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AO2040 Other names:
Gas analyzer AO2040
AO2040 Integrated Analyzer
Continuous gas analyzerAO2040
ABB’s AO2040 is a laser analyzer belonging to the Advance Optima series. It is designed as a universal and explosion-proof model, suitable for various industrial applications. The LS25 model can be integrated with other analyzer modules and remotely operated through an Ethernet network, providing flexibility and ease of use in monitoring and analyzing gas composition.
Main features:
ATEX, IECEx, and CSA certifications: LS25 is certified for use in potentially explosive environments, ensuring safety in hazardous environments.
Remote operation: It can be fully remotely operated in Ethernet networks, allowing for flexible deployment and access to data.
Integration capability: As part of the Advance Optima series, it can be combined with other analyzer modules to expand its analytical capabilities.
Safety and Compliance: Certified for use in potentially explosive environments, meeting strict safety standards.
High precision: Thanks to advanced infrared technology, AO2040 can measure the concentration of various gas components with high precision.
Wide measurement range: This analyzer has a wide measurement range, which can measure both low concentration and high concentration gases, meeting the needs of different application scenarios.
Multi gas measurement: capable of measuring various gas components, providing users with comprehensive gas analysis data.
Automatic calibration: The instrument has an automatic calibration function, which can automatically adjust the measurement parameters to ensure the accuracy and stability of the measurement.
Easy to operate: Designed with a user-friendly interface, the operation is simple and intuitive, making it easy for users to quickly get started and take measurements.
Software and firmware:
The software of the analyzer consists of two programs: device firmware (hidden from the user and integrated into the CPU electronic device) and Windows running on a standard PC connected via RS-232 connection ® Service program. The device firmware performs all necessary calculations and self-monitoring tasks, while the service program allows communication with the device during installation, service, and calibration.
Product composition
AO2040 mainly consists of three independent units: a transmitter unit with purification function, a receiving unit with purification function, and a power supply device. The transmitter unit includes a laser module, a temperature stable diode laser, a collimating optical lens group, and main electronic equipment, all of which are installed in a coated aluminum box. The environmental protection level of both the transmitter and receiver is IP66, and the standard optical window can withstand a maximum pressure of 5 bar (absolute pressure).
Three independent units: The analyzer consists of a transmitter unit with purging function, a receiver unit with purging function, and a power supply unit. Each unit plays a crucial role in the measurement process, contributing to the overall functionality and performance of the system.
Measurement principle:AO2040 uses absorption line method to measure the concentration of specific gases using laser. The laser is transmitted along the path where the gas sample is located, and the receiver detects the light absorbed by the gas molecules. Through this detection, the gas concentration can be calculated.
Installation variants: This analyzer has two variants: universal and explosion-proof, which can meet different environmental conditions and safety requirements. This versatility makes it suitable for various industrial environments.
Troubleshooting and error handling: The device displays potential issues clearly on its LCD screen, including errors related to low transmission, laser alignment, temperature and pressure readings, and power failures. These error messages help to quickly diagnose and solve problems, ensuring uninterrupted operation.
Ethernet connection: AO2040 supports Ethernet connection, making it easy to integrate into modern industrial networks. This feature enables remote monitoring and control, thereby improving operational efficiency.
Error handling and maintenance:
LCD display screen: The basic status information of the instrument is displayed on the LCD installed on the transmitter/host. This includes error messages and maintenance requests, which help to quickly identify and resolve issues.
Troubleshooting: The manual provides detailed information on common faults such as low transmission rate, laser alignment errors, and issues with reading temperature or pressure inputs, and provides measures to be taken. This guide helps to effectively solve problems and minimize downtime to the greatest extent possible.
Maintenance request: The analyzer will also indicate when maintenance is needed to ensure that the equipment remains in optimal condition for accurate and reliable operation. Remote diagnosis and maintenance planning can be achieved through communication with service software via RS232.
The LS25 analyzer provides clear error messages for various issues, such as global errors, maintenance requests, detector errors, and input signal overruns. These messages correspond to LCD error codes and are helpful for troubleshooting and maintenance.
Installation and debugging:
Installation tolerances: Detailed diagrams are provided for the installation of transmitter and receiver units, including tolerances for alignment and flange angles. This ensures correct settings and maximizes measurement accuracy.
Ethernet connection: AO2040 supports Ethernet connection for integration with other systems, facilitating data collection and analysis. This connection option enhances the versatility of the analyzer in various industrial settings.
Application scenarios
Environmental monitoring: used to monitor the concentration of pollutants in the atmosphere, evaluate air quality, and provide data support for environmental protection.
Industrial process control: In the fields of chemical, petrochemical, power and other industries, monitoring the gas composition in the production process to ensure production safety and product quality.
Emission monitoring: Monitor the concentration of pollutants in flue gas emissions, such as sulfur dioxide, nitrogen oxides, etc., to help enterprises achieve environmental emission standards.
Research experiment: Provide precise gas analysis data for researchers to support scientific research and experimental work.
Connection method
The transmitter unit of AO2040 can be connected to the AO2040 central unit (outdoor use, acid and UV resistant) through an Ethernet cable. When using the LS25 service interface, the LS25 Ethernet port will be closed. If AO2040 is integrated into the customer network, the first Ethernet interface X09 must be used to connect to the customer network, and the second Ethernet interface X08 must be used to connect the analyzer to the central unit of AO2040 .
Conclusion:
ABB’s AO2040 laser analyzer is a comprehensive gas analysis tool that provides advanced functionality and safety certification for various industrial applications. A powerful and stable gas analyzer, with its high precision, wide measurement range, multiple gas measurements, and automatic calibration characteristics, its remote operation capability, integration capability, and detailed error handling capability make it a valuable tool for continuous monitoring and analysis of gas composition in potential explosive environments. It has been widely applied in multiple fields. Whether it is environmental monitoring, industrial process control, or scientific research experiments, it can provide accurate and reliable gas analysis data.
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The entire system consists of two main parts:
AO2040 Wall-Mounted Analyzer Cabinet
Advance Optima AO2000 Series Wall-Mounted Unit (Compared to the 19-inch Rack-Mounted AO2020) This unit serves as the system controller, signal processing, human-machine interface, and communication unit. Internally, it houses the LS25 TDLAS laser measurement module, responsible for processing the laser spectral signals transmitted from the transmitting/receiving probes, calculating concentrations, generating alarms, and outputting ERO signals.
LS25 In-Situ Through-Beam Laser Probe (Transmitter + Receiver)
This unit utilizes a tunable diode laser absorption spectroscopy (TDLAS) and is directly installed on both sides of the flue/pipeline. It requires no sample gas extraction and no pretreatment system, making it an in-situ direct-measurement laser analyzer.
II. Measurement Principle (LS25 Core)
Technology: TDLAS tunable diode near-infrared laser (700–2400nm, invisible laser, IEC Class 1 safety laser, no risk of eye damage). Principle: The laser passes through the flue gas; target gas molecules absorb specific wavelengths of light. The main unit calculates the gas concentration using a harmonic detection algorithm, unaffected by cross-interference from dust or water vapor.
Advantages: No sampling pipeline condensation or blockage, extremely fast response, almost zero consumables, minimal long-term drift.
Measurable Gas List (1 component selected per LS25 unit, expandable with multiple modules)
O₂, CO, CO₂, CH₄, NH₃, H₂O, HCl, H₂S, NO
Typical Range (Customizable)
O₂: 0–25% / 0–100%
NH₃: 0–1000ppm (SCR) (Specifically for denitrification and ammonia escape)
CO: 0–5000ppm
H₂O: 0–40%vol
III. Core Performance Parameters
LS25 Laser Probe
Response Time T90 <1s, real-time tracking of dynamic furnace concentration
Optical Path Length: 0.5–10m adjustable (matches flue/pipe width)
Accuracy: ±1% FS; Repeatability <0.5% FS
Laser Safety Class: Class 1 (O₂ version Class 1M)
Probe Protection: IP66, stainless steel housing; ATEX / IECEx Zone 2 explosion-proof certification
Purge Requirements: Clean, dry instrument air 0.3–0.6MPa, continuous purging of optical window to prevent ash accumulation and condensation
Power Supply: DC24V (powered by AO2040 main unit)
Single Probe Weight: Approximately 3.6kg
AO2040 Wall-Mounted Main Unit
Installation Method: Wall-mounted, IP54 protection (purge-type rack optional)
Operating Interface: Color LCD touchscreen + physical buttons, local parameter setting, curve viewing, fault diagnosis
Analog Output: 4–20mA (multi-channel isolation)
Digital Communication: Modbus RTU, Profibus-DP, RS232 (PC debugging), Ethernet
Switch Output: 4DI+4DO, used for alarm, calibration interlock, purge valve control
Operating Environment: -10℃ ~ +45℃; Total power consumption 60–90VA, AC100–240V power supply
Diagnostics: Full-link self-diagnosis (optical path obstruction, abnormal purge pressure, laser attenuation, communication disconnection), dynamic QR code for quick fault log retrieval (ABB Ability maintenance); ABB Group security: Supports SIL2/SIL3 Functional safety certification, applicable to boiler and gas turbine combustion safety interlocks
IV. Complete System Component List
AO2040 Wall-Mounted Main Unit (Built-in LS25 Signal Processing Main Board)
LS25-TX Laser Emitting Probe
LS25-RX Laser Receiver Probe
Fluorite Pairing Flange (with purge gas interface, O-ring seal)
Purge Pressure Regulating Filter Assembly (Instrument Air Purification)
Dual-Core Shielded Dedicated Laser Cable (TX/RX Independent Wiring)
Mounting Bracket, Focusing Fine-tuning Mechanism, Explosion-proof Sealing Joint
Supporting PC Debugging Software (for optical path calibration, range calibration)
V. Standard Installation Procedure Key Points
1. Flue Opening and Flange Installation
Symmetrical openings on both sides of the pipe/flue, coaxiality error ≤ ±2mm, to avoid laser offset and loss of lock-up
Flange M16 1. Tighten bolts evenly, compress the sealing ring to prevent flue gas leakage; flanges must be connected to continuous purge gas.
For pipe temperatures >200℃, extend the heat insulation sleeve to reduce probe body heat.
2. LS25 Probe Calibration (Critical Step)
Purge gas first, power on only after pressure stabilizes.
Coarsely adjust the transmit/receive angle to ensure received light intensity reaches the threshold.
Finely focus using PC software to lock the maximum laser received signal.
Save optical path parameters; the host automatically memorizes the optical path gain.
3. Electrical Wiring Specifications
TX/RX probes should be laid with separate shielded cables, with a distance ≥30cm from power cables.
The shielding layer should only be grounded at a single point on the AO2040 cabinet end to prevent circulating current interference.
Explosion-proof areas should use explosion-proof flexible conduits and sealed glands.
4. AO2040 Host Settings
Configure the measured gas, range, and filtering time.
Set high/low concentration alarms, optical path faults, and purge low-pressure interlocks. Output
Calibration: Zero-point (clean air purging optical path) and range calibration gas two-point calibration; supports remote automatic calibration
VI. Core Advantages Compared to Extractive Analyzers
No Sample Gas Pretreatment: No condenser, filter, or sampling pump, eliminating pipeline blockage and corrosion failures.
Ultra-Fast Response: Millisecond-level capture of combustion fluctuations, suitable for boiler and gas turbine closed-loop optimization.
Extremely Low Maintenance: Only periodic checks and purging of filter elements are required; no filter membranes or reagent consumables.
In-situ Measurement Under Real-World Conditions: No concentration distortion caused by condensation or adsorption; higher accuracy in NH3 escape measurement for denitrification.
Harsh Flue Gas Tolerance: Stable operation in high-dust, high-humidity, and high-temperature flues.
VII. Mainstream Industrial Application Scenarios
Thermal/Gas-fired Power Plants
Boiler and Waste Heat Boiler O₂ and CO Monitoring; Online NH3 Escape Detection at SCR/SNCR Denitrification Inlet and Outlet
Petrochemical/Refining
Heating Furnace and Cracking Furnace Combustion Optimization; Process Piping CH4, H2S Safety Monitoring
Cement and Waste Incineration Kilns
Online Control of O₂ and CO in Kiln Tail Flue Gas, Environmental Emission Monitoring
Iron and Steel Metallurgy
Protective Gas Composition Detection for Blast Furnaces, Converters, and Heat Treatment Furnaces
Chemical Plants
Real-time Monitoring of Trace HCl, CO₂, and Water Vapor in Synthesis Processes
VIII. Common Faults and Maintenance Points
Large Fluctuations in Measurement Values
Troubleshooting: Insufficient Purge Gas Pressure, Ash Accumulation in the Viewfinder; Recalibrate Optical Path Coaxiality
Optical Path Loss (LOS Fault Alarm)
Flue Vibration and Misalignment, Purge Interruption, Flange Seal Ash Leakage Obstructing the Lens
Increased Zero Drift
Purge Gas Source Contains Water and Oil; Upgrade to Precision Filter Dryer Required
AO2040 Communication Interruption
Check Shield Grounding, Bus Termination Resistance, and Communication Address Settings
IX. Differentiation of Series
AO2040: Wall-mounted cabinet, on-site installation, compatible with LS25 All AO2000 modules include laser, Caldos thermal conductivity, and Uras infrared.
AO2020: Standard 19-inch rack mount, installed in a central control cabinet.
LS25: The only in-situ TDLAS laser module; the remaining modules are extractive sample gas analyzers (Caldos25, Magnos206, Uras26).
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