ABB Advance Optima Caldos 15-Ex User manual

Caldos 15-Ex, Caldos 17-Ex,
Magnos 106-Ex, Uras 14-Ex
Category 2G Analyzer Modules
Operator’s Manual 42/24-12-2 EN

2 Advance Optima Ex Analyzer Modules Operator’s Manual 42/24-12-2 EN
Contents
Page
Preface 3
General Safety Precautions 4
Special Safety Instructions for Operating
Explosion-Protected Analyzer Modules 5
Chapter 1 Installation 6
Unpack and Install the Ex Analyzer Module 6
Dimensional Drawing 8
Connect the Gas Lines 9
Check Gas Path Seal Integrity 11
Connect Electrical Lines - Instructions 12
Connection Drawings 14
Connect the System Bus 21
Connect the Power Supply 23
Chapter 2 Operation and Maintenance 25
Start the Ex Analyzer Module 25
Inspection and Maintenance 27
Attachment 29
Ex Analyzer Module Applications and Designs 29
Operating Specifications 30
Declaration of Conformity 32
EC Type Examination Certificate 37
Electrical Equipment in Explosion Hazard Zones:
Legal Principles 40
Electrical Equipment in Explosion Hazard Zones:
Installation Instructions 41
Electrical Equipment in Explosion Hazard Zones:
Maintenance and Repair Instructions 42
Index 43
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42/24-12-2 EN Advance Optima Ex Analyzer Modules Operator’s Manual 3
Preface
Content of the
Operator’s Manual
This operator’s manual for the explosion-protected analyzer module versions
(Ex analyzer modules) is a supplement to the Advance Optima Modular Process
Analyzer System Operator’s Manual (Publication No. 42/24-10 EN).
It contains all the information you will need to safely and efficiently install, start and
operate the Ex analyzer modules.
Note the information on the "Analyzer Data Sheet" shipped with every Ex analyzer
module.
Supplementary
Documentation
The following publications are available to supplement this document and the
42/24-10 EN version of the operator’s manual:
Title Publication No.
CU-Ex (Explosion-protected central unit) Operator’s Manual 42/24-13 EN
Explosion Protection Versions –Descriptions and Design Notes 30/24-100 EN
Explosion Protection in Analysis 30 PY 124 EN
These publications can be ordered from your ABB marketing representative or from
ABB Automation Products GmbH,
Analytical, Marketing Communication,
Fax: [phone], E-Mail: analytical-mkt.de[email protected]om
Additional Informa-
tion on the Internet
Additional information on ABB Analytical products and services is available on the
Internet at http://www.abb.com/analytical.
Identifies safety information to be heeded during Ex analyzer
module operation in order to avoid risks to the user.
FIdentifies specific information on operation of the Ex analyzer
modules as well as on the use of this manual.
Module Name Indicates specific information for individual Ex analyzer modules.
Symbols and Fonts
Used in the Manual
1, 2, 3, ... Identifies reference numbers in figures.

4 Advance Optima Ex Analyzer Modules Operator’s Manual 42/24-12-2 EN
General Safety Precautions
Requirements for
Safe Operation
In order to operate in a safe and efficient manner, the Ex analyzer module should
be properly handled and stored, correctly installed and set-up, properly operated
and carefully maintained.
Personnel
Qualifications
Only persons familiar with the installation, set-up, operation and maintenance of
comparable equipment and certified as being capable of such work should work
on the Ex analyzer module.
Special Information
and Precautions
These include
•The content of this operator’s manual.
•The safety information affixed to the Ex analyzer module.
•Safety precautions for the installation and operation of electrical devices.
•Safety precautions for working with gases, acids, condensates, etc.
•Regulations, standards and guidelines for explosion protection.
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 Ex analyzer module is used in other countries.
Ex Analyzer Module
Safety and Safe
Operation
The Ex analyzer module is designed and tested in accordance with EN 61010 Part 1
/
IEC 1010-1, "Safety Provisions for Electrical Measuring, Control, Regulation and
Laboratory Instruments" and has been shipped ready for safe operation.
To maintain this condition and to assure safe operation, read and follow the safety
information identified with the symbol in this manual. Failure to do so can put
persons at risk and can lead to Ex analyzer module damage as well as damage to
other systems and instruments.
Additional
Information
If the information in this operator’s manual does not cover a particular situation,
ABB Service is prepared to supply additional information as needed.
Contact your local ABB service representative or
ABB Service, Telephone: [phone], Fax: [phone],
E-mail: [e-mail]

42/24-12-2 EN Advance Optima Ex Analyzer Modules Operator’s Manual 5
Special Safety Instructions for Operating Explosion-Protected
Analyzer Modules
Observe Safety
Precautions
Before starting any work on the Ex analyzer module, observe all explosion-
protection safety precautions.
Do Not Work Where
There is a Risk of
Explosion
While there is a risk of explosion, do not work on current-bearing components,
except intrinsically safe circuits, and do not work with equipment that poses an
ignition hazard.
Potential Compen-
sation Connection
The connection to the local potential compensation point must be made before all
other connections.
Risks of a
Disconnected
Protective Lead
The Ex analyzer module can be hazardous if potential compensation is interrupted
inside or outside the Ex analyzer module or if the potential compensation connec-
tion is interrupted.
Risks Involved in
Opening the Covers
Current-bearing components can be exposed when covers or parts are removed,
even if this can be done without tools. Current can be present at some connection
points.
Risks Involved in
Working with an Open
Ex Analyzer Module
The Ex analyzer module must be disconnected from all power sources before
being opened for any work. All work on an Ex analyzer module that is open and
connected to power should only be performed by trained personnel who are
familiar with the risks involved.
While connected to power, the Ex analyzer module housing should only be opened
when the surrounding environment does not pose an explosion threat.
Charged Capacitors The Ex analyzer module power supply capacitors require 10 minutes to discharge
after the system is disconnected from all power sources. Observe the safety
precautions indicated on the housing.
Sample Gas Supply
Cutoff
When working with combustible sample gases, shut off the gas supply before
opening the Ex analyzer module housing.
When Safe Operation
Can no Longer be
Assured
If it can be assumed that safe operation is no longer possible, the Ex analyzer
module should be taken out of service and protected against inadvertent use.
The possibility of safe operation is excluded:
•If the Ex analyzer module is visibly damaged
•If the Ex analyzer module no longer operates
•After prolonged storage under adverse conditions
•After severe transport stresses

6 Advance Optima Ex Analyzer Modules Operator’s Manual 42/24-12-2 EN
Chapter 1 Installation
Unpack and Install the Ex Analyzer Module
FFollow
•the instructions and notes in the "Analyzer System Installation" chapter of
Operator’s Manual 42/24-10 EN,
•the following special instructions and notes as well as
•the notes in the "Electrical Equipment in Explosion Hazard Zones" sections in
the Annex.
CAUTION!
The Ex analyzer module weighs approx. 26 kg! The following points should be
observed:
•Two persons are needed for unpacking and installation.
•The installation location must be stable and in order to support the Ex
analyzer module’s weight.
Quantity Description
1 Ex analyzer module with attached connection cables for 24 VDC
power and system bus
1 Analyzer Data Sheet (in the central unit system housing)
1Operator’s Manual 42/24-10 EN
1Operator’s Manual 42/24-12 EN
1 2.5 mm Hex Wrench
1 220 mm diam. x 3 mm O-Ring
Items Delivered
1 Emitter Wrench (only on Uras 14-Ex analyzer module)
Installation Site The Ex analyzer module can be installed in Zone 1 and Zone 2 explosion hazard
areas (see the “Operating Specifications,”section, Page 30)
FThe Ex analyzer module should not be mounted outdoors.
Conditions Temperature Range
Operation in compliance with sample-measuring data
Caldos 15-Ex, Caldos 17-Ex, Magnos 106-Ex +5 to +50°C
Uras 14-Ex +5 to +45°C
Operation without jeopardizing explosion protection
Caldos 15-Ex, Caldos 17-Ex, Magnos 106-Ex –20 to +50°C
Uras 14-Ex –20 to +45°C
Ambient Temperature
Storage and shipping –25 to +65°C
Continued on next page

42/24-12-2 EN Advance Optima Ex Analyzer Modules Operator’s Manual 7
Unpack and Install the Ex Analyzer Module, continued
Ex Analyzer Module
Installation
4 M8 bolts (not supplied) are needed to install the Ex analyzer module.
Caldos 15-Ex
Magnos 106-Ex
The Caldos 15-Ex and Magnos 106-Ex analyzer modules must be installed with
their housings in the vertical position and their connection ports facing down.
Caldos 17-Ex
Uras 14-Ex
The housings of the Caldos 17-Ex and Uras 14-Ex analyzer modules can be
installed in the vertical or horizontal position.
•If installed vertically the ports must face downward.
•For horizontal installation the O-ring supplied (∅220 x 3 mm) must be installed in
the slot provided between the housing floor and the housing.
•If the Uras 14-Ex analyzer module is installed horizontally it is preferable to orient
the housing so that the identification plate faces up.

8 Advance Optima Ex Analyzer Modules Operator’s Manual 42/24-12-2 EN
Dimensional Drawing
FNote the additional space requirements
•Beneath the analyzer module for connection lines (approx. 10 cm) and
•Above the analyzer module for opening the housing (approx. 40 cm).
Figure 1
Ex Analyzer Module
(dimensions in mm)
5
3
4
8
6
1
2
7
9
10
800 (clearance for opening)
Caldos 15-Ex, Caldos 17-Ex, Magnos 106-Ex
Gas Connections:
1Sample Gas Inlet
2Sample Gas Outlet
3Vent Opening 2)
4Vent Opening 2)
5Purge Gas Inlet 1)
6Purge Gas Outlet 1)
7
Pressure Sensor (Caldos 17-Ex and Magnos 106-Ex 1)
)
Electrical Connections:
8System Bus
924 VDC
10 Potential Compensation
1) Option
2) Version for sample gas under positive pressure only
Uras 14-Ex
Gas Connections:
1)
2) See Analyzer
3) Data Sheet
4)
5Purge Gas Inlet 1)
6Purge Gas Outlet 1)
7Pressure Sensor
Electrical Connections:
8System Bus
924 VDC
1
0
Potential Compensation
1) Option

42/24-12-2 EN Advance Optima Ex Analyzer Modules Operator’s Manual 9
Connect the Gas Lines
FFollow
•the instructions and notes in the "Analyzer System Installation" and "Gas Line
Connection" chapters of Operator’s Manual 42/24-10 EN,
•the following special instructions and notes as well as
•the notes in the "Electrical Equipment in Explosion Hazard Zones" sections in
the Annex.
Gas Connection
Design
(see Figure 1)
All gas connections –with 1/8-NPT female threads –are routed via flame barriers:
•Sample Gas Inlets and Outlets
•Housing Purge (Option)
•Flowing reference gas for the Uras 14-Ex (Option)
•Pressure sensor for Uras 14-Ex, Magnos 106-Ex (Option) and Caldos 17-Ex
The actual gas connection layout of a delivered Ex analyzer module will be shown
in the applicable analyzer data sheet.
Sample Gas Inlet
Conditions
see “Operating Specifications”section, page 30
CAUTION!
The sample gas must not contain corrosive gases (such as chlorine) that
attack stainless steel.
Special Safety
Measures for
Operation with
Positive Pressure in
the Sample Gas Path
A special version of the Ex analyzer modules is needed for operation with positive
pressure in the sample gas path. This version is identified by the words "Messgas-
druck siehe Besondere Bedingungen" [See Special Conditions for Sample Gas
Pressure] on the identification plate.
When operating with positive pressure in the sample gas path the following special
safety measures should be taken:
•To protect the pressure-tight housing, two additional vent openings (implemented
in the same manner as sample gas flame barriers) are incorporated. Their
internal and external openings must always remain open.
•If the positive pressure at the sample gas outlet and inlet is pe< 300 hPa (pabs <
1400 hPa), in a failure mode (e.g. if the sample gas line in the analyzer bursts) this
can lead to a sample gas flow from both sides. For this case, steps must be
taken to assure that the total sample gas flow on both sides cannot exceed the
maximum value of 100 l/h.
•To avoid the development of an explosive mixture in the sample gas path, the
latter must be flushed with an inert gas prior to introducing combustible gases.
Uras 14-Ex The "Flowing Reference Gas" option is not available for the Uras 14-Ex analyzer
module for operation with positive pressure in the sample gas path.
Continued on next page

10 Advance Optima Ex Analyzer Modules Operator’s Manual 42/24-12-2 EN
Connect the Gas Lines, continued
Housing Purge To preserve atmospheric conditions in the pressure-tight housing, two types of
purge operation are possible:
•Limiting purge gas inlet and outlet pressure to a maximum positive pressure
pe≤100 hPa (pabs ≤1100 hPa).
•The purge gas is supplied without pressure at the inlet and is extracted from the
outlet.
During operation, purge gas flow should be limited to 10 liters/hour.
Clean instrument air from non-explosive areas or an inert gas is to be used as the
purge gas.
Pressure Sensor
Connection
•If the pressure sensor connection is routed to the outside, the plug must be
removed from the associated flame barrier (see Figure 1, Page 8) before starting
operation.
•The pressure sensor connection should not be joined with the sample gas path.
Gas Path Seal
Integrity Verification
The seal integrity of the sample gas path and reference gas path (if applicable)
within the Ex analyzer module is factory-tested with helium at a leak rate of
< 2 x 10–4hPa l/s.
Since gas path seal integrity can be compromised during shipping of the Ex
analyzer module (e.g. by strong vibration) a seal integrity check should be
performed on site prior to startup (see "Check Gas Path Seal Integrity, Page 11).
FFor more information on checking gas path seal integrity during operation see the
"Inspection and Maintenance" section (Page 27).