Explosion Protected Model Descriptions and Design … · Explosion Protected Model Descriptions and...
Transcript of Explosion Protected Model Descriptions and Design … · Explosion Protected Model Descriptions and...
Explosion Protected ModelDescriptions and Design Notes
Technical Information 30/24-100-2 EN
30/24-100-2 EN Advance Optima – Explosion Protected Model 3
Table of Contents
Page
Examples of Applications 4
Part A Descriptions
Chapter 1 Ex Analyzer Modules for Zone 1 and Zone 2 (Flammable Sample Gas)Description 6Operating Specifications 7Dimensional Drawing 9
Chapter 2 Ex Central Unit for Zone 1Description 10Monitoring the Pressurized Enclosure 11Operating Specifications 13Dimensional Drawing 14
Chapter 3 Version for Zone 2 (Non-Flammable Sample Gas)Description 15Dimensional Drawings 17
Part B Design Notes
Chapter 4 Connecting the System Bus and 24-VDC Power SupplyNotes on the Connection Diagrams 18Connection Drawings 20System Bus Connection 2824-VDC Supply Connection 30Advance Optima Power Supply Performance 32Flameproof Enclosed 24-VDC Power Supply 33EEx-e Connection Boxes 34
Chapter 5 Connecting Non-Intrinsically Safe and Intrinsically Safe CircuitsIsolation Relays and I.S. Barrier Modules 35Wiring Notes 36Isolation Relay Terminal Layout (Example) 37Isolation Relay Terminal Layout (Blank Form) 38
Chapter 6 AccessoriesAccessory Part Numbers 39
The regulations, standards and guidelines cited in this technical information publication are appli-cable in the Federal Republic of Germany. When using explosion protected Advance Optima modelsin other countries follow the applicable national regulations for installing and operating electricaldevices in explosion hazard zones.
This technical information publication is protected by copyright. The translation, duplication and distribu-tion in any form, even in a revised edition or in extracts, in particular as a reprint, by photomechanical orelectronic reproduction or in the form of storage in data processing systems or data networks are pro-hibited without the consent of the copyright holder and will be prosecuted under civil and criminal law.
4 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Examples of Applications
Use The Advance Optima modular product line offers explosion protected analyzersand multiple analyzer systems for use in Zones 1 and 2 to measure flammable andnon-flammable gases.
Various versions of the analyzer modules and central unit are available for use inZones 1 and 2.
Examples ofApplications
The following table and Figures 1–3 show four examples of applications mostfrequently encountered in the field. They differ in terms of• analyzer module and central unit installation location (Zone 1 or Zone 2 –
external explosion protection)• sample gas properties (flammable or non-flammable – internal explosion
protection)
The following sections describe the analyzer module and central unit versions.
Installation Location Version Case Fig.Sample Gas Properties Analyzer Module Central Unit No. No.
Analyzer Module Zone 1Central Unit Zone 1
EEx d, IP 54 EEx p 1)
Wall-mount IP 541 1
Analyzer Module Zone 1Central Unit Zone 2
EEx d, IP 54 Wall-mount or19-inch housingIP 54 or IP 20
2 2
Analyzer Module Zone 2Flammable sample gasCentral Unit Zone 2
EEx d, IP 54 Wall-mount or19-inch housingIP 54 or IP 20
3 2
Analyzer Module Zone 2Non-flammable sample gasCentral Unit Zone 2
Wall-mount or19-inch housingIP 54 or IP 20
Wall-mount or19-inch housingIP 54 or IP 20
4 3
1) With protective gas monitoring
Notes Case No. 1:This is the “conventional” Zone 1 installation.
Cases No. 2 and No. 3:These are the preferred installations if the analyzer module must be set up in aZone 1 or 2 environment. For instance, case No. 2 is used in explosion-protectedanalyzer equipment rooms (Ex AER) and for hydrogen-cooled turbine generators.The central unit can be installed outside of the hazardous locations. The distancefrom the analyzer module is limited by the system bus maximum lengthrequirement of 350 meters.
Cases No. 3 and No. 4:For information on housing versions and features for use with corrosive samplegas components see the descriptions in the following sections.
Continued on next page
30/24-100-2 EN Advance Optima – Explosion Protected Model 5
Examples of Applications, continued
Figure 1
Zone 1 Installation(Case No. 1)
Protective gas monitoring unit
PowerMaintError
Back
0
1 2 3
4 5 6
7 8 9
. _
IR
Meas
ABB
Advance Optima
EEx ...Sample gas conditioning
Samplegas
Sys
tem
bus
Purging air
Central unit in EEx p enclosure
Analyzer modulein EEx d enclosure
Zone 1
Figure 2
Analyzer Module inZone 1 or 2 (CasesNo. 2 and No. 3)
EEx ...Sample gas conditioning
Central unit
Zone 1/2
PowerMaintError
Back
0
1 2 3
4 5 6
7 8 9
. _
IR
Meas
ABB
Advance Optima
Analyzer modulein EEx d enclosure
Sample gas
Sys
tem
bus
Zone 2
Figure 3
Zone 2 Installation(Case No. 4)
Central unit with analyzer module
PowerMaintError
Back
0
1 2 3
4 5 6
7 8 9
. _
IR
Meas
ABB
Advance Optima
Zone 2
6 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Part A Descriptions
Chapter 1 Ex Analyzer Modules for Zone 1 andZone 2 (Flammable Sample Gas)
Description
Application The Caldos 15-Ex, Caldos 17-Ex, Magnos 16-Ex and Uras 14-Ex analyzer modulesare used for continuous quantitative determination of individual gas components ingas mixtures.
The Ex analyzer modules are capable of measuring non-flammable and flammablegases under atmospheric conditions which can form an explosive atmosphere(Zone 1).
When specially equipped and when special conditions are fulfilled, the Ex analyzermodules are capable of measuring non-flammable and flammable gases underpositive pressure (see the “Operating Specifications” section, Page 7).
Design Ex Analyzer modules for use in Zone 1 and Zone 2 (flammable sample gas) have“Flameproof Enclosure” type of protection per EN 50018. They are enclosed in aflameproof aluminum cylinder (see the dimensional drawing, Fig. 4, Page 9).
The system bus cable and 24-VDC connecting cable are brought into the flame-proof cylinder via flameproof cable openings. The 8- and 3-conductor cables,each 10 meters in length are connected at the factory (see the connectiondiagrams, Figures 9–15, Pages 20–27).
All gas connections are routed via flame barriers.
Housing Purge To protect the Ex analyzer module sensor electronics against the entry of anaggressive atmosphere or corrosive sample gas components, a purge gas can flowthrough the flameproof cylinder.
The purge gas enters and exits via two flame barriers that are open in the interior ofthe flameproof cylinder.
Note: The housing purge has no significance for the purposes of pressurizedenclosure per EN 50016.
Designation EEx d IIC T4
ConformityCertification
BVS 97.D.2021 X
30/24-100-2 EN Advance Optima – Explosion Protected Model 7
Operating Specifications
Explosion Protection Type of Protection Flameproof enclosure “d”
Explosion Group IIC
Temperature Class T4
Installation Site Hazardous Location Zone 1 and Zone 2
Ambient Temperature Caldos 15-Ex +5 to +50 °CCaldos 17-Ex +5 to +50 °CMagnos 16-Ex +5 to +50 °CUras 14-Ex +5 to +45 °C
Sample Gas InletConditions(AtmosphericConditions)
Type of Gas Non-flammable and flammable gases underatmospheric conditions which can form an explosiveatmosphere (Zone 1).
Temperature Caldos 15-Ex +5 to +50 °CCaldos 17-Ex +5 to +50 °CMagnos 16-Ex +5 to +50 °CUras 14-Ex +5 to +45 °C
Inlet Pressure pe ≤ 100 hPa (= 0.1 bar) or pabs ≤ 1100 hPa (= 1.1 bar)
Flow Rate Maximum of 100 l/h, but not greater than the non-explosion-protected version of the analyzer module.
The maximum oxygen content of the sample gas mixture should be 21 Vol.-% O2,corresponding to atmospheric conditions.
If the sample gas consists only of oxygen as well as flammable gases and vapors,the maximum oxygen content should be 2 Vol.-%.
Sample Gas InletConditions(Positive Pressure)
Type of Gas Non-flammable and flammable gases under positivepressure
Temperature Caldos 15-Ex +5 to +50 °CCaldos 17-Ex +5 to +50 °CMagnos 16-Ex +5 to +50 °CUras 14-Ex +5 to +45 °C
Inlet Pressure pe ≤ 300 hPa (= 0.3 bar) or pabs ≤ 1400 hPa (= 1.4 bar)
Flow Rate Maximum of 100 l/h, but not greater than the non-explosion-protected version of the analyzer module.
The sample gas should never be explosive.
If the sample gas consists non-flammable gases and vapors, the maximumoxygen content should be 21 Vol.-% O2, according to atmospheric conditions.
If the sample gas consists only of oxygen as well as flammable gases and vapors,the maximum oxygen content should be 2 Vol.-%.
The sample gas should not contain any significant safety-relevant proportion ofself-igniting gas (e.g. acetylene).
The analyzer should have two ventilation openings.
Uras 14-Ex The “Flowing Reference Gas” option is not available for the Uras 14-Ex.
Continued on next page
8 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Operating Specifications, continued
Power Supply Input Voltage 24 VDC ± 5 %, Safe Low Voltage (SELV) orOperational Low Voltage with definite isolation (PELV),maximum value in failure mode 35 V
Power Consumption Caldos 15-Ex Approx. 35 WCaldos 17-Ex Approx. 18 WMagnos 16-Ex Approx. 35 WUras 14-Ex Approx. 75 W
Housing Design Flameproof aluminum cylinderConformity Certification PTB No. Ex 88.B.1066 U
Housing Protection Type IP 54 (horizontally mounted with O-ring seals only)
Dimensions see Dimensional Drawing (Figure 4, Page 9)
Weight approx. 26 kg
Installation The Caldos 15-Ex and Magnos 16-Ex analyzermodules must be installed with their housings in thevertical position.
The housings of the Caldos 17-Ex and Uras 14-Exanalyzer modules can be installed in the vertical orhorizontal position.Note the following for horizontal mounting:• The analyzer module should not be mounted
outdoors.• The two O-rings supplied must be inserted in the
slots provided between the housing base andhousing as well as between the housing andhousing cover.
30/24-100-2 EN Advance Optima – Explosion Protected Model 9
Dimensional Drawing
Figure 4
Ex Analyzer Module
(dimensions in mm)
5
3
4
8
6
1
27
910
800
(cle
aran
ce fo
r op
enin
g)Uras 14-Ex
Gas Connections:1 Sample Gas Inlet 1 2)
2 Sample Gas Outlet 1 2)
3 Sample Gas Inlet 2 2)
4 Sample Gas Outlet 2 2)
5 Purge Gas Inlet 1)
6 Purge Gas Outlet 1)
7 Pressure Sensor
Electrical Connections:8 System Bus9 24 VDC10 Potential Compensation
1) Option2) The actual sample gas inlet
and outlet configuration isgiven in the documentationsupplied with the instrument.
Caldos 15-Ex, Caldos 17-Ex, Magnos 16-Ex
Gas Connections:1 Sample Gas Inlet2 Sample Gas Outlet3 Ventilation Opening 4)
4 Ventilation Opening 4)
5 Purge Gas Inlet 3)
6 Purge Gas Outlet 3)
7 Pressure Sensor (Caldos 17-Ex andMagnos 16-Ex 3) only)
Electrical Connections:8 System Bus9 24 VDC10 Potential Compensation
3) Option4) Only in model for sample gas under positive
pressure
10 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Chapter 2 Ex Central Unit for Zone 1
Description
Application The Ex Central Unit is used in conjunction with the Caldos 15-Ex, Caldos 17-Ex,Magnos 16-Ex and Uras 14-Ex analyzer modules to control and monitor measure-ment and control processes.
Design The system housing is configured as a wall-mount unit with a box for electrical andgas connections on the bottom.
The system housing is designed for type of protection “Pressurized Enclosure withLeak Loss Compensation” per EN 50016. The required control unit is mounted onthe outside right sidewall of the system housing.
Circuits Non-intrinsically safe and intrinsically safe signal current circuits can be connectedto the Ex central unit.
All non-intrinsically safe circuits to be led out of the Ex central unit must beconnected to isolation relays. Intrinsically safe circuits are connected to suitableI.S. barrier modules (refer to Chapter 5, Page 35).
The display and control unit keypad sheet circuits are intrinsically safe.
Designation EEx ped [ib] IIC T4
ConformityCertification
BVS 97.D.2020
30/24-100-2 EN Advance Optima – Explosion Protected Model 11
Monitoring the Pressurized Enclosure
Structure The following units are used to monitor the pressurized enclosure (see Figure 5)
• Pressure reducer and pressure gauge for adjusting the protective gas inletpressure
• Valve (solenoid) with purge air nozzle and leak air nozzle
• Control unit with pressure switch and
• Key switch (override switch)
Figure 5
Units for MonitoringPressurizedEnclosure QP P
Pressurereducer
Valve(solenoid)
Central unit Control unit
Protective Gas Air Grade 4 per PNEUROP 6611 Recommendation of 1984 is used as the protec-tive gas (refer to the “Operating Specifications” Section, Page 13).
The protective gas is routed from the Ex central unit to the hazardous location. Thecontrol unit outlet opening contains a particle trap to prevent the passage ofsparks and glowing particles.
Preliminary Purge The preliminary purge volume is determined by the diameter of the factory-installedpurge air nozzle and the operating pressure setting (pe = 200–300 kPa [= 2–3 bar]).
The preliminary purge time is factory-set and shown on the identification plate.
After the preliminary purge, the solenoid valve is deactivated, and the power supplyfor the units in the system housing is activated.
Continued on next page
12 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Monitoring the Pressurized Enclosure, continued
Positive PressureMonitoring
During operation, the protective gas flows through the leak air nozzle to maintain apositive pressure pe ≈ 2 hPa (= 2 mbar) inside the system housing.
A relief valve limits the pressure inside the system housing.
The positive pressure is monitored as follows:
If positive pressure ... ... the following occurs:
Falls below the minimum valueof pe = 0.5 hPa (= 0.5 mbar),
• The power supply for the units in the systemhousing is deactivated after a 4-second timedelay
• Circuits connected to the isolation relays arecompletely disconnected.
• After the internal pressure again rises overthe minimum value, a preliminary purge iscarried out
• The power supply and connected circuits arereactivated
Exceeds the maximum valueof pe = 15 hPa (= 15 mbar),
• The power supply for the units in the systemhousing is deactivated after a 4-second timedelay
• Circuits connected to the isolation relays arecompletely disconnected.
• After the fault is cleared and the positivepressure returns to a normal value
• The power supply and connected circuits arereactivated without a preliminary purge.
Overriding PositivePressure Monitoring(Key Switch)
If no explosive atmosphere is present, the power supply for the units in the systemhousing can be turned on, even if the pressurized enclosure is not active. This canbe useful for maintenance or repair purposes.
To accomplish this a key switch is mounted on the system housing’s right sidewall.The key switch will not allow the key to be removed when the switch is on.
The following warning label is affixed next to the key switch: “Explosion ProtectionNot in Effect When Key Switch is On.”
30/24-100-2 EN Advance Optima – Explosion Protected Model 13
Operating Specifications
Explosion Protection Type of Protection Pressurized enclosure “p” with leak losscompensation
Explosion Group IIC
Temperature Class T4
Installation Site Hazardous Location Zone 1
Ambient Temperature Max. of 40 °C with integral isolation amplifier(electrode relay) ER 144, otherwise maximum of 50 °C
Power Supply Input Voltage 230 VAC or 115 VAC (non-switchable), 48–62 Hz
Power Consumption 190 VA
Signal Circuits At the isolation relayterminals To 30 V/0.4 A
The intrinsically safe circuit connection data can be found on the I.S. barriermodule conformity certifications.
Gas Data Internal Volume 36 l
Minimum Flow RatePreliminary Purge 7500 l/hOperation 200 l/h to compensate leak losses
Preliminary Purge Duration 10 min. with integral isolation amplifiers, otherwise4 min.
Pre-Pressure pe = 400–800 kPa (= 4–8 bar)
Operating Pressure pe = 200–300 kPa (= 2–3 bar)
Min. Positive Pressure pe ≥ 0.5 hPa (= 0.5 mbar)
Max. Positive Pressure pe ≤ 15 hPa (= 15 mbar)
Protective Gas Air, Grade 4 per PNEUROP 6611 Recommendation of1984, e.g. max. particle size 40 µm, max. oil content5 mg/m3, max. pressure dew point +2 °C
Housing Design Wall-mount housing with flanged box for electricaland gas connections
Housing Protection Type IP 54
Dimensions see Dimensional Drawing (Figure 6, Page 14)
Weight approx. 28 kg
14 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Dimensional Drawing
Figure 6
Ex Central Unit
(dimensions in mm)
1 2 3 4 5 6 7 8 9
1 Cable Openings for Internal Wiring Connections2 Valve3 Pressure Reducer with Working Pressure Gauge and Protective Gas Inlet4 Cable Openings for Signal, Control and Interface Wiring
Unassigned Cable Openings:3 x PG 13.5 Metal (for shielded leads).3 x PG 13.5 Plastic (number depends on quantity of isolation relays
and I.S. barrier modules installed)2 x PG 13.5 For intrinsically safe wiring (light blue)
5 Cable Opening for Power Supply 1 x PG 13.56 Control Unit for Pressurized Enclosure Monitoring7 Protective Gas Outlet8 Key Switch for Overriding Pressurized Enclosure Monitoring9 Potential Compensation Connector
30/24-100-2 EN Advance Optima – Explosion Protected Model 15
Chapter 3 Version for Zone 2 (Non-Flammable Sample Gas)
Description
Application In the Zone 2 version all analyzer modules (except the Multi-FID 14) are suitable formeasuring non-flammable gases.
Design Analyzer modules are installed• Either in the central unit housing• Or in a separate housing
The housing is either a 19-inch or a wall-mount unit (see the dimensional drawingin Figures 7 and 8, Page 17). Housing protection is per IP 54.
Basic Standards The Zone 2 version satisfies the following standards:
EN 50021:1999 Electrical Devices in Hazardous Locations –Type of Protection “n”
DIN VDE 0165 / 02.91 Installation of Electrical Apparatus in Hazardous Locations,Section 6.3 “Requirements for Installation in Zone 2”
Operating Mode andDesignation
There are three types of explosion protection measures per EN 50021:
Operating Mode Designation
Non-arcing assemblies and components/Non-hot components/Sealed (arcing) devices EEx nAC II T4 X
Simplified Pressurized Enclosure EEx nP II T4 X
Vapor-Proof Housing EEx nR II T4 X
Manufacturer’sCertification
Statement of expertise Pr. No. 97-09-203-Ex
Continued on next page
16 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Description, continued
Non-ArcingAssemblies andComponents/Sealed (Arcing)Devices
In normal operation there cannot be any sparking, arcing or impermissibletemperatures inside the device.
During operation, the ports marked “Housing / Purge In” and “Housing / Purge Out”should be plugged.
Simplified Pressu-rized Enclosure
All separated spaces in the housing are pneumatically connected in series usingfixed tubing.
The ports marked “Housing / Purge In” and “Housing / Purge Out” are used toconnect the protective gas.
When there is continuous purging with an protective gas, pressurized enclosuremonitoring can be implemented indirectly by means of a pressure drop via• A flow monitor with ring initiator connected to the protective gas outlet or• A modified flow sensor in the internal pneumatics module.
Monitoring the Pressurized Enclosure
Protective Gas Air or inert gas
Positive Operating Pressure pe ≥ 0.5 hPa (= 0.5 mbar),pe ≤ 15 hPa (= 15 mbar)
Flow During Nominal Operation 10 l/h equivalent tope ≥ 1.5 hPa (= 1.5 mbar)
Flow Monitor Switching Threshold 5 l/h equivalent tope ≥ 0.5 hPa (= 0.5 mbar)
Recommendation for Devices to be Used
1.6–16-l/h Flow Monitor with Ring Initiator Part Number 23155-5-8018476
Contrans I V17131-53 Isolation Amplifier Part Number 17131-0-5300000
Vapor-Proof Housing The purge gas inlet and outlet ports must be sealed with plugs during operation.
Vapor integrity must be reestablished and reverified each time the housing isopened.
The test pressure is pe = 3 hPa (= 3 mbar). The pressure drop within 3 minutesshould not exceed 1.5 hPa (= 1.5 mbar).
Corrosive SampleGas Components
In the presence of corrosive sample gas components the following analyzermodule versions should be used:
• Magnos 16, Magnos 15, Caldos 15, Caldos 17 Sample cell directly connected inwall housing
• Uras 14: Internal gas lines in the form of rust- and acid-resistant steel tubes.
OperatingSpecifications
Operating specifications corresponding to those of the non-explosion protectionversion are contained in data sheet 10/24-1.10 EN.
30/24-100-2 EN Advance Optima – Explosion Protected Model 17
Dimensional Drawings
Figure 7
Zone 2 Version inWall-Mount Housing
(dimensions in mm)
Figure 8
Zone 2 Version in19-inch Housing
(dimensions in mm)
18 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Part B Design Notes
Chapter 4 Connecting the System Bus and24-VDC Power Supply
Notes on the Connection Diagrams
Connecting the (Ex)Analyzer Modules tothe (Ex) Central Unit
The type and means of connecting (Ex) analyzer modules to the (Ex) central unitdepends on (see the following table):• The zone in which the (Ex) analyzer module and the (Ex) central unit are installed• The separation between the (Ex) analyzer module and (Ex) central unit
The following connection diagrams referred to in the table• Schematically identify the cabling between the (Ex) analyzer module and (Ex)
central unit• Show the details of individual lead to terminal connections
Distance System Bus Connection 24-VDC Connection Fig.
1 Ex Analyzer Module in Zone 1, Ex Central Unit in Zone 1
3–10 meters To isolation relay -K01 andto terminal strip -K05
To power line filter -Z01 9
10–30 meters Via EEx-e connection boxto isolation relay -K01
Via EEx-e connection boxto power line filter -Z01
10
3 Ex Analyzer Modules in Zone 1, Ex Central Unit in Zone 1
10–30 meters Via EEx-e connection boxto isolation relay -K01
Via EEx-e connection boxto power line filter -Z01 (onlyfor one analyzer module) andto external power supply
11
1 Ex Analyzer Module in Zone 1 or Zone 2, Central Unit in Zone 2 or Ex-free
3–10 meters To terminal strip -K06 To power line filter -Z01 12
10–30 meters Via EEx-e connection boxto terminal strip -K06
Via EEx-e connection boxto power line filter -Z01
13
≤ 30 meters Via connection boxwith standard cable and tee
Via connection boxto power line filter -Z01
14
1 Analyzer Module in Zone 2 (non-flammable sample gas), Central Unit Ex-free
≤ 5 meters With standard cable and tees To power line filter -Z01 15
Continued on next page
30/24-100-2 EN Advance Optima – Explosion Protected Model 19
Notes on the Connection Diagrams, continued
Isolation Relay -K01 Isolation relay -K01 is installed in the Ex central unit. It is used to connect thesystem bus cable HIGH, LOW and GROUND leads.
Page 37 shows the standard arrangement of isolation relay -K01.
Terminal Strip -K05 Terminal strip -K05 is installed in the Ex central unit. It is used to connect the 8-wire system bus cable leads not connected to isolation relay -K01.
Terminal Strip -K06 Terminal strip -K06 is installed as an option in the non-explosion protected centralunit version. It is used for system bus cable connections. If this terminal strip is notinstalled, a connection box must be installed outside the central unit.
Power Line Filter -Z01 The (Ex) analyzer module 24-VDC connecting cable can only be connected directlyto the (Ex) central unit if the optional -Z01 power line filter is installed.
If the -Z01 power line filter is not installed, the 24-VDC cable is connected to aseparate power supply.
20 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Connection Drawings
Figure 9 1 Ex Analyzer Module in Zone 1, Ex Central Unit in Zone 1,Distance of 3–10 meters
24 V DC ( 2,5 mm )> 2
-K01 -K05
115 / 230 V AC
Zone 1
-Z01
System Bus ( 0,5 mm )> 2
Ex Analyzer Module
Pow
er S
uppl
y
Central UnitEx
+
24 V DC
HIGH
LOW
GROUND 83
73
63 16
15
14
13
12
11
53
43
33
23
13
-K05-K01
Zone 1
-Z01
System Bus
GN
WH
BN
GY
PK
YE
RD
BU
BN
BU
GNYE
Ex Analyzer Module Ex Central Unit
Continued on next page
30/24-100-2 EN Advance Optima – Explosion Protected Model 21
Connection Drawings, continued
Figure 10 1 Ex Analyzer Module in Zone 1, Ex Central Unit in Zone 1,Distance of 10–30 meters
24 V DC ( 2,5 mm )> 2
EEx-e
-K01
115 / 230 V AC
Zone 1
-Z01
-K05
System Bus ( 0,5 mm )> 2
Ex Analyzer Module
Pow
er S
uppl
y
Central UnitEx
+
24 V DC
RD
HIGH
LOW
GROUND83
73
63
53
43
33
23
13
-K01
HIGH
LOW
GROUND
Zone 1
-Z01
System Bus
EEx e Connection Box
GN
WH
BN
GY
PK
YE
BU
BN
BU
GNYE
Ex Analyzer Module
Ex Central Unit
Continued on next page
22 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Connection Drawings, continued
Figure 11 3 Ex Analyzer Modules in Zone 1, Ex Central Unit in Zone 1,Distance of 10–30 meters
EEx-e
EEx-e
EEx-e
-K01
115 / 230 V AC
Zone 1
-Z01
-K05
External Power Supply
External Power Supply
System Bus ( 0.5 mm )> 2
Ex Analyzer Module
Ex Analyzer Module
Ex Analyzer Module
Pow
er S
upp
ly
Central Unit
Sys
tem
Bus
( 0
.5 m
m)
>2
Sys
tem
Bus
( 0
.5 m
m)
>2
24 V DC ( 2.5 mm )> 2
24 V DC ( 2.5 mm )> 2
24 V DC ( 2.5 mm )> 2
Ex
� If the analyzer module system bus cable is sufficiently long, a single EEx-e con-nection box with the required number of terminals can be used instead of 3 EEx-econnection boxes. In this case the system bus connections are made within thisEEx-e connection box (conductor section ≥ 0.5 mm2).
Continued on next page
30/24-100-2 EN Advance Optima – Explosion Protected Model 23
Connection Drawings, continued
Figure 11 (continued) 3 Ex Analyzer Modules in Zone 1, Ex Central Unit in Zone 1,Distance of 10–30 meters
+ 24 V DC
HIGH
LOW
GROUND83
73
63
53
43
33
23
13
-K01
HIGH
LOW
GROUND
+ 24 V DC
HIGH
LOW
GROUND
+ 24 V DC
HIGH
LOW
GROUND
Zone 1
GNYE
GNYE
GNYE
-Z01
RD System Bus
RD System Bus
RD System Bus
GN
WH
BN
GY
PK
YE
BU
BN
BU
Ex
Ana
lyze
r M
odul
e
Ex Central Unit
EEx e Connection Box
GN
WH
BN
GY
PK
YE
BU
BN
BU
Ex
An
alyz
er M
odul
e
GN
WH
BN
GY
PK
YE
BU
BN
BU
Ex
Ana
lyze
r M
odul
e
External Power Supply
External Power Supply
Continued on next page
24 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Connection Drawings, continued
Figure 12 1 Ex Analyzer Module in Zone 1 or Zone 2 (Flammable Sample Gas),Central Unit Either in Zone 2 or Ex-Free, Distance of 3–10 meters
24 V DC ( 2,5 mm )> 2
-K06
Zone 1 / Zone 2Zone 2 / Ex-free
115 / 230 V AC
-Z01
System Bus ( 0,5 mm )> 2
Ex Analyzer Module
Pow
er S
uppl
y
Central Unit
+
24 V DC
HIGH
LOW
GROUND 19
18
17
16
15
14
13
12
11
-K06
Zone 1 / Zone 2
-Z01
System Bus
GN
WH
BN
GY
PK
YE
RD
BU
BN
BU
GNYE
Ex Analyzer ModuleZone 2 / Ex-free
Central Unit
Continued on next page
30/24-100-2 EN Advance Optima – Explosion Protected Model 25
Connection Drawings, continued
Figure 13 1 Ex Analyzer Module in Zone 1 or Zone 2 (Flammable Sample Gas),Central Unit Either in Zone 2 or Ex-Free, Distance of 10–30 meters
24 V DC ( 2,5 mm )> 2
-K06
115 / 230 V AC
EEx-e
Zone 1 / Zone 2Zone 2 / Ex-free
-Z01
System Bus ( 0,5 mm )> 2
Ex Analyzer Module
Pow
er S
uppl
y
Central Unit
+
24 V DC
HIGH
LOW
GROUND19
18
17
16
15
14
13
12
11
-K06
HIGH
LOW
GROUND
Zone 1 / Zone 2
-Z01
System Bus
GN
WH
BN
GY
PK
YE
RD
BU
BN
BU
GNYE
Ex Analyzer Module
EEx e Connection Box
Zone 2 / Ex-freeCentral Unit
Continued on next page
26 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Connection Drawings, continued
Figure 14 1 Ex Analyzer Module in Zone 1 or Zone 2 (Flammable Sample Gas),Central Unit Either in Zone 2 or Ex-Free, System Bus with Standard Cable
24 V DC (2,5 mm )2
115 / 230 V AC
-Z01
EEx-e
Zone 1 / Zone 2
System Bus (0,24 mm )2
Zone 2 / Ex-free
Pow
er S
uppl
y
Central Unit Ex Analyzer Module
1
2
3
+
24 V DC
HIGH
LOW
GROUND
Zone 1 / Zone 2
-Z01GNYE
System Bus
GN
WH
BN
GY
PK
YE
RD
BU
BN
BU
Ex Analyzer ModuleZone 2 / Ex-free
BN
GN
WH
System Bus ConnectorView to the Pin Side ofthe Cable’s Connector
Continued on next page
30/24-100-2 EN Advance Optima – Explosion Protected Model 27
Connection Drawings, continued
Figure 15 1 Analyzer Module in Zone 2 (Non-Flammable Sample Gas), Ex-Free CentralUnit, Distance of ≤ 5 meters
115 / 230 V AC
Zone 2
-Z01
System Bus
Ex-free
Analyzer Module
Pow
er S
uppl
y
Central Unit
24 V DC(0,5 mm , Length 5 m)2 <
28 Advance Optima – Explosion Protected Model 30/24-100-2 EN
System Bus Connection
System Bus Cable At the factory a 10-meter long system bus cable (8 x 0.5 mm2) is attached to the Exanalyzer module (see Figure 16). The system bus cable passes through a flame-proof cable opening.
Figure 16
System Bus Cable
BUS IN HIGH
BUS OUT HIGH
BUS END LOW
BUS IN LOW
BUS OUT LOW
BUS END HIGH
BUS IN GND
BUS OUT GND
GN
WH
BN
GY
PK
YE
RD
BU
Central UnitConnection
The system bus cable should be connected to the (Ex) central unit via metal PGthreaded connections, with the shield conductor connected to the threads.
Connection Box forDistances > 10 meters
The system bus cable should be routed via a connection box if the distancebetween the Ex analyzer module and central unit is greater than 10 meters (seeFigures 10, 11, 13).
If the connection box is installed in Zone 1, the protection level must be IncreasedSafety “e”. For EMC purposes the connection box must be made of metal andhave metal PG threaded connections for the system bus cable shield conductor.
Connection Box forDistances < 10 meters
The system bus cable should not be routed via a connection box if the distancebetween the Ex analyzer module and central unit is smaller than 10 meters (seeFigures 9, 12).
However, even in these cases we recommend running the system bus cable via aconnection box in order to avoid the need for opening the central unit housing,e.g. when the system is expanded or for maintenance work. Peripheral devices,such as solenoid valves, can then be connected to the central unit via theconnection box.
Continued on next page
30/24-100-2 EN Advance Optima – Explosion Protected Model 29
System Bus Connection, continued
Zone 1 System BusExtension Cable
The yellow system bus cable should not be used to connect the connection boxand isolation relay –K01 in the Ex central unit. Instead, a shielded 4-conductorcable with twisted pairs and a wire section ≥ 0.5 mm2 should be used (part number24009-4-0059201).
The unused conductor should be• connected to the PE (potential compensation) terminal in the connection box• Securely attached at a distance of > 8 mm from current-bearing components in
the Ex central unit
Zone 2 System BusCable
The standard system bus cable (wire section of 0.24 mm2) can be used in Zone 2since in normal operation the system bus is not ignition capable per VDE0165/2.91, Section 6.3.9 (see Figure 15, Page 27).
Terminating Resistor The Ex analyzer module comes with a terminating resistor but it is not connected.Therefore at the last analyzer module the “LOW” and “HIGH” “BUS OUT” and“BUS END” connections must be interconnected (see Figure 11, Page 23).
At the other analyzer modules the “LOW” and “HIGH” “BUS END” connectionsshould be joint at a PE terminal.
These connections are always made in the connection box so that the analyzermodule does not have to be opened, even for expansion or maintenancepurposes.
Total Length The total length of the system bus wiring should not exceed 350 meters.
WARNING!
The 8-conductor system bus cable attached to the Ex analyzer moduleshould not be shortened to less than 3 meters. Otherwise the explosionprotection feature can be compromised.
30 Advance Optima – Explosion Protected Model 30/24-100-2 EN
24-VDC Supply Connection
Power SupplyRequirements
• The Ex analyzer module must be supplied with 24 VDC ± 5 %.The Ex analyzer module can be powered by the central unit power supply if theoptional power line filter -Z01 is installed in the central unit. If this power line filteris not installed the Ex analyzer module is to be powered by a separate powersupply.
• The supply voltage must meet the following safety requirements:• Safe low voltage (SELV) or operating low voltage with safe isolation (PELV)• Maximum value in failure mode 35 V
• The power supply must be disconnectable.
WARNING!
Only one analyzer module should be supplied with 24 VDC from the centralunit power supply. A separate 24-VDC supply is required for additionalanalyzer modules.
24-VDC ConnectingCable
At the factory a 10-meter long 24-VDC cable (3 x 2.5 mm2) is attached to the Exanalyzer module (see Figure 17). The connecting cable passes through a flame-proof cable opening.
Figure 17
24-VDC ConnectingCable
BN
BU
GNYE
Central UnitConnection
The 24-VDC connecting cable is brought into the central unit via a PG threadedconnection and attached to the power line filter -Z01.
Connection to aSeparate PowerSupply
The following configurations are possible:
• The power supply is installed in an explosion hazard-free area.• The 24-VDC connecting cable is attached to an EEx-e connection box. The
connecting cable can be extended to a maximum of 30 meters (3 x 2.5 mm2).• If an adjustable power supply (available on request) is used, the 24-VDC
connection cable can be extended to a maximum of 90 meters (3 x 2,5 mm2).The max. supply voltage should be 25.8 VDC.
• The power supply is installed in an explosion hazard area.In this case a flameproof enclosed power supply is used (see the “FlameproofEnclosed 24-VDC Power Supply” Section, Page 33). The 24-VDC analyzermodule connecting cable should be directly connected to the power supply.
Continued on next page
30/24-100-2 EN Advance Optima – Explosion Protected Model 31
24-VDC Supply Connection, continued
Connection Box Like the system bus cable, depending on the distance between the Ex analyzermodule and central unit, the 24-VDC connecting cable should be routed via aconnection box (see the “System Bus Connection” Section, Page 28).
Zone 1 24-VDCExtension Cable
A three-conductor cable with a conductor section ≥ 2,5 mm2 is used to extend theZone 1 24-VDC connecting cable.
Zone 2 (Non-Flammable SampleGas) 24-VDCConnection Cable
The 24-VDC connecting cable plug for non-explosion protected analyzer modulesused in Zone 2 (non-flammable sample gas) can only accept cables with a wiresection of ≤ 0,5 mm2. The connecting cable length is limited to 5 meters (seeFigure 15, Page 27).
WARNING!
The 3-conductor 24-VDC connecting cable attached to the Ex analyzermodule should not be shortened to less than 3 meters. Otherwise theexplosion protection feature can be compromised.
32 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Advance Optima Power Supply Performance
Rated Output The Advance Optima power supply has a rated output of 144 W.
The power supply provides 24 VDC for the electronics module and for an analyzermodule installed in the central unit or externally.
Rated OutputDecrease
Power supply rated output decreases• as the ambient temperature increases• as the altitude of the installation location increases
This is due to the fact that warmer and less dense air does not efficiently transferheat from the power supply.
The following table shows the power supply rated output based on ambienttemperature and installation location altitude.
AmbientTemperature
Power SupplyRated Power
InstallationLocation Altitude
Power SupplyRated Power
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 Power ConsumptionModulePower Consumption System Controller 20 W
Analog I/O Board 5 W
Digital I/O Board 5 W
8-Way Analog Output Board 10 W
Caldos 15 35 W
Caldos 17 18 W
Limas 11 (no Ex version) 79 W/35 W at +5 °C/+45 °C
Magnos 16 35 W
Magnos 17 (no Ex version) 35 W
Multi-FID 14 (no Ex version) 65 W
Uras 14 20 W/75 W with/without thermostat
Gas Module 10 W/20 W with 1/3 valves
30/24-100-2 EN Advance Optima – Explosion Protected Model 33
Flameproof Enclosed 24-VDC Power Supply
When is a flameproofenclosed powersupply required?
If in a Zone 1 installation the distance between the Ex central unit and the Ex analy-zer module is greater than 30 meters, the analyzer module cannot be poweredwith 24 VDC from the central unit power supply.
A flameproof enclosed power supply is required in this case.
Specifications The following table shows the specifications for the flameproof enclosed 24-VDCpower supply recommended and marketed by ABB Analytical.
Input Voltage 120/230 VAC, 47–63 Hz
Output Voltage 24 VDC ± 3 %
Output Current 5 A
Threaded Cable Connections 5 x CMP 20 E1FX-Z (flameproof)
Part Number 24009-5-8018507
Additional SystemBus Connection
In the flameproof enclosed housing there are additional 8 terminals for a systembus cable extension/connection.
Figure 18
Dimensional Drawing
(dimensions in mm)
280
300
200
320
270
4 x 12∅
M6
34 Advance Optima – Explosion Protected Model 30/24-100-2 EN
EEx-e Connection Boxes
Specifications The following table shows the specifications for the EEx-e connection boxesrecommended and marketed by ABB Analytical.
EEx-e Connection Box With 10 Terminals With 30 Terminals
Material Aluminum Aluminum
Number of Terminals 10 30
Number of PE Terminals 3 5
Threaded Cable Side A 2 x PG 13.5 4 x PG 13.5Connections Side B 2 x PG 13.5; 1 x PG 9 4 x PG 13.5; 1 x PG 9
Part Number 24009-5-8018508 24009-5-8018509
Application Connecting 1analyzer module tothe central unit
Connecting 2 or 3analyzer modules tothe central unit
Figure 19
DimensionalDrawings
(dimensions in mm)
125
80
42 57
113
52
106
2x 4,4∅
10-Terminal Version
250
80
42 57
52
238
2x 4,4∅
231
30-Terminal Version
30/24-100-2 EN Advance Optima – Explosion Protected Model 35
Chapter 5 Connecting Non-Intrinsically Safe andIntrinsically Safe Circuits
Isolation Relays and I.S. Barrier Modules
Zone 1 Circuits Both intrinsically safe and non-intrinsically safe signal circuits can be connected tothe Ex central unit for use in Zone 1.
All non-intrinsically safe circuits should be connected to isolation relays. SuitableI.S. barrier modules are available for the connection of intrinsically safe circuits(see below).
The display and control unit keypad sheet circuits are intrinsically safe.
Zone 2 Circuits The I.S. barrier modules shown below can also be used in the Zone 2 versioncentral unit if there is no analyzer module installed in the housing.
The use of isolation relays is not required in Zone 2 according to the InstallationRequirements (DIN VDE 0165) in effect in Germany.
Isolation Relays forNon-Intrinsically SafeCircuits
One isolation relay with 8 (closing) contacts is standard equipment in the Ex centralunit. Depending on the number of non-intrinsically safe circuits (e.g. on I/O boards),up to three additional isolation relays with 8 contacts each can be installed. Theisolation relay is 75 mm wide.
I.S. Barrier Modulesfor Intrinsically SafeCircuits
Suitable I.S. barrier modules are available for various types of intrinsically safecircuits to be connected. They are listed in the following table along with thequantity possible and the width of each module.
Circuits Module Quantity Width
Digital Inputs Switching Amplifier ER 144for Condensate Monitor
1 60 mm
Contrans I Switching AmplifierV 17131-53, 2-Channel, for Flow Monitor
1–2 20 mm
Digital Outputs Isolation Relay, 1 Opener, 1 Closer 1–4 30 mm
Contrans I Solenoid DriverV 17132-52, 1-Channel
1–4 20 mm
Analog Outputs Contrans I Loop Powered IsolatorV 17153-51, 1-Channel
1–4 20 mm
Analog Inputs Contrans I Isolating Power SupplyV 17151-61, 1-Channel
1–2 20 mm
Installation The isolation relays and I.S. barrier modules are installed on a 35 x 15-mmDIN EN 50022 carrier in the Ex central unit. The carrier is 300 mm long.
36 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Wiring Notes
Interface Lead Wiring The RS-232C, RS-485 and Ethernet 10BASE-T interface leads are not intrinsicallysafe. Therefore, these leads must be connected via an isolation relay.
RS 232C RS 485 Ethernet 10BASE-T
RXD RTXD– 10TT+TXD RTXD+ 10TT–
GND GND 10TR+
10TR–
Device-internal wiring for the interfaces between the system controller andisolation relays is performed exclusively at the factory per customer order.
Ethernet 10BASE2 The Ethernet-10BASE2 interface (coaxial connection) cannot be used in explosionhazard areas.
Unassigned CableOpenings inEx Central Unit
The number of unassigned cable openings (PG threaded connections) on the Excentral unit depends on the number of isolation relays and I.S. barrier modulesinstalled.
The following are unassigned in the standard equipment version (1 isolation relay):3 x PG 13.5 Metal (for shielded leads).3 x PG 13.5 Plastic2 x PG 13.5 For intrinsically safe wiring (light blue)
Cable opening locations are shown in the dimensional drawing (see Figure 6,Page 14).
WARNING!
Device-internal factory wiring connections can be changed by the user byusing the installed components. Any changes carried out should be docu-mented in the device voucher.
The addition of cables to device-internal wiring or the installation of additio-nal electrical equipment represents a change to an electrical device underthe provisions of ElexV. Therefore, such work should only be carried out by aABB Analytical employee with an Ex certificate or an Ex expert. The operatingspecifications and the routing instructions must be followed.
WARNING!
The Ex analyzer module and Ex central unit housings must be connected to alocal potential compensation system when installed in an explosion hazardarea:• Either via the external potential compensation connection• or
• On Ex analyzer modules via the green/yellow wire on the 24-VDCconnection cable
• On the Ex central unit via the internal protective lead connection
30/24-100-2 EN Advance Optima – Explosion Protected Model 37
Isolation Relay Terminal Layout (Example)
Example The following isolation relay -K01 to -K04 terminal configuration example is basedon the standard system controller (connections -X02 and -X03) and I/O board(connections -X11 to -X15) connection layout.
Device-Side User-SideConnection Terminals Function
Isolation Relay -K04 (Option)
14 13DI2 -X13/17 24 23 Meas. range switching 1st component, 2nd range
DI-GND -X13/16 34 33
DI1 -X13/15 44 43 Meas. range switching 1st component, 1st range
DO2 -X13/8 54 53 Measurement range feedback
DO2 -X13/7 64 63 1st component, 2nd measurement range
DO1 -X13/5 74 73 Measurement range feedback
DO1 -X13/4 84 83 1st component, 1st measurement range
Isolation Relay –K03 (Option)14 13
DI2 -X03/19 24 23 Block Autocalibration
DI1 -X03/17 34 33 Start Autocalibration
DI-GND -X03/18 44 43
DO4 -X15/11 54 53 End-point gas valve
DO3 -X15/8 64 63 Zero-point gas valve
DO2 -X15/5 74 73 Sample gas valve
DO-COM-X15/4,7,10 84 83 DO 2, 3, 4 common pole
Isolation Relay -K02 (Option)14 13
DO3 -X02/9 24 23 Limit value or
DO3 -X02/8 34 33 “Maintenance request” status
DO2 -X02/6 44 43 Limit value or
DO2 -X02/5 54 53 “Maintenance mode” status
AO2+ -X11/21 64 63 Measured value Channel 4
AO– -X11/20 74 73 Ground Channels 3, 4
AO1+ -X11/19 84 83 Measured value Channel 3
Isolation Relay -K01 (Standard)DO1 -X02/3 14 13 Overall status orDO1 -X02/2 24 23 “Failure” status
AO2+ -X03/15 34 33 Measured value Channel 2
AO– -X03/14 44 43 Ground Channels 1, 2
AO1+ -X03/13 54 53 Measured value Channel 1
HIGH brown 64 63 System bus HIGH
LOW green 74 73 System bus LOW
GND white 84 83 System bus GROUND
38 Advance Optima – Explosion Protected Model 30/24-100-2 EN
Isolation Relay Terminal Layout (Blank Form)
Terminal LayoutPlanning
The following blank form can be used to plan isolation relay terminal layoutconfigurations.
Device-Side User-SideConnection Terminals Function
Isolation Relay -K04 (Option)
14 1324 23
34 33
44 43
54 53
64 63
74 73
84 83
Isolation Relay -K03 (Option)14 1324 23
34 33
44 43
54 53
64 63
74 73
84 83
Isolation Relay -K02 (Option)14 1324 23
34 33
44 43
54 53
64 63
74 73
84 83
Isolation Relay -K01 (Standard)14 1324 23
34 33
44 43
54 53
64 63
74 73
84 83
30/24-100-2 EN Advance Optima – Explosion Protected Model 39
Chapter 6 Accessories
Accessory Part Numbers
Accessories The following table summarizes the most significant accessories for the design ofexplosion protected Advance Optima systems.
The table indicates the zone for which the accessory is intended and the partnumber.
Designation For Zone Part Number
EEx d power supply, 115 / 230 VAC, 24 VDC, 5 A 1 2 24009-5-8018507
EEx e connection box for Zone 1, 10 terminals 1 2 24009-5-8018508
EEx e connection box for Zone 1, 30 terminals 1 2 24009-5-8018509
Isolation relay * 24309-4-0746610
ER 144 switching amplifier, 230V, 50 / 60 Hz * 23371-4-0741149
ER 144 switching amplifier, 115V, 50 / 60 Hz * 23371-4-0741152
Contrans I isolation amplifier * 17131-4-0338711
Contrans I base * 17111-4-0338498
System bus plug with tee 2 N 24009-4-0746316
System bus plug with terminating resistor 1 2 N 24009-4-0746317
System bus cable 1.0 meter 2 N 24009-4-0746313
System bus cable 2.0 meters 2 N 24009-4-0746314
System bus cable, variable length(≤ 350 meters), 0.24 mm2
2 N 24008-4-0746470BA No. 301 ... m
System bus cable, variable length(≤ 350 meters), 0.5 mm2
1 2 N 24009-4-0059201BA-No. 301 ... m
System bus plug 2 N 24009-4-0746318
System bus receptacle 2 N 24009-4-0746471
Modbus plug with tee 2 N 24009-4-0746617
Modbus plug with RC link 2 N 24009-4-0746616
Modbus cable 1.0 meter 2 N 24009-4-0746619
Modbus cable 2.0 meters 2 N 24009-4-0746620
Modbus cable, variable length, 0.24 mm2 2 N 24008-4-0746622BA-No. 301 ... m
Modbus cable, variable length, 0.5 mm2 1 2 N 24009-4-0059201BA-No. 301 ... m
Modbus plug 2 N 24009-4-0746318
Modbus receptacle 2 N 24009-4-0746471
5-meter power cable, straight plug 2 N 24409-4-0746636
5-meter power cable, angled plug 2 N 24409-4-0746659
24-VDC cable 5 meters with plug connector 2 N 24009-4-0746469
* Installed in Ex central unit
Subject to technical changesPrinted in the Fed. Rep. of Germany
30/24-100-2 EN 09.00