Uras26 en

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Ursula Koeppe, FPT, June 2009
Uras26
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Typical Applications
§ Power plants, burner

optimizing
§ Emission monitoring,
controlling purity steps
§ Inertisation monitoring, coal
mills
§ Gas manufacturing
§ Air separation, Fertilizer plant,
NH3 - production
§ Cement plants process control
§ Blast furnace top gas
monitoring
§ Chemical processes, Ethylene
plant
§ Biogas monitoring, Landfills
§ Automotive industries
© ABB
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Typical components
§ Emissions monitoring in flue gas

(CO, SO2, NO,…)
§ Landfill Monitoring (CH4, CO2)
§ Gas Production / Purity Control
(CO2, CO, N2O)
§ Process Control on Cement Plants
(CO, CO2 NO, SO2)
§ Burner Optimization (CO)
§ Process Monitoring for Chemical
Plants (C2H2, C2H4, C3H6,..)
§ Fermentation Process Control
(CO2 )
© ABB

Certified Components and Ranges
Smallest ranges certified by TÜV
0 ... 75 mg/m³ CO 0... 60 ppm

0 ... 75 mg/m³ SO2 0... 25 ppm
0 ... 100 mg/m³ NO 0... 75 ppm
0 … 100 mg/m³ N2O 0… 50 ppm
0... 10 / 25 Vol% O2
O2 –Sensor or Magnos206
© ABB

NDIR - Photometer
Uras – NDIR-photometer (Non Dispersive Infrared Photometer)

NDIR –The term "infra red" covers the range of the electromagnetic spectrum between
0.78 and 1000 µm.
wavenumber = 1 / wavelength in centimeters
It is useful to divide the infra red region into three sections;

near, mid and far infra red.
§Region wavelength range (µm) wavenumber range

(cm-1)
Near 0.78 – 2,5 12800 - 4000
Middle 2,5 – 50 4000 - 200
Far 50 – 1000 200 - 10
The most useful IR- region lies between 4000 - 670cm-1, corresponding to 2,5 …15µm
the Uras26 works within this middle region 2…15µm
© ABB

Electro magnetic Spectrum
Infra red
visible
Ultra violet
© ABB

Background and Theory
Infrared spectroscopy exploits the fact that molecules have

specific frequencies at which they rotate or vibrate corresponding to
discrete energy levels (vibration modes). These resonant
frequencies
are determined by the shape of the molecular potential energy
surfaces,
the masses of the atoms and, by the associated vibronic coupling.
In order for a vibration mode in a molecule to be IR active,
it must be associated with changes in the permanent dipole.
Heterogeneous gases Homogeneous gases

IR-active IR-inactive
e.g. e.g.
CO, CO2, NO, N2O, NO2 , CH4 H2, N2, O2, Ar, Cl2
© ABB

Background and Theory
Molecular vibrations
The positions of atoms in a molecules are not fixed; they are subject to a
number of
different vibrations.
Vibrations fall into the two main catagories of stretching and bending.
Stretching: Change in inter-atomic distance along bond axis
Bending: Change in angle between two bonds. There are four types of bend
© ABB

Finger print spectra
Ca. 1,5 ... 15

µm
Carbon monoxid CO vapour H2O Sulfur dioxid SO2
100 Carbon dioxid CO2

Trans-
mission
[ %]
0
2 4 6 8 2 4 6 8
2 4 6 8 Wellenlänge [ µm]
Methane CH4 Acetylene C2H2 Etylene C2H4
© ABB

NH3
HF
HCl
SO2
NO
CO
CO2
H2 O @
20vol%
© ABB

Measuring Principle
Sample gas in Sample gas out
I0 I1
cxε
detector
Infrared-
Infrared- Sample cell, length l
source
Lambert - Beer Law

I0 = emitted energy
I1 = received energy
−ε∗c∗l ε = Extinction-constant
I1 = I0 ∗ e c = concentration ( % )
l = length of sample cell ( mm )
© ABB

Absorption, depending on concentration and
length of sample cell
Absorption ( %)
100
3 2
50
Only 3 ......5 % Absorption

are used
for Measurement.
© ABB

Uras26-principle
Gas filled detector
Radiation source aperture Chopper wheel Sample cell
MS
Meas side
CO
CO/N2
N2
Reference side
RS
© ABB

Selectivity of Measurement
Only one type of Sample cell

Radiation source for all Different lengths depending
meas. components on the concentration of
the meas. component
CO
CO/N2
N2
The detector is filled

with the gas component
to be measured
By installation of these
(different) detectors
we get the Selectivity
for the instrument
© ABB

Instrument-design: One detector, no calibration cell
CO
source Sample cell detector
© ABB

Instrument-design: Two detectors, no calibration cell
CO NO
Opt. filter
source Sample cell Detector 1 Detector 2
© ABB

Instrument-design: Two detectors, no calibration cell
Detector 1
CO
NO
source Sample cell Detector 2
© ABB

Instrument-design: Four detectors, no calibration cell
CO SO2
CO2 NO
© ABB

Instrument-design: Four detectors, calibration cells
CO
SO2
N2
CO SO2
N2
N2
N2
N2
CO2 NO
N2
CO2
NO
M
© ABB

Influence parameters
Temperature Working with a constant temperature by using a thermostat

Alternative temperature compensation;
Influence: At zero-point: <1%MRS pro 10°
On sensitivity: <1% of measured value per 10° (with
thermostat)
pressure A pressure sensor for pressure correction is always installed

Effect: At Zero-Point: No effect ,
On sensitivity: <0,2% of measured value per 10 mbar pressure change
Flow-rate in the range 20 …100 l/h

Flow
effect within determination limits
Associated Gas Analyzer calibration should be based on an analysis of the sample gas
Effect / CS Selectivity measures to reduce associated gas effect (optional)
Incorporation of interference filters, filters vessels
or internal electronic cross-sensitivity correction or
carrier gas correction for a sample component by other sample components
measured with the Uras26
© ABB

Signal Processing
Uras26
SSI – board AMC – board CAN-Bus

Syscon board Display
Sensor specific interface Analyzer module controller
SPI-Bus
Distributer- SPI-Bus
AD AD board
M
CO So2
Pressure-
sensor
NO SSI
Flow-
sensor
M AD
SSI
pump
Solenoid-
valve
SSI
© ABB

Cross Interference
General
§ General:
§ The overlapping of the absorption lines of the measurement
component and the interfering Component is named
Cross Sensitivity ( CS ) or Cross Interference
Interference Meas-
absorption
component component
Wavelength [µm]
Cross Sensitivity ( CS )
© ABB

Cross Interference
Reducing with optical filters
Optical (Interference) filter
Absorption line with optical

filter
Remaining cross interference
© ABB

Cross Interference
Elimination with gas filters
Gas filter cell

Filled with the
interfering component
Interference Meas-
Meas-
component component
component
Interference
component
© ABB

Cross Interference
Reducing by Delta Phase Adjustment
Automatic phase
interference component
Meas component
The ∂-Phase is manual adjusted

(by using the TCT)
The ∂-Phase is adjusted to a
minimum reading
of the interference component!!!!
Values for ∂-Phase: -300…+300
© ABB

Module Design
© ABB

Optical Bench
Radiation unit
Emitter Insert Chopper Wheel
Light barrier
The Radiation Unit can be equipped

with one or two emitter inserts
The frequency of the

chopper wheel is 7,3 Hz.
(configured by the software)
motor
No maintenance is required!
After replacement a Phase-Adjustment and a (basic-)calibration are required!
© ABB

Optical Bench
Sample Cells
Different lengths of sample cells are

available
Different materials for the sample

cells are available (aluminum, gold,
stainless steel)
Effects:
contamination inside in the sample
cell leads
to an OFFSET DRIFT
Therefore: Keep the sample cell
clean!
Take care of the sampling system!
After replacement an
Optical Adjustment is required!
Safety Cell
© ABB

Optical Bench
Calibration Unit
§ The calibration cell is gas filled.
§ The calibration cell has a very

high stability.
N2 N2
§ It is used for SPAN calibration

CO instead a test gas from a bottle.
NO N2
§ The calibration cell can be filled

with one or two components.
§ The calibration cell is to measure
once a year.
§ When the calibration cell has lost

the gas filling an
AMPLIFICATION DRIFT Error
will appear after calibration!
© ABB

Optical Bench
optical filters
§ All interference filters are

available in two versions:
§ With a small frame for

with large frame mounting clamp for installation in the calibration unit
filter with large frame
§ With a large frame for installation

between sample cell and
detector or between two
Filter detectors
Calibration unit with small frame
© ABB

Optical Bench
detector
§ The detector is filled with the same gas as the measurement component.
§ Therefore we have different detectors for CO, SO2, CO2, NO,….
§ The detector is always equipped with the preamplifier which includes the AD-
converter!
§ When the detector has lost the sensitivity an Amplification Drift Error will appear
after calibration. After replacement an Optical Adjustment and a Basic-calibration
are required!
© ABB

Module Electronic
SSI-Board (sensor specific interface)
Det. 1 Det. 2 Det. 3 Det. 4 Cal.Cell
24V
SPI
Source 1
Light barrier
Source 2
Wheel motor
heater
LED’s 15…23
© ABB

Module Electronic
SSI-board, LED’s
LED on off Function
1 red (D15) Error OK Software-controlled, indicates software-relevant error
2 green (D16) Booting: blinks Software-controlled, varying function between booting and
Application: blinks during measurement of application
auxiliary variables
3 yellow (D17) Booting: blinks Software-controlled, varying function between booting and
Application: blinks at modulation frequency application
4 green (D18) OK Error Hardware-controlled, high voltage
5 green (D19) OK Error Hardware-controlled, 3.3V
6 green (D20) OK Error Hardware-controlled, 5V
7 green (D21) OK Error Hardware-controlled, 7.2V
© ABB

Module Electronic
AMC-board (Analyzer Module Controller)
24V
RS232 to connect TCT
Ethernet to connect
“AMC update”
SPI-bus CAN-bus to sysconboard
© ABB

Module Electronic
AMC – board, Functionality
§ The AMC-board
§ Contains the module software (e.g. 3.2.16)
§ Contains the analyzer-configuration (TCT-file)
§ Communicates with the Analyzer-module via SPI-bus
§ Communicates with the sysconboard via CAN-bus
© ABB

Module Electronic
AMC – board, Interfaces
§ The RS232 interface is used to communicate with TCT
§ The Ethernet-interface is used to update the module-software

This Ethernet-interface is not connected to the instrument-
backplane
It is a different interface to the Syscon-Ethernet-Interface and uses
an individual IP-address. The standard IP-address for each AMC-
board is 192.168.1.4.
§ The software to update the AMC-board is named “AMC-UT”
© ABB

AMC – board
Update
§ To update the AMC-software we use the tool “AMC_UT”

§ This software contains all the files for the new software, i.e. Vers.
3.2.16
§ After completing the Update-procedure the module comes up with
the existing configuration file (TCT-file)
© ABB

AMC - board
Update-procedure
General Procedure:
1. For safety-reason: Save configuration data with TCT RS232 interface
2. Set the IP-address in your PC to 192.168.1.2
3. Connect the PC to the AMC (crossed cable, point-to-point), use the Ethernet-interface
© ABB

AMC - board
update - procedure
4. Configure the IP address
in AMC_UT:
The address of the AMC-board is

192.168.1.4
5. Start the Update
© ABB

AMC - board
Update - procedure
6. Wait for the message:
“New software loaded successfully”
7. Wait for Rebooting of the AMC-

board.
(2 yellow LED go off)
© ABB

TCT – configuration
general overview
© ABB

Adjustments
optical alignment
The Optical Adjustment is a mechanical adjustment to get a minimum signal at the Zero-Point.
An aperture is covering more or less the reference side .
The Optical Adjustment is performed by injection of ZERO-gas.
Screw for Optical Adjustment
Aperture for Optical Adjustment
CO
An Optical Adjustment is required after re-installation

of any parts of the optical bench!
(Put on Zero-gas!)
© ABB

Adjustments
optical alignment
Screw for Optical Alignment
§ Set point for optical alignment: minimum of raw values

§ Typical raw values: 50 000 …. 500 000
§ The Optical Alignment is to perform separately for each beam path.
§ The Optical alignment is to perform via front panel or with TCT
© ABB

Adjustment
optical alignment
§ Menu – maintenance/test – analyzer spec. adjustments –optical adjust

§ Select the component, provide zero gas, adjust with the screw to a
minimal signal
© ABB

Adjustments
phase alignment
§ The phase adjustment is performed to get an optimized sensitivity for
the detector signal.
§ SPAN - gas is required for each detector!
§ The phase adjustment is an adjustment between the detector signal
and the reference signal. Reference Signal
(Signal from the light barrier)
(The reference signal is used

to control the rectification)
Detector signal
t1 t2 t3 t4
Values for Phase: 0…3600
© ABB

Adjustment
basic calibration
§ The basic calibration (or factory
calibration, initial calibration) is to
carry out after replacement of
significant parts of the optical
bench, especially the detector.
§ The basic calibration is to
perform only in the physical
(high) range. The low range is a
calculated range.
§ The basic calibration does not
calculate any drift parameters.
§ The basic calibration calculates
the parameters Offs fixed and
Ampl fixed
© ABB

Adjustment
re-linearisation
§ The Uras – signal is always linearized.

§ For each individual component a linearization is calculated.
§ To compensate any aging effects regarding the linearization, it is

possible
§ to re-linearize each component at ONE point between zero and span
point.
Indication
with Standard-Linearisation
without Linearisation
with Re-Linearisation
concentration
5 10
0 Vol. % CO2
© ABB

Adjustment
measurement of calibration cell
§ The calibration cells are very stable for a long time. It is recommended to
measure the Calibration Cells once the year.
§ Prior to the measurement of the calibration cells, the Uras must be
calibrated (and re-linearised) with a certified test gas.
§ For the measurement of the calibration cells, zero gas must flow through
the sample cell.
menu – maintenance/test – analyzer spec. adjustment – measure cal cell
© ABB

Adjustment
manual calibration
§ The manual calibration is to perform for each component separately.

§ For SPAN –calibration either the installed calibration cells or a test gas can
be used.
§ The manual calibration is performed as COMMON-calibration, that means
all ranges are adjusted by only ONE Zero- and ONE Span adjustment.
© ABB

Adjustment
automatic calibration
§ The Automatic Calibration calibrates all configured components, inclusive
the O2-sensor, simultaneously.
§ If the analyzer is equipped with calibration cells, these are used for the span
adjustment.
§ Iftest gas is used for the calibration, all components must be available in
ONE test gas cylinder.
§ The Auto Cal can be activated by the internal clock or by a digital signal.
§ All parameters for the Auto Cal must be configured in menu – configuration
– calibration data – auto calibration.
© ABB

Adjustment
basic calibration zero
§ H2O – content of test gases: ≤ 5
ppm
§ 5ppm à dew point ca.-70°C
§ Dew point of cooler: 3°C à
0,75Vol% H2O (7500 ppm)
§ The components NO and SO2 have

an interference to H20:(with
implemented delta Phase) of about
-10mg/m³
§ The first calibration after

commisioning of the system is
carried out as zero basic calibration
§ The zero basic calibration corrects

the shift between dry zero gas
(-70°C) and wet zero gas
(3°C)without any drift calculation.
© ABB

Adjustment
automatic calibration of a system with Uras26
DO1 Failure
Maintenance IO-board
DO2 mode Magnos 206 Uras 26
Central-unit SCC-F
Maintenance
DO3
request SO2, CO
O2
P
DO4 External
solenoid valve Condensate-
NO
trap
Cooler Gas feed unit

Cal-
SCC - C SCC-F
gas
probe
dosing condensate
© ABB

Adjustment
automatic calibration – timing Uras26 with CC
Purge time 1 Wait trend Move Wait Wait trend Remove Purge time 3
5sec
+ 4*t90 Rec.time cal.cell 4*t90 Rec.time cal.cell + 4*t90
5sec. 5sec.
Zero Span
Adjustment
Prewarning 1
Sample- 2
gas
Zero 3
Span 4
5
Pump
Current 6
HOLD
Cal.Status 7
Solenoid
control 8
© ABB


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place picture here

Ursula Koeppe, FPT, June 2009

PDF wurde mit pdfFactory-Prüfversion erstellt. www.context-gmbh.de

§ Power plants, burner

PDF wurde mit pdfFactory-Prüfversion erstellt. www.context-gmbh.de

§ Emissions monitoring in flue gas

PDF wurde mit pdfFactory-Prüfversion erstellt. www.context-gmbh.de

Smallest ranges certified by TÜV

0 ... 75 mg/m³ CO 0... 60 ppm

PDF wurde mit pdfFactory-Prüfversion erstellt. www.context-gmbh.de

Uras – NDIR-photometer (Non Dispersive Infrared Photometer)

It is useful to divide the infra red region into three sections;

§Region wavelength range (µm) wavenumber range

Near 0.78 – 2,5 12800 - 4000

Middle 2,5 – 50 4000 - 200

Far 50 – 1000 200 - 10

PDF wurde mit pdfFactory-Prüfversion erstellt. www.context-gmbh.de

PDF wurde mit pdfFactory-Prüfversion erstellt. www.context-gmbh.de

Infrared spectroscopy exploits the fact that molecules have

Heterogeneous gases Homogeneous gases

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Stretching: Change in inter-atomic distance along bond axis

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Ca. 1,5 ... 15

Carbon monoxid CO vapour H2O Sulfur dioxid SO2

100 Carbon dioxid CO2

Methane CH4 Acetylene C2H2 Etylene C2H4

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Sample gas in Sample gas out

Lambert - Beer Law

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Only 3 ......5 % Absorption

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Gas filled detector

Radiation source aperture Chopper wheel Sample cell

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Only one type of Sample cell

The detector is filled

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source Sample cell detector

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source Sample cell Detector 1 Detector 2

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source Sample cell Detector 2

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Temperature Working with a constant temperature by using a thermostat

pressure A pressure sensor for pressure correction is always installed

Flow-rate in the range 20 …100 l/h

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SSI – board AMC – board CAN-Bus

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Optical (Interference) filter

Absorption line with optical

Remaining cross interference

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