MessKonzept FTC400 Manual de usuario

FTC400

Fast Thermal Conductivity Analyzer

Operating Manual

Messkonzept GmbH

Analytical Technology

About this manual

Thank you for using the FTC400from Messkonzept. It has been designed and manufactured us-

ing highest quality standards to give you trouble free and accurate measurements.

Â© Copyright Messkonzept GmbH 2014. This document is protected by copyright. Neither the

whole nor any part of it or the information contained in may be adapted or reproduced in any form

except with the prior written approval of Messkonzept.

The product described in this manual and products for use with it are subject to continuous de-

velopments and improvement. All information of technical nature and particulars of the product

and its use (including the information in this manual) are given by Messkonzept in good faith.

However, it is acknowledged that there may be errors or omissions in this manual. For the latest

revisions to this manual contact Messkonzept or visit www.Messkonzept.de

Messkonzept welcome comments and suggestions relating to the product and this manual.

The design of this instrument is subject to continuous development and improvement. Conse-

quently, this instrument may incorporate minor changes in detail from information contained in

this manual. In correspondence concerning this instrument, please specify the type number and

serial number as given on the type label on the right side of the instrument.

All correspondence should be addressed to:

Messkonzept GmbH

Niedwiesenstr. 33

60431 Frankfurt

Germany

Tel: +49(0)69 53056444

Fax: +49(0) 69 53056445

email: info@messkonzept.de

http: www.messkonzept.de

This manual applies to: FTC400

Date of Release: January 28, 2019

Software Version: 1.030

File name: Manual_FTC400_1.09KD181129CWI1V01.pdf

Quick Installation Guide

For quick installation of the FTC400we recommend to read the following chapters of this manual:

• Chapter 1 "Operator Safety" with warnings and saftey instuctions and intendes use.

• Chapter 3 "Assembly of instument" describes the mounting, pneumatic and electric con-

nection. Also see Appendix "Dimension Drawing"

• Chapter 6 "Calibration" for recommended calibration intervals and recommended test of

functionallity after bringing into service

File name: Manual_FTC400_1.09KD181129CWI1V01.pdf

Contents

1 Operator safety 4

1.1 Notes on Safety Conventions and Icons . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Warning Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.4 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Principle of Measurement 7

2.1 Determining Concentrations via Thermal Conductivity . . . . . . . . . . . . . . . 7

2.2 Determining Concentrations via Infrared Measurement . . . . . . . . . . . . . . . 8

2.3 Analysis of Complex Gas Mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Assembly of the Instrument 11

3.1 FTC400 Detector Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Installation of the FTC400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.3 Gas Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.4 Electrical Connectors and Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.4.1 Requirements for electrical connectors . . . . . . . . . . . . . . . . . . . . 14

3.4.2 Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.4.3 RS-232 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.5 Particular Features of the FTC400 . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4 The Front Panel 16

4.1 Display......................................... 16

4.1.1 Display Indication Infrared Signals . . . . . . . . . . . . . . . . . . . . . . 16

4.2 LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.3 Keys .......................................... 17

5 Switching on the device 18

5.1 Warm up Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.2 Operation Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.3 Top Level Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6 Calibration 20

6.1 General Information on calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.2 Select Signal to Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.3 Set Offset Gas Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.4 Set Gain Gas Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.5 Offset Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.6 Gain Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.6.1 Use of substitute gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Page 4 of 49

7 Diagnosis 23

7.1 Parameter Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.2 Errors ......................................... 24

8 Setup 25

8.1 The Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

8.1.1 Measuring Gas Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8.1.2 Response Time Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.1.3 Multi Gas Mode List (useful with Option MGM only) . . . . . . . . . . . . . 27

8.2 Relays ......................................... 28

8.2.1 Relay 1 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.2.2 Relay 1 Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8.2.3 Relay 1 Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

8.2.4 Relay 1 Failsafe / Not failsafe . . . . . . . . . . . . . . . . . . . . . . . . . 30

8.2.5 Relay 1 active/frozen during Calibration . . . . . . . . . . . . . . . . . . . 30

8.2.6 Relay 2 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8.2.7 Common Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

8.3 Analog Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

8.3.1 Current Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8.3.2 Analog Output 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8.3.3 Analog Output 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8.3.4 Adjust Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

8.4 Expert Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

8.4.1 Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

8.4.2 Access Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

8.4.3 Reset Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

8.4.4 Test of Relays, Analog Outputs and Connections . . . . . . . . . . . . . . 40

9 Appendix: System Errors 42

10 Appendix: Speciﬁcations 45

10.1 Speciﬁcation of Thermal Conductivitly Measurement . . . . . . . . . . . . . . . . 45

10.2 Speciﬁcation IR Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

10.3 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

10.4 Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

10.5 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

11 Appendix: Dimension Drawing 49

File name: Manual_FTC400_1.09KD181129CWI1V01.pdf

Chapter 1

Operator safety

This section provides information and warnings which must be followed to ensure safe operation

and retain the instrument in safe condition. Read this section carefully before beginning to install

and use the instrument.

1.1 Notes on Safety Conventions and Icons

This icon draws attention to application errors or actions that can lead to safety risks including

the injury to persons or malfunctions, possibly even destruction of the device.

This icon indicates an additional function or hint.

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Page 6 of 49

1.2 Warning Notices

• The manufacturer does not assume liability for inappropriate handling of the device. Mal-

functions caused by inappropriate handling may lead to hazards.

• This device is not suited for the operation in areas exposed to explosion hazards!

• Never lead explosive gases or gas mixtures into the device! Dependent on the model the

device ﬂammable gases may be led in the device. Check item „Glass ball ﬁlling“ in the

device protocol. Flammable gases may be led in devices ﬁlled with glass balls. Here, the

inside space of the housing is densely ﬁlled with glass balls (∼0.6mm). In the unlikely

case that a leakage caused an explosive atmosphere, the small spaces between the glass

balls prevent a coincidental ignition caused by a further malfunction of the device from

propagating.

• Never open the housing of the FTC400, especially because of the loose glass balls. When

the device had been opened it may not work safely with ﬂammable gases.

• Garanty expires if the housing is opend

• Disconnect the device from the power supply to prevent an unintended start of the device,

if a safe operation of the device is not guaranteed.

• For operation of the device in the ﬁeld a rain protection is recommended.

File name: Manual_FTC400_1.09KD181129CWI1V01.pdf

Page 7 of 49

1.3 Safety Instructions

• For safe operation of the device please pay regard to all instructions and warnings in this

manual

• Only put the device into operation after it has been installed properly. A competent and

authorised person is required for installation, connection and operation of the device. This

person has to read the manual and follow all instructions

• Keep the manual to look up questions that can occur later on

• Make sure that the electric installation protection against accidental contact agree to the

applicable safety regulations. The protective earth connection must be made before all

other connections. Any interruption in the protective earth can cause danger

• Pay regard to the local regulations and circumstances regarding electric installations

• Repairs may only be done by Messkonzept.

1.4 Intended Use

Only non-corrosive and condensate-,dust-, aerosol-, oil dust-free gases may be lead in the FTC-

series gas analyser. Flammable gases require appropriate protective measures. Explosive gases

may not be lead in the FTC. Upon installation the protection class has to be considered. The

ambient atmosphere may not be corrosive. OEM-device with protection class IP00 demand

thermal and electric insulation, as well as mechanical protection for operation.The speciﬁca-

tions of the device and its manual have to be observed strictly. Please ﬁll out questionnaire

(2.01.1FB180619MPL1) for registration of your measuring task, if your intended use does not

comply with intended use described above. Based on the information given in the questionnaire

we will examine the measuring task and possibly authorise it. Note: Please keep this manual for

future use.

File name: Manual_FTC400_1.09KD181129CWI1V01.pdf

Chapter 2

Principle of Measurement

2.1 Determining Concentrations via Thermal Conductivity

Thermal Conductivity Detectors (TCD) were used in the chemical industry since the 1920s as

the ﬁrst process gas analyzer for the quantitative composition of gas mixtures. Each gas has a

typical heat conductivity governed by its molar mass and viscosity. The measurement is based

on the principle that the thermal conductivity of a mixture of gases is dependent on the thermal

conductivity of the gas components and their fractional amount in the gas mixture. Thus, the

fraction of the different components can be determined. It is one of the main advantages of the

TCD principle that, unlike the wide spread infrared technique, it is not limited to gases with a

permanent dipole moment. It can identify noble gases (He, Ar, Ne, etc.) as well as homonuclear

gases like H2and N2. Furthermore, it is robust and cost effective. The principle of thermal con-

ductivity measurement works best, if the different gas components have clearly different thermal

conductivity and in addition one of the following conditions is met:

• The mixture contains only two components (binary mixture), e.g. CO2in N2or H2in N2

• The mixture contains more than two components, but only the concentration of two com-

ponents vary

• The thermal conductivity of two or more components is similar, e.g. when measuring H2or

He in a mixture of H2and N2(quasi binary mixture)

The thermal conductivity of gases is rising with temperature and the slope of the increase with

temperature is different for different gases. On customer request it can be checked whether the

temperature of heat sink and/or source can be changed in order to improve the sensitivity of

the measurement or to avoid cross-sensitivity effects. Cross-sensitivity means the sensitivity of

the measurement on other gases than the measured component. Perturbation-sensitivity means

the sensitivity of the measurement on other inﬂuences than the gas-composition, e.g. the gas

pressure.

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Page 9 of 49

Figure 2.1: Scematic drawing of thermal conductivity measurement. The sensor is comprised in

the thermally stabilized stainless steel block.

The FTC400 sensor determines the quantitative composition of gas mixtures by measuring

the thermal conductivity between a heat source and a heat sink through the gas mixture. The

measuring gas is conducted to the sensor through a stainless steel block that is kept at a constant

temperature of 63◦C. This temperature a stabilized using a control loop such that the block can be

used as heat sink. A thin membrane of micro-mechanical silicon chip serves as heat source. Two

thin ﬁlm resistors are integrated into the membrane, one is used for both the membrane the other

for measuring its temperature. A second control loop stabilizes the membrane temperature at

135◦C. Above and below the membrane two small cavities are etched into the silicon, which are

ﬁlled by diffusion with the measuring gas. The surfaces opposite to the membrane are thermally

connected with the heat sink. Dependent on the thermal conductivity of the gas more or less

energy is led off the membrane. The voltage needed to keep the temperature of the membrane

constant is a measure for the thermal conductivity of the gas. Both resistors on the membrane

are protected by an inert coating in order to prevent chemical reactions with the measuring gas.

“Basic range“ is the largest possible measuring range and is set by default. The linearization

is performed over the basic range. The smallest measuring ranges at the beginning and the

end of the basic range can be deduced from calibration. The smallest possible range between

the basic range and the smallest ranges at the end beginning and the end of the range can be

estimated by linear Interpolation. The Multi Gas Mode (MGM) is a conﬁguration that allows for the

consecutive measurement of different gas pairs. The gas pair can be switched at via the control

panel or via the RS232-interface. Gas pairs labeled “Yes“ in the table above are commonly used.

Gas mixtures labelled “On request“ can also be implemented with little effort.

2.2 Determining Concentrations via Infrared Measurement

Selective measurement of infrared-active gases Molecules like CO2, CH4, C2H6, CO, NO, SO2

and H2O absorb infrared radiation. The range of absorption in the wavelength spectrum is a

ﬁngerprint for the identiﬁcation of the sort of molecules. The level of absorption is a measure of

File name: Manual_FTC400_1.09KD181129CWI1V01.pdf

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