Advance Optima

Modular Process Analysis System

Software Version 2.0

Operator’s Manual 42/24-10-5 EN

Magnos 16 Caldos 17
Advance Optima
Modular Process Analysis System
Software Version 2.0

Operator’s Manual
Publication No. 42/24-10-5 EN
Edition 04.01

This 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.
Table of Contents

Page

Preface vii
Relationship between Operator’s Manual and Software Version ix
Important Safety Information x
Safety Tips for Handling Electronic Measurement Devices xi

Chapter 1 Analyzer System Installation

Analyzer System Unpacking 1-1
Analyzer System Identification 1-2
Dimensional Diagrams 1-4
Instructions for Selecting a Location 1-5
Gas Connections 1-7
Analyzer System Installation 1-8

Chapter 2 Gas Line Connection

Analyzer Module Connection Diagrams 2-1
Gas Diagrams 2-4
Gas Inlet and Outlet Conditions 2-5
Housing Purge 2-7
Pressure Sensor 2-9
Gas Line Connection 2-10
Purge Gas Line Connection 2-11

Chapter 3 Electrical Connection

Electronics Module Connections 3-1
I/O Base Module Connection Diagrams 3-2
System Controller Connection Diagram 3-3
Analog I/O Board Connection Diagram 3-4
Digital I/O Board Connection Diagram 3-5
8-Way Analog Output Board Connection Diagram 3-6
Interface Connections 3-7
Signal, Control and Interface Line Connection 3-8
System Bus Connection 3-10

Chapter 4 Analyzer System Start-Up

Installation Check 4-1
Gas Path and Housing Initial Purge 4-2
Power Supply Information 4-3
Advance Optima Power Supply 4-4
Power Supply Line Connection – Safety Notes 4-5
24 VDC Power Supply Line Connection 4-6
115/ 230 VAC Power Supply Line Connection 4-8
Power Supply Activation 4-9
Warm-Up Phase 4-10
Operation 4-11

Continued on next page

ii Advance Optima Operator’s Manual 42/24-10-5 EN

Table of Contents, continued

Page

Chapter 5 Analyzer System Operation

Display and Control Unit 5-1
Screen 5-2
Message Display 5-3
Status LED’s 5-4
Numeric Keypad 5-5
Cancel Keys 5-6
Softkeys 5-7
Text Entry 5-9
Operating by Value Entry 5-10
Operating by Key Entry 5-11
Password Protection 5-12
Changing the Password 5-14
User Interface Priority 5-15
Access Lock 5-16
Menu Tree 5-17

Chapter 6 Analyzer System Configuration

Section A Measurement Component-Specific Functions
Changing Measurement Value Units 6-A-1
Measurement Range Switching 6-A-2
Modifying Range Limits 6-A-3
Limas 11, Uras 14: Notes for Changing Measurement Range Limits 6-A-4
Changing the Number of Decimal Places 6-A-5
Filter Initialization 6-A-6
Auto-Range Initialization 6-A-7
Limit Monitor Initialization 6-A-8
Active Component Selection 6-A-9
Changing Module Name 6-A-10
Section B Function Blocks
The Function Block Concept 6-B-1
Standard Configuration 6-B-2
The "Function Block" Sub-menu 6-B-3
Section C System Functions
Setting the Date 6-C-1
Setting the Time 6-C-2
Selecting User Interface Language 6-C-3
Changing the Password 6-C-4
Setting Up System Modules 6-C-5
Saving the Configuration 6-C-8
Configuring Status Signals 6-C-9
Configuring an Ethernet Connection 6-C-10
Configuring a Modbus Connection 6-C-11

Continued on next page

42/24-10-5 EN Advance Optima Operator’s Manual iii

Table of Contents, continued

Page

Section D Display
Display Features 6-D-1
Display Overview 6-D-3
Page Overview 6-D-4
Parameter Overview 6-D-5
Value Entry 6-D-6
Key Entry 6-D-7
User Page Configuration 6-D-8
Moving a Display Element from One Page to Another 6-D-9
Moving a Display Element Within a Page 6-D-10
Configuring the Bar Display or Point Display 6-D-11
Configuring Value Entries 6-D-12
Configuring Key Entries 6-D-13
Example: Entering and Displaying the Pump Output 6-D-14

Chapter 7 Analyzer System Calibration

Section A Principles
Calibration Control 7-A-1
Manual Calibration 7-A-2
Automatic Calibration 7-A-4
Test Gas Supply Control for Automatic Calibration 7-A-6
Externally Controlled Calibration 7-A-9
Calibration Methods 7-A-10
Section B Calibration Data
The "Calibration Data" Sub-menu 7-B-1
Calibration Data for Manual Calibration 7-B-2
Calibration Data for Automatic Calibration 7-B-3
Calibration Data for Externally Controlled Calibration 7-B-5
Output Current Response 7-B-6
Section C Notes for Calibrating Analyzer Modules
Caldos 15: Notes for Calibrating 7-C-1
Caldos 17: Notes for Calibrating 7-C-2
Caldos 17: Single-Point Calibration with Standard Gas 7-C-3
Caldos 15 and Caldos 17: Substitute Gas Calibration 7-C-4
Limas 11: Notes for Calibrating 7-C-5
Magnos 16, Magnos 106: Notes for Calibrating 7-C-6
Magnos 16, Magnos 106: Single-Point Calibration 7-C-7
Magnos 16, Magnos 106: Substitute Gas Calibration 7-C-9
Magnos 17: Notes for Calibrating 7-C-10
Magnos 17: Substitute Gas Calibration 7-C-11
Uras 14: Notes for Calibrating 7-C-12
Oxygen Sensor: Notes for Calibrating 7-C-13
Section D Calibration
Analyzer Module Manual Calibration 7-D-1
Manual Start of the Automatic Calibration 7-D-2

Continued on next page

iv Advance Optima Operator’s Manual 42/24-10-5 EN

Table of Contents, continued

Page

Chapter 8 Inspection and Maintenance

Inspection 8-1
Checking Gas Path Seal Integrity 8-2
Caldos 15, Magnos 16, Magnos 17: Thermal Link Replacement 8-4
Uras 14: Optical Alignment 8-5
Uras 14: Phase Alignment 8-7
Limas 11, Uras 14: Measurement of Calibration Cells 8-8
Limas 11, Uras 14: Relinearization 8-9
Limas 11: Thermal Link Replacement 8-10
Limas 11: Aluminum Sample Cell Cleaning 8-11
Limas 11: Quartz Sample Cell Cleaning 8-13
Limas 11-UV: Lamp Replacement 8-16
Limas 11: Amplification Optimization 8-18
Gas Module: Disposable Filter Replacement 8-19
Pump 8-20
Changing Analog Output Current Range 8-21
Air Pressure Correction 8-22
Air Pressure Value Correction 8-24
Calibration Reset 8-25
Basic Calibration 8-26
Cross-Sensitivity Alignment 8-27
Carrier Gas Alignment 8-28

Chapter 9 Status Messages, Troubleshooting

Process Status 9-1
System Status: Status Messages 9-2
System Status: Status Signals 9-4
Status Message Categories 9-5
Status Messages 9-7
Analyzer System Problems 9-16
Caldos 15, Caldos 17, Magnos 16/ 106, Magnos 17 Problems 9-18
Limas 11 Problems 9-19
Uras 14 Problems 9-21
Gas Module Problems 9-22
Notify Service 9-23

Chapter 10 Analyzer System Shutdown and Packing

Analyzer System Shutdown 10-1
Preparing the Analyzer System for Shipping 10-2
Analyzer System Packing 10-3

Continued on next page

42/24-10-5 EN Advance Optima Operator’s Manual v

Table of Contents, continued

Page

Appendix 1 Analyzer System Overview

Analyzer System A-1-1
System Controller A-1-2
I/O Boards A-1-2
System Housing A-1-3
Display and Control Unit A-1-3
Analyzer Modules A-1-4
Gas Module with Oxygen Sensor A-1-4

Appendix 2 Analyzer Module Operating Specifications

Caldos 15 Operating Specifications A-2-1
Caldos 17 Operating Specifications A-2-2
Limas 11 Operating Specifications A-2-3
Magnos 16, Magnos 106 Operating Specifications A-2-4
Magnos 17 Operating Specifications A-2-6
Uras 14 Operating Specifications A-2-7
Oxygen Sensor Operating Specifications A-2-8
Electrical Safety A-2-9

Appendix 3 Index
A–C A-3-1
D–E A-3-2
F–L A-3-3
M–P A-3-4
R–S A-3-5
T–W A-3-6

vi Advance Optima Operator’s Manual 42/24-10-5 EN

Preface

Content of the This operator’s manual contains all the information you will need to safely and effi-
Operator’s Manual ciently install, start-up, operate and maintain the Advance Optima analyzer system.
This operator’s manual contains information on all the functional units in the analy-
zer system. The delivered analyzer system may differ from the version described,
especially if it contains only one or a few of the analyzer modules described.

Analyzer Data Sheet Your version of the analyzer system will be described in the "Analyzer Data Sheet"
supplied with each analyzer system shipped (see Section "Analyzer System
Identification", Page 1-2).

Analyzer System This operator’s manual does not describe the design or the operating principles of
Description the analyzer system. This kind of information is contained in the system
description (Publication No. 30/24-110 EN).

Multi-FID 14 This operator’s manual does not contain any information on installation, start-up
Analyzer Module and maintenance of the Multi-FID 14 analyzer module. For the Multi-FID 14
Operator’s Manual analyzer module a separate start-up and maintenance manual is available
(Publication No. 41/24-105 EN) which is added to all analyzer systems with a built-
in Multi-FID 14 analyzer module.

Analyzer System in This operator’s manual does not contain any information on installation, start-up
Explosion Protected and maintenance of the analyzer system in explosion protected version. This kind
Version of information is contained in the operator’s manuals for the analyzer modules and
Operator’s Manual the central unit in explosion protected version (Publication Nos. 42/24-12 EN and
42/24-13 EN).

Additional Publications Title Publication No.

Brochure 50/24-01 EN
Data Sheet 10/24-1.10 EN
System Description 30/24-110 EN
Explosion Protected Model – Descriptions and Design Notes 30/24-100 EN
Function Blocks – Descriptions and Configuration 30/24-200 EN
Modbus – Functions and Components 30/24-310 EN
Optima Remote HMI – Simulation and Emulation of the
Display and Control Unit of Advance Optima 30/24-311 EN
Multi-FID 14 Analyzer Module
Start-Up and Maintenance Manual 41/24-105 EN
Analyzer Modules in Explosion Protected Version
Operator’s Manual 42/24-12 EN
Central Unit in Explosion Protected Version
Operator’s Manual 42/24-13 EN

Continued on next page

42/24-10-5 EN Advance Optima Operator’s Manual vii

Preface, continued

Additional These publications can be ordered from your authorized ABB Automation
Publications Products representative or from
(continued) ABB Automation Products GmbH,
Analytical Division, Marketing Communication,
Telefax: +49-69-79 30-45 66, E-mail: [Link]@[Link]

Documentation on The listed publications as well as the spare parts list are also available on a
CD-ROM CD-ROM which is added to the analyzer system.

Further Information in Further information on the products and services of ABB Analytical will be found in
the Internet the Internet at "[Link]

Typefaces Used in Some types of text are identified with special typefaces:
this Manual
Module Name Indicates specific information for individual analyzer modules.

1, 2, 3, ... Identifies reference numbers in the figures.

'LVSOD\ Identifies a message in the display.
,QSXW Identifies a user entry
• either by pressing a programmable key
• or by selecting a menu item
• or via the numeric keypad
Function Block Identifies a function block designation.
’Name’ Identifies a function block name assigned by the system or
entered by the user.

Symbols Used in Some symbols identify special information text:

this Manual
F Identifies specific information on operation of the analyzer system as well as
on the use of this manual.
Indicates safety information to be heeded during analyzer system operation
in order to avoid risks to the operator.

viii Advance Optima Operator’s Manual 42/24-10-5 EN

Relationship between Operator’s Manual and Software Version

Software Version The Advance Optima Analyzer System’s hardware and software are modular in
design.
The system controller, analyzer modules and I/O boards are all equipped with their
own processor and software.
Each software package is updated separately and bears its own version number.
The system controller software is critical to analyzer system operation. Thus, this
manual will refer only to the system controller software version.

Operator’s Manual This operator’s manual applies to the software version listed on the title page.
Validity
It remains valid until the digit following the first decimal point is changed.

Software Update If a software update involves a modification or expansion of functionality, this is

indicated by changing the version number following the first decimal point.
The operator’s manual is accordingly revised and a new edition is published. This
is reflected by increasing the publication number by one.

Software Versions and Software Version Operator’s Manual Edition (Publication Number)
Operator’s Manual [Link] 42/24-10-0
Edition
[Link] 42/24-10-1
[Link] 42/24-10-2
[Link] 42/24-10-3
42/24-10-4 Edition 11.99
[Link] 42/24-10-4 Edition 03.00
[Link] 42/24-10-5

Where Can I Find the The software version number is shown

Software Version
• On the analyzer system startup screen
Number?
• On the analyzer data sheet (see page 1-3)
• In the following menu item
0(18→'LDJQRVWLF,QIRUPDWLRQ→6\VWHPRYHUYLHZ

42/24-10-5 EN Advance Optima Operator’s Manual ix

Important Safety Information

Intended Application The Advance Optima Analyzer System is designed for continuous measurement of
the concentration of individual components in gases or vapors.
The non-explosion protected model of the Advance Optima Analyzer System must
not be used for measurement of explosive gas/air or gas/oxygen mixtures. For this
application explosion protected models of the analyzer system are available.

Requirements for In order to operate in a safe and efficient manner the analyzer system 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 systems and certified as being capable of such work should work on
the analyzer system.

Special Information These include

and Precautions • The content of this operator’s manual.
• The safety information affixed to the analyzer system.
• 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 analyzer system is used in other countries.

Analyzer System The analyzer system is designed and tested in accordance with EN 61010 Part 1/
Safety and Safe IEC 1010-1, "Safety Provisions for Electrical Measuring, Control, Regulation and
Operation 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 analyzer system 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 Automation service is prepared to supply additional information as needed.
Contact your local ABB Automation service representative or
ABB Automation Service,
Telephone: +49-1 80-5-12 35 80, Telefax: +49-6 21-3 81-51 35,
E-Mail: [Link]@[Link]

x Advance Optima Operator’s Manual 42/24-10-5 EN

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 The analyzer system can be hazardous if the protective lead is interrupted inside
Disconnected or outside the system or if the protective lead is disconnected.
Protective Lead

Proper Operating Be sure the analyzer system voltage setting matches the line voltage before
Voltage connecting 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 analyzer system must be disconnected from all power sources before being
Working with an opened for any work. All work on an analyzer system that is open and connected
Open Analyzer to power should only be performed by trained personnel who are familiar with the
System risks involved.

Charged Capacitors The capacitors in the analyzer system power supply discharge after 10 minutes
when the system 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 fuseholder contacts.

When Safe Operation If it is apparent that safe operation is no longer possible, the analyzer system
can no Longer be should be taken out of operation and secured against unauthorized use.
Assured
The possibility of safe operation is excluded:
• If the analyzer system is visibly damaged
• If the analyzer system no longer operates
• After prolonged storage under adverse conditions
• After severe transport stresses

42/24-10-5 EN Advance Optima Operator’s Manual xi

Chapter 1 Analyzer System Unpacking and Installation

Analyzer System Unpacking

CAUTION!
The analyzer system 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 analyzer system and foam packing or other packaging
materials from the shipping box.
2 Take off the foam packing and other packaging and place the analyzer
system in a clean area.
3 Clean the adhesive packaging residue from the analyzer system.

F If there is shipping damage which points to improper handling file a damage claim
with the shipper (railway, mail or freight carrier) within seven days.
Make sure that none of the enclosed accessories are lost during unpacking.
The following section contains a list of the materials supplied with the analyzer
system.
Keep the shipping box and packaging material for future shipping needs.

Standard Equipment Quantity Description

1 Advance Optima Analyzer System
1 "Analyzer Data Sheet" (in the system housing)
1 Operator’s Manual
1 CD-ROM containing technical documentation and
communication software
10 Plastic tubing connectors
1 Power cord, 5 meters long, with grounded-instrument connector
and separate grounded two-pin plug
1 System bus termination resistor
2 12-pin socket strips to connect system controller

Options Quantity Description

(depending on the Connection cables for analyzer module 24 VDC power supply
version) Connection cables, tees and terminating resistors for the system
bus (per order)
1–5 22-pin socket strips to connect I/O boards (per order)
2 Inserts for PG-21 cable threaded connections in the IP-54 version

42/24-10-5 EN Chapter 1: Analyzer System Unpacking and Installation 1-1

Analyzer System Identification

What do we mean by When we say "Analyzer System Identification" we mean answering the following
"Analyzer System questions:
Identification"?
• For what tasks is the analyzer system intended?
• What are the components that make up the analyzer system?
• What are the characteristics (e.g. power supply voltage, measurement range,
etc.) of the individual modules?

How can you identify Your analyzer system can be identified by

your analyzer • The identification plates affixed to the analyzer system
system? • The "analyzer data sheet" included with the analyzer system

Identification Plates The analyzer system has several identification plates:

• The analyzer system identification plate (see Figure 1-1) is on the outside of the
system housing (as seen from the front).
• On the 19-inch version the system housing identification plates are inside the
right sidewall and on the left sidewall inside the wall-mount housing.
• The analyzer module identification plate is located externally on the connection
board (except for analyzer modules with direct connection to the sample
chamber). Also each analyzer has its own identification plate.
• The electronics module identification plate is located externally on the
connection board over the I/O board ports.
• The gas module identification plate is located at the rear behind the back plate
(behind the flow sensors).

Figure 1-1
Typical Analyzer
System Identification Advance Optima
Plate (Example)
P-No. 24031-0-111000000000 ← Analyzer System Part Number
A-No. 00000604 / 2000 F-No. 3.505229.9 ← Order Number and Production
Number

Baugruppen / Modules
1. P.-No. 24511-0-113110201002, F-No. 3.505250.9 Uras 14 ← Housing and Installed Module
2. P.-No. 24311-0-131100000001, F-No. 3.505215.9 Housing Part and Production Numbers
3. P.-No. 24411-0-110000010011, F-No. 3.505248.9 Electronic

Continued on next page

1-2 Chapter 1: Analyzer System Unpacking and Installation 42/24-10-5 EN

Analyzer System Identification, continued

Analyzer Data Sheet For the central unit and each analyzer module the analyzer data sheet contains the
following information:
• Order Number (A-No.),
• Part Number (P-No.)
• Production date
• Production Number (F-No.)
• Serial Number
• Software Version
• Power Supply Voltage
• Measurement Range Information
• Configured Correction Functions
• Signal Input and Output Connection Drawings
• Gas Inlet and Outlet Connection Drawings
Additionally, you (and ABB Automation Service) can document on the analyzer
data sheet any maintenance work or modifications performed on your analyzer
system.

Where is the analyzer The analyzer data sheet is located in a sleeve which is affixed
data sheet located? • to the inner side of the left side wall (19-inch rack-mount housing) or
• to the inner side of the door (wall-mount housing)

F The analyzer data sheet should be kept with the analyzer system so that it is
always available for reference.

F During operation be sure to note the device- and system-specific data in the
analyzer data sheet. These data can differ from the information contained in this
operator’s manual.

42/24-10-5 EN Chapter 1: Analyzer System Unpacking and Installation 1-3

Dimensional Diagrams

F • The connection box shown with dashed lines in the dimensional diagrams is
flange-mounted to the IP-54 housing.
• 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.

Figure 1-2
19-Inch Housing
(dimensions in mm)

Figure 1-3
Wall-Mount Housing
(dimensions in mm)

1-4 Chapter 1: Analyzer System Unpacking and Installation 42/24-10-5 EN

Instructions for Selecting a Location

Short Gas Paths Install the analyzer system as close as possible to the sampling location.
Locate the gas preparation and calibration assemblies as close as possible to the
analyzer system.

Adequate Air Provide for adequate natural air circulation around the analyzer system. 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 analyzer system 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 1-6)

Environmental Air pressure range 600...1250 hPa

Conditions Relative humidity max. 75 %
Ambient temperature range at storage and transport –25...+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
Caldos 15 +5 to +50°C +5 to +45°C
Caldos 17 +5 to +50°C +5 to +45°C
Limas 11 +5 to +45°C +5 to +45°C
Magnos 16 +5 to +50°C +5 to +45°C
Magnos 106 +5 to +50°C +5 to +45°C
Magnos 17 +5 to +50°C +5 to +45°C
Uras 14 +5 to +45°C +5 to +40°C
Oxygen Sensor +5 to +40°C +5 to +40°C

Continued on next page

42/24-10-5 EN Chapter 1: Analyzer System Unpacking and Installation 1-5

Instructions for Selecting a Location, continued

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

Analyzer Module Vibrations

Caldos 15 max. ±0.04 mm at 5...30 Hz
Caldos 17 max. ±0.04 mm at 5...55 Hz, 0.5 g at 55...150 Hz
Limas 11 max. ±0.04 mm / 0.5 g at 5...150 Hz
Magnos 16 max. ±0.04 mm at 5...20 Hz
Magnos 106 max. ±0.04 mm at 5...20 Hz
Magnos 17 max. ±0.04 mm at 5...60 Hz
Uras 14 max. ±0.04 mm at 5...55 Hz, 0.5 g at 55...150 Hz
slight transient effect on sample value in the region
of the beam modulation frequency

1-6 Chapter 1: Analyzer System Unpacking and Installation 42/24-10-5 EN

Gas Connections

F Since the gas ports are now easily accessible, connect the gas lines to the analyzer
module before the analyzer system is installed.

Gas Port Design The analyzer module gas ports have 1/8-NPT internal threads (connection
diagrams see pages 2-1 to 2-3).

What materials are Material Supplied

needed? Tubing connectors with 1/8 NPT threads and yes
Teflon sealing tape no
or
Threaded connections with 1/8 NPT threads and no
Teflon sealing tape no
or
Threaded connections with G-1/8 threads no
(DIN/ISO 228/1) and O-rings/ sealing washers 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.
Caldos 15 The sample and reference gas connection ports on the Caldos 15 flowing
reference gas version are made of plastic (PVC-C). Do not use metal tubing
connectors or threaded connectors.

Gas Connections Step Action

1 Remove the yellow stopper screws (5 mm Allen screws) from the
connection ports.
2 Screw the tubing or threaded connectors with sealing material (Teflon
sealing tape, O-rings, sealing washers) in the connection ports.
F 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 8-2 for instructions).

F Since the system housing has to be opened if a leak is found, the gas path seal
integrity should be checked before the analyzer system is installed.

42/24-10-5 EN Chapter 1: Analyzer System Unpacking and Installation 1-7

Analyzer System Installation

CAUTION!
A system housing with an electronics module and an analyzer module weighs
from 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
analyzer system’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 1-4 for dimensional diagrams).

F • 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
alignment of the display.
• Multiple system housings in a 19-inch rack should be installed with a separation
of at least one height unit.

What’s next? The analyzer system is now ready for connection of the gas lines and electrical
wiring.

1-8 Chapter 1: Analyzer System Unpacking and Installation 42/24-10-5 EN

Chapter 2 Gas Line Connection

Analyzer Module Connection Diagrams

Caldos 17, Magnos 16, Magnos 106, Magnos 17 with or without gas module,
internal gas connections with plastic tubing

Figure 2-1 1 Not used

2 Span Gas Inlet (Gas Module
Caldos 17 with 3 Valves)*
11 10 1
Magnos 16 3 Zero Gas Inlet (Gas Module
Magnos 106 with 1 or 3 Valves)*
Magnos 17 9 2
4 Sample Gas Inlet
5 Analyzer Purge Gas Inlet
12 8 3 6 Analyzer Purge Gas Outlet
7 Sample Gas Outlet
7 6 5 4
8 Pressure Sensor (Caldos 17
and Magnos 16* only)
9 Housing Purge Gas Outlet*
10 Housing Purge Gas Inlet*
11 System Bus
12 24-VDC Power Supply
* Option

Caldos 15, Caldos 17, Magnos 16, Magnos 17 without gas module, internal
gas connections directly on bottom of module (wall-mount housing only)

Figure 2-2 4 Sample Gas Inlet

5 Analyzer Purge Gas Inlet
Caldos 15 6 Analyzer Purge Gas Outlet
9
Caldos 17 11
7 Sample Gas Outlet
Magnos 16 6
8 8 Pressure Sensor (Caldos 17
Magnos 17 and Magnos 16* only)
14
13 7
9 Housing Purge Gas Outlet*
12 5 4 10 Housing Purge Gas Inlet*
11 System Bus
10 12 24-VDC Power Supply
13 Reference Gas Outlet**
14 Reference Gas Inlet**
* Option
** Caldos 15 with flowing
reference gas only
Caldos 15 The Caldos 15 with flowing reference gas has plastic (PVC-C) sample gas and
reference gas connectors 4, 7, 13 and 14. Do not use metal tubing connectors or
threaded connections.
Caldos 17 For the Caldos 17 direct sample cell connection is possible also in the 19-inch
housing.

Continued on next page

42/24-10-5 EN Chapter 2: Gas Line Connection 2-1

Analyzer Module Connection Diagrams, continued

Magnos 106 without gas module, internal gas connections directly on bottom
of module (wall-mount housing only)

Figure 2-3 4 Sample Gas Inlet

5 Analyzer Purge Gas Inlet
Magnos 106 6 Analyzer Purge Gas Outlet
9
11
7 Sample Gas Outlet
6
8 8 Pressure Sensor (Caldos 17
14
and Magnos 16* only)
13 7
9 Housing Purge Gas Outlet*
12 5 4 10 Housing Purge Gas Inlet*
11 System Bus
10 12 24-VDC Power Supply
* Option

Uras 14 with or without gas module,

sample cells in series, internal gas connections with plastic tubing

Figure 2-4 1 Sample Cell 1 Flowing

Reference Gas Inlet*
Uras 14 2 Sample Cell 1 Flowing
11 10 1
Reference Gas Outlet*
3 Sample Gas Outlet
9 2
4 Sample Cell 2 Flowing
Reference Gas Inlet*
12 8 3 5 Housing Purge Gas Inlet
6 Housing Purge Gas Outlet
7 6 5 4
7 Sample Cell 2* Flowing
Reference Gas Outlet or
Pressure Sensor*
8 Sample Gas Inlet
9 Zero Gas Inlet (Gas Module
with 1 or 3 Valves)*
10 Span Gas Inlet (Gas Module
with 3 Valves)*
11 System Bus
12 24-VDC Power Supply
* Option
One of the several possible Uras 14 connection arrangements is shown. The actual
connection arrangement of an analyzer module is found in the analyzer data sheet
for the delivered instrument.

Continued on next page

2-2 Chapter 2: Gas Line Connection 42/24-10-5 EN

Analyzer Module Connection Diagrams, continued

Limas 11 with or without gas module,

internal gas connections with plastic tubing or pipes

Figure 2-5 1 Sample Gas Inlet

2 Not Used
Limas 11 with 11 8 4 1
3 Housing Purge Gas Inlet
Standard Cell 4 Sample Gas Outlet
9 5 Not Used
6 Housing Purge Gas Outlet
12
6 3 7 Pressure Sensor*
8 Span Gas Inlet (Gas Module
with 3 Valves)*
9 Zero Gas Inlet (Gas Module
7 with 1 or 3 Valves)*
11 System Bus
12 24-VDC Power Supply
* Option

Figure 2-6 1 Sample Gas Inlet

3 Housing Purge Gas Inlet
Limas 11 with 11 4 1
4 Sample Gas Outlet
Quartz Cell 6 Housing Purge Gas Outlet
7 Pressure Sensor *
11 System Bus
12
6 3 12 24-VDC Power Supply
* Option

Figure 2-7 1 Sample Gas Inlet

2 Sample Gas Outlet
Limas 11 with 11 4 1
3 Housing Purge Gas Inlet
Safety Cell 4 Sample Cell Purge Gas Inlet
5 2 5 Sample Cell Purge Gas Outlet
6 Housing Purge Gas Outlet
12
6 3 7 Pressure Sensor *
11 System Bus
12 24-VDC Power Supply

7 * Option

42/24-10-5 EN Chapter 2: Gas Line Connection 2-3

Gas Diagrams

Figure 2-8 Test gas connection for

Option Caldos 17,
Analyzer Module and
Limas 11 without calibration cells,
Gas Module with
Magnos 16,
3 Solenoid Valves MG
Magnos 106,
Magnos 17,
NG
Uras 14 without calibration cells
Option: Flow monitoring, e.g. for
EG flowing reference gas or purge gas
(external needle valve required)

P
O2 c
E

Figure 2-9 Test gas connection for

Option Caldos 17 with single-point calibration,
Analyzer Module and
Limas 11 with calibration cells,
Gas Module with
Magnos 16 with single-point calibration,
1 Solenoid Valve MG
Magnos 106 with single-point calibration,
NG/ Uras 14 with calibration cells
EG
Option: Flow monitoring, e.g. for
P flowing reference gas or purge gas
c (external needle valve required)
O2
E

Figure 2-10 External test gas connection for

Option Caldos 17, Limas 11, Magnos 16,
Analyzer Module and
Magnos 106, Magnos 17, Uras 14
Gas Module without
Solenoid Valves MG Option: Flow monitoring, e.g. for
flowing reference gas or purge gas
(external needle valve required)
P
O2 c
E

Figure 2-11 Caldos 15, Caldos 17, Limas 11,

MG
Magnos 16, Magnos 106, Magnos 17,
Analyzer Module
P Uras 14 without gas supply
without Gas Supply
O2 c
E

MG Sample Gas
NG Zero gas
EG Span Gas
Flow Flow Monitor
O2 Oxygen Sensor (Option)
P Pressure Sensor in Analyzer Module

2-4 Chapter 2: Gas Line Connection 42/24-10-5 EN

Gas Inlet and Outlet Conditions

Gas Inlet Conditions The following sample gas and, if applicable, flowing reference gas inlet conditions
apply to the analyzer modules and the gas module.

3)
Module Temperature Pressure pe Flow Rate
1)2)
Caldos 15 +5 to +50°C 2-100 hPa 10-90 l/h
4)
max. 1000 hPa max. 90-200 l/h
1)2)
Caldos 17 +5 to +50°C 2-100 hPa 10-90 l/h
max. 1000 hPa min. 1 l/h
1)
Limas 11 +5 to +45°C 2-500 hPa 20-100 l/h
8 ± 0.5 l/h
1)2) 5)
Magnos 16 +5 to +50°C 25-100 hPa
6) 7)
max. 1000 hPa 30-60-90 l/h
1)2) 7)
Magnos 106 +5 to +50°C 2-100 hPa 20-60 l/h
max. 1000 hPa
1)2)
Magnos 17 +5 to +50°C 2-100 hPa 20-60 l/h
max. 400 hPa max. 90 l/h
1)
Uras 14 +5 to +45°C 2-500 hPa 20-100 l/h
1)
Oxygen Sensor +5 to +40°C 2-500 hPa 20-60 l/h
≤ 60 l/h
1)
Gas Module +5 to +45°C –80 to +20 hPa

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) Without flow regulator
6) With flow regulator
7) Abrupt changes in gas flow rates should be avoided when using highly
suppressed measurement ranges.

Combustible, Corro- A housing purge is required if the sample gas contains combustible, corrosive or
sive or Toxic Gases toxic components (see "Housing Purge" section, page 2-7).
Please observe additionally the following application restrictions and notes if the
sample gas contains corrosive associated gas components:
Uras 14 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.
Caldos 17 Consultation with ABB Analytical is required if the sample gas contains Cl2, HCl,
HF, SO2, NH3, H2S or other corrosive components.
Magnos 16/106 Consultation with ABB Analytical is required if the sample gas contains Cl2, HCl,
HF or other corrosive components.
Oxygen Sensor H2O dew point ≥ 2 °C. The oxygen sensor should not be used with dry 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.
Continued on next page

42/24-10-5 EN Chapter 2: Gas Line Connection 2-5

Gas Inlet and Outlet Conditions, continued

Gas Module Corrosive associated gas components and aerosols must be cooled or undergo
prior absorption.
Limas 11 Standard Cell Quartz Cell Safety Cell
Application Standard applications Corrosive gases Corrosive, toxic and
combustible gases
Wavelength Range 200 to 10000 nm 200 to 4000 nm CaF2 window: 200 to 10000 nm
SiO2 window: 200 to 4000 nm
1)
Resistance
Suitable for Non-corrosive gases Corrosive gases, Corrosive gases,
measurement of ... e.g. wet Cl2, wet HCl, H2SO4, e.g. dry HCl, dry COCl2
SO3, ozone (< 50 ppm H2O)
Not suitable for Highly corrosive gases, e.g. Fluorine compounds Wet gases containing chlorine,
measurement of ... gases containing chlorine, H2SO4, SO3, fluorine
H2SO4, SO3, fluorine compounds
compounds
Safety Principle
Housing purge (≤ 20 l/h) Housing purge (≤ 20 l/h)
2)
Toxic Gases Cell purge with N2 or with
with sample component-free with sample component-free sample component-free air
air or with N2 air or with N2 with negative pressure and
flow monitoring; additional
monitoring for sample gas
traces possible
Housing purge (≤ 20 l/h)
2)
Corrosive Gases PTFE gas lines, Cell purge with N2 or with
housing purge (≤ 20 l/h) with sample component-free sample component-free air
3)
with sample component-free air or with N2 with excess pressure and
air or with N2 flow monitoring
Housing purge (≤ 20 l/h) Housing purge (≤ 20 l/h)
2)
Combustible Gases Cell purge with N2 with
3)
with N2 with N2 excess pressure and flow
monitoring
Zone 2 Combustible – – Cell purge with N2 with excess
3)
Gases pressure and flow monitoring
–3 –6 –6
Seal Integrity < 1 x 10 hPa l/s < 1 x 10 hPa l/s < 1 x 10 hPa l/s
Pressure Rating
Continuous pe < 500 hPa pe < 500 hPa pe < 500 hPa
Spike – pabs < 300 kPa pabs < 500 kPa
Sample Cell Material
Cell Tube Aluminum Silica glass (SiO2) Stainless steel 1.4571
Window CaF2, adhesive fastening Silica glass (SiO2) CaF2 or SiO2, threaded
fastening
® ®
Seal – FFKM75 (Kalrez ) FFKM70 (Kalrez )
Connectors Stainless steel 1.4571 PFA Stainless steel 1.4571
Gas Line Materials Viton or PTFE PFA Stainless steel 1.4571
Gas Connector Materials Stainless steel 1.4571 PFA Stainless steel 1.4571
Gas Connection Design Connectors with 1/8 NPT Tubes 6/4 mm Pipes with 4-mm OD
internal threads

1) see page 2-5 “Gas Inlet Conditions”

2) purge curtain, optional
3) pe = 0.5 to 100 hPa, 15 to 20 l/h

Gas Outlet Conditions The outlet pressure should be equal to atmospheric pressure.

2-6 Chapter 2: Gas Line Connection 42/24-10-5 EN

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 IP 54 (with
connection box) or IP 65 (without power supply) protection. The purge gas
connection ports (1/8-NPT internal threads) are factory installed per order.

Housing Purge in In systems with the Caldos 15, Caldos 17, Magnos 16, Magnos 106 and Magnos 17
Caldos 15 analyzer modules there is a gas-tight separation between the central unit and
Caldos 17 analyzer. Therefore, the central unit and analyzer can be purged separately
Magnos 16 (parallel) or jointly (series).
Magnos 106
Magnos 17

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.

Housing Purge in In systems with the Limas 11 and Uras 14 analyzer modules there is no gas-tight
Limas 11 separation of the central unit and analyzer. Therefore, they can only be purged
Uras 14 together. If the central unit and analyzer must be purged separately, the analyzer
module must be installed in a separate IP-54 system housing.

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.

Continued on next page

42/24-10-5 EN Chapter 2: Gas Line Connection 2-7

Housing Purge, continued

Purge Gas The following purge gases can be used:

• Nitrogen when measuring combustible gases or
• Instrument air (Class 4 per PNEUROP 6611 recommendation of 1984, i.e. max.
particle size of 40 µm, max. oil content 5 mg/m , max. pressure dew point +2 °C)
3

when measuring corrosive gases.

Limas 11 In systems with the Limas 11 and Uras 14 analyzer modules the purge gas should
Uras 14 not contain any sample gas components. Any sample components in the purge
gas can cause false readings.

Purge Gas Flow Rate Purge gas flow rate at device inlet max. 20 l/h (constant)
Purge gas positive pressure pe = 2 to 4 hPa
Note: Because of leakage losses the purge gas flow rate at the device output is
approx. 5-10 l/h for a purge gas flow rate at the device inlet of 20 l/h.

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 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!

2-8 Chapter 2: Gas Line Connection 42/24-10-5 EN

Pressure Sensor

Which analyzer The following table shows which analyzer modules have or can be fitted with a
modules have a pressure sensor.
pressure sensor?
Analyzer module Pressure sensor Analyzer module Pressure sensor
Caldos 17 yes Uras 14 yes
Limas 11 yes Caldos 15 no
Magnos 16 yes (option) Magnos 17 no
Magnos 106 yes (option) Multi-FID 14 no

F Use the0(18→'LDJQRVWLF,QIRUPDWLRQ→6\VWHPRYHUYLHZmenu
item and select the appropriate analyzer module to determine if a pressure sensor
is installed.

Pressure Sensor in In the Caldos 17 analyzer module the pressure sensor is located in the thermostat
Caldos 17 room and connected to the gas port 8 (see Figures 2-1 and 2-2, page 2-1) via a
Viton pipe.

Pressure Sensor in In the Magnos 16 and Magnos 106 analyzer modules the pressure sensor (optional)
Magnos 16 is located in the thermostat room and connected to the gas port 8 (see Figures 2-1,
Magnos 106 2-2 and 2-3, pages 2-1 and 2-2) via a Viton pipe.
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).

Pressure Sensor in In the Limas 11 and Uras 14 analyzer modules the pressure sensor is located in the
Limas 11 sample gas path if pipes are used as the internal gas lines. The pressure sensor is
Uras 14 connected to an external port via a Viton pipe if tubing is used for the internal gas
lines (see Figures 2-4 to 2-7, pages 2-2 and 2-3). Please consult the pneumatic
diagram in the analyzer data sheet for the actual pressure sensor connection.

Operation of the Please observe the following notes for the correct operation of the pressure
Pressure Sensor sensor:
• Remove the yellow plug from the pressure sensor port before start-up of the
analyzer module.
• 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.

42/24-10-5 EN Chapter 2: Gas Line Connection 2-9

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.

F • Gas port installation is described in Chapter 1 "Analyzer System Unpacking and

Installation".
• 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 lines cannot be connected directly to the oxygen sensor and the gas
module. These two components are connected to the applicable analyzer
module inside the analyzer system.

Gas Line Connection Connect the gas lines – made of a material appropriate for the measurement task –
to the installed gas ports.

Purge Gas Line Connection of the purge gas lines is described in the following section.
Connection

Evacuate Exhaust Exhaust gases should be routed to the atmosphere or to an exhaust pipe directly
Gases or via the shortest possible large-diameter line. Do not route exhaust gases via
flow reducers or shutoff valves.

F Process corrosive, toxic or combustible exhaust gases in an appropriate manner.

Provide for Gas 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.

Flowmeter In the Caldos 15 and Uras 14 versions with flowing reference gas a flow meter with
Installation in a needle valve must be installed in the sample gas line and in the reference gas
Caldos 15 line in order to adjust the flow rate in the two lines to the optimum value.
Uras 14

What’s next? The analyzer system is now ready for connection of the electrical wiring.

2-10 Chapter 2: Gas Line Connection 42/24-10-5 EN

Purge Gas Line Connection

Purge Gas Line Figures 2-12 through 2-25 illustrate the purge gas line connections for various
Connection system configurations:
• Central unit or blank housing without analyzer module (Figure 2-12)
• 1 analyzer module in central unit or blank housing (Figure 2-13 to 2-18)
• 2 analyzer modules in one housing (Figures 2-19 to 2-25)

F Due to differing purge gas supply requirements, the Multi-FID 14 should not be
purged in series with the Caldos 15, Caldos 17, Limas 11, Magnos 16/ 106,
Magnos 17 and Uras 14 analyzer modules.
The following illustrations do not show the Limas 11 analyzer module in combination
with other analyzer modules. Connect the purge gas lines to this analyzer module in
the same manner as for the Uras 14 analyzer module, i.e. Figures 2-21 through 2-23
also apply to the Limas 11 analyzer module. Port 3 = purge gas inlet, Port 6 = purge
gas outlet.
The following illustrations do not show the Magnos 106 analyzer module. Connect
the purge gas lines to this analyzer module in the same manner as for the
Magnos 16 analyzer module; note the different arrangement of the gas connections
in the design for installing in the wall housing (direct installation) (see Figure 2-3,
page 2-2).
When connecting purge gas lines to two different analyzer modules in one housing
(see Figures 2-22 through 2-25) the analyzer module sequence is the determinative
factor rather than the arrangement of modules in the housing.

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.
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!
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.

Legend for Symbols Purge gas connection should be closed off.

User-connected purge gas lines. The arrow indicates purge gas flow
direction.

Continued on next page

42/24-10-5 EN Chapter 2: Gas Line Connection 2-11

Purge Gas Line Connection, continued

Figure 2-12

Figure 2-13

Figure 2-14

Continued on next page

2-12 Chapter 2: Gas Line Connection 42/24-10-5 EN

Purge Gas Line Connection, continued

Figure 2-15

Figure 2-16

Figure 2-17

Continued on next page

42/24-10-5 EN Chapter 2: Gas Line Connection 2-13

Purge Gas Line Connection, continued

Figure 2-18

Figure 2-19

Figure 2-20

Continued on next page

2-14 Chapter 2: Gas Line Connection 42/24-10-5 EN

Purge Gas Line Connection, continued

Figure 2-21

Figure 2-22

Figure 2-23

Continued on next page

42/24-10-5 EN Chapter 2: Gas Line Connection 2-15

Purge Gas Line Connection, continued

Figure 2-24

Figure 2-25

2-16 Chapter 2: Gas Line Connection 42/24-10-5 EN

Chapter 3 Electrical Connection

Electronics Module Connections

Figure 3-1
Electronics Module
Connections -X04
10BASE2

1 1 1

-X05
RS 485

-X01
-X06
RS 232C

BUS-X07
-X02 1 12

-X08
10BASE-T 22 22 22
-X03 13 24
A I/O D I/O D I/O
1 2 3 4 5

-X11 -X12 -X13 -X14 -X15

-X01 115 VAC or 230 VAC Power Supply

-X02 Digital Outputs (System Controller)
-X03 Analog Outputs and Digital Inputs (System Controller)
-X04 Ethernet 10BASE2 Port (Optional)
-X05 RS-485 Port
-X06 RS-232C Port
-X07 System Bus Port
-X08 Ethernet 10BASE-T Port
-X11 –
-X15 I/O Boards (Optional, Sample Installation)
Potential Compensation

42/24-10-5 EN Chapter 3: Electrical Connection 3-1

I/O Base Module Connection Diagrams

Figure 3-2
I/O Base Module
Connection Diagram
(115/230 VAC Power
Supply)
-X01

-X07

-X11 -X12 -X13 -X14 -X15

-X01 115/ 230 VAC Power Supply (internal)

-X07 System Bus Port
-X11 –
-X15 I/O Boards (Optional, Sample Installation)

Figure 3-3
I/O Base Module
Connection Diagram
(24 VDC Power
-X01
Supply)

-X07

-X11 -X12 -X13 -X14 -X15

-X01 24 VDC Power Supply (external)

-X07 System Bus Port
-X11 –
-X15 I/O Boards (Optional, Sample Installation)

3-2 Chapter 3: Electrical Connection 42/24-10-5 EN

System Controller Connection Diagram

Figure 3-4
-X02 Digital Outputs (DO)
System Controller 1 DO1 NC max. 30 V / 1 A
Connection Diagram 2 C
-X02, -X03
3 NO
4 DO2 NC max. 30 V / 1 A
5 C
6 NO
7 DO3 NC max. 30 V / 1 A
8 C
9 NO
10 DO4 NC max. 30 V / 1 A
11 C
12 NO

-X03 Analog Outputs (AO), Digital Inputs (DI)

13 AO1 + 0/4 - 20 mA, max. 750 Ω
14 -
15 AO2 + 0/4 - 20 mA, max. 750 Ω
16 -
+ - 17 DI1 + - 12 - 24 VDC
18
+ - 19 DI2 + - 12 - 24 VDC
20
+ - 21 DI3 + - 12 - 24 VDC
22
+ - 23 DI4 + - 12 - 24 VDC
24

DO1-DO4 Digital Outputs:

Floating double-throw contacts, max. contact load rating 30 V/1 A
F 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).
AO1-AO2 Analog Outputs:
0/ 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.
The output signal cannot be lower than 0 mA.
DI1-DI4 Digital Inputs:
Optocoupler with internal 12-24 VDC power supply, switchable with
floating contacts; alternative: switchable with external voltage
12-24 VDC, common negative pole
Design Two 12-pin terminal strips for braided or solid conductors with a
2
maximum section of 1.5 mm or 16 AWG

F The pin layout with input and output signals for a delivered system will be shown in
the applicable analyzer data sheet (see "Analyzer System Identification", page 1-3).
Relays are shown in the unpowered state. The unpowered state is the failure mode
("fail safe").

42/24-10-5 EN Chapter 3: Electrical Connection 3-3

Analog I/O Board Connection Diagram

Figure 3-5
1
Analog I/O Board 2
Connection Diagram
3 DO1 NC max. 30 V / 1 A
-X11 – -X15
4 C
5 NO
6 DO2 NC max. 30 V / 1 A
7 C
8 NO
+ - 9 DI1 + - 12 - 24 VDC
10
+ - 11 DI2 + - 12 - 24 VDC
12
50 Ω 13 AI1 U -10 - +10 V Rin = 1 M Ω or
14 I -20 - +20 mA into 50 Ω,
15 C to 10 V mutually isolated
16 AI2 U -10 - +10 V Rin = 1 M Ω or
50 Ω
17 I -20 - +20 mA into 50 Ω,
18 C to 10 V mutually isolated
19 AO1 + 0/4 - 20 mA, max. 750 Ω
20 -
21 AO2 + 0/4 - 20 mA, max. 750 Ω
22 -

DO1-DO2 Digital Outputs:

Floating double-throw contacts, max. contact load rating 30 V/1 A
F 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).
DI1-DI2 Digital Inputs:
Optocoupler with internal 12-24 VDC power supply, switchable with
floating contacts; alternative: switchable with external voltage
12-24 VDC, common negative pole
AI2-AI2 Analog Inputs:
–20 to +20 mA into 50 Ω or –10 to +10 V, Rin = 1 MΩ, mutually isolated
to 10 V
AO1-AO2 Analog Outputs:
0/ 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.
The output signal cannot be lower than 0 mA.
Design: One 22-pin terminal strip for braided or solid cable with a maximum
2
section of 1.5 mm or 16 AWG

F The pin layout with input and output signals for a delivered system will be shown in
the applicable analyzer data sheet (see "Analyzer System Identification", page 1-3).
Relays are shown in the unpowered state. The unpowered state is the failure mode
("fail safe").

3-4 Chapter 3: Electrical Connection 42/24-10-5 EN

Digital I/O Board Connection Diagram

Figure 3-6
1
Digital I/O Board 2
Connection Diagram
3 DO1 NC max. 30 V / 1 A
-X11 – -X15
4 C
5 NO
6 DO2 NC max. 30 V / 1 A
7 C
8 NO
9 DO3 NC max. 30 V / 1 A
10 C
11 NO
12 DO4 NC max. 30 V / 1 A
13 C
14 NO
+ - 15 DI1 + - 12 - 24 VDC
16
+ - 17 DI2 + - 12 - 24 VDC
18
+ - 19 DI3 + - 12 - 24 VDC
20
+ - 21 DI4 + - 12 - 24 VDC
22

DO1-DO4 Digital Outputs:

Floating double-throw contacts, max. contact load rating 30 V/1 A
F 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).
DI1-DI4 Digital Inputs:
Optocoupler with internal 12-24 VDC power supply, switchable with
floating contacts; alternative: switchable with external voltage
12-24 VDC, common negative pole
Design: One 22-pin terminal strip for braided or solid cable with a maximum
2
section of 1.5 mm or 16 AWG

F The pin layout with input and output signals for a delivered system will be shown in
the applicable analyzer data sheet (see "Analyzer System Identification", page 1-3).
Relays are shown in the unpowered state. The unpowered state is the failure mode
("fail safe").

42/24-10-5 EN Chapter 3: Electrical Connection 3-5

8-Way Analog Output Board Connection Diagram

Figure 3-7
1
8-Way Analog Output 2
Board Connection
3
Diagram
4 AO1 + 0/4...20 mA, max. 750 Ω
-X11 – -X15
5 -
6 AO2 + 0/4...20 mA, max. 750 Ω
7 -
8 AO3 + 0/4...20 mA, max. 750 Ω
9 -
10 AO4 + 0/4...20 mA, max. 750 Ω
11 -
12
13
14 AO5 + 0/4...20 mA, max. 750 Ω
15 -
16 AO6 + 0/4...20 mA, max. 750 Ω
17 -
18 AO7 + 0/4...20 mA, max. 750 Ω
19 -
20 AO8 + 0/4...20 mA, max. 750 Ω
21 -
22

AO1-AO8 0/ 4 to 20 mA (configurable, factory-set to 4-20 mA), 2 groups of 4

analog outputs with common negative pole, galvanically isolated from
ground, freely connectable to ground, max. gain relative to protective
ground potential 50 V, max. working resistance 750 Ω.
The output signal cannot be lower than 0 mA.
Design: One 22-pin terminal strip for braided or solid cable with a maximum
2
section of 1.5 mm or 16 AWG

F The pin layout with input and output signals for a delivered system will be shown in
the applicable analyzer data sheet (see "Analyzer System Identification", page 1-3).

3-6 Chapter 3: Electrical Connection 42/24-10-5 EN

Interface Connections

Figure 3-8 2 RTxD+

5 4 3 2 1
3 RTxD+
RS-485 Port
5 GND
-X05 9 8 7 6

Design: 9-pin Sub-D female connector

Figure 3-9 2 RxD

1 2 3 4 5
3 TxD
RS-232C Port
5 GND
-X06 6 7 8 9

Design: 9-pin Sub-D male connector

Figure 3-10 1 10TT+

1 8 2 10TT–
Ethernet 10BASE-T
3 10TR+
Port -X08
6 10TR–
Design: 8-pin RJ45 jack

42/24-10-5 EN Chapter 3: Electrical Connection 3-7

Signal, Control and Interface Line Connection

CAUTION!
Follow local regulations on installing and connecting electrical wiring.

F The power supply line connection instructions and precautions are contained in
Chapter 4 "Analyzer System Start-Up", since the analyzer system can begin
operation once the power supply lines are connected.

F Locate the signal, control and interface lines separately from the power supply
lines.
Locate the analog and digital signal leads separately from each other.

F Carefully plan the arrangement of signal lines in the cables as well as the use of
connector box openings in the IP-54 system housing.

What materials are Selection of the required conductors depends on:

needed? • Line length
• Planned current load
2
The maximum conductor section is 1.5 mm , or 16 AWG.
The maximum line length is 3937 feet (1200 meters; transmission rate max.
19200 baud) for RS-485 and 49 feet (15 meters) for RS-232C.
The matching female connector housings for the analog and digital input and
output connection strips in the system controller and on the I/O boards (options)
are supplied with the device.

Connection Box The IP-54 version of the system housing has a connection box on the back of the
electronics module.
The connection box has:
• EN version: Two PG-21 and five PG-13.5 threaded cable connections
• CSA version: One 1-1/4-inch and two 3/4-inch conduits.
Two PG-21 threaded cable connections are provided to route system bus, Modbus
and Ethernet cables.

Continued on next page

3-8 Chapter 3: Electrical Connection 42/24-10-5 EN

Signal, Control and Interface Line Connection, continued

Wiring Connection IP 20 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.

IP 54 Version of System Housing (with connection box):

Step Action
1 Run the cables through the connection box openings.
PG 21: 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.
PG 13.5: Remove the plug from the insert; the ring remains in place as
a gasket and strain relief.
2 Connect the wiring to the connector housing according to the
connection diagrams.
3 Connect the connector housings to the terminal strips.

Configuring the For configuring the Ethernet connection see page 6-C-10.
Ethernet and Modbus
For configuring the Modbus connection see page 6-C-11.
Connections
For additional Modbus information see the "Advance Optima Modbus – Functions
and Components" (Publication No. 30/24-310 EN).

42/24-10-5 EN Chapter 3: Electrical Connection 3-9

System Bus Connection

System Bus The functional components of the analyzer system, i.e. the electronics module, the
I/O boards and the analyzer modules communicate with each other via the system
bus.
The system bus structure is linear with a maximum length of 350 meters.

Analyzer System in The system bus connection is established at the factory when the analyzer system
One System Housing functional components (e.g. an electronics module and an analyzer module) are
installed in one system housing.

F In this case a terminating resistor should be installed in the system bus connector
("BUS") (supplied with the unit, see Figure 3-11).

Figure 3-11 AM Analyzer Module

AM EM PS EM Electronics Module
Analyzer System in
PS Power Supply
One System Housing:
BUS BUS System Bus (Internal)
Terminating Resistor
Terminating Resistor
on the Electronics
Module

Analyzer System in If the analyzer system functional components are installed in several system
Multiple System housings, they must be interconnected externally via the system bus (see Figure
Housings 3-12 and instructions on the following page).

Figure 3-12
EM PS EM PS
Analyzer System in
Multiple System
Housings:
Connection via the
System Bus
BUS BUS

AM PS AM BM PS

AM Analyzer Module EM Electronics Module BUS System Bus (External)

BM Base I/O Module PS Power Supply Terminating Resistor

CAUTION!
Only one electronics module should be connected to a system bus structure.
Multiple electronics modules should never be interconnected via the system
bus!

Continued on next page

3-10 Chapter 3: Electrical Connection 42/24-10-5 EN

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.

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 mm should be used.
2

2
Number and section of conductors 2 x 2 x 0.25 mm
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 PG 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 3-13 shows the pin layout of the 3-pin system bus plug.

Figure 3-13 Pin Wire Color Signal

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

Continued on next page

42/24-10-5 EN Chapter 3: Electrical Connection 3-11

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 3-14) 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 (see "Setting Up System Modules"
section, page 6-C-5).

Figure 3-14 AM Analyzer Modules

AM EM PS EM Electronics Module
Analyzer System with
PS Power Supply
Multiple Analyzer
BUS BUS System Bus (External)
Modules:
Terminating Resistor
Connection via the
System Bus
BUS

AM PS

3-12 Chapter 3: Electrical Connection 42/24-10-5 EN

Chapter 4 Analyzer System Start-Up

Installation Check

Installation Check Make sure the analyzer system is correctly installed before carrying out any start-
up procedures.
Use the following check list:

Step Check
á
1 Is the analyzer system securely fastened?
(See "Analyzer System Installation" section, page 1-8)
r
2 Are all gas lines correctly connected?
(See Chapter 2 "Gas Line Connection")
r
3 Are all signal, control, interface and (if applicable) system bus lines
correctly placed and connected?
r
(See Chapter 3 "Electrical Line Connection")
4 Are all devices needed for gas preparation, calibration and
exhaust processing correctly connected and ready for use?
r

42/24-10-5 EN Chapter 4: Analyzer System Start-Up 4-1

Gas Path and Housing Initial Purge

F Take note of the instructions in the "Housing Purge" section, page 2-7 and in the
"Purge Gas Line Connection" section, page 2-11.

Purge Prior to The gas paths and if necessary, the system housing should be flushed prior to
Start-Up starting the analyzer system.
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 The following purge gases can be used:

• Nitrogen when measuring combustible gases or
• Instrument air (Class 4 per PNEUROP 6611 recommendation of 1984, i.e. max.
particle size of 40 µm, max. oil content 5 mg/m , max. pressure dew point +2 °C)
3

when measuring corrosive gases.

Limas 11 In systems with the Limas 11 and Uras 14 analyzer modules the purge gas should
Uras 14 not contain any sample gas components. Any sample components in the purge
gas can cause false readings.

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
Analyzer Caldos 15, Caldos 17, 200 l/h (max.) approx. 3 min.
Magnos 16, Magnos 106, Magnos 17
separately

F The purge gas flow rates given in the table only apply to the initial purge. The
following values apply during operation (see "Operation" section, page 4-11):
Purge gas flow rate at device inlet max. 20 l/h (constant)
Purge gas positive pressure pe = 2 to 4 hPa

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 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!

4-2 Chapter 4: Analyzer System Start-Up 42/24-10-5 EN

Power Supply Information

Analyzer System There is a power supply in the analyzer system’s central unit. It requires an input
Power Supply voltage of 115 VAC or 230 VAC and provides an output voltage of 24 VDC to power
the electronics module and an 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 can be 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 (see Figure 4-3,
Page 4-7) and
• no analyzer module is installed in the central unit.
• If only one analyzer module is installed in the system housing, the Advance
Optima 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 Advance Optima power supply (see "Advance Optima Power
Supply" section, Page 4-4).

I/O Base Module The I/O base module requires a 24 VDC ±5% voltage supply.
Power Supply
The I/O base module cannot be installed in the central unit, but must be installed in
a separate system housing. A distinction has to be made between two cases:
• The I/O base 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.
• The I/O base module can be powered by an Advance Optima power supply
installed in the same (separate) system housing.

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.

42/24-10-5 EN Chapter 4: Analyzer System Start-Up 4-3

Advance Optima Power Supply

Application The power supply provides 24 VDC for the electronics module and one analyzer
module built-in in the central unit or one external analyzer module or one external
I/O base module.

Advance Optima Input Voltage 85-115-140 VAC or 185-230-250 VAC, 47-63 Hz

Power Supply Input Current max. 1.9 A at 115 VAC, max. 1.1 A at 230 VAC
Specifications
Power Consumption max. 200 VA
Output Voltage 24 VDC ±5%
Rated Output 144 W
Fuse G fuse element per IEC 127 2, 4 A rating, slow-blow
(for both 115 VAC and 230 VAC)
Line Power Connection 3-pin grounded-instrument connector per IEC 320

Rated Output Power supply rated output decreases (see following tables)
Decrease • as the ambient temperature increases (at the power supply)
• as the altitude of the installation location increases

Ambient Power Supply Installation Power Supply

Temperature Rated Output Location Altitude Rated Output
40 °C 144 W 1000 m 144 W
45 °C 137 W 1500 m 132 W
50 °C 128 W 2000 m 120 W
2500 m 110 W
3000 m 98 W
3500 m 86 W

Module Module Power Consumption

Power Consumption System Controller 20 W
Analog I/O Board 5W
Digital I/O Board 5W
8-Way Analog Output Board 10 W
Caldos 15 35 W
Caldos 17 18 W
Limas 11 80 W/ 35 W at +5 °C/ +45 °C
Magnos 16 35 W
Magnos 106 45 W
Magnos 17 35 W
Multi-FID 14 65 W
Uras 14 20 W/ 75 W with/ without thermostat
Gas Module 10 W/ 20 W with 1/ 3 valves

4-4 Chapter 4: Analyzer System Start-Up 42/24-10-5 EN

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 analyzer system 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 analyzer system can be hazardous if the protective lead is interrupted
inside or outside the system 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 (115 VAC or 230 VAC) to a 24-VDC analyzer module
input. This will destroy the analyzer module electronics.
Install a breaker near the analyzer system in order to completely disconnect
it from the power supply. Mark the breaker so that its relationship to the
protected device is clear.

42/24-10-5 EN Chapter 4: Analyzer System Start-Up 4-5

24 VDC Power Supply Line Connection

F 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 and
• To an I/O base module that is not powered by a power supply built-in in the
same system housing

24-VDC Connecting • If an analyzer module is not installed in the central unit but in a separate system
Cable housing and
• If an I/O base module is not powered by a power supply built-in in the same
system housing
2
a 16.4-foot (5-meter) long cable (2 x 0.5 mm , see Figure 4-1) 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 4-2).
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 4-3,
Page 4-7) or
• An external power supply

Figure 4-1
BN +
24-VDC Connecting
Cable

BU -

Figure 4-2 The illustration shows the pin side of the analyzer module
plug and thus the solder side of the matching female jack.
Analyzer Module
24-VDC Connection

24 VDC Connection to Proceed as follows to connect the 24-VDC power supply

an Analyzer Module • To an analyzer module that is not installed in the central unit but in a separate
system housing or
• To an I/O base module that is not powered by a power supply built-in in the
same system housing:

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.

Continued on next page

4-6 Chapter 4: Analyzer System Start-Up 42/24-10-5 EN

24 VDC Power Supply Line Connection, Continued

Figure 4-3
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
CU Central Unit
EM Electronics Module
PS Power Supply
-Z01 Power Supply Filter
BUS System Bus

2
Extending the 24-VDC The 24-VDC connection cable has a wire section of 0.5 mm , it is limited to a
Connection Cable length of 16.4 feet (5 meters).
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 mm .
2

• The extension cable should be no more than 98 ft (30 meters) 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.

42/24-10-5 EN Chapter 4: Analyzer System Start-Up 4-7

115/230 VAC Power Supply Line Connection

What materials are The analyzer system is supplied with a power cord and a separate two-prong
needed? grounded plug. The power cord is 16.4 feet (5 meters) 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
• Planned current load

Figure 4-4 The illustration shows the pin side of the plug on the
N
electronics module.
115/230 VAC PE
Power Supply L
Connection -X01

115/230 VAC Step Action

Connection
1 Make sure the analyzer system power supply is set to the proper
line voltage. Correct the operating voltage setting as necessary.
2 Make sure the power supply leads have an adequately dimensioned
protective device (breaker).
3 Install a breaker in the power supply line or a switched receptacle near
the analyzer system to make sure the analyzer system can be com-
pletely separated from the power source. Mark the breaker so that its
relationship to the protected device is clear.
4 Connect the power cord supplied to the -X01 power supply connector
in the electronics module and secure it with the clip.
5 Connect the other end of the power cord to the power source.
F The analyzer system 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.

4-8 Chapter 4: Analyzer System Start-Up 42/24-10-5 EN

Power Supply Activation

CAUTION!
Before activating the power supply check once again that the analyzer system
operating voltage setting matches the line voltage.

F 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 115/230-VAC power supply with the external breaker
switch.
2 Turn on the separate 24-VDC power supply of the analyzer modules or
the I/O base 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 analyzer system power-on message appears on the screen.
The power-on message shows the software version.
The booting consists of the “Booting Database” and “Booting Display”
phases.
3 After a brief time the screen switches to measurement mode.

4 The 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.
Proceed as follows to check the date and time setting:

Step Action
1 Select the 'DWHWLPH menu item:
0(18→&RQILJXUH→6\VWHP→'DWH7LPH
2 Check and, if necessary, correct the date and time (For more
information see "Setting the Date", page 6-C-1 and "Setting the Time",
page 6-C-2).
3 If applicable, save the corrected date and/or time:
0(18→&RQILJXUH→6\VWHP→6DYH&RQILJXUDWLRQ

42/24-10-5 EN Chapter 4: Analyzer System Start-Up 4-9

Warm-Up Phase

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

Analyzer Module Warm-Up Phase Duration

Caldos 15 2–4 hours, depending on measurement range
Caldos 17 Approx. 30 minutes for class 1 measurement ranges,
1)
Approx. 60 minutes for class 2 measurement ranges
Limas 11 Approx. 1.5 hours
Magnos 16 2-3 hours
Magnos 106 ≤ 1 hours
Magnos 17 2-4 hours
Uras 14 Approx. 30 minutes without thermostat
Approx. 2 hours with thermostat

1) See Data Sheet 10/24-1.10 EN for class details.

F The warm-up phase can take longer if the analyzer system was not brought to
room temperature before the power supply was activated.

F 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 value drift indication is acceptable. This
Duration depends on the size of the measurement range.

4-10 Chapter 4: Analyzer System Start-Up 42/24-10-5 EN

Operation

Readiness At the end of the warm-up phase the analyzer system is ready to carry out
measurements and can be calibrated.
Chapter 7 describes the analyzer system 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 Caldos 15 10-90 l/h (for option T90 < 6 sec.: max. 90-200 l/h)
Caldos 17 10-90 l/h
Limas 11 20-100 l/h
Magnos 16 8 ± 0.5 l/h without flow regulator
30-60-90 l/h with flow regulator
Magnos 106 20-60 l/h
Magnos 17 20-60 l/h, max. 90 l/h
Oxygen Sensor 20-100 l/h
Gas Module ≤ 60 l/h

Caldos 15 In the Caldos 15 and Uras 14 analyzer module versions with flowing reference gas,
Uras 14 the reference gas flow rates must be set to the same value as the sample gas flow
Adjusting Reference rate.
Gas Flow Rate For special applications of the Caldos 15 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 analyzer systems 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
Note: Because of leakage losses the purge gas flow rate at the device output is
approx. 5-10 l/h for a purge gas flow rate at the device inlet of 20 l/h.

42/24-10-5 EN Chapter 4: Analyzer System Start-Up 4-11

Chapter 5 Analyzer System Operation

Display and Control Unit

Overview The display and control unit contains:

• The screen with
• Menu line
• Information field
• Softkey line
• Status LED’s
• Numeric keypad
• Cancel keys
• Softkeys
In both system housing versions the display and control unit is located on the front
face.

Figure 5-1
Screen with
Display and Control
Unit Menu Line Status LED’s

Information
Field
Numeric Keypad
Softkey Line

Softkeys Cancel Keys

Display and control The display and control unit operating modes are
unit operating modes • Measurement
• Menu
The display and control unit operating modes have no effect on measurement
operations, i.e. analyzer system measurement functions continue while in menu
mode.

42/24-10-5 EN Chapter 5: Analyzer System Operation 5-1

Screen

Screen The backlit graphics screen has a 320x240-pixel resolution.

The screen is divided into three panels (see Figure 5-1):
• Menu line
• Information field
• Softkey line

Menu line The menu line appears at the upper edge of the screen. A line separates it from
the information field.
The menu line only appears during menu operation. It shows the current menu
path and thus allows the operator to see where the system is in the menu tree.
Additionally it shows the name of the analyzer being processed.

The information field In the measurement mode the information field shows the following information for
in measurement each sample component in the analyzer modules installed in the analyzer system.
mode • Values in numeric form and as a bar graph
• The physical unit for the measured value
• The measurement component designation
• The measurement range lower and upper limit values on the bar graph
• The analyzer type
• The analyzer name
Values from up to six sample components can be displayed simultaneously.
It is user-configurable (see "Display" section, page 6-D-1)
• which measurement values are shown on the screen and
• at which positions on the screen the measurement values are displayed.
In addition, the user can configure display elements that allow to
• enter a value (pump output for example, see page 5-10) or
• actuate keys (for example to switch measuring components, see page 5-11).

The information field In menu mode the information field contains the menu or individual menu items or
in menu mode parameters with the applicable values, as well as operator prompts.

The softkey line The softkey line appears at the lower edge of the screen. Its gray background
distinguishes it from the information field.
The softkeys are further explained in the "Softkeys" section (see page 5-7).

5-2 Chapter 5: Analyzer System Operation 42/24-10-5 EN

Message Display

Message Display The blinking message display in the softkey line has the following functions:
Functions
• It prompts for the67$7860(66$*(key to be pressed whenever a status
message appears (refer to the "System Status: Status Messages" section,
page 9-2).
• It shows that a password is active (refer to the "Password Protection" section,
page 5-12).
• It shows that the analyzer system is being controlled from a remote HMI (refer to
the "User Interface Priority" section, page 5-15).
• It shows that an automatic calibration process is running in the analyzer system
(refer to the "Automatic Calibration" section, page 7-A-4).

Display of Status When a status message is generated by the Message Generator function block its
Messages text is displayed as configured in the function block. For a complete description of
the function block, see the "Advance Optima Function Blocks – Descriptions and
Configuration" technical bulletin (Publication No. 30/24-200 EN).

42/24-10-5 EN Chapter 5: Analyzer System Operation 5-3

Status LED’s

Status LED’s The three LED’s next to the screen indicate the analyzer system’s status.

The green "Power" LED lights when the power supply is on.

The yellow "Maint" LED lights when the "Maintenance Request" status signal is
active.

The softkey appears on the screen at the same time (see page 5-7).

The red "Error" LED lights when the "Failure" status signal or the overall status
signal is active.

The softkey appears on the screen at the same time (see page 5-7).

F Chapter 9 contains information on status messages and status signals.

5-4 Chapter 5: Analyzer System Operation 42/24-10-5 EN

Numeric Keypad

Numeric Keypad The numeric keypad is located to the right of the screen, under the status LED’s.

The operator can enter values directly with the:

... , • numeric keys "0" through "9"
• decimal point "."
, • minus sign "-"
Examples:
• Test gas concentration
• Date and time
• Air pressure
• Password

F Any digits displayed cannot be overwritten. They must be deleted with the
%$&.63$&(or&/($5key before new digits can be entered.

Entering text with the The "Text Entry" section (see page 5-9) explains how to enter information such as
numeric keypad sample component or user names with the numeric keypad.

42/24-10-5 EN Chapter 5: Analyzer System Operation 5-5

Cancel Keys

Cancel Keys The "Back" and "Meas" keys located under the numeric keypad are designated as
cancel keys.

The "Back" key allows the operator to cancel a function or menu item and return
to the previous menu level.
Only entries confirmed with the(17(5key are stored; unconfirmed items are not
accepted.
The "Back" key also allows the operator to clear analyzer system help text and
messages.

The "Meas" key allows the operator to cancel a function or menu item and to return
to the measured value display in measurement mode.
Only entries confirmed with the(17(5key are stored; unconfirmed items are not
accepted.

F The analyzer system automatically reverts to the measurement mode to display

values if the operator has not pressed a key in menu mode in the last five minutes
("time out").

5-6 Chapter 5: Analyzer System Operation 42/24-10-5 EN

Softkeys

Softkeys The six keys under the screen and the softkey line at the lower edge of the screen
are known as softkeys.
A softkey is the combination of the key and its designation in the softkey line.
A softkey does not have any set function, but is assigned a function for a given
situation as shown in the softkey line of the screen.
Pressing a softkey is the equivalent of pressing the key assigned to the function;
this process is illustrated by the quasi-three-dimensional softkey representation on
the screen.
Softkeys are also called keys in this manual.

The softkey line in The softkeys and appear in measurement mode.

measurement mode
The softkey also appears if an error occurs.

The0(18key 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.

The67$7860(66$*(key appears in measurement mode if an "Failure" or

"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.

F All status messages are listed in Chapter 9.

Continued on next page

42/24-10-5 EN Chapter 5: Analyzer System Operation 5-7

Softkeys, continued

The softkey line in In menu mode, a series of softkeys appears on the softkey line. Their descriptions
menu mode and functions depend on the specific situation.
In menu mode the standard softkeys have the following functions:

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 item selected is reversed, i.e. appearing as bright characters on a dark
background.

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.
The item selected is reversed, i.e. appearing as bright characters on a dark
background.

BACK- The operator can use the %$&.63$&( key to delete characters to the left of the
SPACE
cursor (as in a PC or typewriter keyboard).

The operator can use the &/($5 key to delete all characters in a selected field.

The operator can use the (17(5 key to:

• Call up menu items for processing
• Start functions
• Confirm entries, e.g. parameter settings
The (17(5 key is always at the right margin of the softkey line.

The operator can use the +(/3 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.

F In these instruction entries to be made by the operator will not be identified by key
symbols but by the following type styles (these are examples only):
Press cancel keys: Back, Meas
Press softkeys: 0(18, +(/3, (17(5, %$&.63$&(
Select menu items: &DOLEUDWH, &RQILJXUH
Enter numbers:  ... 

5-8 Chapter 5: Analyzer System Operation 42/24-10-5 EN

Text Entry

Entering text When text, such as measurement components or user names, is to be entered an
image of the numeric keypad appears on the screen.
The following characters are shown using a total of four pages:
• Letters A-Z and a-z
• Symbols Blank * ( ) % & : < > /
• Digits 0 to 9 . -
Each character is accessed using the key in the corresponding position on the
numeric keypad. Examples:
Letters: A L t Blank
Key: 7 - 2 9
An input line appears at the lower edge of the screen for new text to be entered or
existing text to be edited.
Text is entered and modified in two ways:
• The operator enters text in the input mode.
• The operator modifies already entered text in the edit mode.

Softkeys in the The softkeys in the input mode have the following functions:
input mode

PREV NEXT The 35(93$*( and 1(;73$*( keys allow the operator to move to the previous
PAGE PAGE
or next keypad page.

The &$36 key allows the operator to switch between upper- and lowercase letters.

The (',7 key allows the operator to switch into the edit mode.

Softkeys in the The softkeys in the edit mode have the following functions:
edit mode

The two arrow keys allow the operator to move the cursor left and right in the entry
line.

BACK- The operator can use the %$&.63$&( key to delete characters to the left of the
SPACE
cursor (as in a PC or typewriter keyboard).

The ,1387 key allows the operator to change to the input mode.

42/24-10-5 EN Chapter 5: Analyzer System Operation 5-9

Operating by Value Entry

Value Entry Values are entered during measurement mode by pressing the number key that
corresponds to the position of the display element in the display and is indicated
above the display element. In the example below, this is key 4 (see Fig. 5-2). A field
then appears for entering the value (see Fig. 5-3).

Fig. 5-2
Value Entry:
Display During
Measurement Mode
(Example: Setting the
Pump Output)

Fig. 5-3
Value Entry:
Entering a Value
(Example)

Description and The display element9DOXHHQWU\is described on page 6-D-6.

Configuration The configuration is described on page 6-D-12.

5-10 Chapter 5: Analyzer System Operation 42/24-10-5 EN

Operating by Key Entry

Key Entry Key entries are made during measurement mode by pressing the number key that
corresponds to the position of the display element on the display and that is
indicated over the display element. In the example, this is key 4 (see Fig. 5-4).
A softkey line then appears with the configured keys (see Fig. 5-5).

Fig. 5-4
Key Entry:
Display During
Measurement Mode
(Example: Switching
Measuring
Components)

Fig. 5-5
Key Entry:
Using the Keys
(Example)

Description and The display element.H\HQWU\is described on page 6-D-7.

configuration The configuration is described on page 6-D-13.

42/24-10-5 EN Chapter 5: Analyzer System Operation 5-11

Password Protection

Elements of Password protection consists of three elements:

password protection • Access level
• User group
• Password

Access level Each menu item is assigned an access level. Access levels are numbered 0, 1, 2
and 3.
Menu items are assigned to different access levels in order to assure that specific
menu items can only be changed by authorized users.

User group The members of a user group are authorized to access a specific access level, i.e.
to change the menu items at that level.
Some user groups are set-up at the factory.
A user group can be made up of one or more users.

Password Every user group set-up in the system has a password.

The password consists of six digits which can be entered via the numeric keypad.
Passwords are pre-assigned for the factory-set user groups.

Example The following example shows the factory-set password protection:

Factory-set user groups Default passwords Access level

Every user None 0
Maintenance team 471100 0, 1
Specialist team 081500 0, 1, 2
Function block specialist 325465 0, 1, 2, 3

CAUTION!
After entering the password for access level 3, you can access all of the func-
tion block applications. When configuring function blocks, existing applica-
tions with their configurations and links can be damaged or destroyed.

F Technical Bulletin “Advance Optima Function Blocks – Descriptions and Configura-

tion” (publication number 30/24-200 EN) contains complete information on the
“Function Block” concept as well as detailed descriptions of the individual function
blocks.

Continued on next page

5-12 Chapter 5: Analyzer System Operation 42/24-10-5 EN

Password Protection, continued

Viewing menu items All users can view all menu items, regardless of access level, without entering a
password.

Changing menu items All users can execute all access level 0 menu items without entering a password.
Access level 1, 2 and 3 menu items can only be changed if the user belongs to the
group authorized for that level and after the user’s password has been entered.

Change privilege After entering the password the user is authorized to change any menu items
accessible at the user’s level.

Duration of the The change privilege remains in effect until:

change privilege • The analyzer automatically switches to measurement mode if the user has not
pressed a key for more than about 5 minutes (time out).
• Or the user presses the “Meas” key twice in succession.

F The change privilege remains in effect if the user presses the “Meas” key only
once to return to measurement mode. This is indicated by the “Password active”
status message.
In this manner the user does not have to re-enter a password to change a menu
item if he or she returns to the menu mode within approximately 5 minutes.

Note The change privilege thus refers to a temporary authorization to change menu items.
In contrast, the access privilege refers to a fundamental and configurable authoriza-
tion to change menu items at certain access levels.

42/24-10-5 EN Chapter 5: Analyzer System Operation 5-13

Changing the Password

Menu Path 0(18→&RQILJXUH→6\VWHP→&KDQJHSDVVZRUG

Changing the Proceed as follows to change the password:

Password

Step Action Input

1 Select the &KDQJH3DVVZRUG menu item. 0(18
↓
&RQILJXUH
↓
6\VWHP
↓
&KDQJH
SDVVZRUG
2 Use the arrow keys to select the user group for 0DLQWHQDQFH
which the password is to be changed (for example). (17(5
3 Use the numeric keypad to enter the old 6-digit 
password (for example). (17(5
4 Use the numeric keypad to enter the new 6-digit 
password (for example). (17(5
5 Re-enter the new password (for example). 
(17(5

F Access level 0 is not shown in the &KDQJHSDVVZRUG menu item.

5-14 Chapter 5: Analyzer System Operation 42/24-10-5 EN

User Interface Priority

Note The user interface is designated using the acronym "HMI", which stands for
"human machine interface".

User Interfaces The Advance Optima system has several user interfaces.
• The local operation user interface is the display and control unit on the analyzer
system ("local HMI").
• The remote operation user interface is a PC running the "Optima Remote HMI"
software ("remote HMI").
For detailed information on remote operation, see the "Optima Remote HMI"
technical bulletin (Publication No. 30/24-311 EN).

HMI Priority An analyzer system (or more accurately an analyzer module) can only be operated
via one HMI.
The password hierarchy controls which HMI has or retains priority for operation
(refer to the following table). As a rule, the HMI with the Level n+1 password has
priority over an HMI with the Level n password. An exception is the local HMI with
Level n password which has priority over a remote HMI with a Level n password.

1st User: 2nd User:

Remote HMI has priority Local HMI has priority
Remote HMI Level n Priority with Level n+1 Priority with Level n
Local HMI Level n Priority with Level n+1

F If a second user with an HMI receives priority over another HMI, all first user input
not confirmed with the (17(5 key is lost and processes in progress (e.g. calibra-
tion) will be stopped.

Specifics for Manual calibration runs at Level 0, thus no password is needed. It is protected in
Manual Calibration the following manner from being stopped by another HMI:
On entering the &DOLEUDWH menu the Level 1 password is automatically assigned.
Therefore, any other HMI must at least enter a Level 2 password in order to
assume priority for operation. In this event the calibration run would be stopped.

42/24-10-5 EN Chapter 5: Analyzer System Operation 5-15

Access Lock

Access lock Independent of the user interface priority adjustment (see page 5-15) it is possible
to completely lock the access to the operation of the analyzer system from a
certain user interface (HMI).
This lock is effected by configuration of the function block Access Lock. For a
detailed function block description, see the "Advance Optima Function Blocks –
Descriptions and Configuration" technical bulletin (Publication No. 30/24-200 EN).

Access denied When a user tries to operate the analyzer system via a locked HMI, the following
text is displayed after pressing the 0(18 key:

$FFHVVGHQLHG
7KHDQDO\]HUV\VWHPRSHUDWLRQ
LVORFNHG
&DQFHO%$&.!

5-16 Chapter 5: Analyzer System Operation 42/24-10-5 EN

Menu Tree

Menu Tree The following table summarizes the analyzer system menu tree.
For reasons of brevity only the top level parameters and functions are shown; the
menu branches more extensively at most menu items, e.g. into the various
measurement components or into the selection and adjustment of values.
Some menu items are analyzer-specific, i.e. they only appear when particular
analyzer modules are integrated into the analyzer system.

F The "Calibration data" menu is detailed in Chapter 7, Section B.

The "Function blocks" menu is detailed in Chapter 6, Section B.

Continued on next page

42/24-10-5 EN Chapter 5: Analyzer System Operation 5-17

Menu Tree, continued

0HQX
 ↓
 BB &DOLEUDWH  BB 0DLQWHQDQFH7HVW
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  BB 0DQXDOFDOLEUDWLRQ   BB 6\VWHP
     BB $WPSUHVVXUH
  BB $XWRPDWLFFDOLEUDWLRQ  
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 BB &RQILJXUH   BB 3XPS
    BB $WPSUHVVDQO]
  BB &RPSRQHQWVSHFLILF   BB &DOLEUDWLRQUHVHW
   BB 0HDVXUHPHQWUDQJH   BB %DVLFFDOLEUDWLRQ
   BB )LOWHU   BB 0HDVXUHFDOFHOO
   BB 3UHVVXUHFRQWUROOHU   BB 2SWLFDODGMXVWP
   BB $XWRUDQJH   BB 3KDVHDGMXVWP
   BB $FWLYHFRPSRQHQW   BB 5HOLQHDUL]DWLRQ
   BB $ODUPYDOXHV   BB $PSOLILFDWLRQRSWLPL]DWLRQ
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   BB 0DQXDOFDOLEUDWLRQ 
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  
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   BB ,QSXWV   BB $X[LOLDU\UDZYDOXHV
   BB 2XWSXWV   BB 6WDWXV
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   BB 0HDVXUHPHQW 
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↓

5-18 Chapter 5: Analyzer System Operation 42/24-10-5 EN

Chapter 6 Analyzer System Configuration

Section A Measurement Component-Specific Functions

Changing Measurement Value Units

Units of Measure Sample component values and variables can be displayed as

• Physical units (e.g. ppm, Vol.-%, mg/m , l/h, hPa)
3

• Percentage of measurement range scale (% MRS)

• mA
The physical unit is factory-set per customer order.
The unit cannot be changed separately for individual measurement values.

Procedure Pressing the softkey with the analyzer system in measurement mode will
switch the display from physical units to % MRS to mA for all sample components
displayed.

F Additional information on displays can be found in the "Display Features" section,

page 6-D-1.

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-A-1

Measurement Range Switching

Menu Path 0(18→&RQILJXUH→&RPSRQHQWVSHFLILF→

0HDVXUHPHQWUDQJH→6HOHFWFRPSRQHQW→

Selection All measurement ranges configured (at the factory) for a sample component are
displayed.

Procedure Select the measurement range with the arrow keys and press (17(5 to confirm.

F 6DYHFRQILJXUDWLRQ

F The measurement range selected shown on the screen after switching to

measurement mode.

6-A-2 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Modifying Range Limits

Menu Path 0(18→&RQILJXUH→&RPSRQHQWVSHFLILF→

0HDVXUHPHQWUDQJH→6HOHFWFRPSRQHQW→

Selection All measurement ranges configured (at the factory) for a sample component are
displayed.

Procedure Select the measurement range with the arrow keys, press &+$1*(/,0,76, select
67$579$/8( or (1'9$/8(, change the measurement range limit and confirm
with (17(5.

F For the automatic measurement range changeover (see page 6-A-7) to function
properly, the measurement ranges MB1, MB2, ... must be configured in ascending
order.

F 6DYHFRQILJXUDWLRQ

F The measurement range selected or changed and the altered number of decimal
places is shown on the screen after switching to measurement mode.

Steps After Changing Calibration of the associated measurement range should be verified after changing
Measurement Range measurement range limits. If the ratio of the old to the new measurement range is
Limits ≥ 1:10, we recommend manually calibrating the end point.
Parameters of the auto-range function should be verified after changing measure-
ment range limits (see page 6-A-7).

Caldos 15 Measurement ranges are factory-set and cannot be modified.

Magnos 17

Caldos 17 Measurement ranges are freely selectable for binary gas mixtures. They are factory-
calibrated for the largest possible measurement range. There is a limit to the setting
capability. If, for example the measurement ranges cross the explosive limit or areas
of the measurement ranges cannot be implemented due to ambiguities.
Measurement ranges are not freely adjustable in the case of multiple-component
mixtures with "interference components" that have been calibrated at the factory or
if a cross-sensitivity correction has been configured. In these cases the measure-
ment ranges are factory-set per customer order.

Magnos 16/106 Measurement ranges are freely selectable. At the factory they are either set to
0-10/ 15/ 25/ 100 Vol.-% O2 or per order.

Limas 11 Measurement ranges are freely selectable. See the "Limas 11, Uras 14: Instructions
Uras 14 for Changing Measurement Range Limits" section, page 6-A-4.

Oxygen Sensor Measurement range 1 is freely adjustable from 0-5 Vol.-% O2 to 0-25 Vol.-% O2.
Measurement range 2 is factory-set to 0-25 Vol.-% O2.

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-A-3

Limas 11, Uras 14: Notes for Changing Measurement Range Limits

Physical The Limas 11 and Uras 14 analyzer modules have one physical measurement range
Measurement Range per sample component. The limits of this measurement range are determined by
the minimum and the maximum value of the product of the gas concentration and
measurement cell length (c · l)min or (c · l)max.

Measurement Ranges One or two measurement ranges can be ordered for each sample component.
Ordered
If two ranges are ordered for one measurement component, the smaller is range 1
and the larger is range 2. The smaller range can be a starting range or a
suppressed measurement range. The maximum ratio of the spans of range 1 and
range 2 is 1:10.
If only one measurement range (range 1) is requested, a second measurement
range (range 2) will be factory-configured. The end point of range 2 will be 5 times
the end point of range 1.
If a calibration cell is provided for the measurement component, its set point will
always be the upper end of measurement range 2.

After Changing It is recommended after changing the measurement range limits

Measurement Range
• To verify the end point of the new measurement range,
Limits
• To verify the linearity of the new measurement range (see "Limas 11, Uras 14:
Relinearization" section, page 8-9).

Analyzer Module with If the analyzer module is equipped with calibration cells, note the following
Calibration Cells instructions:
• It is recommended to measure the associated calibration cell after changing
measurement range limits (see "Limas 11, Uras 14: Measurement of Calibration
Cells" section, page 8-8).
• If the new measurement range is smaller than the old measurement range, the
associated calibration cell can still be used.
• If the new measurement range is larger than the old measurement range, the set
point of the associated calibration cell cannot be smaller than 30 % of the new
measurement range span. Otherwise the calibration cell must be replaced.

6-A-4 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Changing the Number of Decimal Places

Menu Path 0(18→&RQILJXUH→&RPSRQHQWVSHFLILF→

0HDVXUHPHQWUDQJH→6HOHFWFRPSRQHQW→

Selection All measurement ranges configured (at the factory) for a sample component are
displayed.

F The setting only affects the values indicated on the screen.

The number of decimal places cannot be increased.

Procedure Select the measurement range with the arrow keys, press 6(7'(&,0$/, set the
number of decimal places with the softkeys and confirm the selection by pressing
(17(5.

F 6DYHFRQILJXUDWLRQ

F The altered number of decimal places is shown on the screen after switching to
measurement mode.

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-A-5

Filter Initialization

Menu Path 0(18→&RQILJXUH→&RPSRQHQWVSHFLILF→)LOWHU→

6HOHFWFRPSRQHQW→

Linear and The following table shows the types of filters installed in the individual analyzer
Non-Linear Filter modules:

Analyzer Module Filter Type

Caldos 15, Caldos 17, Limas 11, Linear filter with one low-pass time constant
Magnos 17, Uras 14
Magnos 16, Magnos 106 Non-linear filter with two low-pass time
constants T90-1 and T90-2 and threshold

Range 0–60 seconds

F T90-2 should be adjusted ≤ T90-1 for the non-linear filter.

The switching threshold (in %) is generally based on the largest measurement
range selected (reference measurement range).
Recommendation for T90-1 = 3 sec. T90-2 = 0 sec. Threshold = 0.1 %
Magnos 16/106

Procedure Parameter Explanation Action

Linear Filter:
7 Time constant Set
Non-linear Filter:
7 Time constant for constant measured value Set
7 Time constant for measured value changes Set
7KUHVKROG T90-2 applies to overshoot Set

F 6DYHFRQILJXUDWLRQ

6-A-6 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Auto-Range Initialization

Menu Path 0(18→&RQILJXUH→&RPSRQHQWVSHFLILF→$XWRUDQJH→

6HOHFWFRPSRQHQW→

F The automatic measurement range changeover only functions properly when the
measurement ranges MB1, MB2, ... have been configured in ascending order (see
page 6-A-3).

Lower Threshold, On reaching the value set here (as a percentage of the current measurement range
Upper Threshold scale), the analyzer module automatically switches to the next lower or next higher
range.

Assigned The measurement ranges to be included for autoranging can be initialized. The
Measurement Ranges number of measurement ranges available depends on the analyzer module.

F The parameter cannot be selected if the analyzer module has only two measure-
ment ranges since these are automatically included in the autoranging function.

Status Autoranging can be off or on.

Hysteresis The lower and upper threshold values should be selected so that the analyzer
system is not constantly switching between two measurement ranges (see the
following example).

Example Measurement Range 1: 0–100 ppm, Measurement Range 2: 0–200 ppm

(see Figure 6-A-1) Lower Threshold = 40 % MR2 = 80 ppm, Upper Threshold = 90 % MR1 = 90 ppm

Figure 6-A-1
Lower Threshold = 80 ppm = 40 % MR2
Auto-Ranging
MR2 0 200 ppm

MR1 0 100 ppm

Upper Threshold = 90 ppm = 90 % MR1

Procedure Parameter Range Action

/RZHUWKUHVKROG ... Set
8SSHUWKUHVKROG ... Set
$VVLJQHGUDQJHV 05, 05, 05, 05 Select
6WDWXV RQ or RII Select

F 6DYHFRQILJXUDWLRQ

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-A-7

Limit Monitor Initialization

Menu Path 0(18→&RQILJXUH→&RPSRQHQWVSHFLILF→/LPLW9DOXHV→

6HOHFW/LPLW0RQLWRU→

Selection All available limit value monitors are shown.

Procedure Parameter Explanation Action

'LUHFWLRQ  = Alarm on underflow threshold value Select
! = Alarm on exceeding threshold value
7KUHVKROG in physical units Set
+\VWHUHVLV in physical units Set

F 6DYHFRQILJXUDWLRQ

Standard As a rule, limit value monitoring for those components to be measured by the
Configuration analyzer system is factory-set. This requires that there be enough digital outputs
on the system controller and I/O boards to handle the number of sample
components.

Note Limit value monitors are factory-set or user-configured Limit Monitor function
blocks. Technical Bulletin "Advance Optima Function Blocks – Descriptions and
Configuration" (publication number 30/24-200 EN) contains complete information
on the "Function Block" concept as well as detailed descriptions of the individual
function blocks.

6-A-8 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Active Component Selection

Menu Path 0(18→&RQILJXUH→&RPSRQHQW6SHFLILF→$FWLYH&RPSRQHQW

Active Component The "Active Component" parameter appears with the Caldos 15, Caldos 17,
Magnos 16, Magnos 106 and Magnos 17 analyzer modules.
Several sample components can be calibrated on these analyzer modules.
However, there is always only one component measured and indicated.

Procedure Select the active component with the arrow keys and press (17(5 to confirm.
Subsequently, use the 0HDVXUHPHQWUDQJH item to select the range for the
desired component.

F 6DYHFRQILJXUDWLRQ

F The selected sample component and measurement range are shown on the
screen after switching to measurement mode.

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-A-9

Changing Module Name

Menu Path 0(18→FRQILJXUH→FRPSRQHQWVSHFLILF→PRGXOHWH[W

Module Name The module name is shown in the display next to the module type. Here you can
enter a name relating to the measuring point, for example.

Monolingual or The module name can be entered independent of the language of the user
Bilingual instructions (see page 6-C-3) or separately for both languages.

Text Length The length of the text for the module name is:
• limited to 24 characters for a monolingual entry, and
• limited to two times 10 characters for a bilingual entry.

Entering the Module When entering the module name, use the same procedure as entering text (see
Name page 5-9).

F 6DYHFRQILJXUDWLRQ

F The changed module name is shown in the display after switching to measuring. If
the module name appears next to or under the module type depends on the
configured size for displaying the measured quantity (see the “Display“ section,
page 6-D-1).

6-A-10 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Section B Function Blocks

The Function Block Concept

What are function Function blocks are small units of the processing software with a specific function.
blocks? Information is taken in at the inputs, processed in specific ways and the results
appear at the block outputs.

What are function Function blocks are used for overall and specific configuration and initialization of
blocks used for? analyzer system functions.

Examples of Function The following examples illustrate the operation of function blocks:
Blocks
A Limit value monitor tracks a value to determine if it violates limit values and
passes the result to a digital output.
A Digital input places a signal at a (hardware) digital input for subsequent
processing in other function blocks.
An Add function block combines the signals at its two inputs and places the total
at its output.
A Fan "splits" an input signal into several output signals.
A Component measurement value outputs the measurement signal from an
analyzer module for subsequent processing in other function blocks.

Application = A function block is linked to other function blocks via its inputs and outputs. A
Function Block sequence of interlinked function blocks forms an application in the analyzer system.
Linking
Various function blocks are factory-linked to other function blocks to make
applications (see the "Standard Configuration" section, page 6-B-2).

F The access level 3 password must be entered in order to configure an application.

Make sure that existing application configurations and links are not damaged or
deleted when configuring.

Function Block Various specific parameters, in addition to input and output linking, determine the
Initialization functionality of a block.
The as-delivered analyzer system has standard values assigned to these para-
meters. These standard values can be accepted or reprogrammed.

F Technical Bulletin "Advance Optima Function Blocks – Descriptions and Configura-

tion" (publication number 30/24-200 EN) contains complete information on the
"Function Block" concept as well as detailed descriptions of the individual function
blocks.

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-B-1

Standard Configuration

Standard Various applications are factory-configured. These standard configurations are

Configuration based on
• Standard input/output pin configuration (system controller and I/O boards)
• The available sample components
Some factory-configured applications require field linking of additional function
blocks.

F The standard input/output pin layout is shown on a separate sheet supplied with
each analyzer system.

Example: The limit value monitoring application (see Figure 6-B-1) consists of a factory-
Limit Value configured link between the Component measurement value, Hold, Limit
Monitoring monitor and Digital output function blocks.

Figure 6-B-1
Autocal

‘’

Comp. Hold Limit Digital

meas. monitor output
value

‘CO’ ‘Alarm CO’ ‘Alarm CO’ ‘Alarm CO’

Example: The measurement range switching/feedback application (see Figure 6-B-2)

Measurement Range consists of a factory-configured linkage between
Switching/Feedback • A Range control function block with several Digital input function blocks and a
Component range function block, as well as
• a Range feedback function block with the Component range function block
and several Digital output function blocks.

Figure 6-B-2
Digital Digital
input output
Range Range
control Comp. feedback
‘’ range ‘’

Digital ‘’ Digital
input ‘’ ‘’ output

‘’ ‘’

6-B-2 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

The "Function Block" Sub-menu

0HQX

 BB &DOLEUDWH

 BB &RQILJXUH
↓ 
 BB &RPSRQHQWVSHFLILF

 BB &DOLEUDWLRQGDWD

 BB )XQFWLRQEORFNV
↓ 



42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-B-3

Section C System Functions

Setting the Date

Menu Path 0(18→&RQILJXUH→6\VWHP→'DWH7LPH

Setting the Date Step Action Prompt/Input

1 Select the 'DWH7LPH menu item. 0(18
↓
&RQILJXUH
↓
6\VWHP
↓
'DWH7LPH
2 Press the '$7( softkey. '$7(
3 Enter password if necessary.
4 Use the arrow keys to place the cursor (the _
blinking vertical line) behind the character(s) to
be changed (example).
5 Delete the appropriate character(s). %$&.63$&(
F The separators remain after the characters or
are deleted. &/($5
6 Use the numeric keypad to enter the new date 
in month/day/year format (example).
F Enter year with 4 digits.
7 Confirm the entry. (17(5

F 6DYHFRQILJXUDWLRQ

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-C-1

Setting the Time

Menu Path 0(18→&RQILJXUH→6\VWHP→'DWH7LPH

Procedure Step Action Prompt/Input

1 Select the 'DWH7LPH menu item. 0(18
↓
&RQILJXUH
↓
6\VWHP
↓
'DWH7LPH
2 Press the 7,0( softkey. 7,0(
3 Enter password if necessary.
4 Use the arrow keys to place the cursor (the _
blinking vertical line) behind the character(s) to
be changed (example).
5 Delete the appropriate character(s). %$&.63$&(
F The colons remain after the characters are RU
deleted. &/($5
6 Use the numeric keypad to enter the new time 
in hour:minute:second format (example).
F Enter seconds, too.
7 Confirm the entry. (17(5

F 6DYHFRQILJXUDWLRQ

F To convert from standard to daylight savings time, advance the time by one hour.
To convert from daylight savings to standard time, set the clock back by one hour.

6-C-2 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Selecting User Interface Language

Menu Path 0(18→&RQILJXUH→6\VWHP→/DQJXDJH

Procedure Proceed as follows to change the user interface language from German to English:

Step Action
1

.DOLEULHUHQ
.RQILJXULHUHQ
6HUYLFH7HVW
'LDJQRVH,QIR

.RPSRQHQWHQVSH]LILVFK
.DOLEULHUGDWHQ
)XQNWLRQVEORHFNH
6\VWHP

'DWXP=HLW
6SUDFKH
3DVVZRUW$HQGHUXQJ
6\VWHP0RGXOHHLQULFKWHQ
.RQILJXUDWLRQVSHLFKHUQ
6WDWXVVLJQDOH

6SUDFKH (QJOLVFK 'HXWVFK

5 3DVVZRUWHLQJHEHQ

(System is loading
6\VWHPODHGWQHXH6SUDFKH the new language.
%LWWHZDUWHQ Please wait ...)
6

F 6DYHFRQILJXUDWLRQ

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-C-3

Changing the Password

Menu Path 0(18→&RQILJXUH→6\VWHP→&KDQJH3DVVZRUG

F See Chapter 5 "Analyzer System Operation" for additional information on

"Password Protection".

Procedure Step Action Input

1 Select the &KDQJHSDVVZRUG menu item. 0(18
↓
&RQILJXUH
↓
6\VWHP
↓
&KDQJH
SDVVZRUG
2 Use the arrow keys to select the user group for 0DLQWHQDQFH
which the password is to be changed (for example). (17(5
3 Use the numeric keypad to enter the old 6-digit 
password (for example). (17(5
4 Use the numeric keypad to enter the new 6-digit 
password (for example). (17(5
5 Re-enter the new password (for example). 
(17(5

F 6DYHFRQILJXUDWLRQ

6-C-4 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Setting Up System Modules

Menu Path 0(18→&RQILJXUH→6\VWHP→6HWXSV\VWHPPRGXOHV

Function If system modules, i.e. I/O boards or analyzer modules, are added to an analyzer
system, replaced (changed) or removed, this modification must be configured in
the software.

Serial Number The 14-digit serial number must be entered when adding or replacing (changing)
system modules. The serial number is found in the analyzer data sheet and on a
label affixed to the module, generally on the CPU board. The serial number
contains the following information (for example):

Module serial number
Module type: 002 Analog I/O Board
003 Digital I/O Board
004 Analyzer Module
006 Cooler I/O Board
007 8-Way Analog Output Board
When adding or exchanging (altering) external Weidmüller WINbloc-type I/O
modules, enter the following number:

node ID set like in the external I/O module
(example; permissible range 01...18)

Slots When adding I/O boards, the board slot must always be specified. Slots 1-5 on the
system controller and an external slot (e.g. on the I/O base module or in the
system cooler) are available.

Standard Function If an analog or digital I/O board is added to a default-configured slot the system
Blocks will offer to create the standard function blocks (see "Standard Configuration"
section, page 6-B-2).
There is no default configuration and thus no default function blocks for the 8-way
analog output board.

CAUTION!
When an existing system module is replaced with another system module the
function “DELETE” should not be used to delete the old system module. This
function would irretrievably delete the parameter settings and function block
configuration of the old system module!
In order to preserve the parameter settings and function block configuration
of the old system module when replacing a system module, the function
“CHANGE” must be used.

Continued on next page

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-C-5

Setting Up System Modules, continued

F If no system module is configured in an analyzer system, the1HZ0RGXOH

softkey will appear on the screen. Press this softkey to go directly to the
6HWXS6\VWHP0RGXOHVmenu.

Adding a New System Step Action

Module 1 Select the6HW8S6\VWHP0RGXOHVmenu item.
2 Press the1(:softkey.
3 Enter a password as necessary.
4 Enter the 14-digit serial number for the new system module.
5 When adding I/O boards, select the slot with one of the softkeys. If the
I/O board is in an external slot and not in a slot on the system
controller, press the(;7(51$/,2softkey. The following message
appears if the I/O board is in a default configuration slot:&UHDWH
VWDQGDUGIXQFWLRQEORFNV"Press the<(6or12softkey.
6 In the list the new system module will be shown with a1HZstatus.
7 Save the configuration change by pressing(17(5or discard it by
pressing Back.

Replacing an Existing Step Action

System Module with 1 Select the6HW8S6\VWHP0RGXOHVmenu item.
Another System
2 Select the system module to be replaced and reconfigured.
Module
3 Press the&+$1*(softkey.
Do not press the'(/(7(softkey! This will irretrievably remove
the system module’s parameter settings and function block
configuration!
4 Enter a password as necessary.
5 Enter the 14-digit serial number for the new system module.
The type and configuration must match the characteristics of the old
system module.
6 In the list the new system module will be shown with a5HSODFHG
status.
7 Save the configuration change by pressing(17(5or discard it by
pressing Back.

Continued on next page

6-C-6 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Setting Up System Modules, continued

Removing an Installed Step Action

System Module 1 Select the6HW8S6\VWHP0RGXOHVmenu item.
without a Replacement
2 Select the system module to be removed (and not replaced).
3 Press the'(/(7(softkey.
This will irretrievably remove the system module’s parameter
settings and function block configuration!
4 Enter a password as necessary.
5 In the list the deleted system module’s status will change to
'HOHWHG.
6 Save the configuration change by pressing(17(5or discard it by
pressing Back.

Removing and As a rule, when an existing system module is removed and reinstalled (e.g. after a
Reinstalling an repair) it does not require any setup.
Existing System
When the system module is reconnected to the system bus it is automatically
Module
"recognized" and its configuration is automatically stored. For automatic
recognition to take place the analyzer system must be in measurement mode.

Unknown System There are several reasons for a system module to have an8QNQRZQstatus in the
Module 6HW8S6\VWHP0RGXOHVmenu item:

Cause Corrective Action

The system module was not found after Reestablish the system bus
the power supply was turned on (status connection to the system module
message no. 201). and press the5(67$57softkey.
The system bus connection to the system Reestablish the system bus
module is broken (status message no. 209). connection to the system module
and press the5(67$57softkey.
The system module serial number was Press the&+$1*(softkey and
entered incorrectly. correct the serial number.

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-C-7

Saving the Configuration

Menu Path 0(18→&RQILJXUH→6\VWHP→6DYHFRQILJXUDWLRQ

Function Configuration data and log entries are normally stored in RAM memory for rapid
access. This memory unit has a battery backup.
The "Save Configuration" function transfers the configuration data to non-volatile
(flash) memory. Any configuration data previously stored there are overwritten.

F Each configuration change should be saved with „Save configuration“.

6-C-8 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Configuring Status Signals

Menu Path 0(18→&RQILJXUH→6\VWHP→6WDWXV6LJQDOV

Function The status signal configuration is set at the factory per the customer’s order.
Generally this configuration does not have to be changed in the field.

Selection The following signals are available:

• Individual status signals, i.e. Error, Maintenance Request and Maintenance Mode
• Overall status signal

F For further information on status signals, see the "System Status: Status Signals"
section, page 9-4.

F 6DYHFRQILJXUDWLRQ

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-C-9

Configuring an Ethernet Connection

Menu Path 0(18→&RQILJXUH→6\VWHP→1HWZRUN→7&3,31HWZRUN

Function If the analyzer system is to be used in a network with TCP/IP protocol, the
applicable addresses and interface types must be set.

Addresses IP addresses should be obtained from your system administrator. The same values
should be entered for IP and BIOS IP addresses.

F Addresses of TCP/IP classes D and E are not supported.

F The address bits that can be varied in the address mask cannot all be set to 0 or 1
(broadcast addresses).

Ethernet Type For(WKHUQHW7\SHand%,26(WKHUQHW7\SH, select the interface via

which the analyzer system will be connected to the TCP/IP network.

Figure 6-C-1
TCP/IP

F 5HVHWthe analyzer system.

CAUTION!
If the analysis system is restarted by switching off and on the power supply,
all configuration changes that were not saved using6DYHFRQILJXUDWLRQ
will be lost.

6-C-10 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Configuring a Modbus Connection

Menu Path 0(18→&RQILJXUH→6\VWHP→1HWZRUN→0RGEXV

Function If the analyzer system is to be used in a network with Modbus protocol, the
applicable addresses and interface types must be set.

Modbus The analyzer system supports the Modbus slave protocol with RTU (remote
terminal unit) mode. The Modbus access interval should be >500 ms.
The 0RGEXVDGGUHVV can be set in the 1-255 range; the default is 1.
For 0RGEXVW\SH, select the interface which connects the analyzer system to the
Modbus network (RS 232 or RS 485). The default is RS232.
The data transfer default settings are:
%DXGUDWHEDXG,3DULW\QR,6WRSELWV.

F For additional Modbus information see the "Advance Optima Modbus – Functions
and Components" technical bulletin (Publication No. 30/24-310 EN).

Figure 6-C-2
Modbus

F 6DYHFRQILJXUDWLRQ

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-C-11

Section D Display

Display Features

The display can be In measurement mode the analyzer system screen is freely configurable. A
configured standard layout is configured on each delivered unit (see below).

Display Elements Display elements are:

• the default measured values in the analysis system (measured quantities,
auxiliary quantities, current outputs and current inputs), and
• freely configured displays of measured quantities as well as value entries or key
entries.

"Pages" The screen is divided into "pages", i.e. the values present in the system are
summarized on pages. Up to six measurement values can be displayed per page.
The pages brought up when scrolling with the softkey can be configured.
A value can only be displayed on a single page.

System Pages The analyzer system normally displays its measured values in a fixed sequence on
(Standard Layout) the various screen pages. This also holds true for the measured quantities of
system modules that were added by the user (see “Setting Up System Modules“
section, page 6-C-5).
Since up to six values can be displayed on a page, the number of system pages
depends on the number of values.
The user cannot delete system pages.
The following table shows the standard system page layout in an analyzer system
with no more than six sample components and variables each.

Page Standard Layout On/Off

1 Sample component measurement values in physical units On
2 Sample component measurement values in %Span On
3 Current signals at the analog outputs On
4 Variable measurement values (e.g. flow, temperature, Off
pressure) in physical units
5 Sample component measurement values in %MRS Off
6 Current signals at the analog inputs (if available) On

User Pages In addition to the system pages the user can set up so-called user pages (see
page 6-D-8).

Continued on next page

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-D-1

Display Features, continued

Function Blocks as The values of all the function blocks in the system can be configured as a source
Sources for the display. The source of the display of value entries or key entries is also a
function block that was created when configuring the display elements. The
display of the function block value is independent of the other links of the function
block.
Note: All measuring components, auxiliary quantities, current outputs and current
inputs exist as function blocks in the system, i.e., all of these measured quantities
are displays of function blocks in the system.

Display Element The display elements can be represented in two sizes. A maximum of three large
Positioning on the and six small display elements can be represented on a page. Large and small
Screen display elements can be mixed with each other. The positions are numbered as
shown in Figure 6-D-1. The numbering of the positions corresponds to the
arrangement of the number keys next to the display.

Figure 6-D-1
Position Numbering 8 7 9

5 4 6

2 1 3

Views The following views are available for screen configuration:

• Display overview (see page 6-D-3)
• Page overview (see page 6-D-4)
• Parameter overview (see page 6-D-5)

6-D-2 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Display Overview

Figure 6-D-2
Display Overview

Explanations The screen overview contains the following information:

3DJH Name of page on which the value is displayed
3RV Position of the value on the page (see Figure 6-D-1)
'HVFULSWLRQ Name of the value

Softkeys in the The screen overview softkeys have the following functions:
Screen Overview

PAGE The3$*(/,67softkey calls up the page overview (see page 6-D-4).

LIST

NEW
The1(:softkey starts the configuration of a new value (see pages 6-D-11 to
6-D-13).

DELETE
The'(/(7(softkey deletes the value selected by the user.

The(17(5softkey calls up the parameter overview for the values selected (see
page 6-D-5).

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-D-3

Page Overview

Figure 6-D-3
Page Overview

Explanations The page overview contains the following information:

1R Page number and status ("On" or "Off")
1DPH Name of the page
$VVLJQPHQW Page Assignment
7\SH System: Pages configured by system with standard layout
User: Pages configured by user

Softkeys in the Page The page overview softkeys have the following functions:
Overview

PAGE The3$*(212))softkey toggles the selected screen page on or off.

ON/OFF

NEW
The1(:softkey starts the configuration of a new (user) page (see page 6-D-8).

DELETE
The'(/(7(softkey deletes the page selected by the user.
Only "user" pages can be deleted.

The(17(5softkey allows the user to input text to change the name of the
selected page.

The "Back" key returns the user to the display overview (see page 6-D-3).

6-D-4 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Parameter Overview

Figure 6-D-4
Parameter Overview

Explanations The display parameters have the following functions:

1DPH The1DPHof the display element is set by the system and cannot be changed.

0HDVXULQJSRLQW The description entered for the0HDVXULQJSRLQWappears over the display

element during measurement operation. The description is set by the system; it
can be changed for the user-configured display elements. The maximum length is
20 characters.

6RXUFH The6RXUFHof the display elements is always a function block. The source
cannot be changed for the display elements of the default assignment, i.e. the
measured quantities, and for the key entries.

3DJH The parameter3DJHindicates the page on which the display element is shown.
Each display element can be moved to any system or user page.

3RVLWLRQ The3RVLWLRQof a display element on a system page is determined by the

system. It can be changed by being exchanged with another display element.
The user can freely configure the position on a user page.

6W\OH The6W\OHof display depends on the source type. The following display styles
exist: bar display, point display, value entry and key entry.
Examples of the different display styles are shown as soon as this parameter is
selected.
The value entry and key entry display styles are explained in greater detail in the
following pages.

5DQJH/RZ The5DQJH/RZand5DQJH+LJKparameters determine the measurement

5DQJH+LJK range of the bar display and the point display. They cannot be changed for the
display elements of the default assignment, i.e., the measured quantities.

3ODFHV The3ODFHVparameter determines the number of decimal places for the digital
display of the measured values for the bar display and point display. It cannot be
changed for the display elements of the default assignment, i.e., the measured
quantities.

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-D-5

Value Entry

Figure 6-D-5
Configuring the
Value Entry

Description The source of the display element9DOXH(QWU\is the function block Constant
that is automatically generated during configuration. The output of this function
block accepts the entered value.
For the entered value to be effective, the generated function block must be linked
to a function block application after configuring the display (for details, see the
technical information “Advance Optima Function Blocks – Descriptions and
Configuration“ (document No. 30/24-200 DE)).

Configuration The following are to be configured for the display element9DOXH(QWU\(see

page 6-D-12):
• the start and end of the entry range,
• the number of decimal places in the display,
• two lines of text that are displayed when the display element is used, and
• the access level on which the entry value can be changed.

Use Values are entered during measurement by pressing the number key that corres-
ponds to the position of the display element in the display and is indicated above
the display element. A field then appears for entering the value (see “Operating by
Value Entry“ section, page 5-10). The display element9DOXH(QWU\accordingly
represents a response to the actual value entry.

6-D-6 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Key Entry

Figure 6-D-6
Configuring the
Key Entry

Description The source of the display element.H\(QWU\is one or more Constant function
blocks that is automatically generated during configuration. Upon “actuation“, the
output of this function block assumes the value that was established during
configuration.
For the entered value to be effective, the generated function blocks must be linked
to a function block application after configuring the display (for details, see the
technical information “Advance Optima Function Blocks – Descriptions and
Configuration“ (document No. 30/24-200 DE)).

Configuration The following are to be configured for the display elementNH\HQWU\(see page
6-D-13)
• the number of keys (1...6) – the keys are assigned to the softkeys,
• the key type
• key or
• switch or
• option key,
• the parameters for each key
• label,
• value key released, and
• value key pressed,
• two lines of text that are displayed when the display element is used, and
• the access level on which the keys can be used.

Use Key entries are made during measurement by pressing the number key that corres-
ponds to the position of the display element on the display and is indicated above
the display element. A softkey line then appears with the configured keys (see
“Operating by Key Entry“ section, page 5-11). The display element.H\(QWU\
accordingly represents a response to the actual key entry.

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-D-7

User Page Configuration

User Page Step Action

Configuration 1 Select the'LVSOD\menu item.
2 Call up the page overview.
3 Start configuring a new page with1(:.
4 Either: Enter the page name.
The page overview is displayed.
Or: Go directly to the page overview.
In this case the system assigns the name "Page #" where # = page
number.
5 The new page will appear in the page overview:
No. Assigned by the system, to
Name: Enter as in step 4
Usage: 0% (no values)
Type: User

F 6DYHFRQILJXUDWLRQ

6-D-8 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Moving a Display Element from One Page to Another

Moving a Display Step Action

Element from One 1 Select the menu item'LVSOD\.
Page to Another
2 Select the display element in the display overview.
3 Select the parameter3DJH.
4 In the displayed page overview, select the target page. Only those
pages can be selected with an assignment < 100 %, i.e. in which there
is at least one free position.
5 In the displayed parameter overview of the display element, the new
page and new position are displayed.
If the new page is a:
system page, the display element is located in the first free position.
user page, the display element is located in the same position as
the old page, or if this is already taken, in position 8. If
this is taken, the display element cannot be moved
(display ²²²²).
6 If the new page is a user page and other positions are free, the position
of the display element can be changed.
Select the parameter3RVLWLRQ.
The nine possible positions are graphically represented; free positions
are identified with the position number.
Select the desired position with the corresponding number key.
7 Switch to measuring.
The display element is now shown on the new page.

F 6DYHFRQILJXUDWLRQ

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-D-9

Moving a Display Element Within a Page

Moving a Display Step Action

Element Within a Page 1 Select menu item'LVSOD\.
2 Select the display element in the display overview.
3 Select the parameter3RVLWLRQ.
The nine possible positions are graphically represented.
4 If the display element is on a:
system page, its position can only be exchanged with that of another
display element (the softkey6ZDS'LVSOD\is
pressed.)
user page, Its position can either be exchanged with that of
another display element (the softkey6ZDS'LVSOD\
is pressed), or it can be moved to a free position (the
softkey6ZDS'LVSOD\is not pressed).
Select the desired position with the corresponding number key.
5 Switch to measuring.
The display element is now displayed at the new position.

F 6DYHFRQILJXUDWLRQ

6-D-10 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Configuring the Bar Display or Point Display

Configuring the Step Action

Bar Display or
Point Display
F Save the existing configuration before starting the new configuration.
1 Select menu item'LVSOD\.
2 Start configuring the new display element with1(:.
3 Select the parameter6RXUFH.
The function block menu is displayed.
4 Select the function block whose value is displayed.
F When configuring the display, it does not matter if a link has been
entered for the function block.
5 For the parameters1DPH,0HDVXULQJSRLQWand6RXUFH, the
system default values are displayed. The parameter1DPHcannot be
changed.
6 Select the parameter3DJH.
The page overview is displayed.
7 Select the page on which the display element is to be displayed. Only
those pages can be selected with an assignment < 100 %, i.e. in which
there is at least one free position.
If the selected page is a:
system page, the position of the display element is set by the system;
it can only be changed using6ZDS'LVSOD\(see
page 6-D-10).
user page, the position must be configured.
8 Select the parameter3RVLWLRQ.
The nine possible positions are graphically represented; free positions
are identified with the position number.
9 Select the position with the corresponding number key.
10 Select the parameter7\SH.
11 Select the display type%DUJUDSKor3RLQWJUDSK.
12 Set the parameters5DQJH/RZ,5DQJH+LJKDQG3ODFHV.
If necessary, change the description of the display element in the
parameter0HDVXULQJ3RLQW.
13 Switch to measuring.
The newly configured display element is now shown in the display. The
description of the display element is shown above the display. Shown
to the right of the display are the name and unit of the function block
selected in Step 4. These two parameters can be changed by con-
figuring the function block.

F 6DYHFRQILJXUDWLRQ

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-D-11

Configuring Value Entries

Configuring Step Action

Value Entries
F Save the existing configuration before starting the new configuration.
1 Select the menu item'LVSOD\.
2 Start configuring the new display element with1(:.
3 Select the parameter3DJH.
The page overview is displayed.
4 Select the page on which the display element is to be displayed. Only
those pages can be selected with an assignment < 100 %, i.e., in
which there is at least one free position.
If the selected page is a:
system page, the position of the display element is set by the system;
it can only be changed using6ZDS'LVSOD\(see
page 6-D-10).
user page, the position must be configured.
5 Select the parameter3RVLWLRQ.
The nine possible positions are graphically represented; free positions
are identified by the position number.
6 Select the position with the corresponding number key.
7 Select the parameter7\SH.
8 Select display type9DOXHHQWU\.
This creates a constant function block whose system-issued name,
‘Value page-position’, is displayed in the parameter6RXUFH. This
name cannot be changed here; it can only be changed by configuring
the function block (see Step 11).
9 Select the parameter&RQILJHQWU\and configure the other
parameters: entry range, decimal places, text and access level.
10 Enter the description of the display element in the parameter
0HDVXULQJSRLQW.
11 Select the function block created in Step 8, enter the name and unit,
and link the function block to an application via its output 1 (for details,
see technical information “Advance Optima Function Blocks –
Descriptions and Configuring” (document No. 30/24-200 DE)).
12 Switch to measuring.
The newly configured display element is now shown in the display. The
description of the display element is shown above the display. To the
right of the display, the name and unit of the function block are
displayed that were entered in Step 11.

F 6DYHFRQILJXUDWLRQ

6-D-12 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Configuring Key Entries

Configuring Step Action

Key Entries
F Save the existing configuration before starting the new configuration.
1 Select the menu item'LVSOD\.
2 Start configuration of the new display element with1(:.
3 Select the parameter3DJH.
The page overview is displayed.
4 Select the page on which the display element is to be displayed. Only
those pages can be selected with an assignment < 100 %, i.e., in
which there is at least one free position.
If the selected page is a:
system page, the position of the display element is set by the system;
it can only be changed using6ZDS'LVSOD\(see
page 6-D-10).
user page, the position must be configured.
5 Select the parameter3RVLWLRQ.
The nine possible positions are graphically represented; free positions
are identified with the position number.
6 Select the position with the corresponding number key.
7 Select the parameter7\SH.
8 Select the display type.H\HQWU\.
A single function block, constant, is created whose system-default
name, ‘Value page-position’, is displayed in the parameter6RXUFH.
This name does not appear in the display. If necessary, it can be
changed by configuring the function block (see Step 11).
9 Select the parameter&RQILJNH\Vand configure the other
parameters: key number, key type, label, value released/pressed, text
and access level. If all the keys are configured individually, a separate
constant function block is created for each key.
10 The description of the display element is entered in the parameter
0HDVXULQJSRLQW.
11 Select each of the function blocks created in Steps 8 and 9 and link to
an application with its output 1 (for details, see technical information
“Advance Optima Function Blocks – Descriptions and Configuration”
(document No. 30/24-200 DE)).
12 Switch to measuring.
The newly configured display element is now shown in the display. The
description of the display element is shown above the display.

F 6DYHFRQILJXUDWLRQ

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-D-13

Example: Entering and Displaying the Pump Output

Configuring and The configuration and use of a value entry will be explained using the following
Using a Value Entry example of entering and displaying the pump output.
Figure 6-D-7 shows the function block configuration that results from the confi-
guration of the example. It consists of the function block ‘FB Const Pump’ that is
created when configuring the display element “Input Pump“, and the function
block ‘FB Pump’ that is the system default.
Figures 6-D-8...10 show the parameters of the display elements and function
blocks.
Figure 6-D-11 shows the results of the configuration example in the display on the
left, and the field for entering the value on the right; This is retrieved by pressing
key 4 during measurement (see “Operating by Value Entry“ section, page 5-10).

Figure 6-D-7
I1
Messpunkt
Function Block Pump “Anzeige Pumpe”
Messpunkt
Configuration “Eingabe Pumpe” Constant
I2

‘FB Pump’

‘FB Const Pump’

Configuring Step Action

Value Entry
F Save the existing configuration before starting the new configuration.
1 Configure the display element for the pump output entry (see Figure
6-D-8). The source is the function block ‘FB Const Pump’.
2 Configure the display element for the bar display of the pump output
(see Figure 6-D-9). The source is the function block ‘FB Pump’.
3 Link output 1 of the function block ‘FB Const Pump’ to input I2: Speed
of the function block ‘FB Pump’ (see Figure 6-D-10).

Continued on next page

6-D-14 Chapter 6: Analyzer System Configuration 42/24-10-5 EN

Example: Entering and Displaying the Pump Output, continued

Figure 6-D-8
Configuring
Value Entries

Figure 6-D-9
Configuring
Bar Display

Figure 6-D-10
Linking
Function Blocks

Figure 6-D-11
Left: Display
with Elements:
“Value Entry“ and
“Bar Display“
Right: Value Entry

42/24-10-5 EN Chapter 6: Analyzer System Configuration 6-D-15

Chapter 7 Analyzer System Calibration

Section A Principles

Calibration Control

Calibration Control Depending on the analyzer system version and equipment, there are three
methods for controlling calibration:
• Manual calibration
• Automatic calibration
• Externally controlled calibration
All analyzer modules can be calibrated using any of the three methods.
See Section C, "Notes for Calibrating Analyzer Modules" for details.

Starting Calibration The following table summarizes how calibration can be started depending on the
type of calibration control.
Starting Calibration
Calibration Manual on Interval- Via External
Control Analyzer System Controlled Control Signal
Manual
Automatic
External

Warm-up Phase Calibration should only be started after the warm-up phase.

Analyzer Module Warm-Up Phase Duration

Caldos 15 2-4 hours, depending on measurement range
Caldos 17 Approx. 30/ 60minutes for class 1/ 2measurement ranges
Limas 11 Approx. 1.5 hours
Magnos 16 2-3 hours
Magnos 106 ≤ 1 hour
Magnos 17 2-4 hours
Uras 14 Approx. 30 minutes/ 2 hours with/ without thermostat

Plausibility Test in If during calibration the analyzer system finds implausible values (e.g. if the span
Calibration and zero values are equal), calibration is stopped and an error message is
generated. The values stored after the last calibration remain in effect.

Status Signal The "Maintenance Mode" status signal is set during calibration.

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-A-1

Manual Calibration

Definition Manual calibration means:

Zero and span are calibrated separately by pressing the analyzer system display
and control unit softkeys.

Test Gas Supply The test gas supply can be started by activating a multiple path valve.
Is 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 Fig. 7-A-1), 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 (see page 7-B-3).

Figure 7-A-1 Test gas connection for

Option
Caldos 17 with single-point calibration,
Analyzer Module with
Limas 11 with calibration cells,
Gas Module
MG Magnos 16 with single-point calibration,
Magnos 106 with single-point calibration,
NG Uras 14 with calibration cells
Option: Flow monitoring, e.g. for flowing
P reference gas or purge gas (external
O2 c needle valve required)
E
MG Sample Gas
NG Zero Gas
Flow Flow Monitor
O2 Oxygen Sensor
P Pressure Sensor in Analyzer Module

Test Gas Dew Point The test gas dew point must be nearly identical to the sample gas dew point.

Analyzer Modules In analyzer modules with several detectors (e.g. the Uras 14) each detector should
with Multiple be calibrated sequentially.
Detectors

Air Pressure Effect If the analyzer system 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 analyzer system’s operating site height has changed since the last
calibration
• If the air pressure effect on the measured value is too high (see also Appendix 2,
"Analyzer Module Operating Specifications").
(For instructions, see "Air Pressure Value Correction" section, page 8-24.)

Continued on next page

7-A-2 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Manual Calibration, continued

Waiting Period If the2XWSXW&XUUHQW5HVSRQVHparameter is set to Hold, current output is

Following Manual halted for a specific time to allow the measurement value to stabilize after manual
Calibration calibration.
This interval is:
Test gas→Sample gas purge time + 4 x T90 or
Test gas→Sample gas purge time + 1 x T90-1 + 3 x T90-2.
The waiting period is the same as that following automatic calibration (see
"Automatic Calibration" section, page 7-A-5).

Calibration Data Setting the calibration data is described on page 7-B-3.

Manual Calibration of Manual calibration of an analyzer module is described on page 7-D-1.

an Analyzer Module

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-A-3

Automatic Calibration

Definition Automatic calibration means:

Zero and span are calibrated automatically after starting.

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.
Depending on the gas supply circuit and the number of analyzer modules installed
there are several test gas layout possibilities (see "Test Gas Supply Control for
Automatic Calibration" section, page 7-A-6).

Test Gas Dew Point The test gas dew point must be nearly identical to the sample gas dew point.

Analyzer Modules In analyzer modules with several detectors (e.g. the Uras 14) all detectors are
with Multiple calibrated simultaneously.
Detectors

Starting Automatic Automatic calibration is started

Calibration • At time intervals determined by the internal clock
• By an external control signal
• Manually via the analyzer system’s display and control unit

Internal Start Normally automatic calibration is started on a time interval basis by the internal
clock.
The cycle time is initialized with the calibration data (see "Calibration Data for
Automatic Calibration" section, page 7-B-3).

External Start The “Start automatic calibration” control signal is needed for external starting of
automatic calibration:
Level Low (0-5 V) → High (8-24 V) edge
After the Low → High transition the High level must be present for at
least 1 second.
Input DI1 on system controller per standard configuration

Manual Start Automatic calibration can be started manually on the display and control unit. It is
effected
• Only as zero calibration or
• Only as span calibration (see also “Calibration Data for Automatic Calibration”
section, page 7-B-4) or
• As a common zero and span calibration.
Manual start of the automatic calibration of an analyzer module is described on
page 7-D-2.

Continued on next page

7-A-4 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Automatic Calibration, continued

Blocking The “Block automatic calibration” control signal is needed for blocking automatic
Automatic Calibration calibration:
Level High Level (8-24 V)
Automatic calibration is blocked as long as the High level is present. The
next automatic calibration after switching to a Low level will be started
according to the initialized cycle time.
Input DI2 on system controller per standard configuration

Start, Block and The following table summarizes the methods for starting, blocking and canceling
Cancel automatic calibration.

Start Block Cancel

Controlled by interval,
if "Activation" parameter if "Activation" parameter by appropriate configu-
is set to "on" is set to "off" or with the ration of the&DQFHO
"Block Automatic 0DQDJHPHQWparameter
Calibration" control (see page 7-B-3) or of
signal the Automatic Calibra-
tion function block
(see Technical Bulletin
30/24-200 EN)
Externally controlled
by "Start Automatic with the "Block As per Interval-
Calibration" control Automatic Calibration" Controlled Start
signal control signal
Manually activated
with 67$57 with 6723

F Automatic calibration of an analyzer module is impossible when it is operated with

the test and calibration software Optima TCT.

Message Display During automatic calibration an$XWRFDOUXQQLQJmessage blinks in the

softkey line.

Waiting Period If the2XWSXW&XUUHQW5HVSRQVHparameter is set to Hold, current output is

Following Automatic halted for a specific time to allow the measurement value to stabilize after automatic
Calibration calibration.
This interval is:
Test gas→Sample gas purge time + 4 x T90 or
Test gas→Sample gas purge time + 1 x T90-1 + 3 x T90-2.

Calibration Data Setting the calibration data is described on pages 7-B-3 and 7-B-4.
Setting the time constant T90 is described on page 6-A-6.

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-A-5

Test Gas Supply Control for Automatic Calibration

Test Gas Supply The test gas supply for automatic calibration can be started by means of the gas
module’s integral solenoid valves or via external solenoid valves.
Depending on the gas supply circuit and the number of analyzer modules installed
there are several test gas layout possibilities (see Figures 7-A-2 to 7-A-6):

1 Analyzer Module, To calibrate analyzer modules with simplified calibration procedures:

Gas Module Installed • Caldos 17 with single-point calibration
with 1 Solenoid • Limas 11 with calibration cells
• Magnos 16/ 106 with single-point calibration
• Uras 14 with calibration cells
• Oxygen Sensor

Figure 7-A-2

Sample gas

Test gas
Analyzer Electronics
module module
System bus

1 Analyzer Module, To calibrate all analyzer modules that can be used with the gas module.
Gas Module Installed
with 3 Solenoids

Figure 7-A-3

Sample gas

Zero gas
Analyzer Electronics
Span gas module module
System bus

Continued on next page

7-A-6 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Test Gas Supply Control for Automatic Calibration, continued

1 Analyzer Module, To calibrate analyzer modules with simplified calibration procedures:

External Gas Supply • Caldos 17 with single-point calibration
with 1 Solenoid • Limas 11 with calibration cells
• Magnos 16/ 106 with single-point calibration
• Uras 14 with calibration cells
• Oxygen Sensor
The external solenoid is controlled via a digital output on the electronics module
(standard configuration: System controller DO4).

Figure 7-A-4

Sample gas Digital

output
Test gas
Analyzer Electronics
module module
System bus

1 Analyzer Module, To calibrate all analyzer modules with zero and span gas even without an integral
External Gas Supply gas module.
with 3 Solenoids
The external solenoids are controlled via electronics module digital outputs (stan-
dard configuration: DO1, DO2 and DO3 on the digital I/O board installed in slot 5).

Figure 7-A-5

Sample gas Digital

outputs
Zero gas
Analyzer Electronics
Span gas module module
System bus

Continued on next page

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-A-7

Test Gas Supply Control for Automatic Calibration, continued

3 Analyzer Modules, To calibrate three analyzer modules connected in series with simplified calibration
External Gas Supply procedures:
with 1 Solenoid • Caldos 17 with standard gas calibration
• Limas 11 with calibration cells
• Magnos 16/ 106 with single-point calibration
• Uras 14 with calibration cells
• Oxygen Sensor
The external solenoid is controlled via a digital output on the electronics module
(standard configuration: System controller DO4).

Figure 7-A-6

Sample gas Digital

output
Test gas
Analyzer Electronics
module 1 module

System bus

Analyzer
module 2

Analyzer
module 3

7-A-8 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Externally Controlled Calibration

Definition Externally controlled calibration means:

Zero and span value alignment is triggered by control signals from an external
control unit.

Test Gas Supply The test gases should be started automatically by external solenoid valves also
controlled by the external control unit.

Test Gas Dew Point The test gas dew point must be nearly identical to the sample gas dew point.

Analyzer Modules with In analyzer modules with several detectors (e.g. the Uras 14) all detectors are
Multiple Detectors calibrated simultaneously.

Control Signals The following control signals are needed for externally controlled calibration:
1) 3)
Control Signal Level Input
Low → High Edge
2)
Zero alignment System Controller DI3
Low → High Edge
2)
Span alignment System Controller DI4
4)
Calibration cell in/out In: High, Analog I/O board 1 DI1 or
Out: Low Digital I/O board 4 DI1
Hold current signal High Analog I/O board 1 DI2 or
Digital I/O board 4 DI2

1) Low Level 0-5 V, High Level 8-24 V

2) After the Low → High transition the High level must be present for at least
1 second.
3) Per standard configuration. The analog and digital I/O board numbers
correspond to their slots.
4) Uras 14 analyzer module only

External Control The external control unit must produce the control signals for zero and span
Arrangement alignment and for the external gas components, e.g. solenoids and pumps.
External control of calibration must be set up so that calibration starts only if there
is no "Error" or "Maintenance Mode" status signal.
Also the external calibration control must allow for a purge time from the point of
gas switchover until stabilization of the measurement value, i.e. until the zero or
span calibration is initiated. Depending on the length of the gas paths in the
analyzer system and on the sample components involved, this purge time can take
several minutes.
To allow measurement values to stabilize, the "Hold Current Signal" control signal
should remain set for a specified time after calibration is finished.

Caldos 15 For the Caldos 15, Caldos 17, Magnos 16, Magnos 106 and Magnos 17 analyzer
Caldos 17 modules, the external calibration control must be set up such that the zero point
Magnos 16/106 calibration always precedes end point calibration.
Magnos 17

Calibration data Setting the calibration data is described on page 7-B-5.

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-A-9

Calibration Methods

Calibration Method An analyzer module (detector) can have one or more (gas) components with one or
more measurement ranges each.
To calibrate the analyzer module, establish whether the components and ranges
should be calibrated jointly or individually. This decision is based on the calibration
method configuration.

Single Calibration The analyzer module start and span values for each measurement range are
calibrated individually for each sample component.
Single calibration has no effect on other measurement ranges for the same sample
components and on other sample components.
Single calibration is only possible and practical in the manual calibration mode.
Single calibration is required if there are skips in the readings during measurement
range switches because these indicate differences in the calibrations of the
individual measurement ranges.
Note: Skips in readings during measurement range switches do not occur in the
Uras 14, Limas 11, Magnos 16 and Magnos 106 since these analyzer modules have
only one physical measurement range.

Common Calibration Only the analyzer module start- and end-points in one measurement range are
calibrated for each sample component. The start- and end-points of the other
measurement ranges are then corrected electronically on the basis of the values
established by this calibration.
A common calibration has no effect on the other sample components in the
analyzer module.
In general the start-point (zero) is calibrated in the smallest measurement range
and the end-point (span) is calibrated in the measurement range for which a
suitable test gas is available.

Substitute Gas If test gases are not available for calibration, e.g. because test gas containers can-
Calibration not be filled with them or because of incompatibilities between their components,
an analyzer module can be set to substitute gas calibration. In this case, in addition
to the sample component measurement ranges, one or more ranges are set up at
the factory for substitute gas components.
One start-point and one end-point are calibrated in the analyzer module’s substi-
tute gas measurement ranges. The start- and end-points of all substitute gas and
sample gas measurement ranges are then corrected electronically on the basis of
the values established by the substitute gas calibration.

F Substitute gas calibration must always be used to calibrate all (sample gas and
substitute gas) components for analyzer modules set up for substitute gas calibra-
tion. Single or common calibration either in the sample component or substitute
gas measurement ranges leads to erroneous analyzer module calibration.

Continued on next page

7-A-10 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Calibration Methods, continued

Overview The following table summarizes the various calibration methods.

Quantity Calibration
SC MR Method To configure ... Calibrate ... Calibration affects ...
1 1 Test Gas / • Zero Measurement range
Single • Span
individually for each sample
component and range
≥1 >1 Test Gas / Measurement ranges for • Zero in one measurement All sample component
Common zero and span calibration range measurement ranges
• Span in another range
for each sample component
>1 ≥1 Substitute Components and • Zero in one component All detector components
Gas measurement ranges for measurement range and measurement ranges
zero and span calibration • Span in one range for
another component
for each detector

SC = Sample and Substitute Gas Components

MR = Measurement Ranges per Component

Setting the The calibration method can be set separately for manual, automatic and externally
Calibration Method controlled calibration.
(see Figure 7-A-7) For common and substitute gas calibration the sample ranges for start- and end-
point calibration of all three types of calibration control are adjusted jointly.
For substitute gas calibration the zero and span calibration components should
also be set.

Figure 7-A-7
&DOLEUDWLRQ
Setting the PHWKRG
Calibration Method

7HVWJDV 6XEVWLWXWH
JDV

&RPSRQHQW

&RPPRQ 6LQJOH =HUR 6SDQ

FDOLEUDWLRQ FDOLEUDWLRQ FRPSRQHQW FRPSRQHQW

=HURUDQJH 6SDQUDQJH =HURUDQJH 6SDQUDQJH

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-A-11

Section B Calibration Data

The "Calibration Data" Sub-Menu

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42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-B-1

Calibration Data for Manual Calibration

Menu Path 0(18→&RQILJXUH→&DOLEUDWLRQGDWD→

0DQXDOFDOLEUDWLRQ→

Test Gas The zero and span test gas concentrations to be used as set points for manual
Concentration calibration need to be set for the selected sample component and measurement
range.

Calibration Method The method for manual calibration needs to be set (see also "Calibration Methods"
section, page 7-A-10).
For common calibration select
• Sample component
• The measurement ranges for start and end calibration for the component
selected
For substitute gas calibration select
• The (substitute gas) components for start- and end-point calibration
• The measurement range for the selected component

F The components and measurement ranges settings apply to manual, automatic

and externally controlled calibration.

F 6DYHFRQILJXUDWLRQ

7-B-2 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Calibration Data for Automatic Calibration

Menu Path 0(18→&RQILJXUH→&DOLEUDWLRQGDWD→

$XWRPDWLFFDOLEUDWLRQ→

Activation Automatic calibration is only performed when activated.

The "off" setting applies only to the interval-controlled start of automatic calibration.

Cycle Time The cycle time shows the time intervals over which automatic calibration is to be
carried out.

Date and Time of The analyzer system will perform the next automatic calibration at the time
Next Calibration established here. The cycle time will begin to run at that point.

Test Gas The zero and span test gas concentrations to be used as set points for automatic
Concentration calibration need to be set for the selected sample component and measurement
range.
Limas 11 If the Limas 11 or Uras 14 analyzer module is equipped with calibration cells the
Uras 14 test gas concentration does not have to be set.

Components for The sample components to be calibrated during zero and span calibration need to
Calibration be selected.

Cancel Management Automatic calibration is always terminated when there is a system bus fault and
when the input “block“ is set (for example, when the control signal “Block auto-
matic calibration“ is applied).
You can configure if the automatic calibration is to be terminated when one of the
three states occurs: “system failure“, “analyzer failure“ or “analyzer maintenance
request“.
You can also configure if the analysis system should repeat automatic calibration
after the cause of termination has been eliminated. Set the number of repetitions
and the time between repetitions.

F The configured repetition is not effective when the automatic calibration has been
terminated by enabling the input “Cancel” of the autocalibration function block.
Technical Bulletin "Advance Optima Function Blocks – Descriptions and Configu-
ration" (publication number 30/24-200 EN) contains a detailed description of the
function block.

Pump This determines whether the pump is on or off during automatic calibration. This
setting also applies to manual calibration.

Continued on next page

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-B-3

Calibration Data for Automatic Calibration, continued

Purge Time This determines the length of the interval during which the gas paths will be purged
to eliminate any residual gases that might interfere with calibration or measurement:
• Between turning on the zero gas flow and starting zero calibration
• Between turning on the test gas flow and starting span calibration
• Between restarting the sample gas flow and initiating measurement

F The purge time should be set to at least three times the T90 time of the entire
analyzer system.

Single Zero Determines whether zero calibration will always or never be carried out alone,
Calibration i.e. without subsequent span calibration.

Single Span Determines whether span calibration will always or never be carried out alone,
Calibration i.e. without prior zero calibration.

Zero and Span Determines whether zero and span calibration will be carried out jointly always or
th
Calibration never or at every n automatic calibration.

One possible setting is:

Single Zero Calibration Always
Single Span Calibration Never
th
Common Zero and Span Calibration Every 7
This means that with a cycle time of 1 day, a zero calibration is carried out every
day and a span calibration is carried out once a week.
Caldos 15 For the Caldos 15, Caldos 17, Magnos 16, Magnos 106 and Magnos 17 analyzer
Caldos 17 modules, these parameters must be set up such that the zero point calibration
Magnos 16/106 always precedes end point calibration.
Magnos 17

Calibration Method The method for automatic calibration needs to be set for the selected sample
component (see also "Calibration Methods" section, page 7-A-10).
The zero and span calibration measurement ranges for common and substitute
gas calibration are chosen in the0DQXDOFDOLEUDWLRQ→&DOLEUDWLRQ
PHWKRGparameter.
Limas 11 The "Calibration Method" parameter is not available in the Limas 11 and Uras 14
Uras 14 analyzer modules since automatic calibration is always run as common calibration.

F 6DYHFRQILJXUDWLRQ

7-B-4 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Calibration Data for Externally Controlled Calibration

Menu Path 0(18→&RQILJXUH→&DOLEUDWLRQGDWD→

([WFRQWUROOHGFDO→

F The menu path refers to the Externally Controlled Calibration function block. The
zero and span calibration parameters are selected separately. Technical Bulletin
"Advance Optima Function Blocks – Descriptions and Configuration" (publication
number 30/24-200 EN) contains a detailed description of the function block.

Calibration Method The method for externally controlled calibration needs to be set for the selected
sample component (see also "Calibration Methods" section, page 7-A-10).
The zero and span calibration measurement ranges for common and substitute
gas calibration are chosen in the 0DQXDOFDOLEUDWLRQ→&DOLEUDWLRQ
PHWKRG parameter.
Limas 11 The "Calibration Method" parameter is not available in the Limas 11 and Uras 14
Uras 14 analyzer modules since the externally controlled calibration is always run as
common calibration.

Calculation Method Select whether the calibration is to be calculated as

• Offset calibration
• Amplification calibration
• Offset and amplification calibration

Test Gas The zero and span test gas concentrations to be used as set points for manual
Concentration calibration need to be set for the selected sample component and measurement
range.

Components for The sample components to be calibrated during zero and span calibration need to
Calibration be selected.

F 6DYHFRQILJXUDWLRQ

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-B-5

Output Current Response

Menu Path 0(18→&RQILJXUH→&DOLEUDWLRQGDWD→

2XWSXWFXUUHQWUHVSRQVH→

Output Current Signals at the current outputs (analog outputs)

Response • Are held at the last measured value prior to starting calibration or
• Can follow measurement value changes during calibration.

F 6DYHFRQILJXUDWLRQ

7-B-6 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Section C Notes for Calibrating Analyzer Modules

Caldos 15: Notes for Calibrating

Sample Components The Caldos 15 analyzer module has at least one sample component with one
measurement range.

Associated Gas The Caldos 15 analyzer module measurement technique is based on the differing
Influence thermal conductivity of various gases.
Since this technique is non-selective, the concentration of a sample component
can be accurately measured only in a binary or quasi-binary gas mixture.
If other associated gas components are present in the sample gas their effect on
factory calibration must be considered.

Test Gases Zero Calibration: Sample-component-free process gas or substitute gas

Span Calibration: Use process gas having a known sample gas concentration or
use substitute gas

Calibration with If test gases are not available for calibration, the Caldos 15 analyzer module can be
Substitute Gases factory-set for calibration with substitute gases (see the "Calibration Methods"
section, page 7-A-10).
Substitute gas calibration of the Caldos 15 analyzer module is described using the
example of "CO2 Measurement in Flue Gas", on page 7-C-4.

Sequence of Zero point calibration must always precede end point calibration.
Calibration

Wait Until End of The Caldos 15 analyzer module should only be calibrated after the warm-up phase,
Warm-Up Phase i.e. approx. 2–4 hours after connecting the power supply.
The time required for the warm-up phase depends on the measurement range.

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-C-1

Caldos 17: Notes for Calibrating

Sample Components The Caldos 17 analyzer module has at least one sample component with one
measurement range and, for measurement ranges ≥ Class 1, the standard gas
substitute gas component.

Associated Gas The Caldos 17 analyzer module measurement technique is based on the differing
Influence thermal conductivity of various gases.
Since this technique is non-selective, the concentration of a sample component
can be accurately measured only in a binary or quasi-binary gas mixture.
If other associated gas components are present in the sample gas their effect on
factory calibration must be considered.

Test Gases Zero Calibration: Sample-component-free process gas or substitute gas

Span Calibration: Use process gas having a known sample gas concentration or
use substitute gas

Calibration with If test gases are not available for calibration, the Caldos 17 analyzer module can be
Substitute Gases factory-set for calibration with substitute gases (see the "Calibration Methods"
section, page 7-A-10).
Substitute gas calibration of the Caldos 17 analyzer module is described using the
example of "CO2 Measurement in Flue Gas", on page 7-C-4.

Single-Point Single-point calibration of the Caldos 17 analyzer module with standard gas is
Calibration with described on page 7-C-3.
Standard Gas

Sequence of Zero point calibration must always precede end point calibration.
Calibration

Wait Until End of The Caldos 17 analyzer module should only be calibrated after the warm-up phase,
Warm-Up Phase i.e. approx. 30 minutes after connecting the power supply.
The time required for the warm-up phase depends on the measurement range.

7-C-2 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Caldos 17: Single-Point Calibration with Standard Gas

Single-Point For measurement ranges ≥ measurement range class 1 in the Caldos 17 analyzer
Calibration with module, standard gas can be used for single-point calibration. This standard gas
Standard Gas calibration is carried out exclusively as span calibration and causes an amplification
correction. In this case, separate zero- and end-point calibration with test gases is
inadmissible. Safety-related measurements are excluded from this technique.
Note: Classification of measurement ranges into class 1 and class 2 is specified in
Data Sheet 10/24-1.10 EN.

Measurement Range When the Caldos 17 analyzer module is ordered with standard gas calibration, the
for Standard Gas factory-set measurement range for the standard gas is 0–60,000 rTC (rTC = relative
thermal conductivity). During basic calibration in the factory one standard gas is
calibrated in this measurement range. Due to sensor tolerances the values of other
standard gases can differ by up to 5 % from this scaling (see following table for set-
points).

Set-points for N2 10,000 rTC Ar 7,200 rTC CH4 14,000 rTC H2 60,000 rTC
Standard Gas Air 10,070 rTC CO2 7,500 rTC He 50,000 rTC

Calibration Method Standard gas calibration is fundamentally a substitute gas calibration (see also
"Calibration Methods" section, page 7-A-10). The correction values are transferred
to all the analyzer module's sample components and measurement ranges.

Calibration Data Calibration data for manual calibration

Calibration method Substitute gas calibration
1)
Zero component Standard gas
Span component Standard gas
3)
Test gas concentration Value depending on standard gas
Calibration data for automatic calibration
2)
Calibration method Substitute gas calibration
Single zero calibration never
Single span calibration always
Common zero and span calibration never
3)
Test gas concentration Value depending on standard gas

1) Though standard gas calibration is carried out exclusively as span calibration,

standard gas must also be chosen as zero component.
2) Settings of sample components and measurement ranges for zero and span
calibration are taken over from the calibration data for manual calibration.
3) See table "Set-points for Standard Gas"

Manual Calibration Manual standard gas calibration must be carried out exclusively as span
calibration (see also "Analyzer Module Manual Calibration" section, page 7-D-1).

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-C-3

Caldos 15 and Caldos 17: Substitute Gas Calibration

Example Substitute gas calibration in the Caldos 15 and Caldos 17 is described using the
example of CO2 Measurement in Flue Gas.

CO2 Measurement in The composition of the various combustion products in the sample gas is known
Flue Gas in the case of CO2 measurements of flue gas from single-component firings. The
flue gas out of the cooler primarily contains CO2, O2, N2 and Ar. CO2 cannot be
measured in mixed-firing flue gases.

Test Gases The following table shows test gases for the calibration of the 0-20 Vol.-% CO2
measurement range:

Fuel Test Gas Composition in Vol.-% for

Zero Middle Concentration Span
CO2 O2 N2 Ar CO2 O2 N2 Ar
Gas Air 10 03 86 1 20 – 79 1
Oil Air 10 08 81 1 20 – 79 1
Coal Air 10 10 79 1 20 – 79 1

Calibration with Since the test gases in this table are not available everywhere, the analyzer
Substitute Gases module can be factory-set for calibration with a substitute gas.
In this case an additional measurement range is calibrated for 0–20 Vol.-% CO2 in
N2 (N2 and CO2/N2 mixtures are available practically everywhere).

Measurement Ranges Component 1 CO2 in Flue Gas Meas. Range 1 0-10 Vol.-%
Meas. Range 2 0-20 Vol.-%
Component 2 CO2 in N2 (Substitute Gas) Meas. Range 1 0-20 Vol.-%

Calibration Parameters Calibration Method Substitute Gas Calibration

Zero Component Component 1 Meas. Range 1 or
Component 2 Meas. Range 1
Span Component Component 2 Meas. Range 1

Calibration • Calibrate zero with air (component 1) or N2 (component 2).

• Calibrate span with test gas 18 Vol.-% CO2 in N2.

Other Measurement For other measurement tasks select the test gases and measurement ranges in a
Tasks similar manner according to the sample gas composition.

7-C-4 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Limas 11: Notes for Calibrating

Calibration Calibration can be performed in range 1 and range 2 for each sample component.
It is always a common calibration and thus affects both ranges.

F For additional information on measurement ranges, please refer to "Limas 11,

Uras 14: Notes for Changing Measurement Range Limits" section, page 6-A-4.

Calibration Cells The use of calibration cells allows the Limas 11 analyzer module to be calibrated
without using test gas containers.
A maximum of 5 calibration cells can be installed. Each calibration cell is filled with
a test gas matched to the sample components and measurement ranges set up in
the corresponding beam path.

Test Gases for Zero A zero gas is required for each zero calibration.
Calibration
In addition to nitrogen, ambient air can be used for zero calibration. Water vapor
must be absorbed using a cooler. If the ambient air contains sample gas compo-
nents, these must be removed with a suitable absorber.

Test Gases for Span A test gas is required for each measurement component for span calibration
Calibration without without calibration cells. The span gas concentration should be 70-80% of the end
Calibration Cells value of the largest measurement range.

Test Gases for Span For suppressed ranges, the span gas concentration must be within the suppressed
Calibration of range. If possible, it should be equal to the end value of the suppressed range (and
Suppressed Ranges thus the end value of the larger measurement range).

Wait Until End of The Limas 11 analyzer module should only be calibrated after the warm-up phase,
Warm-Up Phase i.e. approx. 1.5 hours after connecting the power supply.

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-C-5

Magnos 16, Magnos 106: Notes for Calibrating

Sample Components The Magnos 16 and Magnos 106 analyzer modules have at least one sample
component with four measurement ranges.

Test Gases Zero Calibration: Oxygen-free process gas or substitute gas

Span Calibration: Process gas with a known oxygen concentration or a substitute
gas such as dried air
Highly suppressed measurement ranges (≥95-100 Vol.-% O2) should only be
calibrated with test gases with O2 concentrations in the selected measurement
range.

Calibration with If test gases are not available for calibration, the Magnos 16 and Magnos 106
Substitute Gases analyzer modules can be factory-set for calibration with substitute gases (see the
"Calibration Methods" section, page 7-A-10).
Substitute gas calibration of the Magnos 16 and Magnos 106 analyzer modules is
described using the example of "Purity Measurement in CO2" on page 7-C-9.

Single-Point Single-point calibration of the Magnos 16 and Magnos 106 analyzer modules is
Calibration described on page 7-C-7.

Suppressed If suppressed measurement ranges with a suppression ratio of ≥ 1:5 are set in the
Measurement Ranges Magnos 16 and Magnos 106 analyzer modules, the pressure sensor has been
specially adjusted at the factory. In this case, only a common calibration should be
done (not a single or substitute gas calibration).

Sequence of Zero point calibration must always precede end point calibration.
Calibration

Wait Until End of The Magnos 16 and Magnos 106 analyzer modules should only be calibrated after
Warm-Up Phase the warm-up phase, i.e. approx. 2-3 hours or approx. 1 hour after connecting the
power supply.

7-C-6 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Magnos 16, Magnos 106: Single-Point Calibration

Single-Point The long-term sensitivity drift of the Magnos 16 and Magnos 106 analyzer modules
Calibration is less than 0.05 Vol.-% O2 per year. Thus a regular offset correction is sufficient.
This so-called single-point calibration can be conducted at each point on the
characteristic curve since a parallel shift of this curve results. Depending on the
measurement task involved, we recommend performing an additional span
calibration once a year.
Note: The short-term sensitivity drift can amount to 1% of the measured value per
week.

Test Gas A test gas with any concentration of O2 can be used for single point calibration as
long as it lies within one of the measurement ranges in the analyzer module.
Environmental air can also be used as the test gas.
The test gas must have the same moisture content as the process gas.

CAUTION!
In order to avoid accumulations of explosive gas mixtures, do not use air as a
test gas for single-point calibration when measuring combustible gases.

Suppressed Measure- Single point calibration can also be done within a suppressed measurement range
ment Ranges if the suppression ratio is ≤ 1:5. In this case as well, the O2 concentration of the
test gas must lie within the measurement range.

Air Pressure In single point calibration, the current air pressure must be taken into account. This
is done automatically if a pressure sensor is incorporated in the analyzer module.

Calibration Method When the analyzer module has one sample component the single-point calibration
is carried out as common calibration only at the zero point.
When the analyzer module has more than one sample component the single-point
calibration is carried out as an substitute gas calibration only at the zero point.
For detailed information on the calibration methods, see the "Calibration Methods”
section, page 7-A-10.

Continued on next page

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-C-7

Magnos 16, Magnos 106: Single-Point Calibration, continued

Calibration Data for an Calibration data for manual calibration

Analyzer Module with Calibration method Common single-point calibration
1 Sample Component
Calibration measurement range 0-25 Vol.-% O2
(Example: Test gas concentration 20.96 Vol.-% O2
Test Gas = Air)
Calibration data for automatic calibration
Calibration method Common calibration (test gas)
Single zero calibration always
Single span calibration never
Common zero and span calibration never
Test gas concentration zero gas 20.96 Vol.-% O2
Test gas concentration span gas n.a.

Calibration Data for an Calibration data for manual calibration

Analyzer Module with Calibration method Substitute gas calibration
> 1 Sample Component
Zero component O2 in N2
(Example: Zero range 0-25 Vol.-% O2
Test Gas = Air)
Span component n.a.
Span range n.a.
Test gas concentration zero gas 20.96 Vol.-% O2
Test gas concentration span gas n.a.
Calibration data for automatic calibration
1)
Calibration method Substitute gas calibration
Single zero calibration always
Single span calibration never
Common zero and span calibration never
Test gas concentration zero gas 20.96 Vol.-% O2
Test gas concentration span gas n.a.

1) Settings of sample components and measurement ranges for zero and span
calibration are taken over from the calibration data for manual calibration.

7-C-8 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Magnos 16, Magnos 106: Substitute Gas Calibration

Example Substitute gas calibration of the Magnos 16 and Magnos 106 analyzer modules is
described using the example of purity measurement of CO2.

Purity Measurement For CO2 purity measurements, the smallest concentrations of O2 are measured in
of CO2 CO2, e.g. 0-1 Vol.-% O2 in CO2.

Calibration with Since O2 in CO2 is not available as a test gas and, due to the O2 zero shift caused
Substitute Gases by CO2 (see "Magnos 16, Magnos 106 Operating Specifications" section, page
A-2-4), the analyzer module is factory-set for calibration with substitute gas.
In this case an additional measurement range is calibrated for 0-25 Vol.-% O2 in N2
(N2 and O2/N2 mixtures are available practically everywhere).

Measurement Ranges Component 1 O2 in CO2 Meas. Range 1 0-1 Vol.-%

Meas. Range 2 0-15 Vol.-%
Meas. Range 3 0-25 Vol.-%
Meas. Range 4 0-100 Vol.-%
Component 2 O2 in N2 (Substitute Gas) Meas. Range 1 0-25 Vol.-%

Calibration Parameters Calibration Method Substitute Gas Calibration

Zero Component Component 1 Meas. Range 1 or
Component 2 Meas. Range 1
Span Component Component 2 Meas. Range 1

Calibration • Calibrate zero with CO2 (component 1) or N2 (component 2).

• Calibrate span with dried air (containing 20.96 Vol.-% O2).

Other Measurement For other measurement tasks select the test gases and measurement ranges in a
Tasks similar manner according to the sample gas composition.

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-C-9

Magnos 17: Notes for Calibrating

Sample Components The Magnos 17 analyzer module has at least one sample component with one
measurement range and one measurement range for flue gas measurements of
the O2 in N2 substitute gas component.

Associated Gas Because of the thermomagnetic measurement technique employed by the

Influence Magnos 17 analyzer module, associated gases have an effect on results.
For this reason the sample gas composition must be considered during initial
calibration at the factory.

Test Gases Zero Calibration: Oxygen-free process gas or substitute gas

Span Calibration: Process gas with a known oxygen concentration or substitute
gas, e.g. dried air

Calibration with If test gases are not available for calibration, the Magnos 17 analyzer module can
Substitute Gases be factory-set for calibration with substitute gases (see the "Calibration Methods"
section, page 7-A-10).
Substitute gas calibration of the Magnos 17 analyzer module is described using the
example of "Oxygen Measurement in Flue Gas", on page 7-C-11.

Sequence of Zero point calibration must always precede end point calibration.
Calibration

Wait Until End of The Magnos 17 analyzer module should only be calibrated after the warm-up
Warm-Up Phase phase, i.e. approx. 2-4 hours after connecting the power supply.

7-C-10 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Magnos 17: Substitute Gas Calibration

Example Substitute gas calibration of the Magnos 17 analyzer module is described using the
example of Oxygen Measurement in Flue Gas.

Oxygen Measurement The sample gas composition is known in the case of oxygen measurements in flue
in Flue Gas gas.

Test Gases The test gases for zero and span calibration are:
Zero Gas: 16 Vol.-% CO2 in N2
Span Gas: 10 Vol.-% O2 and 8.3 Vol.-% CO2 in N2

Calibration with Since these test gases are not available everywhere, the analyzer module is
Substitute Gases factory-set for calibration with a substitute gas.
In this case an additional measurement range is calibrated for 0-25 Vol.-% O2 in N2
(N2 and O2/N2 mixtures are available practically everywhere).

Measurement Ranges Component 1 O2 in flue gas Meas. Range 1 0-5 Vol.-%

Meas. Range 2 0-10 Vol.-%
Component 2 O2 in N2 (Substitute Gas) Meas. Range 1 0-25 Vol.-%

Calibration Parameters Calibration Method Substitute Gas Calibration

Zero Component Component 2 Meas. Range 1
Span Component Component 2 Meas. Range 1

Calibration • Calibrate zero with N2 (component 2).

• Calibrate span with dried air (containing 20.96 Vol.-% O2) or with an O2/N2 mixture.

Other Measurement For other measurement tasks select the test gases and measurement ranges in a
Tasks similar manner according to the sample gas composition.

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-C-11

Uras 14: Notes for Calibrating

Calibration Calibration can be performed in range 1 and range 2 for each sample component.
It is always a common calibration and thus affects both ranges.

F For additional information on measurement ranges, please refer to „Limas 11,

Uras 14: Notes for Changing Measurement Range Limits“ section, page 6-A-4.

Calibration Cells The use of calibration cells allows the Uras 14 analyzer module to be calibrated
without using test gas containers.
A calibration cell can be installed in each of the analyzer module's beam paths.
Each calibration cell is filled with a test gas matched to the sample components
and measurement ranges set up in the corresponding beam path.

Test Gases for Zero A zero gas is required for each zero calibration.
Calibration
In addition to nitrogen, ambient air can be used for zero calibration. Water vapor
must be absorbed using a cooler. If the ambient air contains sample gas compo-
nents, these must be removed with a suitable absorber (see the following table).

Sample Component Absorber

®
CO HOPCALIT
CO2 Sodium hydroxide on substrate

Test Gases for Span A test gas is required for each detector for span calibration without calibration cells.
Calibration without In the case of automatic and externally controlled calibration, a test gas mixture is
Calibration Cells required for all detectors since all are calibrated simultaneously. The span gas con-
centration should be 70-80% of the end value of the largest measurement range.

Test Gases for Span For suppressed ranges, the span gas concentration must be within the suppressed
Calibration of range. If possible, it should be equal to the end value of the suppressed range (and
Suppressed Ranges thus the end value of the larger measurement range).

Wait Until End of The Uras 14 analyzer module should only be calibrated after the warm-up phase,
Warm-Up Phase i.e. approx. 2 hours after connecting the power supply.

7-C-12 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Oxygen Sensor: Notes for Calibrating

Test Gases The oxygen sensor zero is not calibrated since it is fundamentally stable.
Ambient (non-process) air with a constant oxygen content (e.g. 20.96 Vol.-%) is
required for span calibration. Synthetic air can also be used.

Test Gases for The oxygen sensor and associated analyzer module are calibrated simultaneously
Simultaneous during automatic and externally controlled calibration.
Calibration of the
Therefore when the oxygen sensor is to be calibrated with the following analyzer
Oxygen Sensor and
modules
Analyzer Module
• Caldos 17 with single-point calibration
• Limas 11 with calibration unit
• Magnos 16/ 106 with single-point calibration
• Uras 14 with calibration units
the zero gas should contain the required concentration of oxygen.
In all other cases the span gas should contain the required concentration of
oxygen.

External Control The design of the external control of calibration should take into consideration that
Arrangement the oxygen sensor’s span value is stable only after a waiting period of ≥40 seconds.

Wait Until End of The oxygen sensor is always calibrated at the same time as the associated analyzer
Warm-Up Phase module. Therefore, calibration should begin only after this module’s warm-up
phase.

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-C-13

Section D Calibration

Analyzer Module Manual Calibration

F For information on the calibration data for manual calibration, please refer to page
7-B-2.

F To optimize accuracy, perform a manual zero calibration prior to calibrating the

span value.

Analyzer Module Step Action

Manual Calibration 1 Select the 0DQXDO&DOLEUDWLRQ menu.
0(18→&DOLEUDWH→0DQXDO&DOLEUDWLRQ
2 For Single Calibration:
Select &RPSRQHQWV and 0HDVXUHPHQW5DQJH with the arrow keys.
Zero calibration:
3 Select the =HUR*DV with the arrow keys.
4 Turn on the zero gas supply.
1)
5 If necessary, change the test gas concentration shown with the
numeric keypad, (17(5.
6 When the sample value indication stabilizes, initiate zero calibration
with (17(5.
7 Accept the calibration result with (17(5
or 5(3($7 calibration (back to step 5)
2)

or reject calibration with Back (back to step 6)

or reject calibration with Meas (back to measurement value readout).
Span Calibration:
8 Select the 6SDQ*DV with the arrow keys.
9 Turn on the span gas supply.
1)
10 If necessary, change the test gas concentration shown with the
numeric keypad, (17(5.
11 When the sample value indication stabilizes, initiate span calibration
with (17(5.
12 Accept the calibration result with (17(5
or 5(3($7 calibration (back to step 10)
2)

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. For further infor-
mation see the "Calibration Data for Manual Calibration" section, page 7-B-2.
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.

42/24-10-5 EN Chapter 7: Analyzer System Calibration 7-D-1

Manual Start of the Automatic Calibration

F For information on the calibration data for automatic calibration, please refer to
pages 7-B-3 and 7-B-4.

Manual Start of the Automatic calibration is started

Automatic Calibration • Only as zero calibration or
• Only as span calibration or
• As a common zero and span calibration
Caldos 15 For the Caldos 15, Caldos 17, Magnos 16, Magnos 106 and Magnos 17 analyzer
Caldos 17 modules, it is not admissible to perform only a span calibration. A zero calibration
Magnos 16/106 must always precede a span calibration.
Magnos 17

Proceed as follows to manually start automatic calibration – even outside of the

cycle intervals initialized:

Step Action
1 Select the$XWRPDWLF&DOLEUDWLRQmenu:
0(18→&DOLEUDWH→$XWRPDWLFFDOLEUDWLRQ
2 Only zero calibration: =(52$872&$/
Only span calibration: 63$1$872&$/
Common zero and span calibration: =(52 63$1$872&$/

Manual Stop of the The user can end the automatic calibration process by pressing the6723softkey.
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.

7-D-2 Chapter 7: Analyzer System Calibration 42/24-10-5 EN

Chapter 8 Inspection and Maintenance

CAUTION!
The tasks described in this chapter require special training and under some
circumstances involve working with the analyzer system open and powered
up. Therefore, they should only be performed by qualified and specially
trained personnel.

Inspection

Normal Operation of In normal operation the measured values from the installed analyzer modules are
the Analyzer System shown on the display screen and the green "Power" LED is lit.

Periodic Checks Check the analyzer system modules and assemblies at the intervals shown:

Module, Assembly Function Interval

á
Flowmeter Sample Gas Flow Indication
Caldos 15 10-90 l/h, max. 200 l/h
Regularly
r
Caldos 17 10-90 l/h
Limas 11 20-100 l/h
Magnos 16 8 ± 0.5 l/h without,
30-60-90 l/h with
Flow Regulator
Magnos 106 20-60 l/h
Magnos 17 20-60 l/h, max. 90 l/h
Uras 14 20-100 l/h
O2 Sensor 20-100 l/h
Gas Module 30-60 l/h
Gas Module
Disposable Filter
Staining
(see page 8-19)
Regularly
r
Analyzer System Gas Seal Integrity
Lines (see page 8-2)
Regularly
r
Seals Between Doors Contamination, Foreign Material
and Housing
Before Each
Closing
r

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-1

Checking Gas Path Seal Integrity

When should gas Gas path seal integrity should be checked periodically.
path seal integrity be
It must be verified after the gas paths inside or outside the analyzer system have
checked?
been opened (e.g. after removing or installing an analyzer module).

What materials are Quantity Description

needed? 1 Pressure Gauge
1 Plastic tubing, approx. 3 feet in length
1 Tee with Shut-Off 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.

F The following instructions apply to all gas paths in the analyzer system, therefore
to all sample gas paths and – in the Caldos 15 and Uras 14 analyzer modules – to
the reference gas path.

Continued on next page

8-2 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Checking Gas Path Seal Integrity, continued

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 8-1) 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).
Limas 11 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.
Limas 11 with quartz sample cell:
Test duration 15 minutes.
6 Repeat steps 1-5 for all gas paths in the analyzer system.

Figure 8-1
Seal Integrity Test
11 10 1
(Example: Sample Gas
Path in Magnos 16) 50 hPa
9 2

12 8 3

7 6 5 4

Luft / Air

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-3

Caldos 15, Magnos 16, Magnos 17: Thermal Link Replacement

F The service handbooks describe the procedure for replacing the Caldos 17,
Magnos 106 and Uras 14 thermal link.

When is replacement The thermal link should be replaced if a thermal link failure is the probable cause of a
needed? temperature error (see also "Caldos 15, Caldos 17, Magnos 16/ 106, Magnos 17
Problems" section, page 9-18).

Thermal Link Step Action

Replacement
1 Turn off the analyzer system power supply.
(see Figure 8-2) 2 Open the wall housing door or the 19-inch housing front plate.
3 Disconnect the thermal link from the thermostat connection terminals 2.
4 Bend back the thermal link spring clips on the cable guide and pull the
thermal link 1 from the cavity in the thermostat annular heater.
5 Insert a new thermal link (part number 0740712) in the cavity and close
the spring clips.
6 Connect the new thermal link to the thermostat connection terminals.
7 Close the system housing.
8 Turn on the analyzer system power supply.

Figure 8-2 1 Thermal Link

1 2
2 Thermostat Connection
Location of Caldos 15,
Terminals
Magnos 16 and
Magnos 17 Analyzer
Module Thermal Link

8-4 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Uras 14: Optical Alignment

Definition Optical alignment of the Uras 14 analyzer module will minimize asymmetry of the
radiation which falls in through the sample and reference sides of the sample cell.

When should optical An optical alignment must always be performed

alignment be • If the offset drift has fallen below the permissible range (50% of the physical
performed? measurement range)
• After a component (emitter, sample cell, calibration unit/cell, detector) is installed
in or removed from a beam path.

How should optical Each beam path in an analyzer module must be optically aligned separately. If
alignment be there are two detectors in a beam path, the optical alignment should be performed
performed? in the rearmost detector (as seen from the emitter). During an optical alignment,
beam path intensity is varied by means of mechanical apertures and, if necessary,
by turning the emitter case. For this, the system housing must be opened (see
Figure 8-4, page 8-6).

Receiver Figure 8-3 shows the detector layout. Detector numbers correspond to the
Arrangement numbers assigned to the series of measurement components as shown on the
analyzer module identification plate.

Figure 8-3
2 2 3 2 4
Uras 14 Analyzer 1 1 1 1 1 1
System Detector
Numbering

Test Gas During optical alignment the zero gas supply must be turned on.

Emitter Wrench An "emitter wrench" is required to rotate the emitter case (see Figure 8-4, page 8-6).
It is affixed to the analyzer module.

CAUTION!
Current-bearing components can be exposed when the covers or parts are
removed, even if this can be done without tools. Current can be present at
some connection points. All work on an analyzer system that is open and
connected to power should only be performed by trained personnel who are
familiar with the risks involved.

Menu Path 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHFDGMXVWP→

2SWLFDODGMXVWP
Continued on next page

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-5

Uras 14: Optical Alignment, continued

Procedure Step Action

1 Turn on the zero gas supply.
2 Open the 19-inch housing front plate or the wall housing cover.
3 Select the2SWLFDODGMXVWPmenu item.
4 Select the6DPSOHFRPSRQHQWto be measured in the rear detector
(as seen from the emitter).
5 Minimize the (zero gas) value displayed by turning the applicable beam
path aperture adjustment screw 1 or 2 with a screwdriver (see Figure
8-4).
If Then
The measurement value is much smaller than 1000 Go to Step 10.
The measurement value is greater than 1000 Go to Step 6.
6 Loosen the two emitter case mounting screws 3 and insert the emitter
wrench 6 in openings 4.
7 Turn the emitter case 5 until the displayed value is minimized. (The
minimum can be greater than 1000.)
8 Tighten the emitter unit mounting screws 3.
9 Repeat steps 5-8 until a minimum value is displayed.
10 Close the 19-inch housing front plate or the wall housing cover.
11 If Then
The emitter is replaced Perform a phase alignment for all sample
components (see page 8-7).
The emitter is not replaced Calibrate the zero and span points for all
sample components in the beam path.

Figure 8-4
Uras 14 Analyzer
Module Emitter

1 2

1 Beam path 1 aperture adjustment screw

2 Beam path 2 aperture adjustment screw
3 Two emitter case mounting screws (beam path 2 here)
4 Openings for emitter wrench insertion
5 Emitter Case
6 Emitter Wrench

8-6 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Uras 14: Phase Alignment

Definition Sample/reference signal phasing is optimized in the Uras 14 by performing a phase

alignment.

When should phase A phase alignment must always be performed after optical alignment when the
alignment be emitter is replaced (see page 8-5).
performed?

How should phase A separate phase alignment must be performed for each detector (= sample
alignment be component) in an analyzer module.
performed?
The phase alignment is performed electronically and there is no need to open the
system housing.

Test Gases During the phase alignment a zero and span gas supply should be turned on
successively for each sample component.
If the analyzer module is equipped with calibration units the calibration cells are
automatically inserted in the beam path for span alignment. Meanwhile zero gas
must remain turned on.

Menu Path 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHFDGMXVWP→

3KDVHDGMXVWP

Procedure Step Action

1 Select the3KDVHDGMXVWPmenu item.
2 Select the6DPSOHFRPSRQHQW.
3 Turn on the zero gas supply.
4 Wait until the measurement value reading stabilizes and activate the
alignment procedure.
5 If Then
The analyzer module has no Turn on the span gas supply.
calibration cells
The analyzer module is equipped with Let the zero gas be turned on.
calibration cells
6 Wait until the measurement value reading stabilizes and activate the
alignment procedure.
7 Repeat steps 2-6 for all sample components.
8 Calibrate the zero and span points for all sample components in the
analyzer module.

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-7

Limas 11, Uras 14: Measurement of Calibration Cells

Definition The measurement of a calibration cell in the Limas 11 and Uras 14 analyzer modules
means:
Determining what calibration cell "deflection" is equivalent to the test gas calibration
reading. This "deflection" is stored as the calibration cell "set value".

When should We recommend measuring the calibration cells once a year.

calibration cells be
We recommend measuring the calibration cells after any change in measurement
measured?
range limits (see "Limas 11, Uras 14: Notes for Changing Measurement Range
Limits" section, page 6-A-4) or after a relinearization (see "Limas 11, Uras 14:
Relinearization" section, page 8-9).

Before measuring the Prior to measuring the calibration cells, the zero and end points of the applicable
calibration cells sample components must be calibrated with test gases.

Test Gas During calibration cell measurement the zero gas supply must be turned on.

Menu Path 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHFDGMXVWP→

0HDVXUHFDOFHOO

8-8 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Limas 11, Uras 14: Relinearization

When should Sample component relinearization should be performed

relinearization be • If the linearity deviation exceeds the permissible 1% of span
performed? • If the start of a suppressed measurement range is to be calibrated.
We recommend to perform the relinearization of a sample component after
measurement range limits have been changed (see "Limas 11, Uras 14: Notes for
Changing Measurement Range Limits" section, page 6-A-4).

How should Relinearization is performed separately for each sample component.

relinearization be
performed?

Test Gases Depending on the number and type of measurement ranges, test gases with
varying concentrations are required for relinearization.

Number and Type of Meas. Ranges Test Gas Concentration

1 Measurement Range Approx. 40-60% of the measurement
range end value ("center point gas")
2 Measurement Ranges End value of smaller measurement range
2 Measurement Ranges, Start value of suppressed measurement
1 of which is suppressed range

Menu Path 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHFDGMXVWP→

5HOLQHDUL]DWLRQ

Procedure Step Action

1 Perform the basic calibration for the zero and span of the sample
component to be relinearized (see page 8-26).
2 Select the5HOLQHDUL]DWLRQmenu item.
3 Select the6DPSOHFRPSRQHQW.
4 Turn on the test gas supply.
5 Enter the test gas concentration set point value.
6 Wait until the measurement value reading stabilizes and activate the
alignment procedure.
7 Repeat steps 3-6 for all sample components.

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-9

Limas 11: Thermal Link Replacement

When should a A defective thermal link will usually be indicated by an Insufficient Sample Cell
thermal link be Temperature (75H.) or Lamp Temperature (75H/) error message (see "Status
replaced? Messages" section, page 9-11). In this case check the thermal link and replace as
necessary.

Thermal Link Step Action

Replacement
1 Turn off the analyzer system power supply.
(see Figure 8-5) 2 Open the wall housing door or the 19-inch housing cover.
3 Disconnect the thermal link from the sample cell 1 and/or the lamp 2.
4 Release the spring clips and/or retainer and pull the thermal link from
the opening.
5 Check the continuity of the thermal link; if necessary, insert a new
thermal link (part number 0745836) in the opening and secure it with
the spring clips and/or retainer.
6 Connect the thermal link.
7 Close the system housing.
F Light penetration during operation leads to erroneous measure-
ment values and measurement range overflows ("Intensity"
status message).
8 Turn on the analyzer system power supply.

Figure 8-5 2 1
Thermal Links in the
Limas 11 Analyzer
Module

1 Sample cell thermal link

2 Lamp thermal link

8-10 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Limas 11: Aluminum Sample Cell Cleaning

When should the Sample cell contamination can result in unstable measurement values due to low
sample cell be lamp intensity (see "Limas 11 Problems", page 9-19).
cleaned?

Status Messages When beam intensity becomes too low the appropriate status messages will be dis-
played. For additional information see the "Status Messages" section, page 9-13.

Material Required Quantity Description

For cleaning: Neutral detergent, deionized water, ethanol
For drying: Oil- and dust-free (instrument) air or nitrogen
1 Spray bottle
2 Plug to close off sample cell
2 Pieces of Viton tubing or PTFE pipe

Aluminum Sample Cell Step Action

Cleaning Preparation for sample cell removal:
(see Figure 8-6) 1 Turn off the sample gas supply to the analyzer module.
Turn off the analyzer system power supply.
2 Open the wall housing door or the 19-inch housing cover.
The sample cell is hot (approx. 55 °C)!
Sample cell removal:
3 Loosen the sample gas tubing/pipe from the sample cell ports and
housing wall and pull them from the housing.
When removing the sample gas tubing/pipe make sure no fluids
drip into the housing.
The sample gas tubing / pipe removed should not be reused
since it is contaminated; follow the appropriate rules for disposal.
4 Loosen 4 screws 1 (3-mm Allen screws) and remove 2 mounting
brackets 2.
5 Remove the sample cell from its housing.
Sample Cell Cleaning:
6 Wash the sample cell with a warm detergent/ water mixture.
Do not use other cleaners as they can damage the sample cell.
7 Thoroughly rinse the sample cell with deionized water and then with
ethanol.
8 Dry the sample cell with oil- and dust-free air (30-100 liters/hour).
9 Check that the contamination has been removed.
F Also clean the sample gas line system.

Continued on next page

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-11

Limas 11: Aluminum Sample Cell Cleaning, continued

Step Action
Sample Cell Installation:
10 Place the sample cell in its housing. The index pin should be on the
side of the sample cell that is toward the beam splitter. Turn the
sample cell in its housing until the index pin engages in the hole in the
housing.
11 Install the 2 mounting brackets 2 and secure them with the 4 screws 1.
12 Install the sample gas tubing or pipes on the sample cell ports and on
the module’s rear wall.
13 Check the integrity of the analyzer module gas paths (see page 8-3).
Restarting the analyzer module:
14 Close the system housing.
F Light penetration during operation leads to erroneous measure-
ment values and measurement range overflows ("Intensity"
status message).
15 Turn on the analyzer system power supply.
16 Wait for the warm-up phase to end. Start the sample gas supply.
17 Check linearity.

Figure 8-6 1 2 1 2
Aluminum Sample
Cell in the Limas 11
Analyzer Module

1 Allen Screws (3 mm)

2 Mounting Bracket

8-12 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Limas 11: Quartz Sample Cell Cleaning

When should the Sample cell contamination can result in unstable measurement values due to low
sample cell be lamp intensity (see "Limas 11 Problems", page 9-19).
cleaned?

Status Messages When beam intensity becomes too low the appropriate status messages will be dis-
played. For additional information see the "Status Messages" section, page 9-13.

Material Required Quantity Description

For cleaning: Neutral detergent, deionized water, ethanol
For drying: Oil- and dust-free (instrument) air or nitrogen
1 Spray bottle
2 Plug to close off sample cell
1 Spare parts kit (part number 0768823)

Quartz Sample Cell Step Action

Cleaning Preparation for sample cell removal:
(See Fig. 8-7 and 8-8) 1 Turn off the sample gas supply to the analyzer module.
Turn off the analyzer system power supply.
2 Open the wall housing door or the 19-inch housing cover.
The sample cell is hot (approx. 55 °C)!
Sample cell removal:
3 Loosen the sample gas pipes 2 from the connections on the sample
cell 5 and from the housing back wall 1 and pull them from the housing.
Save the nut, cutting rings and sealing rings for reinstallation.
When removing the sample gas pipes make sure no
contaminants contained in the pipes fall into the housing.
The sample gas pipes removed should not be reused since they
are contaminated; follow the appropriate rules for disposal.
4 Loosen 4 screws 3 (3-mm Allen screws) and remove 2 mounting
brackets 4.
5 Remove the sample cell 6 from its housing.
6 Unscrew the elbow/ pivot fittings 5 from the sample cell.
Sample Cell Cleaning:
7 Wash the sample cell with a warm detergent/ water mixture.
F Acids, alkalis or solvents can be used as cleansers in case of
severe contamination.
Be sure to follow the appropriate instructions for use and
disposal when using acids, alkalis or solvents.
Do not use hydrofluoric acid (HF) as it can destroy the sample
cell.

Continued on next page

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-13

Limas 11: Quartz Sample Cell Cleaning, continued

Step Action
8 Rinse the cell very thoroughly with deionized water until the detergent
is completely removed. Finally, rinse the cell with ethanol until all water
is removed.
9 Dry the sample cell with oil- and dust-free air (30-100 liters/hour).
10 Check that the contamination has been removed.
F Also clean the elbow fittings and the sample gas line system.
Sample Cell Installation:
11 Place new FFKM75 O rings 7 on the sample cell connection ports.
12 Place the internal parts 8 of the elbow/pivot fittings on the connection
ports and tighten them by hand. Place the elbows 9 on the internal
parts with their ports facing toward the housing back wall and secure
them by hand-tightening the nuts 10.
The threaded connections must never be tightened any more
than hand-tight. Otherwise the connections may not be securely
sealed.
13 Place the sample cell 6 in its holder with the gas ports pointing to the
left wall (as seen from the front/ above).
14 Install 2 mounting brackets 4 – making sure that the notches for the
sample cell gas lines also face the left wall – and secure with 4 screws
3.
Connect the sample gas lines to the sample cell.
15 Push the sample gas tubes 2 through the threaded fittings 1 on the
housing back wall.
F Make sure the sample gas lines are smooth and straight on both
ends and that there are no kinks.
16 Slide nuts 13, cutting rings 12 and sealing rings 11 on the sample gas
pipes 2.
17 Slide the sample gas tubes 2 up to the stop in the elbow/pivot fittings
5 on the sample cell and high-tighten nuts 13. Hand-tighten the nuts
on fittings 1 on the housing back wall.
The threaded connections must never be tightened any more
than hand-tight. Otherwise the connections may not be securely
sealed.
18 Check the integrity of the analyzer module gas paths (see page 8-2).
Remember the higher seal integrity requirements.
Restarting the analyzer module:
19 Close the system housing.
F Light penetration during operation leads to erroneous measure-
ment values and measurement range overflows ("Intensity"
status message).
20 Turn on the analyzer system power supply.
21 Wait for the warm-up phase to end. Start the sample gas supply.
22 Check linearity.

Continued on next page

8-14 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Limas 11: Quartz Sample Cell Cleaning, Continued

Figure 8-7 1 2 3 4 5 6 3 4
Quartz Sample Cells
in the Limas 11
Analyzer Module

1 Threaded Fittings on Housing Back Wall 4 Mounting Bracket

2 Sample Gas Tubes 5 Elbow/ Pivot Fittings (see
3 Allen Screws (3 mm) Figure 8-8 for Components)
6 Quartz Sample Cell

Figure 8-8 2 13 12 11 2 Sample Gas Tube

7 FFKM75 O ring
Elbow /Pivot Fitting
8 Internal Part
Components 10
9 Elbow
10 Nut
9 11 Sealing Ring
12 Cutting Ring
13 Nut
8

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-15

Limas 11-UV: Lamp Replacement

When should the Over a period of 2-3 years the plasma-discharge fill gas will dissipate, causing a loss
lamp be replaced? of lamp intensity. The lamp must be replaced when its intensity reaches a value at
which the short-term stability of the smallest measurement range is too low.

Status messages When beam intensity becomes too low the appropriate status messages will be dis-
played. For additional information see the "Status Messages" section, page 9-13.

Determining Lamp Lamp service hours are displayed in the0DLQWHQDQFH7HVW→$QDO\]HU

Service Life VSHFDGMXVWP→$PSOLILFDWLRQ2SWLPL]DWLRQmenu.

Lamp Replacement Step Action

(see Figure 8-9) Prepare to remove the lamp:
1 Turn off the analyzer system power supply.
2 Open the wall housing door or the 19-inch housing cover.
The lamp is hot (approx. 60 °C)!
Remove the old lamp:
3 Remove the connecting cable from filter wheels 1 and 2 as well as
thermostat 3.
4 Remove the 2 retaining screws (3-mm Allen screws) 4 and 5 and pull
the filter wheel and lamp assembly out of the analyzer module.
If space is a consideration, remove the filter wheels separately by
loosening mounting screws 6 and 7.
5 Remove the 2 mounting screws 8 and remove the lamp 9.
6 Remove the connecting cable 10 from the thermostats and remove
the thermostat 11 after taking the 2 mounting screws 12 from the lamp
housing.
Install the new lamp (part number 0746376):
7 Before installing the new lamp, record the serial number shown on the
identification plate. It will be needed during amplification optimization.
8 Secure the thermostat 11 on the new lamp housing with the 2 mount-
ing screws 12 and install the connecting cable 10.
9 Install the lamp 9 and secure it with the 2 mounting screws 8.
10 Install the filter wheels and lamp in the analyzer module and secure
them with the 2 mounting screws 4 a nd 5.
11 Attach the connecting cable to filter wheels 1 and 2 (pay attention to
the order) and to the thermostat 3.

Continued on next page

8-16 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Limas 11-UV: Lamp Replacement, continued

Restart the analyzer module:

12 Close the system housing.
F Light penetration during operation leads to erroneous measure-
ment values and measurement range overflows ("Intensity"
status message).
13 Turn on the analyzer system power supply and wait for the warm-up
phase to end.
14 Perform an amplification optimization (see "Amplification Optimization"
section, page 8-18).
15 Recommendation: Check sensitivity and linearity.

Figure 8-9 9 10 1 5 3 8
Lamp in Limas 11-UV
Analyzer Module

2 7 4 6

1 Connecting cable filter wheel 1

2 Connecting cable filter wheel 2
3 Connecting cable thermostat
4 Retaining screw
5 Retaining screw
6 Mounting screw filter wheel 1
7 Mounting screw filter wheel 2
8 Mounting screws lamp
9 Lamp
10 Connecting cable thermostat
11 Thermostat
12 Mounting screws thermostat

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-17

Limas 11: Amplification Optimization

Definition The amplification optimization procedure automatically seeks and identifies the
optimum measurement range for the sample and reference receiver analog/digital
converter.

When should Amplification optimization should be performed when the receiver signals underflow
amplification the permissible max. and min. limit values (an error message is generated). Also,
optimization the amplification optimization procedure must be performed after the lamp has
be performed? been replaced.

How should The1HZ/DPSsoftkey optimizes all receiver signals for all sample components;
amplification this overwrites any stored initial intensities with a new initial value.
optimization
The2SWLPL]Hsoftkey optimizes receiver signals for a specific sample compo-
be performed?
nent; this does not overwrite the stored initial intensities.
The2SWLPL]H$OOsoftkey optimizes receiver signals for all sample components;
this does not overwrite the stored initial intensities.

Test Gas The zero gas supply should be turned on during amplification optimization.

Menu Path 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHFDGMXVWP→

$PSOLILFDWLRQ2SWLPL]DWLRQ

Procedure Step Action

1 Turn on the zero gas supply.
If a solenoid valve is used to switch to zero gas, the supply will be
activated automatically.
2 Select the$PSOLILFDWLRQ2SWLPL]DWLRQmenu item.
3 Select the component.
4 Press the1HZ/DPSor2SWLPL]Hor2SWLPL]H$OOsoftkey.
After pressing1HZ/DPSa window will be appear for entering the
number of the new lamp. After this the amplification optimization
procedure will run automatically and cannot be interrupted.
5 Wait for measurement value readings to stabilize and end the
amplification optimization procedure by pressing the(17(5key.
6 Confirm the amplification optimization by pressing(17(5(the zero
point will be automatically aligned) or reject the result by pressing
Back or Meas.
7 Repeat steps 3-6 for all sample components.

8-18 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Gas Module: Disposable Filter Replacement

When should the The gas module disposable filter should be changed if it is stained by contaminants.
disposable filter be
We recommend changing the disposable filter (catalog number 23044-5-8018418)
replaced?
every six months.

Disposable Filter Step Action

Replacement
1 Turn off the sample gas supply to the analyzer module.
Turn off the analyzer system power supply.
2 Open the wall housing door or the 19-inch housing front plate.
3 Remove the disposable filter 1 from the bracket.
4 Remove the hose clamps from both sides of the disposable filter and
disconnect the hoses.
F Properly dispose of the contaminated filter.
5 Attach the hoses to the new disposable filter and fasten them with the
hose clamps.
F Pay attention to the flow direction. The flow direction is marked
on the disposable filter housing.
6 Place the disposable filter in the support.
7 Check the integrity of the analyzer module gas paths (see page 8-2).
8 Close the system housing.
9 Turn on the analyzer system power supply.
10 Wait for the warm-up phase to end. Turn on the sample gas supply.

Figure 8-10 1 Disposable Filter

1
Location of
Disposable Filter in
Gas Module

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-19

Pump

Pump Activation The pump installed in the internal gas module and external pumps connected to
appropriately configured digital outputs can be activated and deactivated
manually, for instance in emergency situations.
An emergency shutdown cannot be bypassed by automatic calibration.

Pump Output The output of the pump installed in the internal gas module can be adjusted
Adjustment manually only when the pump is in operation.
If there is a flow sensor in the gas module, its reading is shown when adjusting the
pump output.

Menu Path 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHFDGMXVWP→3XPS

Figure 8-11
Pump Output
Adjustment

8-20 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Changing Analog Output Current Range

Method The current range of the individual analog outputs can be modified by initializing
the applicable Analog output function blocks. Technical Bulletin "Advance Optima
Function Blocks – Descriptions and Configuration" (Publication No. 30/24-200 EN)
contains a detailed description of the function block.

Menu Path 0(18→&RQILJXUH→)XQFWLRQEORFNV→2XWSXWV→

$QDORJRXWSXW

Figure 8-12
Analog Output
Function Block
Parameters

Changing Current The current range is changed using the8VHUUDQJHparameter.

Range

Selection The current range choices are 0-20 mA, 2-20 mA and 4-20 mA.

F The output signal cannot be lower than 0 mA.

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-21

Air Pressure Correction

Air Pressure Effect Atmospheric pressure affects the measurement values determined by the individual
analyzer modules. In other words: A specific amount of change in air pressure will
result in a specific change in a measurement value, depending on the measurement
principle employed by the analyzer module.

Measures to Minimize Air pressure effect can be minimized by:

Air Pressure Effect • installing a pressure sensor in the analyzer module (this can only be done at the
factory)
• Entering the current atmospheric pressure as a correction value
The following table shows which analyzer modules have or can be fitted with a
pressure sensor. For further information please refer to the "Pressure Sensor"
section, page 2-9.

Analyzer Module Pressure Sensor Installed

Caldos 15 No
Caldos 17 Yes
Limas 11 Yes
Magnos 16 Yes (optional)
Magnos 106 Yes (optional)
Magnos 17 No
Uras 14 Yes

F After selecting the appropriate analyzer module, use the0(18→'LDJQRVWLF

,QIRUPDWLRQ→6\VWHPRYHUYLHZmenu item to determine if a pressure
sensor is installed.

Continued on next page

8-22 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Air Pressure Correction, continued

Air Pressure Values Operating Altitude Mean Air Pressure

meters above
mean sea level hPa (mbar) psi mm Hg (Torr) in Hg
–200 1037 15.04 778 30.63
–100 1025 14.87 769 30.28
±0 1013 14.69 760 29.92
+100 1001 14.52 751 29.57
200 989 14.34 742 29.21
300 977 14.17 733 28.86
400 965 14.00 724 28.50
500 955 13.85 716 28.19
600 943 13.68 707 27.84
700 932 13.52 699 27.52
800 921 13.36 691 27.21
900 909 13.18 682 26.85
1000 899 13.04 674 26.54
1100 888 12.88 666 26.22
1200 877 12.72 658 25.91
1300 867 12.57 650 25.59
1400 856 12.42 642 25.28
1500 845 12.26 634 24.96
1600 835 12.11 626 24.65
1700 825 11.97 619 24.37
1800 815 11.82 611 24.06
1900 804 11.66 603 23.74
2000 793 11.50 595 23.43

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-23

Air Pressure Value Correction

F An incorrect air pressure value will produce erroneous measurement values.

When should the air The air pressure value must be checked and readjusted as required in the following
pressure value be cases:
set? • If the analyzer system’s operating site altitude has changed since the last
calibration
• If the air pressure effect on the measured value is too high (see also Appendix 2,
"Analyzer Module Operating Specifications").

Limas 11 A pressure sensor is installed as standard equipment in the Limas 11 and Uras 14
Uras 14 analyzer modules. The pressure sensor is calibrated to 1013 hPa. This is the refer-
Integral Pressure ence pressure for the test gas concentration when measuring the calibration cells.
Sensor If the air pressure value needs to be changed, the following items are also required
• Calibrate the sample components with test gases and then
• Measure the calibration cells

Magnos 16/106 When the Magnos 16 and Magnos 106 analyzer modules have suppressed
with Suppressed measurement ranges with a suppression ratio of > 1:5, a special adjustment of the
Measurement Ranges pressure sensor is carried out in the factory.
In this case the air pressure value correction should not be carried out via the
display and control unit because this will lead to incorrect measurements. The air
pressure value correction must be carried out only using the test and calibration
software.

Air Pressure Value The current atmospheric pressure can be entered as a correction value for each
Correction analyzer module or for all analyzer modules as a group.

Analyzer System 0(18→0DLQWHQDQFH7HVW→6\VWHP→$WPSUHVVXUH

Menu Path

Menu Path for One 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHFDGMXVWP→

Analyzer Module $WPSUHVVDQO]→

F If there is only one analyzer module in the analyzer system, the settings are
identical in both menu items.

F If the pressure sensor is connected to the sample gas output line, the sample gas
flow must be interrupted while calibrating the pressure sensor so that the sample
gas pressure does not distort the measured pressure.

8-24 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Calibration Reset

When should a A calibration reset should be performed if an analyzer module can no longer be
calibration reset be calibrated by normal means. A possible cause of this is calibration of the analyzer
performed? module with the wrong test gases.

What does the A calibration reset returns the analyzer module’s calibration to basic calibration
calibration reset do? values. Additionally, the offset drift and amplification drift are electronically
returned to basic calibration values (see "Basic Calibration" section, page 8-26).

Note The absolute offset and amplification drift values are calculated in cumulative
fashion starting from the last basic calibration.
The relative offset and amplification drift values are calculated between the last and
next to last automatic calibration.
The absolute and relative offset and amplification drift values can be viewed in the
0(18→'LDJQRVWLF,QIRUPDWLRQ→0RGXOHVSHFLILF→6WDWXV
menu item.

Menu Path 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHFDGMXVWP→

&DOLEUDWLRQUHVHW

F The analyzer module should be calibrated after a calibration reset.

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-25

Basic Calibration

When should an basic Basic calibration of an analyzer module should be performed whenever changes
calibration be that affect calibration have been made.
performed?
An analyzer module basic calibration should also be performed if the offset drift
and amplification drift exceed permissible limit values. Prior to this, however,
check and ensure
• That the analyzer system is in proper operating condition
• That the sample preparation units are in proper operating condition
• That the correct test gases are being used.

What does an basic An basic calibration of an analyzer module places the module’s calibration status
calibration do? back in the initial state with respect to all physical changes made to the measure-
ment section (such as those due to aging). Additionally, the offset drift and amplifi-
cation drift are set to zero.

Performing the Basic The basic calibration is performed for each sample component or – for the
Calibration Caldos 15 and Magnos 17 analyzer modules – for each measurement range.
The basic calibration can be performed
• Individually at the zero point
• Individually at the end point, as well as
• Together (successively) at the zero and end points
A calibration reset is also performed in the case of common basic calibration at the
zero and end points.
The current atmospheric pressure value is entered during the basic calibration.

Test Gases The zero and span calibration test gases are required for an basic calibration.

Menu Path 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHFDGMXVWP→

%DVLFFDOLEUDWLRQ

8-26 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Cross-Sensitivity Alignment

Electronic Cross- Advance Optima offers the ability to electronically correct cross sensitivity, in
Sensitivity Correction contrast to using purely physical methods (for example, for infrared absorption,
optical filter or flowing reference gas).
Electronic cross sensitivity correction is possible only with the Caldos 15, Caldos 17,
Limas 11, Magnos 16, Magnos 106 and Uras 14 analyzer modules. In addition, this
function must be factory-set per customer order. It is configured as a function block
application. A detailed description of the function block Cross sensitivity correc-
tion is contained in the Technical Bulletin "Advance Optima Function Blocks –
Descriptions and Configuration" (Publication No. 30/24-200 EN).
Cross sensitivity correction is an offset correction.
Interference component concentration is continuously measured and corrected by
means of the measurement value. Alternatively, the interference component con-
centration can be entered directly as a correction value during the cross sensitivity
alignment.

Internal and External Interference component concentration can be measured in two ways:
Cross Sensitivity • Using the analyzer module with which the sample component is measured
Correction (internal cross sensitivity correction, possible only with the Limas 11 and Uras 14
analyzer modules) or
• With another Advance Optima analyzer module or another analyzer (external
cross sensitivity correction) The correction signal, i.e. the measured value of the
interference component is transferred to the analyzer module with the sample
component to be corrected via the system bus or analog input.

When should a cross A cross sensitivity alignment, i.e. alignment of the cross sensitivity correction
sensitivity alignment function, should not be performed in normal operation.
be performed?
We recommend checking the cross sensitivity correction once a year.

Test Gas for Cross One of the following test gases is needed for the cross sensitivity alignment:
Sensitivity Alignment • Either a sample component-free test gas containing the maximum concentration
of the interference component
• Or the interference component span gas.

Prior to the Cross Prior to the cross sensitivity alignment, the zero and end points of the applicable
Sensitivity Alignment sample and interference components must be calibrated with test gases in the
respective analyzer module.

Menu Path 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHFDGMXVWP→

&URVVVHQVLWLYLW\DGMXVWP

42/24-10-5 EN Chapter 8: Inspection and Maintenance 8-27

Carrier Gas Alignment

Electronic Carrier In principle, the electronic carrier gas correction operates in the same manner as the
Gas Correction cross sensitivity correction (see "Cross Sensitivity Alignment" section, page 8-27).
Carrier gas correction is possible only if the cross sensitivity correction function has
been factory-configured per customer order. Carrier gas correction is similarly con-
figured as a function block application. A detailed description of the function block
Carrier gas correction is contained in the Technical Bulletin "Advance Optima
Function Blocks – Descriptions and Configuration" (Publication No. 30/24-200 EN).
Carrier gas correction is an amplification correction.

When should a carrier A carrier gas alignment, i.e. alignment of the carrier gas correction function, should
gas alignment be not be performed in normal operation.
performed?
We recommend checking the carrier gas correction once a year.

Test Gas for Carrier A gas mixture with the appropriate concentrations of sample and interference
Gas Alignment components is required as the test gas.

Prior to the Carrier Prior to the carrier gas alignment, the zero and end points of the applicable sample
Gas Alignment and interference components must be calibrated with test gases.
If the interference component influences the zero indication of the sample compo-
nent, a cross sensitivity alignment is required prior to the carrier gas alignment.

Set Point Entry Enter the sample component concentration as the set point.

Menu Path 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHFDGMXVWP→

&DUULHUJDVDGMXVWP

8-28 Chapter 8: Inspection and Maintenance 42/24-10-5 EN

Chapter 9 Status Messages, Troubleshooting

Process Status

Definitions Process status provides information on measurement values and the process
being monitored by the analyzer.
System status (see page 9-2) provides information on the analyzer itself.

Process Status The term "process status" includes

• Transgression of measurement range limits
• Transgression of measurement value limit values

Transgression of If a sample component value is more than 100% below or more than 130% above
Measurement Range the range limits, the sample component value in the display flashes. A status
Limits message is also generated which is not entered into the logbook.
The thresholds established cannot be changed.

Transgression of If a sample component value is above or below a limit value, this status can be
Limit Values communicated as a binary signal at one of the system controller or I/O board digital
outputs.
Two prerequisites must be met for this to happen:
• The limit value must be assigned to a digital output by means of function block
configuration (see "Standard Configuration" section, page 6-B-2).
• The limit value monitoring parameters (direction of effect, threshold value,
hysteresis) must be set (see "Limit Monitor Initialization" section, page 6-A-8).
The assignment of limit values to certain digital outputs is factory-set; this is
documented in the analyzer data sheet.

42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-1

System Status: Status Messages

Where are status Status messages are generated

messages • By the analyzer system, i.e.
generated? • The system controller (signal processing, calibration, system bus)
• The analyzer modules
• The gas module:
• The temperature and pressure regulators
• The I/O boards
• By peripherals, for example
• The system cooler
• Other sample gas preparation modules

User-Configured Status messages are automatically generated by the analyzer system.

Status Messages
Additionally, by configuring the Message generator function block, status
messages from the analyzer and peripherals can be linked into the status message
processing system (see Technical Bulletin 30/24-200 EN "Function Blocks –
Descriptions and Configuration" for details).

How are status • Status messages are shown on the screen and recorded in the log.
messages
• Status messages set a corresponding status signal (overall status or individual
processed?
status).
(see Figure 9-1)
• Status signals are indicated using status LEDs and output via the system
controller digital outputs.

Figure 9-1
Component gen
Status Message
era
Processing te s
genera
Module tes Display Screen
tes Status Message Entr y
genera
s
System
n e rate Log
ge
Peripheral sets

Display LEDs
Status Signal Output
Digital
Outputs

Continued on next page

9-2 Chapter 9: Status Messages, Troubleshooting 42/24-10-5 EN

System Status: Status Messages, continued

Status Message The softkey appears as soon as a status message is generated. By pressing
Display the softkey the user can recall the status message summary and view status
message details.

Logging Status Status messages are logged.

Messages
Messages concerning a transient analyzer system state with no direct effect on
measurements are not logged. Such messages include
• "A password is active!"
• "This system is temporarily under remote control!"
• "Automatic calibration in progress."

42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-3

System Status: Status Signals

Overall Status or The status signal is factory-configured to output as an overall or individual status
Individual Status indicator (refer to "Configuring Status Signals" section, page 6-C-9).

Overall Status If the analyzer system is configured to output overall status, status messages are
issued as overall status indications.

Individual Status The following table shows possible causes of individual status signals and how to
evaluate the values measured.

Status Signal Cause Evaluation of Measured Value

Error The analyzer is in a state that The value is invalid.
requires immediate user
intervention.
Maintenance The analyzer is in a state that The value is valid.
Required will soon require user
intervention.
Maintenance The analyzer system is being Discard the value as a process
Mode calibrated or serviced. measurement value.

Individual Status by In principle, the individual status signals apply to the entire analyzer system
Analyzer Module or (system status).
Sample Component
However, by configuring the Message input function block, individual status
messages for each analyzer module or for each sample component can be output
separately via digital outputs (see Technical Bulletin 30/24-200 EN "Function
Blocks – Descriptions and Configuration“ for details).
I/O board status messages are only reported as system status signals.

Status Indication Analyzer system status is indicated by means of status LEDs.

LED Status
Overall or Individual "Error" Status

Individual "Maintenance Required" status

9-4 Chapter 9: Status Messages, Troubleshooting 42/24-10-5 EN

Status Message Categories

Status Message In terms of operator reaction, there are three categories of status messages (see
Categories the summary on the following page):
• Status messages not requiring acknowledgment
• Status messages requiring acknowledgment
• Status messages requiring acknowledgment and intervention

Status Messages The system operates normally after the status is cleared.
Not Requiring
When the status is cleared, the LED goes out, the status signal is reset and the
Acknowledgment
status message is canceled.
Example: Temperature error during the warm-up phase.

Status Messages The system operates normally after the status is cleared; however, the operator is
Requiring aware of the status.
Acknowledgment
When the status is cleared, the LED goes out and the status signal is reset. The
status message is only canceled after operator acknowledgment. In this manner,
the operator is aware of the system malfunction.
Example: No new measurement values from the analog/digital converter.

Status Messages The system may not operate normally after the status condition is cleared;
Requiring therefore, the operator should acknowledge the condition and actively eliminate
Acknowledgment and the cause of the message.
Intervention
The LED goes out, the status signal is reset and the status message is only
canceled after the operator acknowledges the status message and eliminates the
cause.
Example: The offset drift between two calibrations exceeds the permissible range.

Continued on next page

42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-5

Status Message Categories, continued

Summary The following table shows

• The time sequence of the three status message categories (phases 1-3)
• The identifier used to identify the status messages in the summary (T, 4 and ,).

Phase 1 Phase 2 Phase 3

Status Messages Not Requiring Acknowledgment
Status begins Status ends
LED lights up LED goes out
Status signal set Status signal reset
Status message appears Status message canceled
Status Messages Requiring Acknowledgment
Status begins Status ends Acknowledge
LED lights up LED goes out
Status signal set Status signal reset
T Status message appears , Status message remains Status message canceled
Status begins Acknowledge Status ends
LED lights up LED goes out
Status signal set Status signal reset
T Status message appears 4 Status message remains Status message canceled
Status Messages Requiring Acknowledgment and Intervention
Status begins Status ends Acknowledge, correct
LED lights up LED goes out
Status signal set Status signal reset
T Status message appears , Status message remains Status message canceled
Status begins Acknowledge, correct Status ends
LED lights up LED goes out
Status signal set Status signal reset
T Status message appears 4 Status message remains Status message canceled

9-6 Chapter 9: Status Messages, Troubleshooting 42/24-10-5 EN

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 Required" individual status
F x = Status message sets the "Maintenance Mode" individual status
Reaction/
Remark Explanations and corrective measures in case of status messages

Continued on next page

42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-7

Status Messages, continued

No. Text O E M F Reaction/Remark

Runtime Error
1–21 Runtime Error 1–21 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 See page 6-11 for password protection information
delete, press the <MEAS> key Not in log
on the measurement value
display.
110 System ramping up. 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:
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:0(18→'LDJQRVWLFV
,QIRUPDWLRQ→6\VWHPRYHUYLHZ
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. 0(18→'LDJQRVWLFV,QIRUPDWLRQ→6\VWHP
RYHUYLHZ
214 The system is currently x
maintained with Optima SMT.

Continued on next page

9-8 Chapter 9: Status Messages, Troubleshooting 42/24-10-5 EN

Status Messages, continued

No. Text O E M F Reaction/Remark

Analyzer Modules
300 No new measurement values x x Notify service.
from analog/digital converter.
301 Measurement value exceeds x x 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
range; 50% of physical measurement range for Uras 14
303 Offset drift exceeds x x Perform a basic calibration of the detector indicated:
permissible range. 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHF
DOLJQPHQW→%DVLFFDOLEUDWLRQ
Permissible range: 150% of smallest installed measurement
range
304 Amplification drift exceeds half x Check analyzer module and sample preparation.
the permissible range. Permissible range: 50% of detector sensitivity; 50% of
physical measurement range for Uras 14
305 Amplification drift exceeds x x Perform a basic calibration of the detector indicated:
permissible range. 0(18→0DLQWHQDQFH7HVW→$QDO\]HUVSHF
DOLJQPHQW→%DVLFFDOLEUDWLRQ
Permissible range: 50% of detector sensitivity
306 The offset drift between two x Perform manual zero calibration on indicated detector.
calibrations exceeds the (This message is generated by automatic calibration.)
permissible range. Permissible range: 15% of smallest installed measurement
range; for measurements per 17. BlmSchV, 6% of smallest
installed measurement range
307 The amplification drift between x Perform manual span calibration on indicated detector.
two calibrations exceeds the (This message is generated by automatic calibration.)
permissible range. Permissible range: 15% of sensitivity;
for measurements per 17. BlmSchV, 6% of sensitivity
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.

Continued on next page

42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-9

Status Messages, continued

No. Text O E M F Reaction/Remark

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.
from analog/digital converter.
316 Measurement value exceeds x Notify service.
the analog/digital converter
value range.
317 A computer error occurred x Notify service.
during calculation of the
measurement value.
Uras
318 No new measurement values x x Notify service.
from analog/digital converter.
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.
Multi-FID
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
Multi-FID 14 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.

Continued on next page

9-10 Chapter 9: Status Messages, Troubleshooting 42/24-10-5 EN

Status Messages, continued

No. Text O E M F Reaction/Remark

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
being maintained (see page 9-17). Check the analyzer
module thermal link and replace if necessary.
325 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 2. Check if the permissible ambient temperature range is
being maintained (see page 9-17). Check the analyzer
module thermal link and replace if necessary.
Pressure Regulator
326 No new measurement values x x Notify service.
from analog/digital converter.
327 Measurement value exceeds x x Notify service.
the analog/digital converter
value range.
328 A computer error occurred x x Notify service.
during calculation of the
measurement value.
329 Pressure above or below x Multi-FID 14: Check the supply gas pressure.
upper and/or lower limit
value 1.
330 Pressure above or below x Multi-FID 14: Check the supply gas pressure.
upper and/or lower limit
value 2.
331 The pressure regulator control x x Multi-FID 14: Check the supply gas pressure.
variable is beyond the valid
range.

Continued on next page

42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-11

Status Messages, continued

No. Text O E M F Reaction/Remark

I/O Boards
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.
from analog/digital converter.
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.
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.

Continued on next page

9-12 Chapter 9: Status Messages, Troubleshooting 42/24-10-5 EN

Status Messages, continued

No. Text O E M F Reaction/Remark

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 4% of Init value. Check the
middle of permissible range. intensity values in the'LDJQRVWLFV7HVW→0RGXOH
VSHFLILF→/DPS,QWHQVLW\menu.
If all four values have fallen by about the same amount
compared to the Init values, the cause is reduced lamp
intensity. Perform an amplification optimization (see page
8-18 for instructions). If only the two measurement detector
values have dropped, the cause is probably a
contaminated sample cell. Clean the sample cell (see page
8-11 or page 8-13 for instructions) and perform an
amplification optimization.
359 Lamp intensity above or below x x Lamp intensity has fallen to 2% of Init value. Check the
permissible range. intensity values in the'LDJQRVWLFV7HVW→0RGXOH
VSHFLILF→/DPS,QWHQVLW\menu.
If all four values have fallen by about the same amount
compared to the Init values, the cause is reduced lamp
intensity. Change the lamp (see page 8-16 for instructions)
and perform an amplification optimization.
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.
Calibration
500 System bus communication x x
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 Calibration is interrupted.
calibration. Calibration Insufficient span gas concentration – Check.
impossible.
508 Unknown error number. Check Message during automatic calibration. Check analyzer
software versions. module and system controller software versions.
509 Automatic calibration started. For information

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42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-13

Status Messages, continued

No. Text O E M F Reaction/Remark

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 x x
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
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
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 because the
characteristic is linear.
527 Initial calibration for For information
component:
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.

Continued on next page

9-14 Chapter 9: Status Messages, Troubleshooting 42/24-10-5 EN

Status Messages, continued

No. Text O E M F Reaction/Remark

User-Configured Messages
800 An external error occurred x x The Message Generator function block default text is
during: supplemented with the text prepared during function block
configuration.
801 A user-defined error occurred x x The Message Generator function block default text is
during: supplemented with the text prepared during function block
configuration.
802 A user-defined maintenance x The Message Generator function block default text is
requirement occurred during: supplemented with the text prepared during function block
configuration.
803 A user-defined maintenance x The Message Generator function block default text is
mode event occurred during: supplemented with the text prepared during function block
configuration.
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.
System Cooler
1100 Cooler temperature too high. x x SCM gas supply module pump is automatically turned off.
Check the Advance SCC system cooler and sample gas
preparation.
1101 Cooler temperature too low. x x SCM gas supply module pump is automatically turned off.
Check the Advance SCC system cooler and sample gas
preparation.
1102 Condensate penetration in x x SCM gas supply module pump is automatically turned off.
cooler. Check the Advance SCC system cooler and sample gas
preparation.
1103 Flow rate inadequate in cooler. x Check the Advance SCC system cooler and sample gas
preparation.
1105 Cooler condensate level too x Empty the condensate bottle.
high.
1106 Cooler reagent level too low. x Fill the reagent container.

42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-15

Analyzer System Problems

Blinking Measurement Value Readout

Cause Corrective Action

Measured signal Note: Measurement value > +130 % MRS or measurement value < –100 % MRS
violates measurement Additionally, status messages 344 or 345 are generated.
range limits

Blinking ( in Measurement Value Readout

Cause Corrective Action

Problem in measured View status messages. Identify cause and repair.

signal processing

Blinking ( in mA Value Readout

Cause Corrective Action

Problem in output Identify cause (e.g. line break) and repair.

current circuit

Power Supply Fuse Failure

Cause Corrective Action

Wrong voltage setting Use the proper voltage setting and change the fuse (G fuse element per IEC 127-2,
on power supply 4 A rating, slow-blow for both 115 VAC and 230 VAC).

Power supply defect Contact Service.

Flow Problem
Cause Corrective Action

External gas lines or Disconnect the analyzer system from the gas preparation system.
filters dirty, plugged Blow out the gas lines with compressed air or clear them mechanically.
or leaking Change the filter elements and packings.
Check gas line seal integrity.

Continued on next page

9-16 Chapter 9: Status Messages, Troubleshooting 42/24-10-5 EN

Analyzer System Problems, continued

Flow Problem
Cause Corrective Action

Analyzer system gas Disconnect the analyzer system from the gas preparation system. Check the analy-
paths crimped or zer module gas lines and the gas module lines for crimping or loose connections.
leaking Check the integrity of the analyzer module gas paths and (if applicable) of the lines
to the gas module (see page 8-2 for instructions).

Temperature Problem
Cause Corrective Action

Analyzer system still The duration of the warm-up phase depends on which analyzer module is installed
in warm-up phase in the system.
Analyzer Module Warm-Up Phase Duration
Caldos 15 2-4 hours, depending on measurement range
Caldos 17 Approx. 30/ 60 minutes for class 1/ 2 measurement ranges
Limas 11 Approx. 1.5 hours
Magnos 16 2-3 hours
Magnos 106 ≤ 1 hour
Magnos 17 2-4 hours
Uras 14 Approx. 30 minutes w/out, approx. 2 hours with thermostat

Excessive air Reduce the flow of air around the analyzer system.
movement Install shielding against drafts.

Ambient temperature Protect the analyzer system from cold and heat sources such as the sun, ovens
outside of and vats. Maintain the permissible ambient temperature range:
permissible range
Ambient Temperature Range with
Analyzer Module Installed in a System Housing
without Electronics with Electronics Module or
Analyzer Module Module with Power Supply only
Caldos 15 +5 to +50°C +5 to +45°C
Caldos 17 +5 to +50°C +5 to +45°C
Limas 11 +5 to +45°C +5 to +45°C
Magnos 16 +5 to +50°C +5 to +45°C
Magnos 106 +5 to +50°C +5 to +45°C
Magnos 17 +5 to +50°C +5 to +45°C
Uras 14 +5 to +45°C +5 to +40°C
Oxygen Sensor +5 to +40°C +5 to +40°C

42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-17

Caldos 15, Caldos 17, Magnos 16/106, Magnos 17 Problems

Flow Problem
Cause Corrective Action

Magnos 16 Check the measured value of the installed flow monitor.

Flow monitor Reset the zero-point.
Check the flow monitor sensor capillary for plugging.

Temperature Problem
Cause Corrective Action

Faulty temperature Check the connecting lines and plugs.

sensor or heater Check the line seating in the insulated jackets.
connections

Defective thermal link Check thermal link continuity and replace if necessary (see page 8-4 for
instructions).

Leaking thermostat Check the seal integrity between the thermostat chamber and the mounting
or open purge gas flange; tighten mounting bolts or replace O rings as needed.
connections Seal the analyzer purge gas inlet and outlet with sealing connectors.
Check the purge gas flow (maximum operating level of 20 l/h; positive pressure
pe = 2 to 4 hPa) and reduce as needed.

Unstable Readings
Cause Corrective Action

Magnos 16 Take measures to reduce vibration.

Vibration Permissible vibration levels: for analyzer max. ±0.04 mm at 5 to 20 Hz; when
–2
installed in cabinet max. 0.01 ms at 0.1 to 200 Hz.
Increase the low pass time constant T90 (see page 6-A-6 for instructions).

Gas path leakage Check the integrity of the analyzer module gas paths and (if applicable) of the lines
to the gas module (see page 8-2 for instructions).

9-18 Chapter 9: Status Messages, Troubleshooting 42/24-10-5 EN

Limas 11 Problems

Temperature Problem
Cause Corrective Action

Faulty temperature Check the connecting lines and plugs.

sensor or heater Check the line seating in the insulated jackets.
connections

Defective thermal link Check thermal link continuity and replace if necessary (see page 8-10 for
instructions).

Unstable Readings
Cause Corrective Action

Gas path leakage Check the integrity of the analyzer module gas paths and (if applicable) of the lines
to the gas module (see page 8-2 for instructions).

Emitter intensity too Read the current intensity value using the'LDJQRVWLFV7HVW→0RGXOH
low VSHFLILF→/DPS,QWHQVLW\menu item (start the zero gas supply for this)
and compare this value to the Init value displayed (the Init values were stored
following amplification optimization after installation of a new lamp). A significant
decrease (by a factor of 10 or more) is the probable cause of unstable measure-
ment value readings. Three different cases can be identified:
1. If only the measurement receiver values have dropped the sample cell is
probably contaminated. Clean the sample cell (see page 8-11 or page 8-13 for
instructions).
2. If all four values are have dropped by similar amounts then lamp intensity has
probably decreased. Perform an amplification optimization (see page 8-18 for
instructions) or replace the lamp (see page 8-16 for instructions).
3. For NO measurement only: If the reference receiver "Reference" value has
increased or not as markedly decreased as a percentage relative to the reference
receiver "Measurement" value and if at the same time the sensitivity span has
decreased (loss of sensitivity), aging of the selectivity cell is the probable cause
(see the service manual for more information).

Continued on next page

42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-19

Limas 11 Problems, continued

"Sample Value Overflow or Underflow" Status Signal

Cause Corrective Action

Drift or aging of Determine the cause and clean or replace the affected elements.
optical elements Perform an amplification optimization (see page 8-18 for instructions) to bring the
(lamp, sample cell, receiver signal back to its optimal range.
detector, etc.)

9-20 Chapter 9: Status Messages, Troubleshooting 42/24-10-5 EN

Uras 14 Problems

Temperature Problem
Cause Corrective Action

Faulty temperature Check the connecting lines and plugs.

sensor or heater Check the line seating in the insulated jackets.
connections

Defective thermal link Check thermal link continuity and replace if necessary.

Unstable Readings
Cause Corrective Action

Vibration Take measures to reduce vibration.

Permissible vibration levels: for analyzer max. ±0.04 mm at 5 to 55 Hz, 0.5 g at
–2
55 to 150 Hz; when installed in cabinet max. 0.01 ms at 0.1 to 200 Hz.
Increase the low pass time constant T90 (see page 6-A-6 for instructions).

Gas path leakage Check the integrity of the analyzer module gas paths and (if applicable) of the lines
to the gas module (see page 8-2 for instructions).

Loss of sensitivity Check the sensitivity variation:

Indication < 75%: The "Maintenance required" status signal appears.
The detector involved will need to be changed soon.
Indication < 50 %: The "Failure" status signal appears.
Replace the detector involved.

Uneven emitter Remove the emitter ( The emitter temperature is approx. 55 °C in the thermostat
modulation version of the Uras 14) and check if the chopper wheel turns smoothly. Check the
clamp ring seating. The chopper wheel should not extend beyond the notch. Have
the emitter and modulator assembly checked by the service department.

42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-21

Gas Module Problems

Flow Problem
Cause Corrective Action

Condensation in the Disconnect the analyzer system from the gas preparation system.
flow meter Dry the flow meter by heating it and blowing it with compressed air.
Check the operation of the upstream sample gas cooler.

Inadequate gas Connect the flow meter, ball chamber or pressure gauge directly to the gas supply
supply pump and measure the pressure or vacuum.
Check the pump and change the membrane as necessary.
Check and, if necessary, replace the disposable filter (see page 8-9 for instructions).
Check and, if necessary, replace the solenoid(s).

9-22 Chapter 9: Status Messages, Troubleshooting 42/24-10-5 EN

Notify Service

Who to contact for Contact your local ABB Automation service representative or
further help?
ABB Automation Service,
Telephone: +49-1 80-5-12 35 80, Telefax: +49-6 21-3 81-51 35,
E-Mail: [Link]@[Link]

Before you notify Before calling for service because of a problem or status message, determine
service ... whether there actually is an error and whether the analyzer system is actually
operating out of specifications (see Appendix 2).

When you notify When calling for service because of a problem or status message have the
service ... following information available:
• The Production number (F-No.) of the system housing in which the defective or
improperly operating unit is located.
It is located on the system housing identification plate, inside the right wall of the
19-inch rack unit and inside the left wall of the wall-mount housing, as well as in
the analyzer data sheet.
• The system controller and system module software versions are found in the
0(18→'LDJQRVWLFV,QIRUPDWLRQ→6\VWHPRYHUYLHZ
menu item
• An exact description of the problem or status as well as the status message text
or number
This information will enable service personnel to help you quickly.

F When calling for service because of a problem or status message have the
analyzer data sheet available. It contains important information that will help the
service personell find the cause of the fault.

When you return a When returning an analyzer system or an analyzer module to the service depart-
unit to the service ment, e.g. for repair, please indicate which gases have been supplied to the
department ... analyzer module. This information is needed so that service personnel can take
any safety precautions required for harmful gases.

42/24-10-5 EN Chapter 9: Status Messages, Troubleshooting 9-23

Chapter 10 Analyzer System Shutdown and Packing

Analyzer System Shutdown

Analyzer System Step Action

Shutdown Temporary Shutdown:
1 Turn off the sample gas and, if applicable, reference gas supplies.
2 Purge the gas lines and analyzer module with dry fresh air or nitrogen
for at least 5 minutes.
3 Turn off the analyzer system power supply.
Long-Term Shutdown:
4 Remove the gas lines from the analyzer module ports. Tightly seal the
gas ports.
5 Disconnect the electrical wiring from the electronic module and, if
applicable, the analyzer module connections.

Ambient Temperature Ambient temperature during storage and transport: –25 to +65 °C

42/24-10-5 EN Chapter 10: Analyzer System Shutdown and Packing 10-1

Preparing the Analyzer System for Shipping

CAUTION!
A system housing with an electronics module and an analyzer module weighs
from 18 to 23 kg. Two persons are needed for removal.

Preparation for Proceed as follows to prepare the analyzer system for shipping:
Shipping
Step Action
1 Remove the system bus terminating resistor from the
electronics module and secure it to the housing, e.g. with
adhesive tape. If the terminating resistor remains in the
electronics module it can be broken during shipment causing
damage to the resistor as well as to the electronic module
system bus receptacle.
2 Unscrew the adapters from the gas ports.
3 Tightly seal the gas ports with plugs.
4 In the IP-54 version of the system housing close off the connection
box cable openings by inserting the appropriate plates.

F When returning an analyzer system or an analyzer module to the service depart-

ment, e.g. for repair, please indicate which gases have been supplied to the
analyzer module.
This information is needed so that service personnel can take any safety precau-
tions required for harmful gases.

10-2 Chapter 10: Analyzer System Shutdown and Packing 42/24-10-5 EN

Analyzer System Packing

Packing Step Action

1 If the original packaging is not available, wrap the analyzer system in
bubble foil or corrugated cardboard.
2 Place the analyzer system in an adequately sized box lined with
cushioning material (foam or similar substance).
F The cushioning material’s thickness should be adequate for the
analyzer system’s weight.
3 Mark the box as "Fragile Material".

Additional Steps when Step Action

Shipping Overseas 1 Place the analyzer system in a 0.2-mm thick polyethylene bag, add a
drying agent (such as silica gel) and seal the bag air-tight.
F Use an amount of drying agent appropriate for the package
volume and the planned shipping schedule (at least 3 months).
2 Also wrap the box in a layer of protective waterproof wrapping.

Ambient Temperature Ambient temperature during storage and transport: –25 to +65 °C

42/24-10-5 EN Chapter 10: Analyzer System Shutdown and Packing 10-3

Appendix 1 Analyzer System Overview

Analyzer System

Components The Advance Optima modular process analyzer system consists of :

• a central unit and
• analyzer modules.
The central unit consists of:
• the electronics module, consisting of the system controller, the I/O boards
(optional) and the power supply, and
• the system housing with the display and control unit.

Equipment Levels The smallest analyzer system equipment level is made up of the central unit and
one analyzer module. Up to three analyzer modules for measuring up to six
sample components can be connected to a central unit.

Gas module A gas module can be connected to supply gases to an analyzer module.

System Housing Electronics module, power supply and an analyzer module can be installed
together in one system housing. Additional analyzer modules are installed in
separate system housings.

Power Supply A 115-V-AC or 230-V-AC power supply is required for the central unit. The analyzer
modules are powered with 24 VDC from the central unit power supply or from
separate power supplies.

System Bus The system controller, the I/O boards and the analyzer modules are interconnected
via the system bus. The system bus is linear in design and has a maximum length
of 350 meters.

Interfaces Various types of interfaces can be used by the analyzer system to communicate
with external systems. These include an available Ethernet interface for remote
control and remote maintenance applications (TCP/IP protocol) and the RS 485 or
RS 232C interface (alternatively, Modbus protocol or Profibus DP protocol).

Explosion Protection Special analyzer system versions are available for use in explosion risk Zone 1
areas:
• The Ex central unit is designed for "Positive Pressure Containment with Leak
Compensation" ignition protection (Ex p).
• The Caldos 15-Ex, Caldos 17-Ex, Magnos 16-Ex and Uras 14-Ex are designed for
"Pressure-Tight Containment" ignition protection (Ex d).

42/24-10-5 EN Appendix 1: Analyzer System Overview A-1-1

System Controller

System Controller The system controller carries out the following functions:
Functions • Processing and communicating the measurement values supplied by the
analyzer module sensor electronics
• Controlling system functions, e.g. calibration
• Display and operator control
• Controlling associated devices, e.g. system components for sample gas
conditioning
• Communication between the analyzer system and external systems
The system controller has its own processor.

Interfaces The system controller has the following features for controlling associated systems
and for communicating with external systems:
• Two analog outputs
• Four digital inputs
• Four digital outputs
• An Ethernet interface (TCP/IP protocol)
• An RS 485 and an RS 232C interface (alternatively, Modbus protocol or
Profibus DP protocol).

I/O Boards

I/O Board Functions The I/O boards supplement the interfaces found on the system controller.
Up to five I/O boards can be installed in the electronics module or in the I/O base
module.
Each I/O board has its own processor.

I/O Board Types There are three types of I/O boards:

• The analog I/O board has two analog inputs, two analog outputs, two digital
inputs and two digital outputs
• The digital I/O board has four digital inputs and four digital outputs
• The 8-way analog output board has eight analog outputs

A-1-2 Appendix 1: Analyzer System Overview 42/24-10-5 EN

System Housing

Versions The system housing is available as a 19-inch housing or a wall-mount housing with
IP 20 or IP 54 housing protection.
IP 65 protection is in effect if no power supply and no display and control unit is
installed in the system housing (e.g. if two analyzer modules are installed together
in one system housing).

Housing Purge Housing Purge is possible in system housings with IP 54 protection (with
connection box) or IP 65 protection (without power supply).
The purge gas connection ports (1/8-NPT internal threads) are factory installed per
order. The electrical cable connection openings are either PG threaded
connections or conduits.
The housing is generally purged via the analyzer module purge gas ports. Separate
purge gas ports are installed to purge a central unit that has no analyzer module
installed.

Display and Control Unit

Display and Control The display and control unit contains:

Unit Components • A back-lit graphics screen (320x240-pixel resolution)
• Three status indication LED’s
• A keypad with six softkeys, two cancel keys and a numeric keypad

Readout Values Readout values from the analyzer modules, as well as from other sensors (e.g.
flow, pressure and temperature), are displayed as:
• Numeric values with the applicable physical units
• A horizontal bar graph
Values from up to six sample components can be displayed simultaneously.

User Interface A menu-driven user interface allows the operator to use, initialize and configure
the analyzer system.
Menus, values and operator prompts appear on the display.

42/24-10-5 EN Appendix 1: Analyzer System Overview A-1-3

Analyzer Modules

Analyzer Modules Analyzer modules:

• Caldos 15 thermal conductivity analyzer module
• Caldos 17 thermal conductivity analyzer module
• Limas 11-IR/ -UV process photometer analyzer module
• Magnos 16 oxygen analyzer module
• Magnos 106 oxygen analyzer module
• Magnos 17 oxygen analyzer module
• Multi-FID 14 FID analyzer module
• Uras 14 infrared analyzer module

Components Each analyzer module consists of:

• A sensor
• The associated electronics with an integral processor.

Gas Module with Oxygen Sensor

Gas Module The gas module is used to supply gases to the analyzer system. A fully equipped
gas module contains the following elements:
• One gas supply pump
• One or three solenoids to control test gas supply
• One or two disposable fine-filtration elements
• One or two flow monitors
The gas module is always associated with an analyzer module. It is installed in the
same housing as the analyzer module and is controlled and monitored by the
latter’s sensor electronics components.

Oxygen Sensor The electrochemical oxygen sensor available as an option is installed in the gas
module.
The oxygen sensor also is always associated with an analyzer module and is
controlled by the latter’s sensor electronics components.

A-1-4 Appendix 1: Analyzer System Overview 42/24-10-5 EN

Appendix 2 Analyzer Module Operating Specifications

Caldos 15 Operating Specifications

Linearity deviation ≤ 2 % of span

Repeatability ≤ 1 % of span
Zero-point drift ≤ 1 % of span per week
Sensitivity drift ≤ 1 % of measured value per week
Output signal variation ≤ ±0.5 % of smallest measurement range span at 2 σ and
electronic T90 time = 0 sec.
Detection limit ≤ 0.2 % of span
Flow influence Depending on sample cell connection:
≤ 1 to 5 % of span at a flow change of ±10 l/h. At the same sample and test gas
flow rate the flow influence is automatically compensated.
Associated gas influence Analyzer calibration should be based on an analysis of the sample gas.
Temperature influence At zero point and on sensitivity: ≤ 1 % of span per 10 °C, based on temperature
during calibration
Ambient temperature = +5 to +45/ 50 °C, thermostat temperature = 60 °C
Air pressure influence No effect in pabs = 600 to 1250 hPa range
Power supply influence 24 VDC ± 5 %: ≤ 0.2 % of span
Position influence < 1 % of span up to 10° deviation from horizontal orientation
T90 time Typical T90 = 10 to 20 sec.; Option: T90 < 6 sec.
(applies to an analyzer system with one analyzer module)

42/24-10-5 EN Appendix 2: Analyzer Module Operating Specifications A-2-1

Caldos 17 Operating Specifications

Linearity deviation ≤ 2 % of span

Repeatability ≤ 1 % of span
Zero-point drift ≤ 2 % of the smallest possible measurement range per week
Sensitivity drift ≤ 0.5 % of the smallest possible measurement range per week
Output signal variation ≤ ±0.5 % of smallest measurement range span at 2 σ and
electronic T90 time = 0 sec
Detection limit ≤ 0.5 % of span

F The stability data apply only to measurement ranges ≥ Class 1.

Flow influence ≤ 0.5 % of span at a flow change of ±10 l/h. At the same sample and test gas
flow rate the flow influence is automatically compensated.
Associated gas influence Analyzer calibration should be based on an analysis of the sample gas.
Temperature influence At zero point and on sensitivity: ≤ 0.5 % of span per 10 °C, based on temperature
during calibration
Ambient temperature = +5 to +45/ 50 °C, thermostat temperature = 60 °C
Air pressure influence ≤ 0.25 % of span per 10 hPa for the smallest possible ranges given; in larger
measurement ranges the influence effect is correspondingly smaller.
Working range of installed pressure sensor: pabs = 600 to 1250 hPa
Option: Operating altitude over 2000 m
Power supply influence 24 VDC ± 5 %: ≤ 0.2 % of span
Position influence < 1 % of span up to 30° deviation from horizontal orientation
T90 time T90 ≤ 2 sec. with direct sample chamber connection and sample gas flow = 60 l/h
(applies to an analyzer system with one analyzer module)

A-2-2 Appendix 2: Analyzer Module Operating Specifications 42/24-10-5 EN

Limas 11 Operating Specifications

Linearity deviation ≤ 1 % of span

Repeatability ≤ 0.5 % of span
Zero-point drift ≤ 1 % of span per week;
for ranges smaller than Class 1 to Class 2: ≤ 2 % of span per week
Sensitivity drift ≤ 1 % of measured value per week
Output signal variation Limas 11-UV: ≤ 0.5 % of span at 2 σ and electronic T90 time = 10 sec.;
Limas 11-IR: ≤ 0.5 % of span at 2 σ and electronic T90 time (static / dynamic) =
60/ 5 sec.
for ranges smaller than Class 1 to Class 2: ≤ 1 % of span
Detection limit ≤ 0.5 % of span;
for ranges smaller than Class 1 to Class 2: ≤ 1 % of span
Flow influence Flow in 20 to 100 l/h range: within detection limit
Associated gas influence/ Analyzer calibration should be based on an analysis of the sample gas.
Cross-sensitivity Selectivization measures to reduce associated gas effect (optional): Installation
of filter cells or internal electronic cross-sensitivity correction or carrier gas cor-
rection for a sample component by other sample components measured with
the Limas 11.
Temperature influence At zero-point: ≤ 1 % of span per 10 °C,
for ranges smaller than Class 1 to Class 2: ≤ 2 % of span per 10 °C
On sensitivity: ≤ 1 % of measured value per 10 °C
Ambient temperature = +5 to +45 °C, thermostat temperature = 55 °C
Air pressure influence At zero-point: no influence effect
On sensitivity with pressure correction via integral pressure sensor: ≤ 0.2 % of
measured value per 1 % air pressure change
The pressure sensor is located in the sample gas path if hoses are used as the
internal gas lines. An external port is used for the pressure sensor if tubing is
used for the internal gas lines.
Pressure sensor working range: pabs = 600 to 1250 hPa
Power supply influence 24 VDC ± 5 %: ≤ 0.2 % of span
T90 time T90 = 4 sec. for measurement cell length = 262 mm and sample gas flow = 60 l/h
without signal damping (low pass filter). Low-pass time constant adjustable from
0 to 60 sec.

42/24-10-5 EN Appendix 2: Analyzer Module Operating Specifications A-2-3

Magnos 16, Magnos 106 Operating Specifications

Linearity deviation ≤ 0.5 % of span

Repeatability ≤ 0.5 % of span
Zero-point drift ≤ 0.03 Vol.-% O2 per week. After extended shipping and storage periods the drift
may be higher in the initial weeks of operation.
Sensitivity drift ≤ 0.1 % Vol.-% O2 per week or ≤ 1 % of measured value per week (not
cumulative), the smaller value applies
Output signal variation ≤ ±0.5 % of smallest measurement range span at 2 σ and
electronic T90 time (static / dynamic) = 3/ 0 sec.
Detection limit ≤ 0.5 % of span
Flow influence ≤ 0.1 Vol.-% O2 in permissible range
Associated gas influence The effect of associated gases with a concentration of 100 Vol.-% as a shift of
the zero-point (∆Zero) in Vol.-% O2 can be estimated using the guidelines in the
following table:
Associated Gas Concentration 100 Vol.-% ∆Zero in Vol.-% O2
Hydrogen H2 +0.28
Hydrogen sulfide H2S –0.45
Argon Ar –0.26
Helium He +0.30
Neon Ne +0.13
Nitrogen N2 ±0.00
Nitrogen oxide NO +43.00
Nitrogen dioxide NO2 +28.00
Nitrous oxide N2O –0.20
Carbon monoxide CO –0.01
Carbon dioxide CO2 –0.32
Carbon oxysulfide COS –0.90
Ethane C2H6 –0.46
Ethylene C2H4 –0.29
Methane CH4 –0.24
Propane C3H8 –0.98
Propylene C3H6 –0.55
Trichloroethylene C2HCl3 –2.17
Vinyl chloride CH2CHCl –0.75

Temperature influence At zero-point: ≤ 0.02 Vol.-% O2 per 10 °C

On sensitivity: ≤ 0.1 % of measured value per 10 °C
Ambient temperature = +5 to +45/ 50 °C, thermostat temperature = 64 °C

Continued on next page

A-2-4 Appendix 2: Analyzer Module Operating Specifications 42/24-10-5 EN

Magnos 16, Magnos 106 Operating Specifications, continued

Air pressure influence At zero-point: no influence effect

On sensitivity without pressure correction: ≤ 1 % of measured value per 1 % air
pressure change
On sensitivity with pressure correction by means of internal pressure sensor
(option): ≤ 0.01 % of measured value per 1 % air pressure change or ≤ 0.002
Vol.-% O2 per 1 % air pressure change, the greater value applies
Pressure sensor working range: pabs = 600 to 1250 hPa
Power supply influence 24 VDC ± 5 %: ≤ 0.2 % of span
Position influence Zero-point shift ≤ 0.02 Vol.-% O2 per 1° deviation from horizontal orientation.
Position has no effect on the hard-mounted unit.
T90 time Depending on sample gas flow, flow regulator installation and sample chamber
connection;
T90 ≤ 3.5 to 10 sec. at sample gas flow = 60 l/h or 8 l/h and electronic T90 time
(static / dynamic) = 3/ 0 sec., gas switching from N2 to air (applies to an analyzer
system with one analyzer module)

42/24-10-5 EN Appendix 2: Analyzer Module Operating Specifications A-2-5

Magnos 17 Operating Specifications

Linearity deviation ≤ 2 % of span

Repeatability ≤ 1 % of span
Zero-point drift ≤ 1 % of span per week
Sensitivity drift ≤ 2 % of measured value per week
Output signal variation ≤ ±0.5 % of smallest measurement range span at 2 σ and
electronic T90 time = 0 sec.
Detection limit ≤ 0.5 % of span
Flow influence ≤ 1 % of span at a flow change of ±10 l/h
At the same sample and test gas flow rate the flow influence is automatically
compensated.
Associated gas influence Magnos 17 calibration applies only to the sample gas (= sample component +
associated gas) shown on the identification plate.
Temperature influence At zero-point: ≤ 2 % of span per 10 °C
On sensitivity: ≤ 0.5 % of measured value per 10 °C
both based on temperature during calibration
Ambient temperature = +5 to +45/ 50 °C, thermostat temperature = 61 °C
Air pressure influence At zero-point: no influence effect
On sensitivity: ≤ 1.5 % of measured value per 1 % air pressure change
Air pressure pabs = 600 to 1250 hPa
Option: Operating altitude over 2000 m
Power supply influence 24 VDC ± 5 %: ≤ 0.2 % of span
Position influence Approx. 3 % of smallest measurement range span per 1° deviation from
horizontal orientation. Position has no effect on the hard-mounted unit.
T90 time T90 = 10 to 22 sec., depending on sample gas flow and sample chamber
connection (applies to an analyzer system with one analyzer module)

A-2-6 Appendix 2: Analyzer Module Operating Specifications 42/24-10-5 EN

Uras 14 Operating Specifications

Linearity deviation ≤ 1 % of span

Repeatability ≤ 0.5 % of span
Zero-point drift ≤ 1 % of span per week;
for ranges smaller than Class 1 to Class 2:
≤ 3 % of span per week
Sensitivity drift ≤ 1 % of measured value per week
Output signal variation ≤ 0.2 % of span at 2 σ and electronic T90 time = 5 sec.
Detection limit ≤ 0.5 % of span
Flow influence Flow in 20 to 100 l/h range: within detection limit
Associated gas influence/ Analyzer calibration should be based on an analysis of the sample gas.
Cross-sensitivity Selectivization measures to reduce associated gas effect (optional): Installation
of interference filters or filter cells or internal electronic cross-sensitivity
correction or carrier gas correction for a sample component by other sample
components measured with the Uras 14.
Temperature influence At zero-point: ≤ 1 % of span per 10 °C,
for ranges smaller than Class 1 to Class 2: ≤ 2 % of span per 10 °C
On sensitivity with temperature compensation: ≤ 3 % of measured value
per 10 °C
On sensitivity with thermostat effect at 55 °C (option): ≤ 1 % of measured value
per 10 °C
Ambient temperature = +5 to +40/ 45 °C
Air pressure influence At zero-point: no influence effect
On sensitivity with pressure correction via integral pressure sensor: ≤ 0.2 % of
measured value per 1 % air pressure change
The pressure sensor is located in the sample gas path if hoses are used as the
internal gas lines. An external port is used for the pressure sensor if tubing is
used for the internal gas lines.
Pressure sensor working range: pabs = 600 to 1250 hPa
Power supply influence 24 VDC ± 5 %: ≤ 0.2 % of span
T90 time T90 = 2.5 sec. for measurement cell length = 200 mm and sample gas flow =
60 l/h without signal damping (low pass filter). Low-pass time constant
adjustable from 0 to 60 sec.

42/24-10-5 EN Appendix 2: Analyzer Module Operating Specifications A-2-7

Oxygen Sensor Operating Specifications

Linearity deviation Linear in the range > 1 Vol.-% O2

Repeatability ≤ 0.5 % of span
Zero-point drift Stable over long-term due to absolute zero point
Sensitivity drift ≤ 1 % of measurement range scale per week
Detection limit ≤ 0.5 % of measurement range scale
Flow influence Flow rate in 20 to 100 l/h range:
≤ 2 % of measurement range scale
Temperature influence Ambient temperature in +5 to +40 °C range: ≤ 0.2 Vol.-% O2 per 10 °C
Air pressure influence At zero-point: No effect
On sensitivity without pressure correction: ≤ 1 % of measured value per 1 % air
pressure change
On sensitivity with pressure correction: ≤ 0.2 % of measured value per 1 % air
pressure change
Pressure correction is only possible if the oxygen sensor is connected to an
analyzer module with an integral pressure sensor.
Pressure sensor working range: pabs = 600 to 1250 hPa
T90 time T90 ≤ 30 seconds, depending on sample gas flow and system layout

A-2-8 Appendix 2: Analyzer Module Operating Specifications 42/24-10-5 EN

Electrical Safety

Test per EN 61010-1/ IEC 1010-1

Protection Class Central unit with electronics module (power supply): I
Analyzer module without electronics module (power supply): III
Overload Category/ Electronics module power supply 115/ 230 VAC: III/ 2
Pollution Level Ex central unit power supply 115/ 230 VAC: II/ 2
Analyzer module power supply 24 VDC: II/ 2
Signal inputs and outputs: II/ 2
Safe Isolation The 115/ 230 VAC power supply is galvanically isolated from other circuits by
means of reinforced or double insulation. Operational low voltage (PELV) on low-
voltage side

42/24-10-5 EN Appendix 2: Analyzer Module Operating Specifications A-2-9

Appendix 3 Index

A C
Access level 5-12 Calculation method
Access lock 5-16 for externally controlled calibration 7-B-5
Active component 6-A-9 Caldos 15
Air pressure correction 8-22 Associated gas influence 7-C-1
Air pressure effect Calibration
during calibration 7-A-2 Test gas 7-C-1
Air pressure value with substitute gas 7-C-1, 7-C-4
Setting 8-24 Connection diagram (gas connections) 2-1
Ambient temperature 1-5 Flowmeter installation 2-10
Amplification calibration Gas inlet conditions 2-5
→ Calculation method Housing purge 2-7
Analog I/O board Modifying range limits 6-A-3
→ I/O boards Operating specifications A-2-1
Analog output Reference gas flow rate 4-11
Changing current range 8-21 Thermal link replacement 8-4
Analyzer data sheet 1-3 Troubleshooting 9-18
Analyzer modules A-1-4
Caldos 17
Connection diagrams 2-1
Arrow keys 5-8 Associated gas influence 7-C-2
Associated gas influence Calibration
Caldos 15 7-C-1 Single-point calibration 7-C-2, 7-C-3
Caldos 17 7-C-2 Test gas 7-C-2
Magnos 17 7-C-10 with substitute gas 7-C-2, 7-C-4
Automatic calibration Connection diagrams (gas connections) 2-1
→ Calibration Gas inlet conditions 2-5
Automatic measurement range switching Housing purge 2-7
Initialization 6-A-7 Modifying range limits 6-A-3
Operating specifications A-2-2
Pressure sensor 2-9
Troubleshooting 9-18
B Calibration
Back key 5-6 Automatic calibration 7-A-4, 7-D-2
%$&.63$&( key 5-8 Calibration data 7-B-3
Basic calibration 8-26 Test gas supply 7-A-6
Control 7-A-1
Externally controlled calibration 7-A-9
Calibration data 7-B-5
Manual calibration 7-A-2, 7-D-1
Calibration data 7-B-2
Single-point calibration
Caldos 17 (with standard gas) 7-C-2, 7-C-3
Magnos 16/ 106 7-C-6, 7-C-7
Substitute gas calibration 7-A-10
Caldos 15 7-C-1, 7-C-4
Caldos 17 7-C-2, 7-C-4
Magnos 16/ 106 7-C-6, 7-C-9
Magnos 17 7-C-10, 7-C-11

Continued on next page

42/24-10-5 EN Appendix 3: Index A-3-1

Index, continued

Calibration cells D
Limas 11 6-A-4, 7-C-5
Dampening (T90 time)
Uras 14 6-A-4, 7-C-12
→ Filter
Measurement 8-8
Date
Calibration data 7-B-1
of next automatic calibration 7-B-3
Automatic calibration 7-B-3
Setting (system) 6-C-1
Calibration data sub-menu 7-B-1
Decimal places
Externally controlled calibration 7-B-5
Changing 6-A-5
Manual calibration 7-B-2
Digital I/O board
Output current response 7-B-6
→ I/O boards
Calibration method 7-A-10
Dimensional diagrams 1-4
→ Calibration data
Display and control unit A-1-3, 5-1
Calibration reset 8-25
Cancel keys 5-6
Cancel keys 5-6
Numeric keypad 5-5
Carrier gas alignment 8-28
Operating modes 5-1
Central unit A-1-1
Screen 5-2
Housing purge 2-7
Softkeys 5-7
&/($5 key 5-8
Status LED’s 5-4
Common calibration 7-A-10
Disposable filter in the gas module
Configuration 6-A-1
Replacing 8-19
Saving 6-C-8
Drift 8-25
Connection box (IP 54 version) 3-8
Connection diagrams
8-way analog output board 3-6
Analog I/O board 3-4 E
Analyzer modules 2-1 Electrical safety A-2-9
Digital I/O board 3-5 Electronics module A-1-1
Electronics module 3-1 Connection diagram 3-1
Ethernet 10BASE-T port 3-7 (17(5 key 5-8
I/O base module 3-2 Environmental conditions 1-5
RS 232 port 3-7 Error LED 5-4
RS 485 port 3-7 Error messages
System controller 3-3 → Status messages
Control signals Ethernet 10BASE-T port
Automatic calibration 7-A-4, 7-A-5 Connection diagram 3-7
Externally controlled calibration 7-A-9 TCP/IP network 6-C-10
Cross sensitivity alignment 8-27 Exhaust gases
Current range Evacuate 2-10
Changing 8-21 Explosion protection A-1-1
Cycle time External control
for automatic calibration 7-B-3 → Calibration (automatic)
→ Calibration (externally controlled)

Continued on next page

A-3-2 Appendix 3: Index 42/24-10-5 EN

Index, continued

F I
Failure Identification plate 1-2
→ Status Inspection 8-1
Filter (T90 time) Installation 1-8
Initialization 6-A-6 Interfaces A-1-2
Flow problem I/O base module
in the analyzer system 9-16 Connection diagrams 3-2
in the gas module 9-22 I/O boards A-1-2
in Caldos 15, Caldos 17, Connection diagrams 3-4, 3-5, 3-6
Magnos 16/ 106, Magnos 17 9-18
Flowmeter
Installation 2-10 L
Function blocks
Language of the user interface
Concept 6-B-1
Selecting 6-C-3
Standard Configuration 6-B-2
LED’s
Sub-menu 6-B-3
→ Status LED’s
Fuse
Power supply fuse failure 9-16 Limas 11
Amplification optimization 8-18
Calibration 7-C-5
Calibration cells 7-C-5
G Test gas 7-C-5
Gas connections Calibration cells 6-A-4
Installation 1-7 Measurement 8-8
Connection diagrams 2-1 Connection diagrams (gas connections) 2-3
Gas diagrams 2-4 Emitter replacement 8-16
Gas inlet conditions 2-5 Gas inlet conditions 2-5
Gas line connection 2-10 Housing purge 2-7
Gas module A-1-4 Measurement ranges 6-A-4
Gas inlet conditions 2-6 Modifying range limits 6-A-4
Replacing disposable filter 8-19 Operating specifications A-2-3
Troubleshooting 9-22 Pressure sensor 2-9, 8-24
Gas outlet conditions 2-6 Purge gas 2-8, 4-2
Gas path seal integrity Relinearization 8-9
Checking 8-2 Sample cell cleaning 8-11, 8-13
Thermal link replacement 8-10
Troubleshooting 9-19
H Limit value monitor
+(/3 key 5-8 Initialization 6-A-8
HMI Line connection
→ User interface Power supply lines 4-6, 4-8
Housing Signal, control and interface lines 3-8
→ System housing System bus 3-10
Housing purge 2-7 Location 1-5

Continued on next page

42/24-10-5 EN Appendix 3: Index A-3-3

Index, continued

M N
Magnos 16/106 Network configuration 6-C-10, 6-C-11
Air pressure value correction 8-24 Numeric keypad 5-5
Calibration
Single-point calibration 7-C-6, 7-C-7
Test gas 7-C-6 O
with substitute gas 7-C-6, 7-C-9 Operating specifications
Connection diagrams (gas connections) 2-1, 2-2 Caldos 15 A-2-1
Gas inlet conditions 2-5 Caldos 17 A-2-2
Housing purge 2-7 Limas 11 A-2-3
Modifying range limits 6-A-3 Magnos 16/ 106 A-2-4
Operating specifications A-2-4 Magnos 17 A-2-6
Pressure sensor 2-9 Uras 14 A-2-7
Thermal link replacement 8-4 Oxygen sensor A-2-8
Troubleshooting 9-18 Operation 4-11
Magnos 17 Optical alignment (Uras 14) 8-5
Associated gas influence 7-C-10 Output current range
Calibration Changing 8-21
Test gas 7-C-10 Output current response
with substitute gas 7-C-10, 7-C-11 during calibration 7-B-6
Connection diagrams (gas connections) 2-1 Oxygen sensor A-1-4
Gas inlet conditions 2-5 Calibration 7-C-13
Housing purge 2-7 Gas inlet conditions 2-5
Modifying range limits 6-A-3 Modifying range limits 6-A-3
Operating specifications A-2-6 Operating specifications A-2-8
Thermal link replacement 8-4
Troubleshooting 9-18
Maint LED 5-4 P
Maintenance mode Packing 10-3
→ Status Password
Maintenance required Changing 5-14, 6-C-4
→ Status Password protection 5-12
Manual calibration Phase alignment (Uras 14) 8-7
→ Calibration Potential compensation 4-8
Meas key 5-6 Power LED 5-4
Measurement component-specific functions Power consumption
Configuration 6-A-1 of the analyzer modules 4-4
Measurement range Power supply 4-3
Automatic measurement range switching 6-A-7 Activation 4-9
Modifying range limits 6-A-3 Analyzer modules 4-3
Switching 6-A-2 Analyzer system 4-3
Measurement value units Connection
Changing 6-A-1 115/ 230 V AC 4-8
0(18 key 5-7 24 V DC 4-6
Menu tree 5-17 Fuse failure 9-16
Message display 5-3 I/O base module 4-3
Modbus 6-C-11 Performance 4-4
Specifications 4-4

Continued on next page

A-3-4 Appendix 3: Index 42/24-10-5 EN

Index, continued

Pressure sensor 2-9 Serial number

→ Air pressure correction of the system modules 6-C-5
Pump Shipping 10-2
Activation 8-20 Shutdown 10-1
Activation during automatic calibration 7-B-3 Signal line connection 3-8
Output adjustment 8-20 Single calibration 7-A-10
Purge gas 2-8, 4-2 Single-point calibration
Purge gas line connection 2-11 Caldos 17 (with standard gas) 7-C-2, 7-C-3
Purge gas flow rate 2-8, 4-2, 4-11 Magnos 16/ 106 7-C-6, 7-C-7
Purge time Softkeys 5-7
for automatic calibration 7-B-4 Software version ix
Purging Standard equipment 1-1
during operation 4-11 Starting calibration 7-A-1, 7-A-4
prior to start-up 4-2 Start-up 4-1
Status
Process status 9-1
R System status 9-2
Status LED’s 5-4
Reference gas flow rate 4-11
67$7860(66$*( key 5-7
Relinearization (Limas 11, Uras 14) 8-9
Status messages 9-2
RS 232 port
List 9-7
Connection diagram 3-7
Status signals 9-4
Modbus 6-C-11
Configuration 6-C-9
RS 485 port
Substitute gas calibration 7-A-10
Connection diagram 3-7
Caldos 15 7-C-1, 7-C-4
Modbus 6-C-11
Caldos 17 7-C-2, 7-C-4
Magnos 16/ 106 7-C-6, 7-C-9
Magnos 17 7-C-10, 7-C-11
S System bus
Safety information x, xi Connection 3-10
Sample gas flow rate 4-11 System controller A-1-2
Screen 5-2, 6-D-1 Connection diagram 3-3
Configuring the Bar Display or System functions
Point Display 6-D-11 Configuration 6-C-1
Key entry 6-D-7 System housing A-1-3
Configuring 6-D-13 Dimensional diagrams 1-4
Moving a Display Element from System modules
One Page to Another 6-D-9 Setting up 6-C-5
Moving a Display Element Within a Page 6-D-10
Page overview 6-D-4 Continued on next page
Parameter overview 6-D-5
Screen overview 6-D-3
User page configuration 6-D-8
Value entry 6-D-6
Configuring 6-D-12

42/24-10-5 EN Appendix 3: Index A-3-5

Index, continued

T U
T90 time Unpacking 1-1
Initialization 6-A-6 Unstable readings
TCP/IP network 6-C-10 in Caldos 15, Caldos 17,
Temperature problems Magnos 16/ 106, Magnos 17 9-18
in the analyzer system 9-17 in Limas 11 9-19
in Caldos 15, Caldos 17, in Uras 14 9-21
Magnos 16/ 106, Magnos 17 9-18 Uras 14
in Limas 11 9-19 Calibration 7-C-12
in Uras 14 9-21 Calibration cells 7-C-12
Test gas concentration Test gas 7-C-12
for automatic calibration 7-B-3 Calibration cells 6-A-4
for externally controlled calibration 7-B-5 Measurement 8-8
for manual calibration 7-B-2 Connection diagrams (gas connections) 2-2
Test gas supply Flowmeter installation 2-10
for automatic calibration 7-A-4, 7-A-6 Gas inlet conditions 2-5
for externally controlled calibration 7-A-9 Housing purge 2-7
for manual calibration 7-A-2 Measurement ranges 6-A-4
Test gases Modifying range limits 6-A-4
Caldos 15 7-C-1 Operating specifications A-2-7
Caldos 17 7-C-2 Optical alignment 8-5
Limas 11 7-C-5 Phase alignment 8-7
Magnos 16/ 106 7-C-6 Pressure sensor 2-9, 8-24
Magnos 17 7-C-10 Purge gas 2-8, 4-2
Uras 14 7-C-12 Reference gas flow rate 4-11
Oxygen sensor 7-C-13 Relinearization 8-9
Text entry 5-9 Troubleshooting 9-21
Thermal link replacement User group 5-12
in Caldos 15, Magnos 16, Magnos 17 8-4 User interface
in Limas 11 8-10 Language 6-C-3
Time Priority 5-15
of next automatic calibration 7-B-3
Setting (system) 6-C-2
Troubleshooting
in the analyzer system 9-16 W
in the gas module 9-22 Warm-up phase 4-10
in Caldos 15, Caldos 17,
Magnos 16/ 106, Magnos 17 9-18
in Limas 11 9-19
in Uras 14 9-21

A-3-6 Appendix 3: Index 42/24-10-5 EN

 Subject to technical changes
Printed in the Fed. Rep. of Germany
42/24-10-5 EN 04.01