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MessKonzept FTC320 Operating Manual

Gas analysis using thermal conductivity measurement
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Operating Manual
FTC320
Gas analysis using thermal
conductivity measurement

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  • Page 1 Operating Manual FTC320 Gas analysis using thermal conductivity measurement...

  • Page 2: About This Manual

    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. Images and drawings may not be in scale. For the latest revisions to this manual contact Messkonzept or visit www.messkonzept.de.
  • Page 3 Page 2 of 61 Quick Installation Guide For quick installation of the FTC320 we recommend reading the following chapters of this manual: • Chapter 1 "Operator Safety": Important warnings, safety instructions and intended use. • Chapter 3 "Installation of the Instrument": Mounting, pneumatic and electric connection. Also see Chapter 10 "Appendix: Dimensional Drawing"...

  • Page 4: Table Of Contents

    3.1 Mounting of the FTC320 ........
  • Page 5 9.5 Dimensions ......... . 59 10 Appendix: Dimensional Drawing File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 6: Operator Safety

    The exclamation mark symbol draws attention to application errors or actions that can lead to safety risks, including injury to persons or malfunctions - possibly destruction of the device. This icon indicates an additional function or hint. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 7: Intended Use

    • Repairs should only be carried out by Messkonzept. 1.2 Intended Use • Messkonzept GmbH does not assume any liability in case of improper handling of the measuring device. Improper handling can cause hazards due to malfunction of the measuring device.

  • Page 8: Disposal Instructions

    • The housing of the FTC320 must never be opened, in particular in case of devices filled with glass beads. After opening, the necessary filling density is no longer given.

  • Page 9: Principle Of Measurement

    Cross-sensitivity is the sensitivity of the measurement on other gases than the measured component. Perturbation-sensitivity means the sensitivity of the measurement to other influences than the gas-composition, e.g., the gas pressure. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...
  • Page 10 The FTC320 contains a thermal conductivity sensor that analyzes the quantitative composition of gas mixtures. The measurement is based on the heat transfer between a heat source and a heat sink.
  • Page 11 0% - 2% 96% - 100% request Table 2.1: Measuring ranges of typical gas compositions for analysis with the FTC320, concentrations are given in Vol.%. As mentioned in section 1.2, explosive gases should not be led into the device without suitable protective measures.

  • Page 12: Ftc320 Detector Unit

    2.1.1 FTC320 Detector Unit Figure 2.2: FTC320 Detector Unit The FTC320 is a highly precise and stable Thermal Conductivity Detector (TCD) that is designed for use as a gas detector. The unit consists of a hermetically sealed pressure proof stainless-steel block with a gas duct.

  • Page 13: Calibration

    Gain, which correspond to the ordinate intercept and the slope of a linear equation calculated in the device. Figures 2.3 and 2.4 explain how offset and gain correction works. before a�er offset calibra�on Real concentra�on [Vol.%] reference concentra�on (offset gas) Figure 2.3: Offset calibration File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...
  • Page 14 0 Vol.% – 100 Vol.%, use pure O2 as offset test gas (Offset Gas = 0 Vol.% H2 in O2) and pure H2 as the gain test gas (Gain Gas = 100 Vol.% H2 in O2). Figure 2.5: Setting the actual gas concentration of a test gas bottle as reference concentration for gain calibration File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...
  • Page 15 The gas purities are selected such that the devices comply with the specifications for the smallest measuring range. Messkonzept recommends gases of the same purity for on-site calibration. If your own requirements differ, please choose the appropriate gas purity. Please contact Messkonzept if you would like advice.
  • Page 16 flow, will cause a certain disturbance to the thermostated measurement in the FTC320. This is particularly the case if you accidentally had a very high gas flow, even for a very short time. It may a while for the temperatures in the FTC320 to reach equilibrium again and for the measurement indication to provide a stable and reproducible value in the ppm range.

  • Page 17: Performing Calibration

    Instead of using toxic or explosive gases for calibration, substitute gases may be used. A substitute gas has (at a certain concentration) the same thermal conductivity as the test gas it is substituting, such it can also be used for the calibration instead. Please contact Messkonzept for details on possible substitute gases for your application.

  • Page 18: Installation Of The Instrument

    Installation of the Instrument 3.1 Mounting of the FTC320 The FTC320 is designed for wall fastening. The four mounting holes are shown in Figure 3.1. M4 cylinder head bolts are suitable. Please remember to keep additional space for adequate assembly of gas hoses and cables (see Chapter 10 "Appendix: Dimensional Drawing"...

  • Page 19: Gas Ports

    Page 18 of 61 3.2 Gas Ports On the bottom of the FTC320 housing two tubes with 6mm outer diameter for gas connection are lo- cated. They are labeled with “GAS IN “ and “GAS OUT“. For low requirements regarding gas tightness and resistance to pressure, the tubes can be used as hose connectors.

  • Page 20: Ground

    GND on the low-voltage side of your 24V power supply is connected to protective earth (PE), see Figure 3.3. Some power supplies are internally wired like this already. Inside the FTC320 there is a connection between GND and the device casing, also the gas duct is connected to GND.

  • Page 21: Data Exchange Via Serial Interface (Rs-232)

    The serial interface allows operation of the instrument and the display and storage of measurement data with the program SetApp 3.0. More information and a link to download the software can be found at www.messkonzept.de. If you plan to develop or use your own software solutions for communication via the RS-232 interface, you may need more detailed information on the available parameters.

  • Page 22: The Front Panel

    ENTER (measurand selection) (device configuration) acknowledgement key Figure 4.1: Front view schematic of the FTC320 front panel during operation 4.1 Display 4.2 Keys RIGHT / Selection Key On the operation screen, the <RIGHT> key can be used to select one of the measured variables displayed on the work screen.
  • Page 23 The <ENTER> key calls the item that is marked as selected. Menu items are selected by the <RIGHT> key. In submenus with an “ESC/OK“ option the <ENTER> key confirms the selection of “ESC“ or “OK“. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 24: Instrument Display

    Act: 58.30 °C Figure 5.1: Warmup screen of the FTC320 The warm-up screen shows the current block temperature during warm-up (see „Act:“ in the figure above). The target value of the block temperature, 63 C for the standard version or 70 C for the high temperature version, is shown as the Set-value.

  • Page 25: Display Of One Measured Value

    0.30 2/N2 Figure 5.2: FTC320 operation screen (one measured parameter) In the center of the display the currently measured gas concentration is shown, the associated unit of the measurement (ppm or Vol.%) is indicated in the bottom left corner of the operation screen. The currently measured gas pair, e.g.

  • Page 26: General Instrument Settings

    The menu paths shown in the following chapters all start from the main menu. 6.2 Diagnosis The FTC320 has several integrated diagnosis and test functions that can be accessed through the diagnosis menu. The menu provides the following functions: • A parameter menu in which device-internal parameters/variables can be read out •...

  • Page 27: Parameter Menu

    P000 Figure 6.2: parameter menu for advanced diagnosis The configuration of the FTC320 is defined by a list of internal parameters. The “Parameter“ menu gives read-only access to these parameters. This may help an experienced user to diagnose malfunctions caused by wrong settings. The parameter menu allows you to scroll through the entire parameter list.
  • Page 28 Separate the device from the process pneumatically (both gas inlet and gas outlet) and remove the power supply from the device. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 29: Test Of Relays, Analog Outputs And Connections

    Note! All test signals are permanently on until leaving the “I/O Test“ menu. It is the responsibility of the expert to assure that I/O tests do not interfere with connected systems and processes in an unintended way. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 30: Instrument Setup

    P56 (see Section 6.5.1) sets the number of digits after the decimals point between 1 and 4 when the display unit is set to Vol.%. The resolution in ppm is always 1 ppm. All internal calculations of the FTC320 are in ppm. Values retrieved through the RS-232 interface will always be in ppm with 1ppm resolution.

  • Page 31: Access Modes

    Warning: Careless operation in this access mode can configure parameters in the FTC320 in such a way that it is impossible for the customer to restore the device to its original state or the device may be permanently damaged. The default password is: 222.000.

  • Page 32: Output Setup

    The measuring range is typically mapped to a current output of 4mA to 20mA, where a signal of 4mA corresponds to the beginning of the measuring range and 20mA correspond to the end of the measur- ing range. The current output of the FTC320 can be configured to one of four available current output modes.
  • Page 33 Const. I-Out, clicking <ENTER>, and entering the desired value followed by clicking OK (see Figure 6.8). If you are not using the current output, it can be set to a constant value of File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...
  • Page 34 I/O Mode Ch.5: H2 > Cal. active > Error I-Out ESC/OK ESC/OK 0-20mA (Err) > Ch.5: H2 > ESC/OK 0-20mA > Ch.5: H2 > ESC/OK Const. Outp. > Const. I-Out ESC/OK Figure 6.9: Current output setup File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...
  • Page 35 Figure 6.10: The mode 4-20mA (Err) corresponds to the NAMUR recommendation NE43. Example: FTC320 with range: 0-5 Vol.% H2 in N2 Current output mode: 4-20 mA (Err) (default) As long as the measurement value is in the range 0-5 Vol.% the H2-concentration can be...

  • Page 36: Voltage Output Setup

    The FTC320 has 2 voltage outputs that can be mapped to two different gas concentrations. Either or each of them can be mapped to a measuring channel. The typical assignments of the channels, which are the voltage signal’s possible sources, are listed in Table 6.1 above.
  • Page 37 > I/O Mode Ch.5: H2 > Cal. active > ESC/OK ESC/OK 2-10V (Err) > Ch.5: H2 > ESC/OK 0-5V > Ch.5: H2 > ESC/OK Const. Outp. > Const. U-Out ESC/OK Figure 6.12: Voltage output setup File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 38: Relay Setup

    The Multi Gas Mode allows to measure changing gas pairs by thermal conductivity with a single FTC320 (see Section 7.1). When the active gas pair is changed (for example, from H2 in N2 to He in CO2), a gas pair-specific linearization, calibration, and range setting is loaded into measurement channel 5 (thermal conductivity measurement) of the instrument.
  • Page 39 Select the line with the <RIGHT> key and press <ENTER> to toggle the state between ”ON” and ”OFF”. Multiple triggers can be selected for one relay. 4. Confirm the selection with ”OK” or discard the made changes with ”ESC”. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...
  • Page 40 A switching condition (depending on the setting: limit value, device error, maintenance request) is signaled by opening the working contacts. This has the advantage that both an interruption of the supply voltage of the FTC320, as well as line interruption at the working contacts can be perceived as error cases.

  • Page 41: Expert Setup

    The setting ”Cal. frozen” only has an effect if calibration is triggered via the display interface of the FTC320. When calibrating via the service tool (SetApp) or otherwise via the digital interface (RS232/RS485), the setting has no effect. In this case, the inlet of the calibration gas does not represent an operating state that is separated from the regular operation - the relays and analog outputs therefore react to the incoming gas.

  • Page 42: Parameter

    P009 Figure 6.17: Parameter change in expert mode The configuration of the FTC320 is represented by an internal list of parameters. These parameters govern all settings and functions of the device. In the expert-menu’s parameter list press <ENTER> to scroll forward through the list and backwards by pressing <UP>. Some parameters cannot be changed (e.g.

  • Page 43: Reset Functions

    The ”Save Setup” function overwrites the factory settings and cannot be reversed. This function should only be used in special cases and in consultation with Messkonzept service. File name:...

  • Page 44: Measurand Related Settings

    In a device with multi-gas mode, the gas pair measured using thermal conductivity can be changed. This allows the use of a FTC320 in changing applications - for example to monitor the purity of different gases one after the other. The desired gas pairs, which are available in multi-gas mode, must be spec- ified when ordering the device;...
  • Page 45 If it is not possible to select the first screen line, Multi Gas Mode is not available for your device or you may have selected an external measured variable for which Multi Gas Mode is not available on a device with several measured variables (e.g. with an external oxygen sensor). File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 46: Calibration

    Figure 7.3: The calibration functions can be found amongst the measurement related settings In this section the calibration via the display interface of the FTC320 is explained. Before beginning with the actual calibration procedure, please review section 2.2, which explains how calibration affects the measurement value and how the calibration should be planned.

  • Page 47: Offset Calibration

    Here it is important to calibrate in the operating point, where the compensation is not active - typically this is in the complete absence of the disturbance, for example in dry gas. Please contact Messkonzept regarding the best practices for your device-specific compensation routine.

  • Page 48: Gain Calibration

    Vol% H2/N2 Figure 7.8: Indication of an exceeded limit / process alarm on the FTC320. Up to two limit values (limits) can be set for each measuring channel. If the monitored measured variable exceeds the limit value, this is indicated by the measured variable flashing on the display, see Figure 7.8.

  • Page 49: Configuration Of A Limit

    <RIGHT> button and press <ENTER>. The value after "set:" indicates the current setting, the <RIGHT> button can be used to select the digits of the new value to be set "new:" and manipulated with the <UP> button. The setting can be confirmed with "OK" and discarded with "ESC". File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...
  • Page 50 The setting is made in the measuring unit used (e.g. Vol % or ppm). The hysteresis is implemented as follows in FTC320: • L/H: Limit value switches on when the threshold is exceeded, it is switched off when the threshold - hysteresis is undershot, see Figure 7.10.

  • Page 51: Examples

    [Vol. %] set: 19.0000 set: 0.30000 Threshold new: 19.0000 new: 0.30000 Hysteresis [Vol%] ESC/OK [Vol%] ESC/OK ESC/OK CO2 in Ar Figure 7.14: Monitoring of a process window: Gas mixer control for shielding gases for welding. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 52: Mapping Of Analog Output

    C->Min. Outp. Calibration C->Max. Outp. set: 0.00000 0.30 Limit Setup new: 0.00000 Output Conc. H2/N2 [Vol%] ESC/OK C->Max. Outp. C->Min. Outp. C->Max. Outp. set: 0.00000 new: 0.00000 [Vol%] ESC/OK Figure 7.15: Adjusting the output concentration. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 53: Appendix: System Errors

    Some issues can be resolved through remote maintenance. If the error persists you might be requested to send the FTC320 back to Messkonzept. Please pay attention to these points when sending the device: •...
  • Page 54 The device is still BT MIN(WARMUP) not yet reached SetTemp-2K warming up, will therefore not (warm-up) measure according to specification. Please wait for a couple of minutes and see if the temperature is reached. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...
  • Page 55 No connection to differential Send the device to FLOW SENS ERR pressure sensor Messkonzept with description needed for flow of error. measurement Table 8.1: Description of System Errors File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 56: Appendix: Specifications

    Error due to change of flow at 80 l/h 10 l/h Error due to change of pressure < 1 % of smallest range per (800 hPa < p < 1200 hPa) 10 hPa Table 9.1: Specification of TC measurement File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 57: Gas Flow

    Permissible range: 1 - 60 l/h Table 9.2: Recommended and permissible gas flow of the different device variants. * Example of a custom calibration. Ideally calibration is performed at the same or similar flow rate as during measurement. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 58: Electrical Specifications

    Typical current draw: 500 mA Safeguard: PELV (Protective Extra Low Voltage) Digital Interface Type: RS-232 Baud rate: 19.2 kbaud Data: 8 bit Parity: None Stop: Flow control None Reference potential: ground Table 9.3: Electrical Specifications File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 59: Permissible Conditions Of The Sample To Be Measured

    -5 C to 50 C (23 F to 122 F) Storage temperature: -25 C to 70 C (-15 F to 160 F) (not-condensing) Protection class IP 65 (if cables are plugged and/or all unused jacks are sealed using protective caps) Table 9.5: Environmental conditions. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 60: Dimensions

    Page 59 of 61 9.5 Dimensions Dimensions: Depth: 85 mm Width: 144 mm Height: 80 mm without connectors Weight: max. 1800 g Mounting: Wall mounting Table 9.6: Dimensions. File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...

  • Page 61: Appendix: Dimensional Drawing

    Page 60 of 61 Chapter 10 Appendix: Dimensional Drawing File name: FTC320 Operating Manual_1.09KD201009MPO5V05.pdf...
  • Page 64 Messkonzept GmbH Analytical Technology Niedwiesenstr. 33 60431 Frankfurt Germany Telefon +49 69 53056444 +49 69 53056445 info@messkonzept.de www.messkonzept.de Managing Director Dr. Axel-Ulrich Grunewald Place of jurisdiction Frankfurt HRB 49940 VAT ID: DE211207233...

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