygen Sensor +5 to +40°C 1) 2 to 500 hPa 20 to 100 l/h
1)
Gas Module +5 to +45°C –80 to +20 hPa 30 to 60 l/h
1) The sample gas dew point should be at least 5°C below the ambient
temperature throughout the sample gas path. Otherwise a sample gas
cooler or condensate trap is required. Water vapor can result in cross
sensitivity.
2) When there is a direct sample chamber connection the maximum sample
gas dew point is 55°C. Water vapor can result in cross sensitivity.
3) pe = pabs – pamb where
pe = positive pressure, pabs = absolute pressure, pamb = atmospheric pressure
4) For option T90 < 6 sec
5) Abrupt changes in gas flow rates should be avoided when using highly
suppressed measurement ranges.
6) Pressure resistance of the analyzer pe ≤ 1000 hPa (1 bar)
7) Pressure resistance of the analyzer pe ≤ 400 hPa (0.4 bar)
Note: Sample gas temperature, pressure and flow rate should be maintained
constant to such a degree that the fluctuation influence on the accuracy of
measurement is acceptable.
Gas Outlet Conditions The outlet pressure should be equal to atmospheric pressure.
Page 290 of 3829

Sample Gas Inlet and Outlet Conditions, continued
Flammable, Corrosive A housing purge is required if the sample gas contains flammable, corrosive or
or Toxic Gases toxic components (see “Housing Purge” section, page 26).
Please observe additionally the following application restrictions and notes:
Module Application Restrictions and Notes

Caldos27 If the sample gas contains Cl2, HCl, HF, SO2, NH3, H2S or other corrosive
components, operation of the analyzer is allowed only when the sample gas
composition has been taken into account during configuration at the factory.
Magnos206 If the sample gas contains Cl2, HCl, HF or other corrosive components, operation
of the analyzer is allowed only when the sample gas composition has been taken
into account during configuration at the factory.
Uras26 Highly corrosive associated gas components, e.g. chlorine (Cl2) and hydrogen
chloride (HCl), as well as gases or aerosols containing chlorine must be cooled or
undergo prior absorption.
Limas11 Standard Cell Quartz Cell Safety Cell
Suitable for Non-corrosive gases Corrosive gases, Corrosive gases,
measurement of … e.g. wet Cl2, wet HCl, e.g. dry HCl, dry COCl2
H2SO4, SO3, ozone (< 50 ppm H2O)
Not suitable for Highly corrosive gases, Fluorine compounds Wet gases containing
measurement of … e.g. gases containing chlorine, H2SO4, SO3,
chlorine, H2SO4, SO3, fluorine compounds
fluorine compounds
Toxic Gases Housing purge (≤ 20 l/h) Housing purge (≤ 20 l/h) Cell purge 1) with N2 or
with sample component- with sample component- with sample component-
free air or with N2 free air or with N2 free air with negative
pressure and flow
monitoring; additional
monitoring for sample gas
traces possible
Corrosive Gases Housing purge (≤ 20 l/h) Housing purge (≤ 20 l/h) Cell purge 1) with N2 or
with sample component- with sample component- with sample component-
free air or with N2, free air or with N2 free air with excess
PTFE gas lines pressure 2) and flow
monitoring
Flammable Gases Housing purge (≤ 20 l/h) Housing purge (≤ 20 l/h) Cell purge 1) with N2
with N2 with N2
Zone 2 – – Cell purge with N2 with
Flammable Gases excess pressure 2) and
flow monitoring
Oxygen Sensor H2O dew point ≥ 2 °C. The oxygen sensor should not be used with dry and with
flammable sample gas. It should not be used if the associated gas contains the
following components: H2S, chlorine or fluorine compounds, heavy metals,
aerosols, mercaptane, base components.
Gas Module Corrosive associated gas components and aerosols must be cooled or undergo
prior absorption. The gas module should not be used with flammable sample gas.
1) purge curtain
2) pe = 7 to 20 hPa, 15 to 20 l/h
Page 291 of 3829

Test Gases for Calibration
Analyzer Module Zero Calibration Span Calibration

Caldos25, Test gas or sample- Test gas or process gas having a known sample
Caldos27 component-free process gas gas concentration or substitute gas
or substitute gas
Magnos206 Oxygen-free process gas or Process gas with a known oxygen concentration
substitute gas or a substitute gas
with suppressed Measurement ranges ≥ 95 to 100 Vol.-% O2:
measurement range Test gas with O2 concentration in the selected
measurement range.
with single point Test gas with any concentration of O2 within one
calibration of the measurement ranges or ambient air.
Same moisture content as in the process gas.
In order to avoid accumulations of explosive gas
mixtures, do not use air as a test gas for single-
point calibration when measuring flammable
gases!
Magnos27 Oxygen-free process gas or Process gas with a known oxygen concentration
substitute gas or a substitute gas
Uras26, Nitrogen or air Calibration cells (optional)
Limas11
If the ambient air contains Span calibration without calibration cells: Test gas
sample gas components, for each detector or measurement component.
these must be removed with a Span gas concentration 70 to 80 % of the end
suitable absorber. value of the largest measurement range.
For suppressed ranges: Span gas concentration
within the suppressed range, if possible equal to
the end value.
only for Uras26 Water vapor must be Automatic and externally controlled calibration:
absorbed using a cooler. Test gas mixture for all detectors since all are
calibrated simultaneously.
only for Limas11 Observe the notes in the “Analyzer Data Sheet”
when preparing the test gas mixtures.
All analyzer modules During calibration of a multi-component analyzer,
possible cross-sensitivity and/ or carrier gas
corrections by internal or external measurement
components are switched off. Therefore,
corrected measurement components should be
calibrated only using a test gas consisting of the
measurement component and an inert gas like N2.
Oxygen Sensor Zero is not calibrated since it Ambient (non-process) air with a constant oxygen
is fundamentally stable. content (20.96 Vol.-%) or synthetic air.
Test Gas Dew Point The test gas dew point must be nearly identical to the sample gas dew point.
Page 292 of 3829

Purge Gas for Housing Purge
Purge Gas The following purge gases can be used:

• Nitrogen when measuring flammable gases or
• Instrument air when measuring corrosive gases (quality per ISO 8573-1 Class 3,
i.e. max. particle size of 40 μm, max. oil content 1 mg/m3, max. pressure dew
point +3 °C).
For the Limas11 and Uras26 analyzer modules the purge gas should not contain
any sample gas components. Any sample components in the purge gas can cause
false readings.
Purge Gas Flow Rate The purge gas flow and the duration of the purge process depend on the volume
during Initial Purge to be purged (see the following table). If the purge gas flow rate is lower than
indicated the duration of the process must be increased correspondingly.
Volume to be Purged Purge Gas Flow Rate Duration

Gas Path 100 l/h (max.) approx. 20 sec.
Central Unit with or without 200 l/h (max.) approx. 1 hr.
Analyzer Module
Analyzer separately : Caldos25, 200 l/h (max.) approx. 3 min.
Caldos27, Magnos206, Magnos27
Purge Gas Flow Rate Purge gas flow rate at device inlet max. 20 l/h (constant)
during Operation Purge gas positive pressure pe = 2 to 4 hPa
• Because of leakage losses the purge gas flow rate at the device output is
approx. 5 to 10 l/h for a purge gas flow rate at the device inlet of 20 l/h.
• Notes for selection and use of flow meters:
• Measuring range 7 to 70 l/h
• Pressure drop < 4 hPa
• Needle valve open
• Recommendation: Flow meter 7 to 70 l/h, Catalog No. 23151-5-8018474
CAUTION!
Purge gas can escape from the housing if there are any leak points. When
using nitrogen as the purge gas, take all required precautions against
suffocation.
CAUTION!
Purge gas flow must always be restricted upstream of the purge gas inlet!
If the purge gas flow is restricted after the purge gas outlet, the housing
seals are subjected to full purge gas pressure which can result in damage
to the keypad!
Page 293 of 3829

Power Supply Information
Gas Analyzer There is a power supply in the gas analyzer’s central unit. It provides the supply
Power Supply voltage to power the electronics module and one analyzer module.
Analyzer Module The analyzer module requires a 24 VDC ± 5 % voltage supply.

Power Supply
If the analyzer module is installed in the central unit, power is supplied by the
central unit power supply.
If the analyzer module is installed in a separate system housing rather than in the
central unit, a distinction has to be made between three cases:
• The analyzer module can be powered by the central unit power supply if the
optional power line filter -Z01 is installed in the central unit and no analyzer
module is installed in the central unit.
• If only one analyzer module is installed in the system housing, the AO2000
power supply installed in the system housing can be used.
• If two analyzer modules are installed in the system housing, a power supply
outside the system housing must be provided. This power supply must equal
the rating of the AO2000 power supply (see below).
CAUTION!
Only one analyzer module should be supplied with 24 VDC from the central
unit power supply. A separate 24-VDC supply is required for additional
analyzer modules.
Power Supply Input Voltage 100–240 VAC, –15 %, +10 %

Specifications Input Current max. 2.2 A
Line Frequency Range 50–60 Hz ± 3 Hz
Power Consumption max. 187 W
Output Voltage 24 VDC ± 5 %
Line Power Connection 3-pin grounded-instrument connector per EN 60320/
C14
Page 294 of 3829

Scope of Delivery
Standard Equipment Quantity Description

1 AO2000 Series Gas Analyzer
1 “Analyzer Data Sheet” (in the system housing)
1 Operator’s Manual
1 CD-ROM containing technical documentation and
communication software
1 Power cord, 5 meters long, with grounded-instrument connector
and separate grounded two-pin plug
1 System bus termination resistor
Plastic tubing connectors (quantity equal to the number of gas
ports)
Options (depending Quantity Description

on the version) Connection cables for analyzer module 24 VDC power supply
Connection cables, tees and terminating resistors for the system
bus (per order)
Terminal strips to connect I/O modules (per order)
2 Inserts for M32 cable threaded connections in the IP54 version
Page 295 of 3829

Material Needed for Installation (not delivered)
Gas Connections • Threaded connections with 1/8 NPT threads and PTFE sealing tape.
Flow Meter • In the Caldos25 and Uras26 versions with flowing reference gas a flow meter
with a needle valve must be installed in the sample gas line and in the reference
gas line in order to adjust the flow rate in the two lines to the optimum value.
Installation 19-inch housing:

• 4 oval-head screws (Recommendation: M6; this depends on the cabinet/shelf
system).
• 1 pair of rails (Design depends on cabinet/shelf system).
Wall-mount housing:
• 4 M8 or M10 bolts.
Signal Lines • Selection of the required conductors depends on line length and planned current
load.
• Notes regarding conductor section for I/O module connection:
• The maximum capacity of terminals for stranded or solid conductors is 1 mm2
(17 AWG).
• The stranded conductor may be tinned on the tip or twisted for simplified
connection.
• When using wire end ferrules the total section should not exceed 1 mm2,
i.e. the maximum stranded conductor section is 0.5 mm2. The Weidmüller
PZ 6/5 crimping tool must be used for crimping the ferrules.
• Maximum line length 1200 meters (3940 feet, transmission rate max. 19200 bit/s)
for RS485.
• Maximum line length 15 meters (50 feet) for RS232.
Analyzer Module Extension cable:

24 VDC Supply
• Minimum conductor section 2.5 mm2.
• Maximum line length 30 m (100 feet).
Power supply:
• If two analyzer modules are installed in the system housing, a power supply
outside the system housing must be provided. This power supply must equal
the rating of the AO2000 power supply (see page Fehler! Textmarke nicht
definiert.).
Power Supply Line • If the power cord supplied is not used, make your selection of a suitable cable
based on line length and planned current load.
• Provide a breaker in the power supply line or a switched receptacle to make
sure the gas analyzer can be completely separated from the power source.
Page 296 of 3829

Chapter 2 Gas Analyzer Unpacking and Installation
Gas Analyzer Unpacking
CAUTION!
The gas analyzer can weigh from 18 to 23 kg (40 to 50 pounds).
Two persons are needed for unpacking and carrying.
Unpacking Step Action

1 Remove the gas analyzer and foam packing or other packaging
materials from the shipping box.
2 Take off the foam packing and other packaging and place the gas
analyzer in a clean area.
3 Clean the adhesive packaging residue from the gas analyzer.
• Make sure that none of the enclosed accessories are lost during unpacking (see
“Scope of Delivery” section, page 19).
• Keep the shipping box and packaging material for future shipping needs.
Page 297 of 3829

Gas Connections Installation
Since the gas ports are now easily accessible, connect the gas lines to the
analyzer module before the gas analyzer is installed.
Gas Port Design The analyzer module gas ports have 1/8-NPT internal threads (connection diagrams
see pages 26 to 34).
What materials are Material Supplied

needed? Tubing connectors with 1/8 NPT threads and yes
PTFE sealing tape no
or
Threaded connections with 1/8 NPT threads and no
PTFE sealing tape no
CAUTION!
The fittings must be clean and free of residue. Contaminants can enter the
analyzer and damage it or lead to false measurement results.
Do not use sealing compounds to seal the gas connections. Sealing
compound components can lead to false measurement results.
The gas connections on the gas module are made of plastic (PVDF). Do not
use metal tubing connectors or threaded connectors.
The gas connection ports on the Caldos25 versions for flowing reference
gas and for corrosive sample gas are made of plastic (PVC-C). Do not use
metal tubing connectors or threaded connectors.
Gas Connection Step Action

Installation 1 Remove the yellow stopper screws (5 mm Allen screws) from the
connection ports.
2 Screw the tubing or threaded connectors with sealing material (PTFE
sealing tape, O-rings, sealing washers) in the connection ports.
Screw the fittings on carefully and not too tightly. Follow the
manufacturer’s installation instructions.
Gas Path Seal The sample gas and reference gas (if applicable) path seal integrity is checked in
Integrity Verification the factory. Since the gas path seal integrity can be affected during shipping, this
check should be performed at the installation site (see page 23 for instructions).
Since the system housing has to be opened if a leak is found, the gas path seal
integrity should be checked before the gas analyzer is installed.
Page 298 of 3829

Checking Gas Path Seal Integrity
When should gas Gas path seal integrity should be checked periodically. It must be verified after the
path seal integrity be gas paths inside or outside the gas analyzer have been opened (e.g. after
checked? removing or installing an analyzer module).
What materials are 1 pressure gauge, 1 plastic tubing, approx. 1 m (3 feet) in length, 1 tee with shut-off
needed? valve, air or nitrogen
CAUTION!
If the seal test is to be carried out with air and there is the possibility of a
combustible gas being present in the gas paths or if a combustible gas is to
be introduced later, the gas paths should first be purged with nitrogen.
Otherwise the seal integrity test can be performed with nitrogen.
The following instructions apply to all gas paths in the gas analyzer, therefore to all
sample gas paths and – in the Caldos25 and Uras26 analyzer modules – to the
reference gas path.
Checking Gas Path Step Action

Seal Integrity 1 Plug the outlet of the gas path to be tested (7 in the example).
(see example in 2 Connect plastic tubing with a tee fitted with a shutoff valve to the inlet
Figure 1) of the gas path to be tested (4 in the example).
3 Connect the free end of the tee to the pressure gauge.
4 Blow air or nitrogen through the shutoff valve until the gas path is
pressurized to pe ≈ 50 hPa (= 50 mbar). Close the shutoff valve.
Maximum pressure pe = 150 hPa (= 150 mbar).
Limas11 with quartz sample cell: Gauge pressure pe ≈ 400 hPa
(= 400 mbar), maximum gauge pressure pe = 500 hPa (= 500 mbar).
5 The pressure should not change measurably in 3 minutes. A sharp
pressure drop is a sign of a leak in the gas path being tested.
Limas11 with quartz sample cell: Test duration 15 minutes.
6 Repeat steps 1-5 for all gas paths in the gas analyzer.
Figure 1
Seal Integrity Test
(Example: Sample Gas 10 1
Path in Magnos27)
50 hPa
14 9 2
11
8 3
13 12
7 6 5 4
Luft / Air
Page 299 of 3829

Dimensional Diagrams
Figure 2 483 413 35
19-Inch Housing
Error Maint Power
(dimensions in mm)
177
563
597
Figure 3
Wall-Mount Housing
(dimensions in mm)
Error Maint Power
• The connection box shown with dashed lines in the dimensional diagrams is
flange-mounted to the IP54 housing.
• Observe the installation location requirements (see page 12).
• The connecting lines require additional installation clearance (approx. 100 mm).
• When installing the wall-mount housing note that clearance (approx. 60 mm) is
required on the left side to allow the door to swing open.
• The 19-inch housing and the wall-mount housing should be installed with
vertical orientation of the display.
• Multiple system housings in a 19-inch rack should be installed with a separation
of at least one height unit.
Page 300 of 3829

Gas Analyzer Installation
CAUTION!
A system housing with an electronics module and an analyzer module
weighs from 18 to 23 kg (40 to 50 pounds). The following points should be
observed:
• Two persons are needed for installation.
• The location (e.g. bay, 19-inch rack, wall) must be capable of supporting the
gas analyzer’s weight.
• The 19-inch housing must be supported with rails in the bay or rack.
• Neither the 19-inch nor the wall-mount housings use hinges to secure the
housing cover. The cover can drop when opened.
What materials are Quantity Fastener (not supplied)

needed? 19-inch housing:
4 Oval-head screws (Recommendation: M6; this depends on the
cabinet/ shelf system)
1 pair Rails (Design depends on cabinet/shelf system)
Wall-mount housing:
4 M8 or M10 bolts
Installation Install the system housing in the cabinet/shelf or on the wall with the required
fasteners (see page 24 for dimensional diagrams).
Page 301 of 3829

Chapter 3 Gas Line Connection
Magnos206: Gas Connections
Figure 4
13 14
12 11 10 9 8 7
1 2
3 4
Gas Connections 1 Sample Gas Inlet

2 Sample Gas Outlet
3 Purge Gas Inlet Analyzer 2)
4 Purge Gas Outlet Analyzer 2)
7 Purge Gas Inlet Housing 1)
8 Purge Gas Outlet Housing 1) (also with Flow Sensor)
9 Pressure Sensor 1 1)
Pneumatics Module 1):

11 Sample Gas Inlet
12 End Point Gas Inlet (with 3 solenoids)
13 Test Gas/ Zero-Point Gas Inlet (with 1 or 3 solenoids)
14 Sample Gas Outlet – Connect with Inlet 1
1) Option
2) not in version with performance test for emission monitoring
Page 302 of 3829

Figure 5
10 1
14 9 2
11
8 3
13 12
7 6 5 4
Gas Connections 1 Purge Gas Inlet Housing 1)

3 –
4 Sample Gas Inlet
5 Purge Gas Inlet Analyzer
6 Purge Gas Outlet Analyzer
7 Sample Gas Outlet
8 –

11 Sample Gas Inlet
1) Option
Page 303 of 3829

Sample Cell Direct Connection, only in Wall-Mount Housing
Figure 6
6
8
7
1 5 4
2 10
Gas Connections 1 Purge Gas Inlet Housing 1)

4 Sample Gas Inlet
7 Sample Gas Outlet
8 –
1) Option
Page 304 of 3829

Caldos25, Caldos27: Gas Connections
Figure 7
13 14
12 11 10 9 8 7
3 4
2 1

2 Sample Gas Outlet

11 Sample Gas Inlet
1) Option
Page 305 of 3829

Caldos25: Gas Connections
Corrosive Sample Gas or Flowing Reference Gas
Figure 8
13 14
12 11 10 9 8 7
3 4
6 5
1 2

2 Sample Gas Outlet
5 Reference Gas Inlet 2)
6 Reference Gas Outlet 2)
Pneumatics Module 1) 2):

11 Sample Gas Inlet
1) Option
2) Not in version for corrosive sample gas
Gas ports 1 to 6 are made of PVC-C. Do not use metal adapters!
Page 306 of 3829

Limas11: Gas Connections
Standard Cell, Quartz Cell, Quartz Cell with Center Connection
Figure 9
BUS
8 4 1
Service 9
6 3
24 V DC

4 Sample Gas Outlet
6 Purge Gas Outlet Housing 1)
7 Pressure Sensor 2)
8 End-Point Gas Inlet (with 3 solenoids) 1) 3)
9 Zero-Point Gas Inlet (with 1 or 3 solenoids) 1) 3)
1) Option
2) only for standard cell with PTFE hoses
3) not for version with PTFE hoses
This connection diagram applies for the following versions of the Limas11 analyzer
module:
• Standard cell with FPM or PTFE hoses
• Quartz cell with FPM hoses
• Center connection cell made of aluminum with FPM or Cr hoses (60 °C)
• Center connection cell made of quartz with PTFE/FPM or PTFE/Cr hoses (60 °C)
The Limas11 HW analyzer module for hot/wet measurement of NO, NO2, NH3 is
described in Supplement 2 to Operator’s Manual 42/24-10 EN.
Page 307 of 3829

Quartz Cell with PFA Tubes
Figure 10
BUS
4 1
Service
6 3
24 V DC

4 Sample Gas Outlet
7 Pressure Sensor
1) Option
Page 308 of 3829

Safety Cell
Figure 11
BUS
4 1
Service 5 2
6 3
24 V DC

2 Sample Gas Outlet
4 Purge Gas Inlet Sample Cell
5 Purge Gas Outlet Sample Cell
7 Pressure Sensor
1) Option
Page 309 of 3829

Uras26: Gas Connections
Figure 12
10 1
14 9 2
11
8 3
13 12
7 6 5 4
Gas Connections 1 Pressure Sensor for External Pressure Measurement 1)

2 –
3 Sample Gas Inlet Gas Path 1
4 Sample Gas Outlet Gas Path 1
7 Sample Gas Inlet Gas Path 2 1)
8 Sample Gas Outlet Gas Path 2 1)
9 Reference Gas Inlet Gas Path 1 1)
10 Reference Gas Outlet Gas Path 1 1)

11 Sample Gas Inlet Gas Path 1
13 or Sample Gas Inlet Gas Path 2 (only with Flow Sensor)
14 Test Gas/ Zero-Point Gas Inlet (with 1 or 3 solenoids) or
1) Option
One of the several possible Uras26 connection arrangements is shown. The actual
connection arrangement of an analyzer module is found in the analyzer data sheet
for the delivered instrument.
Page 310 of 3829

Housing Purge
When should the A housing purge is required if the sample gas contains combustible, corrosive or
housing be purged? toxic components.
Housing Design A housing purge is possible if the system housing is designed for IP54 (with
connection box) or IP65 (without power supply) protection. The purge gas
connection ports (1/8-NPT internal threads) are factory installed per order.
Housing Purge In gas analyzers with the Caldos25, Caldos27, Magnos206 and Magnos27
analyzer modules there is a gas-tight separation between the central unit and
analyzer. Therefore, the central unit and analyzer can be purged separately
(parallel) or jointly (series).
In gas analyzers with the Limas11 and Uras26 analyzer modules there is no gas-
tight separation of the central unit and analyzer. Therefore, they can only be
purged together. If the central unit and analyzer must be purged separately, the
analyzer module must be installed in a separate IP54 system housing.
Due to differing purge gas supply requirements, the Limas11, Uras26, Caldos25,
Caldos27, Magnos206 and Magnos27 analyzer modules should not be purged in
series with the MultiFID14 analyzer module.
CAUTION!
For joint purging of the analyzer and central unit, the purge gas must first be
routed through the central unit and then through the analyzer. Flow direction
inversion and leaks in the sample gas path can result in damage to
electronics by corrosive sample gas components.
An analyzer module used to measure corrosive sample gas components
should be the last unit connected in a series.
Central Unit A central unit with no analyzer module installed can be ordered as a “housing
Housing Purge purge” version. In this case the purge gas connection ports are factory installed in
the terminator plate which installed at the back or bottom of the system housing
instead of an analyzer module.
Purge Gas Supply Nitrogen or instrument air should be used as purge gas (refer to the “Purge Gas
Requirements for Housing Purge” section, page 17, for detailed information).
CAUTION!
Purge gas can escape from the housing if there are any leak points.
When using nitrogen as the purge gas, take all required precautions against
suffocation.
Purge gas flow must always be restricted ahead of the purge gas inlet!
If the purge gas flow is restricted after the purge gas outlet, the housing
seals are subjected to full purge gas pressure which can result in damage
to the keypad!
Page 311 of 3829

Gas Line Connection
CAUTION!
The lines and fittings must be free of any residues (e.g. particles left over
from manufacturing). Contaminants can enter the analyzer and damage it or
lead to false measurement results.
• Gas port installation is described in the “Gas Connections Installation” section

(see page 22).
• Follow the fittings manufacturer’s installation instructions. Be sure to use a
backup wrench when tightening gas line threaded connections.
• Follow the manufacturer’s instructions when laying and connecting the sample
gas line.
• If gas lines made of high-grade steel are connected to the analyzer modules with
a direct measuring chamber connection, the lines also need to be connected to
the building-side equipotential bonding.
• Never connect more than three analyzer modules in series.
Gas Line Connection Connect the gas lines – made of a material appropriate for the measurement task –
to the installed gas ports.
Evacuate Exhaust gases should be routed to the atmosphere or to an exhaust pipe directly
Exhaust Gases or via the shortest possible large-diameter line. Do not route exhaust gases via
flow reducers or shutoff valves.
Process corrosive, toxic or combustible exhaust gases in an appropriate manner.
Provide for Gas Line Install a shutoff valve in each gas inlet line (this is definitely recommended for
System Flushing pressurized gases) and provide a means of flushing the gas line system via the
sampling port with an inert gas, e.g. nitrogen.
Flow Meter In the Caldos25 and Uras26 versions with flowing reference gas a flow meter
Installation in the with a needle valve must be installed in the sample gas line and in the reference
Reference Gas Line gas line in order to adjust the flow rate in the two lines to the optimum value.
Page 312 of 3829

Pressure Sensor
Notes for Proper • Remove the yellow plug from the pressure sensor port before start-up of the
Pressure Sensor analyzer module.
Operation
• For a precise pressure correction, the pressure sensor port must be connected
to the sample gas outlet via a tee and short lines. To reduce the flow effect, the
lines must be kept as short as possible or, if longer lines are necessary, the inner
diameter must be sufficiently large (≥ 10 mm).
• If the pressure sensor is connected to the sample gas path, the sample gas
must not contain corrosive components nor may it be flammable or at risk of
explosion.
• If the pressure sensor port is not connected to the sample gas outlet, precise
pressure correction can only take place if the pressure sensor and the sample
gas outlet are on the same pressure level.
• Magnos206 : For measurements in suppressed measurement ranges, the
pressure sensor port and the sample gas outlet must be connected via a tee and
short lines. Please observe that the exhaust line is kept as short as possible or, if
longer lines are necessary, that the inner diameter is sufficiently large (≥ 10 mm).
Page 313 of 3829

Chapter 4 Electrical Connection
Electronics Module Connections
Figure 13
Electronics Module
Connections
-X28 -X29
-X26 -X27
-X24 -X25
1 1
6 6
-X22 -X23
-X01 1
6
-X07 -X20 -X21
-X08 -X09
For connection see

-X01 Power Supply Connection Page 55
-X07 System Bus Port Page 47
-X08, -X09 Ethernet 10/ 100/ 1000BASE-T Interface
-X20 to -X29 I/O Modules (5 slots), Options:
– Profibus Module Page 39
– Modbus Module Page 40
– 2-Way Analog Output Module Page 41
– 4-Way Analog Output Module Page 42
– 4-Way Analog Input Module Page 43
– Digital I/O Module Page 44
Potential Compensation Connection Page 55
The connection drawing shows an example for the I/O modules equipment.
Page 314 of 3829

Profibus Module: Electrical Connections
Figure 14
RS485 MBP
Profibus Module
Connection Diagram
1
6 1 2 3 4
RS485 Interface:
1 – not used
2 M24 24 V Output Ground
3 RxD/TxD-P Receive/ Transmit Data Plus, B-Line
4 – not used
5 DGND Data Transmission Potential (Reference Potential for VP)
6 VP Supply Voltage Plus (5 V)
7 P24 24 V Output Voltage Plus, max. 0.2 A
8 RxD/TxD-N Receive/ Transmit Data N, A-Line
9 – not used
Design: 9-pin Sub-D female connector
MBP Interface (non-intrinsically safe):

1 +
2 Shield
3 –
4 not used
Design: 4-pin terminal strip for stranded or solid conductors with a maximum
section of 1 mm2 (17 AWG). Note: Observe the information on needed materials
(see page 50).
Page 315 of 3829

Modbus Module: Electrical Connections
Figure 15
RS232 RS485
Modbus Module
Connection Diagram
1 1
6 6
RS232 Interface: RS485 Interface:

2 RxD 2 RTxD–
3 TxD 3 RTxD+
5 GND 5 GND
Design: 9-pin Sub-D male connector Design: 9-pin Sub-D female connector
Page 316 of 3829

2-Way Analog Output Module: Electrical Connections
Figure 16
2-Way Analog Output
Module
Connection Diagram 1 2 3 4
1 AO1 + 0/4 to 20 mA, max. 750 Ω

2 -
3 AO2 + 0/4 to 20 mA, max. 750 Ω
4 -
AO1-AO2 Analog Outputs:

0/ 4-20 mA (configurable, factory-set to 4-20 mA), common negative
pole, galvanically separated from ground, freely connectable to
ground, max. gain vs. local protective ground potential 50 V,
max. working resistance 750 Ω. Resolution 16 bit. The output signal
cannot be lower than 0 mA.
Design: 4-pin terminal strip for stranded or solid cable with a maximum section of
1 mm2 (17 AWG). Observe the information on needed materials (see page 50).
“Standard Terminal Connections” section (see page 46) contains information on
standard terminal assignment. Please observe also the specifications in the
analyzer data sheet.
Page 317 of 3829

4-Way Analog Output Module: Electrical Connections
Figure 17
4-Way Analog Output
Module
Connection Diagram 1 2 3 4 5 6 7 8
1 AO1 + 0/4 to 20 mA, max. 750 Ω

2 -
3 AO2 + 0/4 to 20 mA, max. 750 Ω
4 -
5 AO3 + 0/4 to 20 mA, max. 750 Ω
6 -
7 AO4 + 0/4 to 20 mA, max. 750 Ω
8 -
AO1-AO4 Analog Outputs:

0/4-20 mA (configurable, factory-set to 4-20 mA), common negative
pole, galvanically separated from ground, freely connectable to
ground, max. gain vs. local protective ground potential 50 V,
max. working resistance 750 Ω. Resolution 16 bit. The output signal
cannot be lower than 0 mA.
Design: 8-pin terminal strip for stranded or solid cable with a maximum section of
1 mm2 (17 AWG). Observe the information on needed materials (see page 50).
analyzer data sheet.
Page 318 of 3829

4-Way Analog Input Module: Electrical Connections
Figure 18
4-Way Analog Input
Module 1 3 5 7 9
Connection Diagram
2 4 6 8 10
50 Ω
1 AI1 I 0 to 20 mA into 50 Ω
50 Ω 2 C
50 Ω 4 C
50 Ω 6 C
8 C
9 +24 V Power supply for
10 GND external sensor
AI1-AI4 Analog Inputs:

0 to 20 mA into 50 Ω
+24 V Current Output:
+24 VDC for supply of an external sensor, fused with 100 mA
(resettable fuse)
Design: 2x5-pin terminal strip for stranded or solid cable with a maximum section
of 1 mm2 (17 AWG). Observe the information on needed materials (see page 50)!
Page 319 of 3829

Digital I/O Module: Electrical Connections
Figure 19
DI4 DI3 DI2 DI1 DO4 DO3 DO2 DO1
Digital I/O Module
Connection Diagram
1 3 5 7 9 11 13 15 17 19 21 23
2 4 6 8 10 12 14 16 18 20 22 24
1 DI4 -
2 +
12-24 V
24V 3 GND
5 DI3 -
6 +
12-24 V
24V 4 GND
7 DI2 -
8 +
12-24 V
24V 9 GND
11 DI1 -
12 +
12-24 V
24V 10 GND
13 DO4 NO max. 30 V / 1 A
15 Common
17 NC
14 DO3 NO max. 30 V / 1 A
16 Common
18 NC
19 DO2 NO max. 30 V / 1 A
21 Common
23 NC
20 DO1 NO max. 30 V / 1 A
22 Common
24 NC
DI1-DI4 Digital Inputs:

Optocoupler with internal 24 VDC power supply. Control with floating
contacts, with external voltage 12–24 VDC or with open collector
drivers PNP or NPN..
DO1-DO4 Digital Outputs:
Floating double-throw contacts, max. contact load rating 30 V/1 A
Relays must at all times be operated within the specified data range.
Inductive or capacitive loads are to be connected with suitable
protective measures (self-induction recuperation diodes for inductive
loads and series resistors for capacitive loads).
Design: 2x12-pin terminal strip for stranded or solid cable with a maximum section
of 1 mm2 (17 AWG). Observe the information on needed materials (see page 50).
analyzer data sheet. Relays are shown in the unpowered state. The unpowered
state is the failure mode (“fail safe”).
Page 320 of 3829

Digital I/O Module: Electrical Connections, continued
Connections of the Status Signals / Externally Controlled Calibration:

Standard Function Single Status Signals: Collective Status Signal:
Block Applications DO1 Failure Collective Status
DO2 Maintenance Mode Limit Value
DO3 Maintenance Request Limit Value
DO4 External Solenoid Valve External Solenoid Valve
DI1 Start Automatic Calibration Start Automatic Calibration
DI2 Inhibit Automatic Calibration Inhibit Automatic Calibration
DI3 Adjust Zero-Point Adjust Zero-Point
DI4 Adjust End-Point Adjust End-Point
Measuring Range Control:
DO1 Measuring Range Feedback
DI1 Measuring Range Switchover
Limit Values:
DO1 Limit Value
DO2 Limit Value
DO3 Limit Value
DO4 Limit Value
DI1 Calibration Cells In/Out
DI2 Hold Current Output
DI3 Pump On/ Off
DI4 External Failure
Calibration Control:
DO1 External Solenoid Valve Sample Gas
DO2 External Solenoid Valve Zero Gas
DO3 External Solenoid Valve Span Gas
DO4 External Pump On/ Off
DI1 Pump On/ Off
Page 321 of 3829

Standard Terminal Connections
Basic Principles The terminal connections are allocated

• in the order of the registered analyzer modules and
• within an analyzer module, in the order of the sample components.
The order of the analyzer modules and sample components is documented in the
analyzer data sheet and on the type plate. Beginning with analyzer module 1 and
sample component 1, the input and output functions are first of all allocated in turn
to available free connections of the I/O modules (slots –X20 to –X29).
Profibus, Modbus The slot of the optional Profibus module is always –X20. The slot of the optional
Modbus module is –X20, or –X22 if a Profibus module is present.
Analog Outputs Analog outputs are available at the 2-way analog output module or the 4-way
analog output module. An analog output is allocated for each sample component
in the order of the sample components.
Alarm Values Alarm values are available at the digital I/O module “Status signals/ external
calibration” (if the gas analyzer has been set to collective status during the
installation of an analyzer module) or the digital I/O module “Alarm values”. An
alarm value is allocated for each sample component in the order of the sample
components.
Standard Application Measuring range control can be implemented for all sample components with
Measuring Range more than one measuring range. Each digital I/O module includes
Control • 4 digital inputs (DI) for the measuring range switch-over and
• 4 digital outputs (DO) for the measuring range feedback signal.
Sample component with … Assignment DI and DO configuration
2 measuring ranges 1 DI and 1 DO NO open: Measuring range 1,
NO closed: Measuring range 2
3 measuring ranges 3 DI and 3 DO NO closed: active meas. range
4 measuring ranges 4 DI and 4 DO NO closed: active meas. range
The measuring range control is not installed across I/O modules.

Example: A gas analyzer contains 4 sample components with the following
number of measuring ranges:
Sample components Number of measuring ranges
Sample component 1 (SC1) 3 measuring ranges (MR1, MR2, MR3)
Sample component 2 (SC2) 3 measuring ranges (MR1, MR2, MR3)
Sample component 3 (SC3) 2 measuring ranges (MR1, MR2)
Sample component 4 (SC4) 2 measuring ranges (MR1, MR2)
The following connection assignments result from this:

Assignment for 1st I/O Module Assignment for 2nd I/O Module
DI/ DO 1: SC1: MR1 DI/ DO 1: SC2: MR1
DI/ DO 4: SC3: MR1, MR2 DI/ DO 4: SC4: MR1, MR2
Page 322 of 3829

System Bus Connection
System Bus The system bus structure is linear with a maximum length of 350 meters.
One System Housing The system bus connection is established at the factory when the gas analyzer
functional components (e.g. an electronics module and an analyzer module) are
installed in one system housing.
In this case a terminating resistor should be installed in the system bus connector
(supplied with the unit, see Figure 21).
Figure 21 AM Analyzer Module

AM EM PS EM Electronics Module
One System Housing:
PS Power Supply
Terminating Resistor BUS BUS System Bus (Internal)
on the Electronics
Terminating Resistor
Module
Multiple System If the gas analyzer functional components are installed in several system housings,
Housings they must be interconnected externally via the system bus (see Figure 22 and
instructions on the following page).
Figure 22
AM PS EM PS
Multiple System
Housings:
Connection via the
System Bus
BUS
AM Analyzer Module PS Power Supply Terminating

EM Electronics Module BUS System Bus (External) Resistors
CAUTION!
Only one electronics module should be connected to a system bus structure.
Multiple electronics modules should never be interconnected via the system
bus!
Page 323 of 3829

System Bus Connection, continued
What materials are The required system bus cables, tees and terminating resistors are supplied per
needed? the order.
CAUTION!
For system bus connections use only the yellow system bus cables, tees and
terminating resistors. Do not use the violet connectors as they are only for
Modbus connections.
The modules should never be interconnected without using tees and termi-
nating resistors.
System Bus Step Action

Connection 1 Place a tee on the system bus connection (designated “BUS”) of each
module (electronics and analyzer).
2 Connect the tees with the system bus cables.
3 Place a terminating resistor on the open ends of each tee.
System Bus Cable Note the following information if using other than the standard system bus cables
Extension and plugs to extend the system bus:
• For extension purposes a shielded 4-conductor cable with twisted pairs and a
wire section ≥ 0.5 mm2 should be used.
Number and section of conductors 2 x 2 x 0.25 mm2
Inductance approx. 0.67 mH/ km
Impedance approx. 80 Ω
Coupling (1 kHz) approx. 300 pF/ 100 m
Operating capacitance Conductor–Conductor approx. 120 nF/ km
Conductor–Shield approx. 160 nF/ km
• For EMC purposes route the system bus cable via metal connection boxes with
metallic cable threaded connections. Connect the shield to the threaded con-
nections. Connect the unused wires in the 4-conductor extension cable in the
connection box to a PE clamp.
• Figure 23 shows the pin layout of the 3-pin system bus plug.
Figure 23 Pin Wire Color Signal

System Bus Plug 1 green System Bus LOW
1 3 2 brown System Bus HIGH
Layout
(Seen from pin side of 3 white System Bus GROUND
2
cable plug)
Page 324 of 3829

System Bus Connection, continued
Adding an Analyzer Step Action

Module to the 1 Open the internal system bus connection between the existing analyzer
System Bus module and the electronics module.
(see Figure 24) 2 Place a tee on the system bus connection (designated “BUS”) of each
module (electronics and all analyzer modules).
3 Connect the tees with the system bus cables.
4 Place a terminating resistor on the open ends of each tee.
5 Set up the added analyzer module (MENU → Configure →
System → Setup system modules).
Figure 24 AM Analyzer Modules

AM EM PS EM Electronics Module
Multiple Analyzer
PS Power Supply
Modules: BUS BUS System Bus (External)
Connection via the
Terminating Resistors
System Bus
BUS
AM PS
Page 325 of 3829

Signal, Control and Interface Line Connection
CAUTION!
Follow local regulations on installing and connecting electrical wiring.
• Locate the signal, control and interface lines separately from the power supply
lines.
• Locate the analog and digital signal leads separately from each other.
• Carefully plan the arrangement of signal lines in the cables as well as the use of
connector box openings in the IP54 system housing.
What materials are • Selection of the required conductors depends on line length and planned current
needed? load.
• Notes regarding conductor section for I/O module connection:
• The maximum capacity of terminals for stranded or solid conductors is 1 mm2
(17 AWG).
• The stranded conductor may be tinned on the tip or twisted for simplified
connection.
• When using wire end ferrules the total section should not exceed 1 mm2,
i.e. the maximum stranded conductor section is 0.5 mm2. The Weidmüller
PZ 6/5 crimping tool must be used for crimping the ferrules.
• Maximum line length 1200 meters (3940 feet, transmission rate max. 19200 bit/s)
for RS485.
• Maximum line length 15 meters (50 feet) for RS232.
• The matching female connector housings for the analog and digital input and
output connection strips on the I/O modules (options) are supplied with the
device.
Connection Box The IP54 version of the system housing has a connection box on the back of the
electronics module.
The connection box has:
• EN version: Five M20 and two M32 threaded cable connections
• CSA version: One 1-1/4-inch and two 3/4-inch conduits.
Two M32 threaded cable connections are provided to route system bus, Modbus,
Profibus and Ethernet cables.
Protective Cap A protective cap is factory-installed on the rear of the electronics module when the
Limas11 UV analyzer module is installed in the central unit.
It is imperative to re-install the protective cap after connection of the electrical
lines! Otherwise light penetration during operation may lead to erroneous measure-
ment values and measurement range overflows.
Page 326 of 3829

Signal, Control and Interface Line Connection, continued
Wiring Connection IP20 Version of System Housing:

Step Action
1 Connect the wiring to the connector housing according to the
connection diagrams.
2 Connect the connector housings to the terminal strips.
Version of System Housing with connection box:

Step Action
1 Run the cables through the connection box openings.
M20: Remove the plug from the insert; the ring remains in place as a
gasket and strain relief.
M32: Remove the plugs from the threaded connections. Press the
insert from the accessory kit over the cable; seal off the free
opening with the pin from the accessory kit.
2 Connect the wiring to the connector housings according to the
connection diagrams.
3 Connect the connector housings to the terminal strips.
Mark the cables or the connector housings of the I/O modules so that their
respective relationship to the I/O module is clear.
Page 327 of 3829

Power Supply Line Connection – Safety Notes
CAUTION!
Follow all applicable national safety regulations for the preparation and
operation of electrical devices as well as the following safety precautions.
The gas analyzer voltage must be set to match the line voltage before the
power supply is connected.
The protective lead should be attached to the protective lead connector
before any other connection is made. The protective lead connection is
assured when the power cable supplied is used.
The gas analyzer can be hazardous if the protective lead is interrupted inside
or outside the gas analyzer or if the protective lead is disconnected.
Only fuses of the specified type and rated current should be used as
replacements. Never use patched fuses. Do not short-circuit the fuse holder
contacts.
If the power supply fuse fails, some power supply switch components can
still carry current.
Never connect line voltage to a 24-VDC analyzer module input. This will
destroy the analyzer module electronics.
Install a breaker near the gas analyzer in order to completely disconnect it
from the power supply. Mark the breaker so that its relationship to the
protected device is clear.
Page 328 of 3829

Power Supply Line Connection to the Analyzer Module
• The following information and instructions should be followed when connecting

the 24-VDC power supply to an analyzer module that is not installed in the
central unit but in a separate system housing.
• Information in the “Power Supply Information” section, page 18, should also be
followed.
24-VDC Connecting If an analyzer module is not installed in the central unit but in a separate system
Cable housing a 5-meter (16.4-feet) long cable (2 x 0.5 mm2, see Figure 25) will be
supplied.
The receptacle on one cable end is designed to connect to the 24-VDC male plug
on the analyzer module or the I/O base module (see Figure 26).
The wires on the free end of the connecting cable are intended for connection to
• The power supply filter -Z01 in the central unit (for an example see Figure 27) or
• An external power supply
Figure 25 BN +
24-VDC Connecting
Cable
BU -
Figure 26 3
The illustration shows the pin side of the analyzer module
4 2
plug and thus the solder side of the matching female jack.
24-VDC Connection
1
Figure 27
CU
Connecting 24-VDC
Power from the
Central Unit Power
Supply to a Separate EM
Analyzer Module AM
-Z01
PS
24 V DC
(0.5 mm2, < 5 m)
BUS
115 / 230 V AC
AM Analyzer Module EM Electronics Module -Z01 Power Supply Filter

CU Central Unit PS Power Supply BUS System Bus
Page 329 of 3829

Power Supply Line Connection to the Analyzer Module, continued
24 VDC Connection Step Action

1 Connect the supplied connection cable with receptacle to the 24 VDC
connection on the analyzer module or the I/O base module.
2 Connect the wires on the free end of the cable to the power supply
filter -Z01 in the central unit or to the external power supply.
Extending the 24-VDC The 24-VDC connection cable has a wire section of 0.5 mm2, it is limited to a
Connection Cable length of 5 meters (16.4 feet).
Note the following conditions if the connection cable has to be extended:
• The extension cable must have a wire section of at least 2.5 mm2.
• The extension cable should be no more than 30 meters (98 ft) long.
• The extension cable should be connected as close as possible to the receptacle
of the supplied 24-VDC connection cable, i.e. the supplied 24-VDC connection
cable should be made as short as possible.
Page 330 of 3829

Power Supply Line Connection
What materials are The gas analyzer is supplied with a power cord and a separate two-prong
needed? grounded plug. The power cord is 5 meters (16.4 feet) long and has a three-prong
grounded-instrument plug for connection to the power supply.
If the power cord supplied is not used, make your selection of a suitable cable
based on line length and planned current load.
Figure 28 The illustration shows the pin side of the plug in the power supply.
L
Power Supply PE
Connection N
Power Supply Line Step Action

Connection 1 Make sure the power supply leads have an adequately dimensioned
protective device (breaker).
2 Install a breaker in the power supply line or a switched receptacle near
the gas analyzer to make sure the gas analyzer can be completely
separated from the power source. Mark the breaker so that its
relationship to the protected device is clear.
3 Connect the power cord supplied to the –X01 power supply connector
in the electronics module and secure it with the clip.
4 Connect the other end of the power cord to the power source.
The gas analyzer may start when the power supply is
connected.
Potential The electronics module and the analyzer modules have a potential compensation
Compensation connector designated by the symbol . The connector has M5 internal threads
Connection for the installation of a matching screw or clamp.
Use this connection to link each module to the building’s potential compensator in
accordance with local regulations.
Page 331 of 3829

Chapter 5 Gas Analyzer Start-Up
Installation Check
Installation Check Make sure the gas analyzer is correctly installed before carrying out any start-up
procedures.
Use the following check list:
Check
• Is the gas analyzer securely fastened?
(See “Gas Analyzer Installation” section, page 25)
• Are all gas lines correctly connected?
(See Chapter 3 “Gas Line Connection”, page 26)
• Are all signal, control, interface, power supply and (if applicable) system
bus lines correctly placed and connected?
(See Chapter 4 “Electrical Connection”, page 38)
• Are all devices needed for gas preparation, calibration and exhaust
processing correctly connected and ready for use?
Page 332 of 3829

Gas Path and Housing Initial Purge
Take note of the instructions in the “Housing Purge” section, page 26.
Purge Prior to The gas paths and if necessary, the system housing should be purged prior to
Start-Up starting the gas analyzer.
First this ensures that the gas paths and system housing are free from contami-
nants (e.g. corrosive gases) and dirt on start-up.
Second this prevents the possibility of an explosive gas/air mixture being present
in the gas paths or system housing when the power supply is connected.
Purge Gas Supply Nitrogen or instrument air should be used as purge gas (refer to the “Purge Gas
Requirements for Housing Purge” section, page 17, for detailed information).
Purge Gas Flow and The purge gas flow and the duration of the purge process depend on the volume
Duration of Purge to be purged (see the following table). If the purge gas flow rate is lower than
Process indicated the duration of the process must be increased correspondingly.
Volume to be Purged Purge Gas Flow Rate Duration

Gas Path 100 l/h (max.) approx. 20 sec.
Central Unit with or without 200 l/h (max.) approx. 1 hr.
Analyzer Module
Caldos25, Caldos27, Magnos206, 200 l/h (max.) approx. 3 min.
Magnos27 (analyzer separately)
The purge gas flow rates given in the table only apply to the initial purge. During
operation other values apply (see “Operation” section, page 60).
CAUTION!
Purge gas can escape from the housing if there are any leak points. When
using nitrogen as the purge gas, take all required precautions against
suffocation.
CAUTION!
Purge gas flow must always be restricted upstream of the purge gas inlet! If
the purge gas flow is restricted after the purge gas outlet, the housing seals
are subjected to full purge gas pressure which can result in damage to the
keypad!
Page 333 of 3829

Power Supply Activation
CAUTION!
For gas analyzers with Limas11 or MultiFID14 analyzer modules:
Before activating the power supply check once again that the gas analyzer
operating voltage setting matches the line voltage.
The sample gas supply should be turned on only at the end of the warm-up phase
and after calibration.
Power Supply Step Action

Activation 1 Turn on the power supply of the gas analyzer with the external breaker
switch.
2 Turn on the separate 24-VDC power supply of the analyzer module if
necessary.
Function Check The following events will occur after the power supply is turned on:
Phase Description
1 The three “Power”, “Maint” and “Error” LEDs light up.
2 The different booting phases are displayed on the screen.
Also the software version is displayed.
3 After a brief time the screen switches to measurement mode.
STATUS
4 The MESSAGE softkey appears on the screen. This indicates the possibility
of a temperature or flow problem during the warm-up phase. By
pressing the softkey the user can recall the status message summary
and view status message details.
Date and Time Check A correct date and time setting is required for proper operation of functions such
as automatic calibration and time/ date logging of error messages.
Step Action
1 Select the Date/time menu item:
MENU → Configure → System → Date/Time
2 Check and, if necessary, correct the date and time.
The gas analyzer is factory-set to the GMT+1 time zone.
Page 334 of 3829

Warm-Up Phase
Warm-Up Phase The duration of the warm-up phase depends on which analyzer module is installed
in the gas analyzer.
Analyzer Module Warm-Up Phase Duration

Caldos25 1.5 hours
Caldos27 Approx. 30/ 60 minutes for class 1/ 2 measurement ranges 1)
Limas11 Approx. 2.5 hours
Magnos206 ≤ 1 hour
Magnos27 2 to 4 hours
Uras26 Approx 0.5/ 2 hours without/ with thermostat
1) See “AO2000 Series” Data Sheet (publication number 10/24-1.20 EN) for
class details.
• The warm-up phase can take longer if the gas analyzer was not brought to room
temperature before the power supply was activated.
• During the warm-up phase measurement values can be outside the ranges
specified in the data sheet.
Warm-Up Phase The warm-up phase is over when the measured value drift indication is accept-
Duration able. This depends on the size of the measurement range.
Page 335 of 3829

Operation
Readiness At the end of the warm-up phase the gas analyzer is ready to carry out measure-
ments.
Calibration The gas analyzer is calibrated in the factory. Transport stresses as well as pressure
Verification and temperature conditions at the installation location may however influence the
calibration. Thus it is recommended to verify the gas analyzer calibration at the
installation location.
Chapter 7 describes the gas analyzer calibration procedures.
Sample Gas Supply The sample gas supply should be turned on only after calibration.
Adjusting Sample Gas Module Sample Gas Flow Rate

Flow Rate Caldos25 10–190 l/h (for option T90 < 6 sec.: max. 90–200 l/h)
Caldos27 10–190 l/h min. 1 l/h
Limas11 20–100 l/h
Magnos206 30–190 l/h
Magnos27 20–190 l/h
Uras26 20–100 l/h
Oxygen Sensor 20–100 l/h
Gas Module 30–160 l/h
Adjusting Reference In the Caldos25 and Uras26 analyzer module versions with flowing reference
Gas Flow Rate gas, the reference gas flow rates must be set to the same value as the sample gas
flow rate.
For special applications of the Caldos25 the reference gas flow rate must be set
to lower values down to 1 l/h.
Adjusting Purge Gas The purge gas flow should be set as follows in gas analyzers with the housing
Flow Rate purge capability:
Purge gas flow rate at device inlet max. 20 l/h (constant),
Purge gas positive pressure pe = 2 to 4 hPa
• Because of leakage losses the purge gas flow rate at the device output is
approx. 5 to 10 l/h for a purge gas flow rate at the device inlet of 20 l/h.
• Notes for selection and use of flow meters:
• Measuring range 7 to 70 l/h
• Pressure drop < 4 hPa
• Needle valve open
• Recommendation: Flow meter 7 to 70 l/h, Catalog No. 23151-5-8018474
Page 336 of 3829

Chapter 6 Gas Analyzer Operation
Display and Control Unit
Figure 29
Screen with
Display and Control
Unit Error Maint Power
Menu Line Status LED’s
7 8 9
Information
4 5 6
Field
Numeric
1 2 3
Softkey Line Keypad
0 .
Softkeys Cancel Keys
Power The green “Power” LED lights when the power supply is on.
Maint The yellow “Maint” LED lights when the “Maintenance Request” status signal is
active.
Error The red “Error” LED lights when the “Failure” status signal or the overall status
signal is active.
Back
The “Back” key allows the operator to cancel a function or menu item and return
to the previous menu level.
Meas
The “Meas” key allows the operator to cancel a function or menu item and to
return to the measured value display in measurement mode.
Only entries confirmed with the ENTER key are stored; unconfirmed items are not
accepted.
Page 337 of 3829

Softkeys
MENU
The MENU key is used to call the main menu and switch to menu mode when in
measurement mode.
The >> key allows the operator to scroll to the next display “page”. This key only
allows forward scrolling.
The “Back” key is used for backward scrolling.
STATUS The STATUS MESSAGE key appears in measurement mode if an “Failure” or

MESSAGE
“Maintenance request” condition arises.
This key allows the operator to call up the status message log and view the status
messages.
The user can also call up a detailed display for any message in the log.
All status messages are listed in Chapter 8.
The operator uses these two arrow keys to move the selection cursor up or down
in a menu or list to choose menu items.
The operator uses these two keys to move the selection cursor left or right, e.g.
into or out of a submenu or to select an item in a subordinate list.
BACK- The operator can use the BACKSPACE key to delete characters to the left of the
SPACE
cursor (as in a PC keyboard).
CLEAR
The operator can use the CLEAR key to delete all characters in a selected field.
ENTER
The operator can use the ENTER key to:
• Call up menu items for processing
• Start functions
• Confirm entries, e.g. parameter settings
HELP
The operator can use the HELP key to access context-sensitive help. The screen
will then show a help message explaining the menu item selected.
The operator can use the “Back” key to clear the help message.
Page 338 of 3829

Changing the Password
Menu Path MENU → Configure → System → Change password
Factory Setting User group Access to Password levels Password

Every user 0 None
Maintenance team 0, 1 471100
Specialist team 0, 1, 2 081500
Function block specialist 0, 1, 2, 3 325465
Procedure Select the Change password menu item, select the user group, enter the old
password, enter the new password (6 digits), re-enter the new password, leave the
menu item with Back.
CAUTION!
After entering the password for password level 3, you can access all of the
function block applications. When configuring function blocks, existing
applications with their configurations and links can be damaged or
destroyed.
Page 339 of 3829

Menu Tree
Menu
⏐ ↓
⏐ _ Calibrate ⏐_ Maintenance/Test
⏐ ⏐ ⏐ ⏐
⏐ ⏐ _ Manual calibration ⏐ ⏐_ System
⏐ ⏐ ⏐ ⏐ ⏐_ Atm. pressure
⏐ ⏐ _ Automatic calibration ⏐ ⏐ ⏐_ Display test
⏐ ⏐ ⏐ ⏐_ Keyboard test
⏐ _ Configure ⏐ ⏐
⏐ ⏐ ⏐ ⏐_ Analyzer spec. adjustm.
⏐ ⏐ _ Component specific ⏐ ⏐_ Pump
⏐ ⏐ ⏐ _ Measurement range ⏐ ⏐_ Atm. press. anlz
⏐ ⏐ ⏐ _ Filter ⏐ ⏐_ Calibration reset
⏐ ⏐ ⏐ _ Pressure controller ⏐ ⏐_ Basic calibration
⏐ ⏐ ⏐ _ Autorange ⏐ ⏐_ Measure cal. cell
⏐ ⏐ ⏐ _ Alarm values ⏐ ⏐_ Optical adjustm.
⏐ ⏐ ⏐ _ Active component ⏐ ⏐_ Phase adjustm.
⏐ ⏐ ⏐ _ Module text ⏐ ⏐_ Relinearization
⏐ ⏐ ⏐ ⏐_ Amplification optimization
⏐ ⏐ _ Calibration data ⏐ ⏐_ Cross sensitivity adjustm.
⏐ ⏐ ⏐ _ Manual calibration ⏐ ⏐_ Carrier gas adjustm.
⏐ ⏐ ⏐ _ Automatic calibration ⏐ ⏐_ Electr. zero cal. FID
⏐ ⏐ ⏐ _ Ext. controlled cal. ⏐ ⏐_ Restart FID
⏐ ⏐ ⏐ _ Output current response ⏐
⏐ ⏐ ⏐_ Diagnostics/Information
⏐ ⏐ _ Function blocks ⏐
⏐ ⏐ ⏐ _ Miscellaneous ⏐_ System overview
⏐ ⏐ ⏐ _ Inputs ⏐
⏐ ⏐ ⏐ _ Outputs ⏐_ Module specific
⏐ ⏐ ⏐ _ Mathematics ⏐ ⏐_ Raw values
⏐ ⏐ ⏐ _ Multiplexer/Demultiplexer ⏐ ⏐_ Auxiliary raw values
⏐ ⏐ ⏐ _ Measurement ⏐ ⏐_ Status
⏐ ⏐ ⏐ _ Sample system ⏐ ⏐_ Controller values
⏐ ⏐ ⏐ _ Calibration/Correction ⏐ ⏐_ Lamp intensity
⏐ ⏐ ⏐ ⏐_ Uras26 Status
⏐ ⏐ _ System ⏐
⏐ ⏐ _ Date/Time ⏐_ Logbook
⏐ ⏐ _ Language
⏐ ⏐ _ Change password
⏐ ⏐ _ Setup system modules
⏐ ⏐ _ Save configuration
⏐ ⏐ _ Status signals
⏐ ⏐ _ Network
⏐ ⏐ _ Display
↓
Page 340 of 3829

Chapter 7 Gas Analyzer Calibration
Manual Calibration
Test Gas Supply The test gas supply can be started by activating a multiple path valve.
If the analyzer module is assigned to a gas module and the gas module is fitted
with a single solenoid valve to control the test gas supply (see Figure 28), the zero
gas and span gas must be fed to the zero gas inlet (NG). This also applies if an
external solenoid valve is used and controlled via a digital output.
The pump status (on /off during manual calibration) matches the setting for
automatic calibration.
Figure 30 Test gas connection for

Gas Module
Caldos27 with single-point calibration,
Analyzer Module with opt. Magnos206 with single-point calibration,
Gas Module
MG Limas11 with calibration cells,
Uras26 with calibration cells
NG Option: Flow monitoring, e.g. for flowing
reference gas or purge gas (external
P needle valve required)
O2 c
E MG Sample Gas
NG Zero Gas
Flow Flow Monitor
O2 Oxygen Sensor
P Pressure Sensor in Analyzer Module
c/ E Analyzer
Analyzer Modules with In analyzer modules with several detectors (e.g. the Uras26) each detector should
Multiple Detectors be calibrated sequentially.
Air Pressure Effect If the gas analyzer does not have a pressure sensor for air pressure correction, the
air pressure value should be checked and reset as required prior to calibrating the
analyzer module:
• If the gas analyzer’s operating site height has been changed since the last
calibration
• If the air pressure effect on the measured value is too high.
Page 341 of 3829

Manual Calibration, continued
To optimize accuracy, perform a manual zero calibration prior to calibrating the

span value.
Analyzer Module Step Action

Manual Calibration 1 Select the Manual Calibration menu.
MENU → Calibrate → Manual Calibration
2 For Single Calibration:
Select Components and Measurement Range.
Zero calibration:
3 Select the Zero Gas.
4 Turn on the zero gas supply.
5 If necessary, change the test gas concentration 1) shown, ENTER.
6 When the sample value indication stabilizes, initiate zero calibration
with ENTER.
7 Accept the calibration result with ENTER
or REPEAT 2) calibration (back to step 5)
or reject calibration with Back (back to step 6)
or reject calibration with Meas (back to measurement value readout).
Span Calibration:
8 Select the Span Gas.
9 Turn on the span gas supply.
10 If necessary, change the test gas concentration 1) shown, ENTER.
11 When the sample value indication stabilizes, initiate span calibration
with ENTER.
12 Accept the calibration result with ENTER
or REPEAT 2) calibration (back to step 10)
or reject calibration with Back (back to step 11)
or reject calibration with Meas (back to measurement value readout).
For Single Calibration:
Repeat steps 2–12 for the other components and measurement ranges.
1) The initialized test gas concentration is shown as the set point. By changing the
set point in this step the initialized test gas concentration will be overwritten.
2) It may be necessary to repeat calibration if the measurement value is still not
stable after calibration has been started. The subsequent process is based on
the measurement value obtained in the previous calibration.
Page 342 of 3829

Automatic Calibration
Test Gas Supply The test gas supply can be started automatically by means of the gas module’s
solenoid valves or via external solenoid valves.
Analyzer Modules with In analyzer modules with several detectors (e.g. the Uras26) all detectors are
Multiple Detectors calibrated simultaneously.
Start Normally automatic calibration is started on a time interval basis by the internal
clock.
Manual Start of the Automatic calibration is performed

Automatic Calibration • Only as zero calibration or
• Only as span calibration or
• As a common zero and span calibration.
For the Caldos25 , Caldos27 , Magnos206 and Magnos27 analyzer modules,
it is not admissible to perform only a span calibration. A zero calibration must
always precede a span calibration.
Proceed as follows to manually start automatic calibration – even outside of the
cycle intervals initialized:
Step Action
1 Select the Automatic Calibration menu:
MENU → Calibrate → Automatic calibration
2 Only zero calibration: ZERO AUTOCAL
Only span calibration: SPAN AUTOCAL
Common zero and span calibration: ZERO & SPAN AUTOCAL
Manual Stop of the The user can end the automatic calibration process by pressing the STOP softkey.
Automatic Calibration
When automatic calibration is stopped, the analyzer module is in an indefinite
state. For instance, it is possible for zero calibration to be finalized while span
calibration has not yet been started.
For this reason, automatic calibration will have to be restarted and allowed to run
to completion after any cancellation of automatic calibration.
Page 343 of 3829

Chapter 8 Status Messages
Status Messages
List Layout The status message list contains the following information:
No. Number of the status message as shown in the detailed display
Text Full text of the status message as shown in the detailed display
O x = Status message sets the overall status
E x = Status message sets the “Error” individual status
M x = Status message sets the “Maintenance Request” individual status
F x = Status message sets the “Maintenance Mode” individual status
Reaction /
Remark Explanations and corrective measures in case of status messages
Page 344 of 3829

Status Messages, continued
No. Text O E M F Reaction /Remark

Runtime Error
1–21 Runtime Error 1 to 21 Notify service if these status messages occur repeatedly.
System Controller
101 System controller shut down For information; shows date and time
at
102 System controller starts up at For information; shows date and time as well as warm start
or cold start
103 Installing Module: For information
104 Removing Module: For information
105 Reactivating Module: For information
106 A user installed module: For information
107 A user removed module: For information
108 A user replaced module: For information
109 A password is active! To Not logged
delete, press the <MEAS> key
on the measurement value
display.
110 System booting. Not logged
111 This system is temporarily Not logged
under remote control!
112 Display/control unit Not logged
synchronizing with analyzer.
Please wait.
113 The system time was changed Not logged
from -> to:
114 The system is saving the
changed parameters. Please
wait!
116 The Profibus Module is x x
mounted on the wrong slot!
The Profibus interface is not
working. Please remount the
Profibus Module on slot
X20/X21.
117 The configuration backup was
saved.
118 The configuration backup was
loaded. The system has been
restarted.
119 The system configuration
could not be loaded! This
system contains no configu-
ration now. Please enter menu
Configure/System/Save confi-
guration to load your backup
configuration. Or use SMT to
re-install your configuration.
Page 345 of 3829


System Bus
201 The selected system bus x x Check plug connections and terminating resistors on the
module could not be found. system bus. Make sure the system bus module serial
number is correctly entered: MENU → Diagnostics/
Information → System overview
203 The selected system bus x x Check plug connections and terminating resistors on the
module does not exist. system bus.
208 The system bus was not able x x The system bus module software version is not compatible
to transfer data into the with that of the system controller; update the system
database. controller software.
209 The system bus connection to x x Check the system bus connection to the indicated module.
this module is interrupted. Check the power supply system of the indicated system
bus module.
210 The system bus module x x For information; the configuration data are automatically
configuration has changed. updated
211 The system bus module has x x Check the system bus module configuration:
no more on-board memory. MENU → Diagnostics/Information → System
overview
214 The system is currently
maintained with Optima SMT.
215 The analyzer module has an x x Notify service.
internal communication error!
216 The analyzer module has an x x Notify service.
internal program error!
Analyzer Modules
300 No new measurement values x x Notify service.
from analog/digital converter.
301 Measurement value exceeds x x Check sample gas concentration. Notify service.
the analog/digital converter
value range.
302 Offset drift exceeds half the x Check analyzer module and sample preparation.
permissible range. Permissible range: 150% of smallest installed measurement
303 Offset drift exceeds x x range; 50% of physical measurement range for Uras26.
permissible range. Notify service when drift exceeds these values.
304 Amplification drift exceeds x Check analyzer module and sample preparation.
half the permissible range. Permissible range: 50% of detector sensitivity.
305 Amplification drift exceeds x x Notify service when drift exceeds these values.
permissible range.
306 The offset drift between two x These messages are generated by automatic calibration.
calibrations exceeds the Check calibration for plausibility. Fix possible cause of
permissible range. implausibility. Perform manual zero (no. 306) or end point
307 The amplification drift x (no. 307) calibration on indicated detector. Permissible
between two calibrations range: 15% of smallest installed measurement range; for
exceeds the permissible measurements in facilities requiring authorization and per
range. 27th and 30th BlmSchV, 6% of smallest installed measure-
ment range.
Page 346 of 3829


308 A computer error occurred x x Notify service.
during calculation of the
measurement value.
309 The temperature regulator is x See the status message from the applicable temperature
defective. detector
310 Temperature correction turned x See the status message from the applicable temperature
off for this component detector
because of invalid
temperature measurement
value.
311 The pressure regulator is x x See the status message from the applicable pressure
defective. detector
312 Pressure correction turned off x See the status message from the applicable pressure
for this component because of detector
invalid pressure measurement
value.
313 Cross-sensitivity correction is x See the status message from the applicable correction
impossible for this component detector
because the correction value
is invalid.
314 Carrier gas correction is x See the status message from the applicable correction
impossible for this component detector
because the correction value
is invalid.
Auxiliary Detector
315 No new measurement values x Notify service.
316 Measurement value exceeds x Notify service.
value range.
317 A computer error occurred x Notify service.
measurement value.
Uras
Caldos, Magnos
319 The measurement bridge is x x Notify service.
improperly balanced.
320 The measurement amplifier x x Notify service.
offset is too high.
Page 347 of 3829


MultiFID
321 The detector temperature is x x Status message during the warm-up phase.
below the lowest permissible If the status message appears after warm-up:
temperature. Check the thermal link and replace as needed (see the
MultiFID14 analyzer module start-up and maintenance
manual, publication number 41/24-105 EN).
322 The flame is out. x x Status message during the warm-up phase.
If the status message appears after warm-up:
Check the gas supply.
323 The analyzer is in the fail-safe x x Inadequate combustion gas supply; turn power supply off
state. and back on after ≥ 3 seconds.
Notify service.
Temperature Regulator
324 Temperature above or below x Status message during the warm-up phase.
upper and/or lower limit If the status message appears after warm-up:
value 1. Check if the permissible ambient temperature range is
325 Temperature above or below x being maintained (see page 10-Fehler! Textmarke nicht
upper and/or lower limit definiert.). Check the analyzer module thermal link and
value 2. replace if necessary.
Pressure Regulator
327 Measurement value exceeds x x Notify service.
value range.
328 A computer error occurred x x Notify service.
measurement value.
329 Pressure above or below x MultiFID14: Check the supply gas pressure.
upper and/or lower limit
value 1.
330 Pressure above or below x MultiFID14: Check the supply gas pressure.
value 2.
331 The pressure regulator control x x MultiFID14: Check the supply gas pressure.
variable is beyond the valid
range.
I/O Devices
332 Accessory voltage defect on x x Defective I/O board. Replace the board.
I/O board.
333 Unavailable I/O type x x Correct the configuration with the test and calibration
configured. software.
334 No new measurement values x x Defective I/O board. Replace the board.
335 Measurement value exceeds x x Check signals at analog inputs.
the analog/digital converter If OK, check the configuration and calibration of the analog
value range. inputs.
Page 348 of 3829


336 A computer error occurred x x Check the configuration and calibration of the analog
during calculation of the inputs and outputs.
measurement value.
337 Broken analog output line. x x Check the analog output lines.
338 Broken digital input line x x Check the moisture sensor in the system cooler.
(moisture sensor).
339 Broken or shorted analog x x Check system cooler temperature.
input line.
340 Analog input value above or x Check system cooler temperature.
below upper or lower limit
value 1.
341 Analog input value above or x Check system cooler temperature.
below upper or lower limit
value 2.
Flow Monitor (Gas Module)
342 Flow rate under limit value 1. x Check sample preparation.
Limit value 1 = 25% MRS.
343 Flow rate under limit value 2. x x Check sample preparation.
Limit value 2 = 10 % MRS.
Automatic calibration is interrupted and locked out.
Measurement Value
344 Value above measurement Value > +130 % MRS, not logged
value range.
345 Value below measurement Value < –100 % MRS, not logged
value range.
Limas
356 Analyzer in warm-up phase. x x Status message during warm-up phase.
If the status message appears after warm-up, a temperature
error has occurred in the lamp or in the sample cell or in the
measurement or reference detector amplifier. Notify service.
357 Limas motor optimization in x x Status message after warm-up phase
progress.
358 Lamp intensity above or below x Lamp intensity has fallen to 10% of Init value. Check the
middle of permissible range. intensity values in the Diagnostics/Test → Module
specific → Lamp Intensity menu.
If all four values have fallen by about the same amount
compared to the Init values, the cause is reduced lamp
intensity. The lamp should soon be replaced. If only the
two measurement detector values have dropped, the
cause is probably a contaminated sample cell. Clean the
sample cell or exchange it.
359 Lamp intensity above or below x x Lamp intensity has fallen to 5% of Init value. Check the
permissible range. intensity values in the Diagnostics/Test → Module
specific → Lamp Intensity menu. If all four values
have fallen by about the same amount compared to the Init
values, the cause is reduced lamp intensity. Replace the
lamp and perform an amplification optimization.
Page 349 of 3829


360 Filter wheel 1 cannot be x x Notify service.
initialized.
361 Filter wheel 2 cannot be x x Notify service.
initialized.
362 The calibration filter wheel x x Notify service.
cannot be initialized.
363 The Limas analyzer board x x Notify service.
cannot be initialized.
364 A new lamp is installed and For information
the amplifiers settings are
optimized.
365 The LIMAS amplifiers settings For information
are optimized.
LS25
366 The LS25 analyzer has an x x
error.
367 The LS25 analyzer has a x x
maintenance request.
368 The LS25 analyzer starts x x
measurement.
369 LS25 analyzer detector error # x x
370 The beam transmission x Low transmission
exceeds the permissible
range.
371 The temperature input signal x T out of range
range.
372 The pressure input signal x P out of range
range.
373 The flow sensor signal x
range.
374 The detector signal is too low x x Laser line-up error
for measurement.
375 The input current loop x x T-read error, P-read error
(4-20mA) has an error.
376 This LS25 module is under x x Communication with service software via RS232. No
maintenance. measured values are transferred.
Uras
378 Chopper wheel jammed. x x Notify service.
379 Chopper wheel speed not OK. x x Notify service.
380 IR radiator or electronics x x Notify service.
faulty.
381 High voltage at preamplifier x x Notify service.
faulty.
Page 350 of 3829


382 Meas. value is influenced by x x
shock.
Flow Controller
398 No new measuring values x x Notify service.
399 The measuring value exceeds x x Check sample gas concentration. Notify service.
the range of the analog/digital-
converter.
400 A calculation error occurred x x Notify service.
measurement value.
401 The flow exceeds upper or x Check sample gas path. Notify service.
lower limit 1.
402 The flow exceeds upper or x x Check sample gas path. Notify service.
lower limit 2.
403 The controller output value is x x Notify service.
out of range.
ZO23
404 Temperature above or below x x Notify service.
value 2.
405 A ZO23 function test has been For information
performed:
406 This ZO23 analyzer has failed x Change test factor or check cell with test gas.
the function test!
407 A ZO23 function test is x
running.
408 The ZO23 function test is x Keep sample gas concentration constant or use test gas.
canceled!
Calibration
500 System bus communication
defect.
501 Requested function is not Check the analyzer module software version and perform
available on the system an update if needed.
module.
502 A system error occurred in the Calibration is interrupted.
system module addressed. Notify service.
503 Amplification error during x Calibration is interrupted.
calibration. Calibration Insufficient span gas concentration – Check.
impossible.
507 A combination of the following
errors occurred: Half Drift
Limit, Drift Limit, Amplification
or Delta Drift.
508 Unknown error number. Check Message during automatic calibration. Check analyzer
software versions. module and system controller software versions.
Page 351 of 3829


509 Automatic calibration started. For information
510 Automatic calibration ended. For information
511 Automatic calibration For information
externally interrupted.
512 Automatic calibration in x For information, not logged
progress.
513 System bus communication
defect during automatic
calibration.
514 External calibration started. For information
515 External calibration ended. For information
516 External calibration in x For information, not logged
progress.
517 Device being serviced. x For information, e.g. during manual calibration, not logged
518 The calibration could not be
done, because the value is not
stable.
519 Preamplifier overflow error:
Calibration could not be
performed because of
preamplifier override.
520 Initial zero calibration started. For information
521 Initial zero calibration ended. For information
522 Initial zero calibration For information
interrupted.
523 Initial zero calibration For information
incomplete. System bus
communication defect during
calibration.
524 Initial zero calibration in x For information, not logged
progress.
525 Linearization impossible: See message text
Linearization did not produce
a valid result. Measurement
value possibly inaccurate.
Check center point gas.
526 Linearization impossible: See message text
Linearization could not be
performed Ie the characteristic
is linear.
527 Initial calibration for For information
component:
528 Autocalibration not started Ie For information
manual calibration was
running.
Page 352 of 3829


529 Calibration stopped because x x
no raw measurement values
were found.
530 Calibration stopped because x x
the pressure switch did not
detect any calibration gas.
531 Automatic validation started. For information
532 Automatic validation ended. For information
533 Automatic validation externally For information
interrupted.
534 Automatic validation in x For information, not logged
progress.
535 Automatic validation
successful for:
536 Automatic validation out of
limits for:
537 Automatic validation out of x
limits for:
User-Configured Messages
800 An external error occurred x x These Message Generator function block default texts are
during: supplemented with the text prepared during function block
801 A user-defined error occurred x x configuration.
during:
802 A user-defined maintenance x
requirement occurred during:
803 A user-defined maintenance x
mode event occurred during:
Miscellaneous Messages
1000 This function block has an x x Supplemented with a reference to the function block type.
error:
1001 Condensate penetration. Overall message for guiding reaction to condensate
penetration; not logged
1002 Flow rate excessive at this x x Currently not used
point.
1003 Flow rate inadequate at this x x Currently not used
point.
Page 353 of 3829


System Cooler
1100 Cooler temperature too high. x x Sample gas feed module pump is automatically turned off.
1101 Cooler temperature too low. x x Check the system cooler and sample gas preparation.
1102 Condensate penetration in x x
cooler.
1103 Flow rate inadequate in cooler. x Check the system cooler and sample gas preparation.
1104 Cooler condensate level too x
high.
1105 Cooler condensate level too x Empty the condensate bottle.
high.
1106 Cooler reagent level too low. x Fill the reagent container.
Page 354 of 3829

Appendix ZO23 Trace Oxygen Analyzer Module
Safety Information
WARNING!
The analyzer module must not be used for measurement of ignitable gas/air
or gas/oxygen mixtures. The concentration of flammable gases in the sample
gas must not exceed 100 ppm.
The presence of corrosive gases and catalyst poisons, e.g. halogens,
sulfurous gases and heavy-metal dusts, results in faster aging and/or the
destruction of the measuring cell.
The ingress of liquids into the analyzer module can lead to serious damage
including the destruction of the measuring cell.
After disconnection of the power supply, the case of the measuring cell has
an excess temperature of approx. 95 °C, which decreases only slowly.
Intended Application The trace oxygen analyzer module ZO23 is intended for the continuous measure-
ment of the oxygen concentration in pure gases (N2, CO2, Ar).
Please refer to the “Information for the Installation and Sample Conditioning” (see
page 82).
Page 355 of 3829

Requirements at the Installation Site
Ambient Temperature +5 to +45 °C with installation in a system housing with an electronics module
Heat Sources and No heat sources or instruments which generate strong magnetic fields (e.g. elec-
Magnetic Fields tric motors or transformers) may be located in the proximity of the installation site.
Sample Gas Inlet Conditions
Conditions at the Temperature: +5 to +50 °C

Sample Gas Inlet of
Pressure: 2 to 20 hPa positive pressure
the Gas Analyzer
Sample Gas 5 to 10 l/h. The flow rate must be kept constant to ±0.2 l/h in this range. The flow
Flow Rate rate is kept constant to 8 ± 0.2 l/h with integrated pump and flow control. The
sample gas must be taken from a bypass at zero pressure.
If the sample gas flow rate is too low, contaminants from the gas lines (leaks,
permeability, desorption) will adversely affect the measuring result.
If the sample gas flow rate is too high, asymmetrical cooling of the sensor may
cause measuring errors. This can also cause faster aging or damage to the
measuring cell.
Flammable and The analyzer must not be used for measurement of ignitable gas/air or gas/oxygen
Corrosive Gases mixtures. The concentration of flammable gases in the sample gas must not
exceed 100 ppm.
The presence of corrosive gases and catalyst poisons, e.g. halogens, sulfurous
gases and heavy-metal dusts, results in faster aging and/or the destruction of the
measuring cell.
Associated Gas Inert gases (Ar, CO2, N2) have no effect. Flammable gases (CO, H2, CH4) in
Effect stoichiometric concentrations to the oxygen content: Conversion of O2 < 20 % of
the stoichiometric conversion. If higher concentrations of flammable gases are
present, higher O2 conversions must be expected.
Page 356 of 3829

Test Gases
Test Gases Reference point Clean ambient air; its oxygen concentration is established
(= electrical zero): from the value for dry air and the factor for consideration of
the water vapor content
Example:
Water vapor content at 25 °C and 50 % relative humidity
= 1.56 % Vol. O2 ⇒ Factor = (100 % – 1.56 %) / 100 % = 0.984
O2 concentration = 20.93 % Vol. O2 × 0.984 = 20.6 % Vol. O2
End-point: Test gas with oxygen concentration in the smallest measuring
range (e.g. 2 ppm O2 in N2)
Note The pressure conditions at reference point and end point must be identical!
Connection Diagram
Figure 31
Connection Diagram
8 7
2 1
1 Sample gas inlet (3 mm Swagelok®) 7 Housing purge gas inlet 1)

2 Sample gas outlet (1/8 NPT female thread for 8 Housing purge gas outlet 1)
®
commercially available adapter, e.g. Swagelok ) 1) only in IP54 version
Page 357 of 3829

Information for the Installation and Sample Conditioning
Figure 32
ZO23 with 30 l/h 8 ± 0.2 l/h
Internal Pump and
Flow Sensor:
≥3m
NW4
Example of Sample
≥3m
NW4
F 5
Conditioning
NW2
ZrO2
6
4 7
1
9
8
NW2
Reference Air /
Referenzluft
11 12 13 Stainless Steel Tube / Edelstahlrohr

N2 O2/N2 O2/N2
2 ppm 8 ppm FPM Hose / FPM-Schlauch
Figure 33
ZO23 without 30 l/h 8 ± 0.2 l/h
Internal Pump and
≥3m
NW4
Flow Sensor: F F
5 10
Example of Sample
≥3m
NW4
Conditioning
NW2
ZrO2
4
1
9
NW2
3
2
Reference Air /
Referenzluft
8 14 15
11 12 13 Stainless Steel Tube / Edelstahlrohr

N2 O2/N2 O2/N2
2 ppm 8 ppm FPM Hose / FPM-Schlauch
Page 358 of 3829

Information for the Installation and Sample Conditioning, Continued
Legend for Figures 1 Sampling point with primary 8 Air filter 1)

32 and 33 shut-off valve 9 Gas analyzer
2 Multi-way ball valve 10 Flow meter without needle valve, with alarm
3 3-way ball valve 1) contact
4 Fine-control valve 11 Test gas cylinder with N2 1)
5 Flow meter with needle 12 Test gas cylinder with e.g. 2 ppm O2 in N2 2)
valve and alarm contact 13 Test gas cylinder with 8 ppm O2 in N2 1)
6 2-way ball valve 1) 14 Pump 1)
7 2-way ball valve 1) 15 Needle valve 1)
1) Option
2) A hard-mounted test gas cylinder is normally adequate. The annual check of
the reference point can also be carried out by means of a non-stationary air
supply.
The following information for installation and sample conditioning has to be

observed when executing measurement and controlled calibration (manual,
automatic and externally controlled calibration). Manually operated valves have to
be replaced by controlled valves which are suitable for trace oxygen measurement
if required.
Gas Sampling The nominal diameter of the line from the sampling point to the first switch-over
valve should be 4 mm.
A bypass can be placed upstream of the first switch-over valve to obtain a faster
analysis. With a nominal diameter of 4 mm, the bypass should be longer than 3 m
to prevent back diffusion from the ambient air.
The sample gas pressure must be reduced at the sampling point. A heated adjust-
able pressure regulator is also to be provided if samples are taken from liquid gas
lines.
Sample Gas The sample gas supply line must consist of stainless steel tubing, be as short as
Supply Line possible and have the fewest joints possible.
The diameter of tube from the beginning of the first switch-over valve should be
3 mm externally and 2 mm internally. The sample gas connection to the gas ana-
lyzer is specified for a tube with an external diameter of 3 mm. Swagelok® fittings
should be used for the connections.
The trace oxygen analyzer module ZO23 may not be series-connected to other
ZO23 analyzer modules or other gas analyzers.
For the gas analyzer version without internal pump and flow sensor, a fine-control
valve must be provided to set the flow (see section “Sample Gas Flow Rate”,
page 80). The primary pressure must be kept constant in order to obtain a stable
flow rate.
Gas Outlet Line Flexible tubing can be used for the gas outlet line. With a nominal diameter of
4 mm, its length should be more than 3 m to prevent back diffusion from the
ambient air.
Page 359 of 3829

Information for the Installation and Sample Conditioning, Continued
Bypass The gas analyzer is connected to a constant gas flow (approx. 40 l/h) in the
bypass. The needle valve is installed upstream of the branch to the gas analyzer,
and the bypass flow meter downstream of the branch to the gas analyzer.
The gas analyzer takes 8 l/h from the gas flow. There is a surplus of approx. 30 l/h.
If several ZO23 analyzer modules are supplied with gas in parallel (redundant
measurement), the flow must be set in such a way that the bypass has a surplus
of 30 l/h.
With a nominal diameter of 4 mm, the exhaust gas line from the outlet of the gas
analyzer should be longer than 3 m to prevent back diffusion from the ambient air.
On account of possible leaks, the flow meters are always placed in the bypass
feed path downstream of the branch to the gas analyzer, respectively, downstream
of the gas analyzer; they may on no account be installed in the sample gas supply
line upstream of the measuring cell.
Exhaust Gas The sample gas and the bypass must be conducted to the atmosphere or to an
unpressurized exhaust gas collecting system at an adequate distance from the
gas analyzer. Long conduction paths and pressure variations must be avoided.
For measurement and safety-related reasons, sample gas and bypass may not be
discharged into the atmosphere in the proximity of the gas analyzer, since the
ambient air serves as reference air, and also in order to exclude asphyxiation as a
result of oxygen deficiency. It must be ensured that any exhaust gas which gets
into respiratory air is sufficiently diluted.
Start-Up
Gas Analyzer Step Action

Start-Up Procedure, 1 Switch on the power supply to the gas analyzer.
Initial Calibration at After approx. 15 minutes, the measuring cell has reached its
the Installation Site operating temperature. If required, the gas analyzer can be
calibrated at the reference point (see step 3) and the end-point
(see step 5) before measurement is started.
2 For setting the reference point (= electrical zero), feed ambient air
(flow rate see page 80) and wait until the measured value has
stabilized (duration approx. 2 hrs).
Meanwhile, purge the test gas valves and the gas supply line with
oxygen-free gas (e.g. with nitrogen from a loop feeder) or with sample
gas (flow rate 5 to 10 l/h).
3 Set reference point to 20.6 % Vol. O2. Please refer to page 81 for
calculation of the oxygen concentration.
4 Feed end-point gas (e.g. 2 ppm O2 in N2) and wait until the measured
value has stabilized (duration max. 2 hrs).
5 Set end-point value in accordance with the certificate of analysis of
the test gas cylinder used.
6 The gas analyzer is ready for performing measurements; feed sample
gas.
Page 360 of 3829

Page 361 of 3829
ABB has Sales & Customer Support expertise The Company’s policy is one of continuous product
in over 100 countries worldwide. improvement and the right is reserved to modify
the information contained herein without notice.
www.abb.com
41/24100 EN Rev. 6
Printed in the Fed. Rep. of Germany (03.09)
© ABB 2009
ABB Automation GmbH

Analytical
Stierstaedter Strasse 5
60488 Frankfurt am Main
Germany
Phone: +49 69 793040
Fax: +49 69 79304566
EMail: analyticalmkt.deapr@de.abb.com
Page 362 of 3829

User Guide OI/TB82PH/ATEX–EN Rev. E
Type TB82PH Advantage SeriesTM

2-wire pH/ORP/pION transmitter
Page 363 of 3829

TB82PH ATEX Product Instruction Manual ABB
CONTENTS USE OF INSTRUCTIONS
Section Page
Warning.
An instruction that draws attention to the
CONTENTS.......................................................................2
risk of injury or death.
USE OF INSTRUCTIONS .................................................2
INTRODUCTION...............................................................3
PRODUCT IDENTIFICATION ...........................................3
EUROPEAN ATEX DIRECTIVE INFORMATION..............4 Caution.
TRANSMITTER MOUNTING DETAILS...........................12 An instruction that draws attention to the
ELECTRICAL CONNECTIONS - Power Wiring ..............13 risk of damage to the product, process or
SENSOR CONNECTIONS – Model TB5 & TBX5 surroundings.
Sensor Connections ....................................................14
OPERATING PROCEDURES .........................................16
Note.
Commissioning the Instrument ..................................16
Clarification of an instruction or additional
Flow Chart For Basic Operation Mode.......................17
information.
CONFIGURE MODE .......................................................18
Flow Chart For Advanced Mode ................................20
CALIBRATE MODE.........................................................21 Information.
OUTPUT/HOLD MODE ...................................................21 Further reference for more detailed
SECURITY MODE ..........................................................22 information or technical details.
SECONDARY DISPLAY MODE......................................22
MAINTENANCE ..............................................................22
DISMANTLING AND RE-ASSEMBLY .............................23
SPECIFICATIONS ..........................................................24 Although Warning hazards are related to personal injury,
and Caution hazards are associated with equipment or
property damage, it must be understood that operation of
damaged equipment could, under certain operational
conditions, result in degraded process system
performance leading to personal injury or death.
Therefore, comply fully with all Warning and Caution
notices.
Information in this manual is intended only to assist our

customers in the efficient operation of our equipment. Use
of this manual for any other purpose is specifically
prohibited and its contents are not to be reproduced in full
or part without prior approval of Technical
Communications Department, ABB Inc.
Health and Safety

To ensure that our products are safe and without risk to health, the following points must be noted:
1. The relevant sections of these instructions must be read carefully before proceeding.
2. Warning labels on containers and packages must be observed.
3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in
accordance with the information given.
4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in
conditions of high pressure and/or temperature.
5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal
safe handling procedures must be used.
6. When disposing of chemicals ensure that no two chemicals are mixed.
Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets
(where applicable) may be obtained from the Company address on the back cover, together with servicing and
spares information.
2 TB82PH-ATEX-EN-C
Page 364 of 3829
ABB TB82PH ATEX Product Instruction Manual
INTRODUCTION PRODUCT IDENTIFICATION

This manual describes the installation, safe usage, The data plates shown in Figure 1 identify the instrument.
commissioning, adjustment, and maintenance procedures The Nameplate (Reference A) provides information
related to the Analog versions of the TB82PH and concerning the product identity code (i.e., nomenclature),
ML82PH pH/ORP/pION Product Family. product name, operating voltage range, output type, serial
number, test personnel badge number, and dielectric
strength verification stamp.
The Agency Approval label (Reference B) is included

when the transmitter is purchased for compliance with
hazardous area regulations (e.g., intrinsic safety
protection) for a specific country (e.g., CSA, FM, or
ATEX).
EC conformance is identified using a CE label (Reference

C). Optional tagging, as specified by customer
requirements, is provided via an additional tag. (Reference
D)
9716 S. VIRGINIA ST. 82 TWO-WIRE TRANSMITTER SERIES

SUITE E
RENO, NV 89521
Reference C - EC Conformance Label

INTRINSICALLY SAFE EEx ia IIC T4
II 1G
CENELEC
LCIE 02 ATEX 6115 X
0344

SUITE E
RENO, NV 89521
NONINCENDIVE T5
CLASS I; DIVISION 2; GROUPS A, B, C, D
NEMA 4X CLASS II; DIVISION 2; GROUPS F, G
CLASS III 9716 S. VIRGINIA ST.
SUITE E
82 TWO-WIRE TRANSMITTER SERIES
INTRINSICALLY SAFE T3C

RENO, NV 89521

INTRINSICALLY SAFE EEx ia IIC T4
II 1G
CLASS II; DIVISION 1; GROUPS E, F, G CENELEC
APPROVED CLASS III

LCIE 02 ATEX 6115 X
0344
WHEN CONNECTED PER DRAWING P0807

Vmax=42V Imax=250mA Ci=0 Li=0mH
MAX. AMBIENT TEMPERATURE: 60 C
OUTPUT TO SENSORS IS SUITABLE FOR NONINCENDIVE FIELD
WIRING WHEN USED WITH ABB SENSORS PER DRAWING P0807

SUITE E
RENO, NV 89521

Reference D - Optional Tag
TYPE 4X CLASS II; DIVISION 2; GROUPS E, F, G
CLASS III
INTRINSICALLY SAFE Exia T3C Product Nomenclature
CLASS I; DIVISION 1; GROUPS A, B, C, D X Signify Product Options
CLASS II; DIVISION 1; GROUPS E, F, G TAG
CLASS III
WHEN CONNECTED PER DRAWING P0806 Reno, NV.
Vmax=24V Imax=250mA Ci=0 Li=0mH

TB82PHX2XXXXX
OUTPUT TO SENSOR IS SUITABLE FOR NONINCENDIVE FIELD WIRING FOR
CLASS I LOCATIONS WHEN USED WITH ABB SENSORS PER DRAWING P0806
TB82PHX2XXXXX 9 - 32 Vdc, Profile Type 113
RENO, NV U.S.A Phone 775-850-4800
9 - 32 Vdc, Profile Type 113

Reference B
RENO, NV U.S.A Phone 775-850-4800
Product Nameplate is for Foundation Fieldbus

Product Variation and is only shown for
reference purposes.
Reference A
Figure 1 – Product Identification

Labels are shown for information only
Refer to ATEX Certificate for electrical parameters
TB82PH-ATEX-EN-C 3
Page 365 of 3829
EUROPEAN ATEX DIRECTIVE INFORMATION
Special conditions for safe use
The TB82/ML82 product variations can be installed in explosive atmospheres designated by the product labeling. These
product variations must only be combined with an associated, certified intrinsically safe apparatus. This combination must
be compatible as far as intrinsic safety is concerned (See section A6 of the following ATEX certificate). Temperature
Class T4 corresponds to an ambient temperature range from –20°C to +60°C.
Deutsch
1 EG-TYPENPRÜFUNGSZERTIFIKAT
2 Gerät oder Schutzsystem für den Einsatz in potenziellen
Ex-Bereichen
Richtlinie 94/9/EG
3 Nummer des EG-Typenprüfungszertifikats: LCIE 02 ATEX
6115 X
4 Gerät oder Schutzsystem: pH- oder Leitfähigkeits-
Messumformer,
Typ: TB82…/ML82…
5 Antragsteller:
6 Adresse:
7 Dieses Gerät oder Schutzsystem und alle akzeptablen
Varianten werden in der Anlage dieses Zertifikats und in
den dort genannten Dokumenten angegeben.
8 LCIE, Benannte Stelle Nr. 0081 gemäß Artikel 9 der
Richtlinie 94/9/EG des Europäischen Parlaments und Rats
vom 23. März 1994, bestätigt hiermit, dass dieses Gerät
oder Schutzsystem die grundlegenden Gesundheits- und
Sicherheitsanforderungen an die Konstruktion und den
Aufbau des Geräts oder Schutzsystems erfüllt, das für den
Einsatz in potenziellen Ex-Bereichen nach Anhang II dieser
Richtlinie vorgesehen ist. Die Prüfung und die
Testergebnisse sind im vertraulichen Bericht Nr. 41 023
010 festgehalten.
9 Die Erfüllung der grundlegenden Gesundheits- und
Sicherheitsanforderungen wurde gemäß der folgenden
Richtlinien festgestellt: - EN 50014 (1997) + Anhang 1 und
2, - EN 50020 (1994)
10 Wenn die Zertifikatsnummer auf den Buchstaben „X“ endet,
bedeutet dies, dass das Gerät oder Schutzsystem den
besonderen Bedingungen für den sicheren Einsatz gemäß
der Anlage dieses Zertifikats unterliegt.
11 Dieses EG-Typenprüfungszertifikat erstreckt sich
ausschließlich auf die Konstruktionsprüfung und die
Prüfung des genannten Geräts oder Schutzsystems gemäß
Richtlinie 94/9/EG.
Das Fertigungsverfahren und die Lieferung dieses Geräts
oder Schutzsystems unterliegen weiteren Anforderungen
der Richtlinie, die durch dieses Zertifikat nicht abgedeckt
werden.
12 Die Kennzeichnung des Geräts oder Schutzsystems muss
Folgendes enthalten: Ex II 1 G, EEx ia IIC T4
Español
1 CERTIFICADO DE EXAMEN DE TIPO CE

2 Equipo o sistema de protección para uso en atmósferas potencialmente explosivas: Directiva 94/9EC
3 Número de certificado de examen de tipo CE: LCIE 02 ATEX 6115 X
4 Equipo o sistema de protección
transmisor de pH o de conductividad: Tipo: TB82…/ML82…
5 Solicitante:
6 Dirección:
7 Este equipo o sistema de protección y cualquier variación aceptable del mismo se especifica en el anexo al presente certificado y en los documentos
a los que se hace referencia en el mismo.
8 El LCIE, organismo notificado número 0081, de acuerdo con el artículo 9 de la directiva 94/9/EC del Parlamento Europeo y el Consejo del 23 de
marzo de 1994, certifica que este equipo o sistema de protección cumple con los Requisitos Esenciales de Salud y Seguridad relacionados con el
diseño y la fabricación de equipos y sistemas de protección para uso en atmósferas potencialmente explosivas, en virtud del Anexo II de la directiva.
El examen y los resultados de las pruebas han sido registrados en el informe confidencial No. 41 023 010.
9 El cumplimiento con los Requisitos Esenciales de Salud y Seguridad se ha asegurado con el cumplimiento de las normas: -EN 50014 (1997) +
enmiendas 1 y 2, -EN 50020 (1994)
10 Si el signo X aparece después del número de certificado, indica que el equipo o sistema de protección se encuentra sujeto a condiciones especiales
para su uso seguro especificado en el anexo al presente certificado.
11 El presente certificado de examen de tipo CE se refiere únicamente al examen de diseño y a las pruebas del equipo o sistema de protección
especificado de acuerdo con la directiva 94/9/EC.
Otros requisitos de la Directiva se aplican al proceso de fabricación y suministro de este equipo o sistema de protección. El presente certificado no
cubre dichos requisitos.
12 Las marcas identificatorias del equipo o sistema de protección deben incluir lo siguiente: Ex II 1 G, EEx ia IIC T4
4 TB82PH-ATEX-EN-C
Page 366 of 3829
Deutsch
(A1) ANLAGE
(A2) EG-TYPENPRÜFUNGSZERTIFIKAT
LCIE 02 ATEX 6115 X
(A3) Beschreibung des Geräts oder Schutzsystems
Die Messumformer TB82... oder ML82... liefern ein

Ausgangssignal von 4 bis 20 mA als Reaktion auf die Ausgabe
des angeschlossenen pH-Sensors (xx82PH) oder des
Leitfähigkeitssensors mit vier Elektroden (xx82EC) oder des
Leitfähigkeitssensors mit zwei Elektroden (xx82TE) oder des
Toroidal-Leitfähigkeitssensors (xx82TC). Das HART-
Datenübertragungsprotokoll kann dem 2-Leiter-Regelkreis
überlagert werden. Die Modelle ML82 sind elektronisch mit den
Modellen TB82 identisch; der Unterschied liegt in der Software.
Die Modellausführungen werden in der Beschreibung näher
erläutert.
Die Kennzeichnung lautet wie folgt:

ABB Inc.
Adresse: …
Typ: TB82…/ML82…
Seriennummer
Herstellungsjahr
Ex II 1 G
EEx ia IIC T4
LCIE 02 ATEX 6115 X
Das CE-Zeichen muss mit der ID-Nummer der benannten Stelle

versehen sein, die für die Überwachung des Qualitätssystems
zuständig ist (0081 für LCIE).
Das Gerät muss außerdem mit den üblichen Kennzeichnungen

gemäß den einschlägigen Fertigungsstandards für solche Geräte
versehen sein.
(A4) Dokumente mit Beschreibungen:
Technische Datei Nr. A27-TB82ATEX-ER02-002A.

Diese Datei umfasst 43 Punkte (97 Seiten).
Español
(A1) ANEXO
(A2) CERTIFICADO DE EXAMEN DE TIPO CE
LCIE 02 ATEX 6115 X
(A3) Descripción del equipo o sistema de protección
Los transmisores TB82… o ML82… proporcionan una señal de salida de 4-20 mA como respuesta a la salida del sensor de pH conectado (xx82PH) o del
sensor de conductividad de cuatro electrodos (xx82EC) o del sensor de conductividad de dos electrodos (xx82TE) o del sensor de conductividad toroidal
(xx82TC).Pueden configurarse para el protocolo de comunicación HART superpuesto sobre el lazo de 2 hilos. Los modelos ML82 son electrónicamente
idénticos a los modelos TB82, la única diferencia radica en el software. Remítase a las notas descriptivas para verificar el significado de modelo.
Las marcas identificatorias son las siguientes:

ABB Inc
Dirección:…
Tipo: TB82…/ML82…
Número de serie
Año de fabricación
Ex II 1 G
EEx ia IIC T4
LCIE 02 ATEX 6115 X
La marca identificatoria CE estará acompañada por el número de identificación del organismo notificado responsable de la supervisión del sistema de
calidad (0081 para el LCIE).
El equipo también debe presentar las marcas identificatorias convencionales requeridas por las normas de fabricación que se aplican a dichos equipos.
(A4) Documentos descriptivos:
Archivo técnico n° A27-TB82ATEX-ER02-002A.

Este archivo comprende 43 elementos (97 páginas).
TB82PH-ATEX-EN-C 5
Page 367 of 3829
Deutsch
(A1) ANLAGE
(A2) EG-TYPENPRÜFUNGSZERTIFIKAT
LCIE 02 ATEX 6115 X (Fortsetzung)
(A5) Besondere Bedingungen für den sicheren Einsatz
Das oben definierte eigensichere Gerät kann in Ex-Bereichen

aufgestellt werden.
Eine Kombination des Geräts ist ausschließlich mit einem
zugehörigen, ebenfalls eigensicheren, zertifizierten Gerät
zulässig. Diese Kombination muss zudem im Hinblick auf die
Eigensicherheit kompatibel sein (siehe (A6)).
Die Temperaturklasse T4 bezeichnet einen
Umgebungstemperaturbereich von –20 °C bis +60 °C.
Die nachstehenden Sensoren sind für den Anschluss an den

Klemmenblock TB2 vorgesehen.
TB82PH/ML82PH
Kombinierte pH-Sensoren der Advantage-Serie:
Kombinierte pH-Sensoren mit Festkörperreferenz:
Externe Thermokompensator-Sensoren:
TB82EC/ML82EC
Leitfähigkeitssensoren mit vier Elektroden:
TB82TE/ML82TE
Leitfähigkeitssensoren mit zwei Elektroden:
TB82TC/ML82TC
Toroidal-Leitfähigkeitssensor:
(A6) Grundlegende Gesundheits- und Sicherheitsanforderungen
Die Konstruktion des Geräts entspricht den europäischen

Normen EN 50014 (1997) + Anhang 1 und 2 sowie EN 50020
(1994).
Spezielle Parameter für den oder die betroffenen Schutzarten:
Individuelle Prüfungen und Tests:

Keine
Español
(A1) ANEXO
(A2) CERTIFICADO DE EXAMEN DE TIPO CE
LCIE 02 ATEX 6115 X (continuación)
(A5) Condiciones especiales para la utilización segura
Los aparatos intrínsecamente seguros descritos anteriormente pueden instalarse en atmósferas explosivas.
El aparato debe combinarse únicamente con aparatos asociados intrínsecamente seguros, certificados, y dicha combinación debe ser compatible en lo que
respecta a la seguridad intrínseca. (ver (A6)).
La clase de Temperatura T4 corresponde a un rango de temperatura ambiente de entre –20ºC y +60ºC.
Los siguientes sensores son aptos para la conexión con el bloque terminal TB2.
TB82PH/ML82PH
Sensores de la serie Advantage Combinación de sensores de pH
Referencia de estado sólido Combinación de sensores de pH
Sensor termocompensador externo
TB82EC/ML82EC
Sensores de conductividad de cuatro electrodos:
TB82TE/ML82TE
Sensor de conductividad de dos electrodos:
TB82TC/ML82TC
Sensor de conductividad toroidal:
(A6) Requisitos Esenciales de Salud y Seguridad
El diseño del equipo cumple con las normas europeas EN 50014 (1997 + enmiendas 1 y 2) y EN 50020 (1994).
Parámetros específicos de los modos de protección involucrados:
Exámenes y pruebas individuales:

Ninguno.
6 TB82PH-ATEX-EN-C
Page 368 of 3829
TB82PH-ATEX-EN-C 7
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8 TB82PH-ATEX-EN-C
Page 370 of 3829
TB82PH-ATEX-EN-C 9
Page 371 of 3829
10 TB82PH-ATEX-EN-C
Page 372 of 3829
TB82PH-ATEX-EN-C 11
Page 373 of 3829
TRANSMITTER MOUNTING DETAILS
PIPE
MOUNT 3/8"
Warning. BRACKET LOCKWASHER (4)
For installation in Hazardous

Areas, i.e. areas with danger
3/8"
FLATWASHER (4)
of fire and/or explosion,

irrespective of the protection
mode used, the installation
must carried out in accordance Pipe
with local authority regulations.

5/16" U-BOLT (2)
Ensure also that the tem-
perature of the transmitter
does not exceed the value 5/16"
NUT (4)
indicated in the Agency
Approval Label. 3/8" X 5/8"
5/16"
5/16"
LOCKWASHER (4)
BOLT (4)
FLATWASHER (4)
Figure 3 – Pipe Mounting Detail
Note.
When mounting the trans-
mitter, choose a location that
has ample clearance for the TOP VIEW FRONT VIEW
removal of the front bezel and FASTENERS FOR

WALL (SUPPLIED BY
S.S. HINGE 3/8"
FLATWASHER (4)
rear cover. The location OTHERS) 3/8" X 3/4"

BOLT (8)
should provide easy access
for maintenance procedures
and not be in a highly cor-
rosive environment. Excessive
mechanical vibrations and PIPE MOUNT
shocks as well as relay and WALL BRACKET
power switches should not be "L" BRACKET
in the immediate area. Signal 3/8"

LOCKWASHER (8)
wiring should not be placed in 3/8" NUT (8)

3/8"
FLATWASHER (8)
3/8" X 5/8" 3/8"
BOLT
conduit or open trays that
LOCKWASHER (4)
contain power wiring for heavy

electrical equipment.
Figure 4 – Hinge Mounting Detail
Caution. PIPE
Besides the normal MOUNT

BRACKET
3/8"
precautions for storage and FLATWASHER (4)
handling of electronic equip- FASTENERS FOR WALL
ment, the transmitter contains (SUPPLIED BY OTHERS)
static sensitive devices. Since

semiconductors can be
WALL
damaged by the direct WALL
discharge of static electricity,

avoid contact with terminal
block conductors and elec-
tronic components on the
circuit board.
3/8" X 5/8" 3/8"
BOLT (4) LOCKWASHER (4)
Figure 5 – Wall Mounting Detail
12 TB82PH-ATEX-EN-C
Page 374 of 3829
9.5 MAXIMUM PANEL

PANEL
0.38 THICKNESS
CUTOUT
PANEL MOUNTING
+1.3 PANEL MOUNTING SCREWS (4)
135.4 –0.8 BRACKET (4)
+0.05
5.33 –0.03
135.4 +1.3
–0.8 REAR COVER
+0.05 REMOVED
5.33 –0.03
11.9
0.47
11.9 EXTERNAL REAR VIEW

0.47 PANEL GASKET GROUND SCREW
MINIMUM PANEL DEPTH = 144.8 MM (5.70 IN.) 3/8-IN.
PANEL LOCKWASHER (4)
3/8-16 x 1/2-IN.
HEX SCREW (4)
T01088E
Figure 6 – Panel Mounting Detail
ELECTRICAL CONNECTIONS - Power Wiring
To ensure fault-free communication on fieldbus (FF or PA)

Warning.
installations, the bus must be properly terminated at both
Use this equipment only in those classes of
ends. Only approved bus terminators must be used for
hazardous locations listed on the nameplate.
intrinsically safe circuits.
Uses in other hazardous locations can lead to
unsafe conditions that can injure personnel and
damage equipment.
The TB82PH Transmitter is powered by DC voltage. See SENSOR CONNECTIONS POWER/OUTPUT

the appropriate power requirements in the Specification TB2 CONNECTIONS
Section for the particular type of TB82 Transmitter in use

(Analog, HART, PROFIBUS or Foundation Fieldbus (FF)). BLUE 1 SENSE
Power is connected to the POWER/OUTPUT area on YELLOW 2 GUARD
TB1, terminals 1 and 2 (see Figure 7). BLACK 3 REF +1

SIGNAL POWER
GREEN 4 SOL GND -2
RED 5 RTD AMETER +3
The terminal blocks located in the rear of the transmitter WHITE 6 RTD TERMINALS - 4
TEST
accept wire sizes from 12 to 24 AWG. Pin-style HVYGRN 7 SHIELD
terminations should be used for all connections. The 8

terminal block label identifies all electrical connections and
should be followed when wiring the transmitter.
Normal grounding practice is to terminate all grounds at

the control room side, in which case the field side of the
screen should be adequately protected to avoid contact Figure 7 - Power Connections
with metallic objects. The transmitter case should be
grounded. Ground connections are provided internally (in
the terminal compartment) and externally.
For IS systems the grounding should be at the safety

barrier earth connection. For bus-powered systems the
grounding of the screen should be close to the power
supply unit. The specific noise immunity and emitted
interference are only guaranteed when bus screening is
fully effective (e.g., ensuring that screening is maintained
through any existing junction boxes.) Appropriate equi-
potential bonding must be provided to avoid differences in
potential among the individual plant components.
TB82PH-ATEX-EN-C 13
Page 375 of 3829
SENSOR CONNECTIONS – Model TB5 & TBX5 Sensor Connections
SENSOR CONNECTIONS
TB2
BLUE 1 SENSE
YELLOW 2 GUARD
BLACK 3 REF
GREEN 4 SOL GND
RED 5 RTD
WHITE 6 RTD
HVYGRN 7 SHIELD
8
Figure 8 – Sensor Connections
BLACK COAX with BNC
To Sensor BLUE
BLACK
4TB9515-0164 BNC Adapter

WHITE
RED
Figure 9 - TB5 BNC cable & BNC adapter
HEAVY
GREEN
RED WHITE
WHITE RED
To Sensor To Sensor GREEN
BLACK BLACK
BLUE
YELLOW
BLUE
Figure 10 – TB5 cable with pin leads Figure 11 - TBX5 Advantage Sensor Cable
14 TB82PH-ATEX-EN-C
Page 376 of 3829
AP100, AP200, AP300 7660 and 7650 sensors have different color-coding in the cable assemblies than TB5 and TBX5
sensors. Use the table below to properly connect the sensor cable to the TB82PH.
TB82PH Terminal TB2 ABB Sensor Models

3
Color Number Description TB5 TBX5 AP100 AP121/AP200 AP300 7650/7660
Blue 1 Measuring electrode Blue1 Blue Clear Clear Blue Clear
Shield for measuring
Yellow 2 None Yellow None Red None None
electrode
1
Black 3 Reference Black Black Black Blue Black Black
Solution (diagnostic)
Green 4 None Green None Green/Yellow None None
Ground
Red4
Red2 5 RTD Red Red Red Gray & White Red
(2 total)
White2 6 RTD White White White Green White White
Heavy Green
Heavy Green 7 Shield (Screen) None None None None Yellow
(Shield)
None 8 Not Used None None None None None None
Notes:
1. BNC adapter required on sensors provided with BNC termination (See Figure 9).
2. Red and White wires not present on sensors sold without temperature compensators
3. Cut away and discard gray wire on AP100 sensors (if present)
4. Place both red wires in terminal 5
Note.
TB5, AP100, AP300 and 7650/7660 sensors do not have a
solution ground rod required to fully utilize all the TB82PH
on-line sensor diagnostics. When configuring the
transmitter for use with these sensors the DIAGS
(diagnostics) choice must be set to OFF. See the
Configure Mode section for details.
Note.
If an automatic temperature compensator is not used the
TB82PH must be configured for manual temperature
compensation. See the Configure Mode section for details.
TB82PH-ATEX-EN-C 15
Page 377 of 3829
OPERATING PROCEDURES
Figure 12 shows the TB82PH keypad and display with all possible icons
in the display activated. For any given operation only the icons involved
TB82
Hidden Key
in the operation will be shown. ABB (User Mode)
OUTPUT SPIKE FAULT

Key Functions HELD
7.00
Exit to MEASURE - Escapes back to the Measure Mode from all other MEASURE
%
modes or programming states of operation. mV CALIBRATE
pH
OUT/HOLD
FAULT Info - Accesses information on diagnostic or error conditions.
CONFIGURE
SELECT - Selects the mode or programming state of operation shown
25°C
M SECURITY
in the secondary display region DISPLAY
ENTER - Accepts the mode or programming state of operation shown in
the secondary display region exit to
MEASURE SELECT YES NO
FAULT info ENTER NEXT MENU
NEXT - Increments through a series of programming states
YES - Affirms the action that is about to take place
NO - Denies the action that is about to take place.
MENU - Increments through the modes of operation
Increases numerals & moves through a series of parameters
Moves the flashing data entry value one space to the right Figure 12
Decreases numeric values & moves through a series of parameters
7.00
MEASURE
Figure 13 shows the TB82PH in the MEASURE mode of operation.
CALIBRATE
Pressing the key at the far right, underneath the MENU icon, provides pH
OUT/HOLD
access to all other instrument functions. CONFIGURE
25°C
M SECURITY
Figure 14 shows the display after the MENU key has been pressed DISPLAY
once. The CALIBRATE menu can now be accessed by pressing the key
underneath the SELECT icon. If the MENU key is pressed again the
display will change to the next menu function choice, OUT/HOLD. MENU
Pressing again will activate the CONFIGURE menu choice, and so on.
There are six MENU functions:

MEASURE - Normal operational display Figure 13
CALIBRATE – Allows calibration of the pH (ORP) and temperature
sensors, restoring calibration to the original factory values, tuning of
the analog output and also allows the ability to view or change the
7.00
MEASURE
sensor’s slope and offset.
CALIBRATE
OUT/HOLD - Allows the output to be re-ranged, held or released pH
OUT/HOLD
(Analog version only) CONFIGURE
CONFIGURE - Sets up how the transmitter operates
Calibr
SECURITY
SECURITY - Sets password protection to the CONFIGURE, DISPLAY
CALIBRATE and OUTPUT menus exit to

MEASURE SELECT
DISPLAY - Displays temperature in °F or °C, current output in mA, MENU
reference impedance, mV input, spike output status and software
revision. Sets what will be displayed under the secondary display
when in the measure mode.
Figure 14
Commissioning the Instrument
To commission the TB82:

1. Configure the instrument as required for the application.
2. Calibrate the sensor(s).
3. Set up parameters on the receiving devices (e.g. PLC, DCS recorder) to properly recognize the TB82 outputs.
16 TB82PH-ATEX-EN-C
Page 378 of 3829
Flow Chart For Basic Operation Mode

MEASURE
CALIBRATE
pH Cal
1 Point Calibration
2 Point Calibration
Temperature Cal
Enter Temp
Edit Calibration
Enter Slope
Enter Offset
Reset Cal
Output Cal
Adjust 4 mA
Adjust 20 mA
Back to pH Cal
OUT/HOLD
Hold Output
Release Hold
Hold to XXX%
Rerange Output
4 mA Point
20 mA Point
Damping
XX.X Seconds
Back to Hold Output
CONFIGURE
Modify/View
Basic
Analyzer
pH pH Glass
ORP Antimony
pIon
Temp. Sensor
None
3k Balco
Pt 100
Temp. Comp. Type
Manual
Auto
Output
4 mA Point
20 mA Point
Damping
Enter Seconds
Diagnostics
On or Off
Safe Mode
Fail Low
Fail High
SECURITY
Set Level
Calibrate
Output
Configure
Password
DISPLAY
Temperature °C
Temperature °F
Current Output
Diagnostic Alarms
Reference Impedance
Millivolt Input
Software Revision
TB82PH-ATEX-EN-C 17
Page 379 of 3829
CONFIGURE MODE
Before the instrument can be put into a process measurement loop it must be configured. The TB82PH Transmitter
operation (non-fieldbus versions) can be set in either a BASIC or ADVANCED Mode. BASIC mode is sufficient for 95% of
all measurements. ADVANCED functions are described in Italic print in the ‘alternatives’ section of the default
configuration table and in the ‘Configure Mode - Flow Chart for ADVANCED Mode’ section. Figures 15 through 25 show
typical screen flows for a BASIC pH Configuration.
Default Configuration
Parameter Default Alternative
Mode BASIC ADVANCED
Analyzer pH ORP, pIon,
Ion Concentration
Analyzer input pH Glass Antimony,
Custom sensor
Reference Impedance
Temperature Sensor None 3K Balco
Pt100 RTD
Temperature Manual Auto,
Compensation Type Auto Solution
Output 4 mA = 0.00 pH Any 1 pH to 16 pH span,
20 mA = 14.00 pH any span above 100 mV from
–1999 mV to +1999 mV,
non-linear function generator,
Damping 00.5 seconds Adjustable to 99.9 seconds
Diagnostics Off On
Safe Mode* Fail low Fail high
Spike* 0% Spike Magnitude 0 to 100% magnitude
Note: Alternatives in Italics are available in ADVANCED mode only
* Safe Mode and Spike functions not available on fieldbus versions
7.00 7.00
MEASURE MEASURE
CALIBRATE CALIBRATE
pH pH
OUT/HOLD OUT/HOLD
CONFIGURE CONFIGURE
CONFIG SECURITY
DISPLAY MODIFY SECURITY
DISPLAY
exit to exit to
MEASURE SELECT MEASURE SELECT
MENU NEXT
Figure 15 Figure 16
7.00 7.00
MEASURE MEASURE
CALIBRATE CALIBRATE
pH pH
OUT/HOLD OUT/HOLD
CONFIGURE CONFIGURE
Basic SECURITY
DISPLAY ANALZR SECURITY
DISPLAY
exit to exit to
MEASURE SELECT MEASURE SELECT
NEXT NEXT
Figure 17 Figure 18
18 TB82PH-ATEX-EN-C
Page 380 of 3829
7.00 0.00
MEASURE MEASURE
CALIBRATE CALIBRATE
pH pH
OUT/HOLD OUT/HOLD
CONFIGURE CONFIGURE
PH.GLAS SECURITY
DISPLAY 4MA.PT SECURITY
DISPLAY
exit to exit to
MEASURE MEASURE
ENTER NEXT ENTER
Figure 19 Figure 20
0.05 OFF
MEASURE MEASURE
CALIBRATE CALIBRATE
oH pH
OUT/HOLD OUT/HOLD
CONFIGURE CONFIGURE
SECS SECURITY
DISPLAY DIAGS SECURITY
DISPLAY
exit to exit to
MEASURE MEASURE
ENTER ENTER
Figure 21 Figure 22
7.00 7.00
MEASURE MEASURE
CALIBRATE CALIBRATE
pH pH
OUT/HOLD OUT/HOLD
CONFIGURE CONFIGURE
SAFE.MD SECURITY
DISPLAY Fail.lo SECURITY
DISPLAY
exit to exit to
MEASURE MEASURE
FAULT info ENTER NEXT FAULT info ENTER NEXT
Figure 23 Figure 24
Caution.
7.00
MEASURE If a programming change has been made,
CALIBRATE pressing the Exit to MEASURE key will activate
pH
OUT/HOLD the SAVE? display (Figure 25). YES and NO
CONFIGURE keys will also appear. Press the YES key to save
Save? SECURITY
DISPLAY
the changes. If the NO key is pressed any
configuration or programming changes will not be
saved.
exit to
MEASURE YES NO
Note.
Diagnostics is a function valid only with a TBX5
Advantage pH sensors or an AP200 with a
Figure 25 solution ground rod that is connected to Terminal
TB2-4 (green, SOL GND). Diagnostics must be
turned ‘OFF’ if TB5, AP100, AP300, 7650/7660,
ORP or sensors without an integral solution
ground are used.
TB82PH-ATEX-EN-C 19
Page 381 of 3829
Flow Chart For Advanced Mode
MEASURE
CONFIGURE
Modify/View
Basic
Analyzer
pH
pH glass
Antimony
Custom
ORP
pIon
Ion Concentration
Units (ppm, ppb)
Valence
Magnitude (log)
End Magnitude
End Millivolt
Reference Impedance k-ohms
(appears for all sensor choices)
Temp. Sensor
None
3k Balco
Pt 100
Temp. Comp. Type
Manual
Auto
Auto - Solution
+/-X.XX pH/10C
Output
4 mA Point
20 mA Point
Linear
Non-linear
Program X1=Y1
through X5+Y5
Damping
Enter Seconds
Diagnostics
On or Off
Safe Mode
Fail Low
Fail High
Spike
Spike Magnitude
(0-100%)
20 TB82PH-ATEX-EN-C
Page 382 of 3829
CALIBRATE MODE
Before an instrument can properly measure pH the sensor must be calibrated to the instrument. Periodic update
calibrations must be performed during the time the sensor is in service. The frequency of re-calibration is application
dependent. This mode also defines calibration of the temperature input and fine tuning the 4-20 mA output for non-
fieldbus versions.
MEASURE
CALIBRATE
pH Cal
1 Point Calibration
Stable?
Enter New Value
2 Point Calibration
O
Change Temp C
Low Value Buffer
Stable?
High Value Buffer
Stable?
PV Slope %
PV Offset mV
Temperature Cal
Enter Temp
Edit Calibration
Enter Slope
Enter Offset
Reset Cal
Output Cal
Adjust 4 mA
Adjust 20 mA
Back to pH Cal
Caution.
The Reset Calibrate State will reset all calibration
values; therefore, the process sensor and
temperature sensor will require calibration after
performing the Reset Calibrate procedure.
OUTPUT/HOLD MODE
MEASURE
CALIBRATE
OUT/HOLD
Hold Output
Release Hold
Hold to XXX%
Rerange Output
4 mA Point
20 mA Point
Damping
XX.X Seconds
Back to Hold Output
Output/Hold screen flow only valid for non-fieldbus versions.
TB82PH-ATEX-EN-C 21
Page 383 of 3829
SECURITY MODE
MEASURE
CALIBRATE
OUT/HOLD
CONFIGURE
SECURITY
Set Level
Calibrate
Output
Configure
Password
Enter 3 digit code
SECONDARY DISPLAY MODE
MEASURE
CALIBRATE Note.
OUT/HOLD If an ‘M’ appears after the
M
CONFIGURE temperature display (e.g. 25°C )
SECURITY the TB82PH is programmed for
DISPLAY manual temperature compensation
Temperature °C
(default 25°C).
Temperature °F
Current Output
Diagnostic Alarms
Reference Impedance
Millivolt Input
Software Revision
Back to Temp °C
MAINTENANCE
Preventative Maintenance Tasks Interval (months)
Check, tighten and clean all wiring and connections 12
Clean and lubricate all gaskets and o-rings Each time seals are disturbed
Analyzer Validation Per user’s requirements (minimum 12)
Clean and inspect sensor As required by application
(minimum monthly)
Sensor calibration As required by application
(minimum monthly)
22 TB82PH-ATEX-EN-C
Page 384 of 3829
DISMANTLING AND RE-ASSEMBLY
3. Remove Microprocessor/Display PCB Assembly by

Warning. unscrewing the four Phillips screws and unplug the
Substitution of any components other than keypad cable by lifting the locking arms on the side of
those assemblies listed in this section will the connector and remove the cable from the
compromise the certification listed on the connector.
transmitter nameplate. Invalidating the 4. Remove the cable hubs by screwing the retaining nut
certifications can lead to unsafe conditions and removing the hub from the Shell Assembly.
that can injure personnel and damage
equipment. Reassembly
Check that the gaskets are not damaged and have a thin
layer of silicone grease. If the gaskets are damaged,
replace gaskets.
Caution.
Dismantling and reassembly should not be 1. Install the Microprocessor/Display by securing the
carried out on site because of the risk of assembly with the four Phillips screws and installing
damage to components and printed the keypad cable into the connector and locking it into
circuits. The dismantling and reassembly place by pushing down the two locking arms on the
procedures should be carried out in the side of the connector.
listed order to avoid instrument damage. 2. Install the Power Supply and/or Input PCB
Assemblies into their respective connector and secure
the assemblies with the two Phillips screws per
Dismantling assembly.
1. Use the bladed screwdriver to loosen the four captive 3. Attach cable hubs by installing the gaskets onto the
screws that secure the Front Bezel and/or Rear Cover hubs and insert the hubs into the ports in the Shell
Assemblies (depending on which component is being assembly. Secure the hubs by tightening the nut onto
replaced) and remove the cover(s). the hub threads.
2. Remove Power Supply and/or Input PCB Assemblies 4. Install the Front Bezel and/or Rear Cover Assemblies
by unscrewing the two Phillips screws and unplug the and secure by tightening the four captive screws per
assemblies from their connectors. assembly using a bladed screwdriver.
POWER SUPPLY PCB ASSY KITS:

HART/NON-HART VERSIONS -
TB82 NON-HART 4TB9515-0158
TB82 HART 4TB9515-0159
FF VERSIONS -
TB82 4TB9515-0253
PA VERSIONS-
TB82 4TB9515-0254
REAR COVER KITS:

4TB9515-0162 (82)
4TB9515-0214 (84)
POWER SUPPLY PCB ASSY KIT
4TB9515-0207 (TB84)
INPUT PCB ASSY KITS:

4TB9515-0153 (PH)
4TB9515-0176 (EC)
4TB9515-0226 (TC)
4TB9515-0187 (TE) SHELL KITS:
4TB9515-0161 (82PH)
4TB9515-0175 (82EC/TE)
4TB9515-0224 (82TC)
4TB9515-0212 (84PH)
4TB9515-0213 (84EC/TE)
4TB9515-0225 (84TC)
4TB9515-0165 (FOR TB5 SENSORS)

MICROPROCESSOR/DISPLAY PCB ASSY KITS:
FRONT BEZEL KIT HART/NON-HART VERSIONS - PROFIBUS PA VERSIONS - 4TB9515-0163 (FOR TBX5/TB4 SENSORS)
TB82 VERSIONS: TB82PH 4TB9515-0154 TB82PH 4TB9515-0260 1/2 LIQUID TITE FITTING KIT
4TB9515-0160 (TB82 non-FM) TB82EC/TC/TE 4TB9515-0178 TB82EC 4TB9515-0261
4TB9515-0181 (TB82 FM) FF VERSIONS - TB82TE 4TB9515-0262
4TB9515-0208 (TB84 non-FM) TB82PH 4TB9515-0255 TB82TC 4TB9515-0263
4TB9515-0210 (TB84 FM) TB82EC 4TB9515-0256 LINE POWER ANALYZER VERSIONS - 4TB9515-0191
TB82TE 4TB9515-0257 TB84PH 4TB9515-0199
TB82TC 4TB9515-0258 TB84EC 4TB9515-0201 4TB9515-0198
TB84TE 4TB9515-0205 PG9 LIQUID TITE FITTING KIT (TB84)
TB82TC 4TB9515-0203
Figure 26 - TB82PH Transmitter Exploded View
TB82PH-ATEX-EN-C 23
Page 385 of 3829
SPECIFICATIONS
Property Characteristic/Value
Process Display Range
pH -2.00 to +16.00 pH
ORP -1999 to +1999 mV
pIon -1999 to +1999 mV
Temperature 0 to 140°C
Power Requirements
Analog 14.0 to 55 VDC (14.0 to 42 VDC for agency certified applications).
See Figure 27 below
HART Versions 14.0 to 55 VDC (14.0 to 42 VDC for agency certified applications).
See Figure 27 below
PROFIBUS PA 9 to 32 VDC (9 to 24 VDC for agency certified applications)

15 mA quiescent current
FOUNDATION Fieldbus (FF) 9 to 32 VDC (9 to 24 VDC for agency certified applications)

15 mA quiescent current
Ambient Temperature Effect

pH ±0.007 pH/°C @ 95% Relative Humidity
ORP ±0.4 mV/°C @ 95% Relative Humidity
pION ±0.4 mV/°C @ 95% Relative Humidity
Temperature ±0.16°C/°C @ 95% Relative Humidity
Maximum Sensor Cable Length 100 ft (30.5 m)
Environmental
Operating temperature -20° to 60°C (-4° to 140°F)
LCD Range -20° to 60°C (-4° to 140°F)
Storage temperature -40° to 70°C (-40° to 158°F)
Enclosure Classification NEMA 4X
IP65
Size
Height 144 mm high x 144 mm wide x 171 mm long (5.67 in. high x 5.67 in. wide x 6.75 in.
long)
Minimum panel depth 145 mm (5.70 in.)
Maximum panel cutout 136.7 mm x 136.7 mm (5.38 in. x 5.38 in.)
Recommended panel cutout 135 mm x 135 mm (5.33 in. x 5.33 in.)
Weight 1.9 kg (4.2 lb) without mounting hardware
3.4 kg (7.5 lb) with Pipe Mounting Hardware
2000 2100
1800
1500
LOAD RESISTANCE
1200
(OHMS)
900
HART
COMMUNICATIONS
600 RANGE
250 300
0
14 19 24 29 34 39 44 49 54 (HART)
13.5 18.5 23.5 28.5 33.5 38.5 43.5 48.5 53.5 (Analog)
Supply Voltage VDC
Figure 27 – Supply Voltage Requirements, HART and Analog Versions
24 TB82PH-ATEX-EN-C
Page 386 of 3829
Products and customer support
Automation Systems Customer support
For the following industries: We provide a comprehensive after sales service via a
— Chemical & Pharmaceutical Worldwide Service Organization. Contact one of the following
— Food & Beverage offices for details on your nearest Service and Repair Centre.
— Manufacturing
— Metals and Minerals USA
— Oil, Gas & Petrochemical
ABB Inc.
— Pulp and Paper
Tel: +1 800 HELP 365 (435 7365)
Drives and Motors Fax: +1 860 298 7669
— AC and DC Drives, AC and DC Machines, AC Motors to
1kV
UK
— Drive Systems
— Force Measurement ABB Limited
— Servo Drives Tel: +44 (0)1453 826661
Fax: +44 (0)1453 829671
Controllers & Recorders
— Single and Multi-loop Controllers
— Circular Chart and Strip Chart Recorders China
— Paperless Recorders ABB Engineering (Shanghai) Limited
— Process Indicators Tel: +86 (0) 21 6105 6666
Fax: +86 (0) 21 6105 6992
Flexible Automation
— Industrial Robots and Robot Systems
Flow Measurement
— Electromagnetic Flowmeters
— Mass Flowmeters
— Turbine Flowmeters
— Wedge Flow Elements
Marine Systems & Turbochargers
— Electrical Systems
— Marine Equipment
— Offshore Retrofit and Refurbishment
Process Analytics
— Process Gas Analysis
— Systems Integration
Transmitters
— Pressure
— Temperature
— Level
— Interface Modules
Valves, Actuators and Positioners
— Control Valves
— Actuators
— Positioners
Water, Gas & Industrial Analytics Instrumentation
— pH, Conductivity and Dissolved Oxygen Transmitters and
Sensors
— Ammonia, Nitrate, Phosphate, Silica, Sodium, Chloride,
Fluoride, Dissolved Oxygen and Hydrazine Analyzers Client Warranty
— Zirconia Oxygen Analyzers, Katharometers, Hydrogen Prior to installation, the equipment referred to in this
Purity and Purge-gas Monitors, Thermal Conductivity manual must be stored in a clean, dry environment, in
accordance with the Company's published specification.
Periodic checks must be made on the equipment's
condition. In the event of a failure under warranty, the
following documentation must be provided as
substantiation:
— A listing evidencing process operation and alarm logs
at time of failure.
— Copies of all storage, installation, operating and
maintenance records relating to the alleged faulty unit.
Page 387 of 3829

Contact us
10.2012
ABB Inc. Note
Process Automation We reserve the right to make technical changes or
modify the contents of this document without prior
843 N Jefferson Street
notice. With regard to purchase orders, the agreed
OI/TB82PH/ATEX–EN Rev. E
PO Box 831 particulars shall prevail. ABB does not accept any
Lewisburg 24901-9509 responsibility whatsoever for potential errors or
USA possible lack of information in this document.
Tel: +1 304 647 4358

We reserve all rights in this document and in the
Fax: +1 304 645 4236 subject matter and illustrations contained therein.
Any reproduction, disclosure to third parties or
utilization of its contents in whole or in parts – is
forbidden without prior written consent of ABB.
ABB Limited
Process Automation Copyright© 2012 ABB
Oldends Lane All rights reserved
Stonehouse
Gloucestershire GL10 3TA TB82PH-ATEX-EN-C
UK
Tel: +44 1453 826 661
Fax: +44 1453 829 671
ABB Engineering (Shanghai) Ltd.

Process Automation
No5, Lane 369, Chuangye Road Sales
201319, Shanghai
P.R. China
Phone: +86 (0) 21 6105 6666
Fax: +86 (0) 21 6105 6992
Service
www.abb.com
Software
Page 388 of 3829

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Advance Optima Continuous Gas Analyzers

Instructions for Installation,

Page 277 of 3829

Instructions for Installation,

Publication No. 41/24100 EN Rev. 6

Page 279 of 3829

Chapter 1 Preparing the Installation 12

Chapter 2 Gas Analyzer Unpacking and Installation 21

Chapter 3 Gas Line Connection 26

4 Advance Optima AO2000 Series Condensed Operator’s Manual 41/24-100 EN Rev. 6

Page 280 of 3829

Chapter 4 Electrical Connection 38

Chapter 5 Gas Analyzer Start-Up 56

Chapter 6 Gas Analyzer Operation 61

Chapter 7 Gas Analyzer Calibration 65

Chapter 8 Status Messages 68

Appendix ZO23 Trace Oxygen Analyzer Module 79

41/24-100 EN Rev. 6 Advance Optima AO2000 Series Condensed Operator’s Manual 5

Page 281 of 3829

Symbols and Indicates safety information to be heeded during gas analyzer

Identifies specific information on operation of the gas analyzer

6 Advance Optima AO2000 Series Condensed Operator’s Manual 41/24-100 EN Rev. 6

Page 282 of 3829

Special Information These include

41/24-100 EN Rev. 6 Advance Optima AO2000 Series Condensed Operator’s Manual 7

Page 283 of 3829

8 Advance Optima AO2000 Series Condensed Operator’s Manual 41/24-100 EN Rev. 6

Page 284 of 3829

41/24-100 EN Rev. 6 Advance Optima AO2000 Series Condensed Operator’s Manual 9

Page 285 of 3829

Designation II 3G EEx nAC II T4 X

Description In undisturbed operation there cannot be any sparking, arcing or impermissible

10 Advance Optima AO2000 Series Condensed Operator’s Manual 41/24-100 EN Rev. 6

Page 286 of 3829

Step Action see Page

41/24-100 EN Rev. 6 Advance Optima AO2000 Series Condensed Operator’s Manual 11

Page 287 of 3829

Installation Location Requirements

Protection from Protect the gas analyzer from:

Environmental Air pressure range 600 to 1250 hPa

1) +5 to +40°C when I/O modules are installed

Continued on next page

12 Advance Optima AO2000 Series Condensed Operator’s Manual 41/24-100 EN Rev. 6

Page 288 of 3829

Installation Location The maximum installation location altitude is 2000 m.

Analyzer Module Vibrations

41/24-100 EN Rev. 6 Advance Optima AO2000 Series Condensed Operator’s Manual 13

Page 289 of 3829

Gas Inlet Conditions Module Temperature Pressure pe 3) Flow Rate

Continued on next page

14 Advance Optima AO2000 Series Condensed Operator’s Manual 41/24-100 EN Rev. 6

Page 290 of 3829

Module Application Restrictions and Notes

41/24-100 EN Rev. 6 Advance Optima AO2000 Series Condensed Operator’s Manual 15

Page 291 of 3829

Analyzer Module Zero Calibration Span Calibration

16 Advance Optima AO2000 Series Condensed Operator’s Manual 41/24-100 EN Rev. 6

Page 292 of 3829

Purge Gas The following purge gases can be used:

Volume to be Purged Purge Gas Flow Rate Duration

41/24-100 EN Rev. 6 Advance Optima AO2000 Series Condensed Operator’s Manual 17

Page 293 of 3829

Analyzer Module The analyzer module requires a 24 VDC ± 5 % voltage supply.