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


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


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


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.



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.


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


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


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.



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.”


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


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


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



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.


Dimensional Drawings

Figure 7

Zone 2 Version inWall-Mount Housing

(dimensions in mm)

Figure 8

Zone 2 Version in19-inch Housing

(dimensions in mm)


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



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.


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



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


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




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


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).




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


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






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


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




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


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


Zone 2 / Ex-freeCentral Unit




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




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 <


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.



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.


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.



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.


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


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


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


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.


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


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


Isolation Relay -K01 (Standard)DO1 -X02/3 14 13 Overall status orDO1 -X02/2 24 23 “Failure” status


AO– -X03/14 44 43 Ground Channels 1, 2


HIGH brown 64 63 System bus HIGH

LOW green 74 73 System bus LOW

GND white 84 83 System bus GROUND


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


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

explosion protected model descriptions and design … · explosion protected model descriptions and...

Documents