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Summary of Contents for MessKonzept FTC320 Ex
- Page 1 Operating Manual FTC320 Ex Gas analysis using thermal conductivity measurement for zone 2 ATEX II 3G Ex nR IIC T4 Gc...
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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 63 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"...
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Page 4: Table Of Contents
Page 3 of 63 Contents 1 Operator Safety 1.1 Notes on Safety Conventions and Icons ......1.2 Safety instructions for use in explosion hazard areas Zone 2 . - Page 5 Page 4 of 63 6.2.2 Errors and Maintenance Requests ......28 6.2.3 Test of Relays, Analog Outputs and Connections ....30 6.3 Instrument Setup .
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Page 6: Operator Safety
Page 5 of 63 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 installing the device and using the software. 1.1 Notes on Safety Conventions and Icons 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... -
Page 7: Safety Instructions For Use In Explosion Hazard Areas Zone 2
1.3 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. • The FTC-series of gas analyzers offer high-precision measurement and detection of non-corrosive, dust-, condensate-, aerosol and oil mist-free gases unless the design of the equipment is explic- itly declared to be suitable for this purpose. - Page 8 Mess- konzept GmbH. In the evaluation of the measurement task by Messkonzept GmbH, it is also recorded whether the measurement task can be carried out with the proposed devices. In addi- tion, restrictions can be demanded by Messkonzept GmbH, which must then be implemented by the customer.
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Page 9: Disposal Instructions
Page 8 of 63 • The gas path inside the device is free of oil and grease and suitable for applications with pure oxygen ("Cleaned for Oxygen"). For such applications, contamination, such as that caused by the introduction of not oil-free compressed air, must be avoided. •... -
Page 10: Principle Of Measurement
Page 9 of 63 Chapter 2 Principle of Measurement 2.1 Determining Concentrations via Thermal Conductivity Thermal Conductivity Detectors (TCD) have been used in the chemical industry since the 1920s as the first process gas analyzers for the quantitative composition of gas mixtures. Every gas has a unique heat conductivity that is governed by its molar mass and viscosity. - Page 11 Page 10 of 63 ˚ ˚ Gas Out Gas In Figure 2.1: Schematic drawing of thermal conductivity measurement. The sensor is comprised in the stainless-steel block which is kept at a constant temperature. The FTC320 contains a thermal conductivity sensor that analyzes the quantitative composition of gas mixtures.
- Page 12 Page 11 of 63 Mea- Smallest Carrier Basic Multi Gas suring Smallest range suppressed range Mode zero range 0% - 100% 0% - 0.5% 98% - 100% / air 0% - 100% 0% - 0.5% 98% - 100% 0% - 100% 0% - 0.4% 99% - 100% 20% - 100%...
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Page 13: Ftc320 Detector Unit
Page 12 of 63 For flammable gases, such as H , CH , etc., the use of a FTC320 with the option “glass-beads filling“ is strongly recommended. If a mixture of a combustible gas with an inert gas is present in a mixing ratio such that even adding any amount of air will not make the mixture explosive, it is called totally inert. -
Page 14: Calibration
Page 13 of 63 2.2 Calibration This section explains how the readjustment of the device should be planned and carried out on site. Different installation, dew point, pressure, flow rate and test gas quality can lead to a shift in the indica- tion right from the start. - Page 15 Page 14 of 63 a�er offset calibra�on a�er gain calibra�on Real concentra�on [Vol.%] reference concentra�on note: rota�on around (gain gas) offset reference point (offset gas) Figure 2.4: Gain calibration after offset calibration For a determination of offset and gain a two-point calibration must be performed. The concentration of the offset test gases should be close to the start-point and the concentration of the span (Gain) test gas should be close to end-point of the measuring range - a difference of ±10% of the measuring range from the start- or end-point is permissible.
- Page 16 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 17 Page 16 of 63 – months for a measurement task in the basic or medium measuring ranges. – days to weeks for small measurement (low- or sub-vol%) ranges. – directly before each measurement if maximum accuracy is required. 2.2.1.d Gas supply during calibration Ensure that the appropriate test gas has fully entered the device before performing an offset or gain calibration.
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Page 18: 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 19: Installation Of The Instrument
Page 18 of 63 Chapter 3 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 20: Gas Ports
Page 19 of 63 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 21: Requirements For Electrical Connections
Page 20 of 63 parts package. The cables have open ends. The cross-section of the conductors in cable A and C is 0,14mm , for cable B 0,25mm . Cable A for connection of the analog voltage signals is shipped upon request. -
Page 22: Ground
Page 21 of 63 3.4.2 Ground power supply PELV 24V DC ERROR MAINT REQ POWER GAS IN GAS OUT Figure 3.3: Grounding the FTC320 To comply with EN 60204-1 and to ensure your device’s function, the device has to be installed such that GND on the low-voltage side of your 24V power supply is connected to protective earth (PE), see Figure 3.3. -
Page 23: 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 24: The Front Panel
Page 23 of 63 Chapter 4 The Front Panel measured gas concentration device error blinking: ERROR limit exceeded 0.30 maintenance request MAINT REQ (abnormality during Vol% H2/N2 POWER calibration) display unit: Vol% or ppm power supply (blinks at measuring frequency) RIGHT selection key UP selection key ENTER... - Page 25 Page 24 of 63 UP / Selection Key In menus or submenus, the <UP> key quits the recent menu and brings you back to the menu above and ultimately to the main menu. To quit menus with an “ESC/OK“ option, select one of these fields with the <RIGHT> key and confirm with <ENTER>.
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Page 26: Instrument Display
Page 25 of 63 Chapter 5 Instrument display This chapter describes the device start-up routine. The warm-up screen, see Figure 5.1, shows the set temperature and actual temperature of the instrument during warm-up. After the warm-up, the device switches to the operation screen, see Figure 5.2. From the operation screen the main menu can be opened. -
Page 27: Display Of One Measured Value
Page 26 of 63 5.2.1 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 28: General Instrument Settings
Page 27 of 63 Chapter 6 General instrument settings 6.1 Top Level Main Menu Diagnosis Instr. Setup Output Setup Expert Setup Figure 6.1: main menu of the FTC320 The main menu of the general instrument settings can be accessed from the operation screen (display of measured values) by pressing the <UP>... -
Page 29: Parameter Menu
The parameter menu allows you to scroll through the entire parameter list. Contact Messkonzept for detailed information on the listed parameters. The first display line contains the name of the parameter, in the second line the parameter value is shown. The last line shows the parameter index. - Page 30 Page 29 of 63 through the list of current errors, press <UP>. If you want to exit the error menu, select either NO or YES (selection via the <RIGHT> button) and confirm with the <ENTER> button. If you select YES, the errors or maintenance requests are reset.
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Page 31: Test Of Relays, Analog Outputs And Connections
Page 30 of 63 6.2.3 Test of Relays, Analog Outputs and Connections Parameters Current Out Test Curr. Diagnosis Errors/Maint R Voltage Out 1 set: 10.0000 Instr.Setup I/O Test Voltage Out 2 new: 10.0000 Output Setup Device Info Relays [mAmp] ESC/OK Expert Setup Test AOut1 Current Out... -
Page 32: Instrument Setup
Page 31 of 63 6.3 Instrument Setup 6.3.1 Display Unit Diagnosis Unit: Vol% Instr. Setup 0.30 T90 Response Output Setup Access Modes Expert Setup Vol% H2/N2 Unit: ppm T90 Response Access Modes Figure 6.5: changing the displayed unit for gas concentrations. The first item of the instrument setup menu allows selection of the display unit. -
Page 33: Access Modes
Page 32 of 63 The T90-time is the time in which a sudden change of the measurand (e.g. the gas concentration) reaches 90% of its final value. 6.3.3 Access Modes To protect the FTC320 from unintentional misuse, there are various access levels protected by pass- words: •... -
Page 34: Output Setup
Page 33 of 63 6.4 Output Setup The FTC320 is equipped with three analog outputs: • One isolated current output with an output range of 0 to 20 mA called Current Out. • Two non-isolated voltage outputs with an output range from 0 to 10 V: –... - Page 35 Page 34 of 63 output mode current range error indication output current range: 4-20 mA, 4-20mA (Err) minimum: 3.8 mA, maximum: freely configurable 20.5 mA output current range: 0-20 mA, 0-20mA (Err) error value: 21 mA minimum: 0 mA, maximum: 20.5 mA output current range: 0-20 mA, 0-20mA no error indication...
- Page 36 Page 35 of 63 Const. Outp. > Iout1 Const mA set: 20.0000 Const. I-Out new: 20.0000 ESC/OK [mAmp] ESC/OK Figure 6.8: Setting a constant current output. Diagnosis Current Out Instr. Setup Voltage Out 1 0.30 Output Setup Voltage Out 2 Expert Setup Relay Setup Vol%...
- Page 37 Page 36 of 63 e.g. 0-5 Vol.% H2 in N2 Measurement information Transition region Error/ Outage 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 calculated from the current signal 5Vol %...
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Page 38: Voltage Output Setup
Page 37 of 63 6.4.2 Voltage Output Setup The voltage outputs setting is analogous to the current output’s in structure and operation. This section will describe in detail how the voltage output settings can be adjusted as desired. 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. - Page 39 Page 38 of 63 Output Mode Voltage Range Error Indication output voltage range: 0-10 V, minimum: 0 V, 0-10V no error indication maximum: 10.5 V output voltage range: 0-5 V, Minimum: 0 V, 0-5V no error indication maximum: 5 V output voltage range: 2-10 V, minimum: 2-10 (Err) error value: 1.5 V...
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Page 40: Relay Setup
By clever setting of the limits and relays, many conceivable circuit concepts can still be realized despite this limitation. Feel free to contact Messkonzept if you need further information or support with the setup. File name:... - Page 41 Page 40 of 63 6.4.3.a Relay Trigger Diagnosis Relay 1 Current Out Instr. Setup Relay 2 Voltage Out 1 0.30 Output Setup Relay 3 Voltage Out 2 Expert Setup Relay Setup Vol% 2/N2 Relay1 Trigger Limit 1 (Ch.5) Limit 1 (Ch.5) Limit 1 (Ch.5) Not failsafe Trigger: OFF...
- Page 42 Page 41 of 63 6.4.3.b Relay failsafe / not failsafe Relay1 Trigger Relay1 Trigger Not failsafe Failsafe Cal. active Cal. active ESC/OK ESC/OK Figure 6.14: Failsafe: Switching contact of the relay is normally closed, it opens when the switching criterion occurs. Each relay can be configured as failsafe or not failsafe.
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Page 43: Expert Setup
Page 42 of 63 and press <ENTER>. To make a changed setting effective, the relay settings must be confirmed with "OK". 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. -
Page 44: Parameter
Page 43 of 63 6.5.1 Parameter Parameters Compound ppm Passwords set: 2105.13 Reset Functs. ------------ Ignored Errors P009 LCD Contrast LCD Contrast LCD Contrast set: 25.0000 set: 25.0000 set: 25.0000 new: 25.0000 Change ? Change ? ESC/OK P009 P009 Figure 6.17: Parameter change in expert mode The configuration of the FTC320 is represented by an internal list of parameters. -
Page 45: 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 46: Measurand Related Settings
Page 45 of 63 Chapter 7 Measurand related settings For each measured variable, usually given by a gas concentration, measurand-related settings can be changed. The settings related to the measured parameter can be accessed from the working screen by selecting the measured parameter with the <RIGHT> key and confirming with the <ENTER> key (see Figure 7.1). - Page 47 Page 46 of 63 H2/N2 0.30 0.30 Calibration Limit Setup H2/N2 Vol% H2/N2 Vol% Output Conc. O2/N2 Calibration Limit Setup Output Conc. O2/CO2 Calibration Limit Setup Output Conc. H2/O2 Calibration Limit Setup Output Conc. Figure 7.2: Multi Gas Mode: Changing the active gas pair The currently active gas pair is displayed in the first line of the measurement-related settings.
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Page 48: Calibration
Page 47 of 63 7.2 Calibration H2/N2 0.30 0.30 Calibration Limit Setup H2/N2 Vol% H2/N2 Vol% Output Conc. 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 49: 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 50: Gain Calibration
Page 49 of 63 The following menu offers the option to proceed with the gain calibration. Choosing “YES“ leads to the gain calibration menu described below. If only a single-point calibration is desired, NO is selected, whereupon the Apply Process Gas menu opens. -
Page 51: Configuration Of A Limit
Page 50 of 63 7.3.1 Configuration of a Limit The process limits are configured via the measurement related settings: Starting from the main view, the measured variable can be selected with the <RIGHT> button (see marking of "H2/N2" at the top left in Figure 7.9). - Page 52 Page 51 of 63 7.3.1.a Hysteresis In order to avoid frequently changing switch-on and switch-off processes of relays at an alarm limit value, a hysteresis value can be set. The setting is made in the measuring unit used (e.g. Vol % or ppm).
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Page 53: Examples
Page 52 of 63 7.3.2 Examples Example 1 - Monitoring a lower explosion limit Limit values can be used, for example, to monitor an explosion limit. For hydrogen in oxygen under atmospheric pressure, the lower explosion limit (LEL for short) is approx. 4 Vol.% - a reasonable alarm threshold may be at 50 % LEL, i.e. -
Page 54: Mapping Of Analog Output
Page 53 of 63 7.4 Mapping of Analog Output By default, the (analog) output range of a measured variable is preset to the measuring range (see nameplate). If required, this output range can also be configured to other start and end values. Under Output Conc., the minimum and maximum output concentrations can be set as follows: (see Figure 7.15) •... -
Page 55: 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 56 Error reading or Repeat procedure. If the error writing data to or persists, send the device to EEPROM ERROR from internal Messkonzept with description FLASH-EEPROM of error. Check if the used test gas concentration gives the set Calibration gain concentration. Repeat CAL GAIN ER exceeding max.
- Page 57 Consider the device specifications. If the error persists, send the device to Messkonzept with description of error. Block temperature BT MAX ER above specified SetTemp+2K See BT MIN ER.
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Page 58: Appendix: Specifications
Page 57 of 63 Chapter 9 Appendix: Specifications 9.1 Specification of Thermal Conductivity Measurement Attribute Range / Precision Linearity < 1 % of range Approx. 20 min; up to 1 h for Warm up time small measuring ranges 10 l/h - 150 l/h, Flow rate 60 l/h - 80 l/h (recommended) <... -
Page 59: Gas Flow
Page 58 of 63 9.1.1 Gas Flow Article Calibrated Description Flow at atmospheric pressure at... Recommended value: 60 l/h A120B900 without protection 60 l/h Recommended range: 40 - 80 l/h A120B901 Protection against corrosion 60 l/h Permissible range: 10 - 120 l/h Protection against condensate A120B902 60 l/h... -
Page 60: Electrical Specifications
Page 59 of 63 9.2 Electrical Specifications Unit / Interface Feature Value Display 128 x 64 dot graphic LCD Keypad 3 short-travel keys Analog Input 1/2 Voltage range: 0 to 10 V Reference potential: ground Input resistance approx. 50 k Resolution 24 bit Current Loop... -
Page 61: Permissible Conditions Of The Sample To Be Measured
Page 60 of 63 9.3 Permissible Conditions of the sample to be measured Standard version: max. 20 bar abs. with flow measurement: max. 2 bar abs. Pressure (absolute) for flammable gases: max. 3 bar abs. Note the deviations of special models! At 60 l/h: - max. -
Page 62: Dimensions
Page 61 of 63 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: FTC320Ex Operating Manual_1.09KD201009MPO3V05.pdf... -
Page 63: Appendix: Dimensional Drawing
Page 62 of 63 Chapter 10 Appendix: Dimensional Drawing File name: FTC320Ex Operating Manual_1.09KD201009MPO3V05.pdf... - Page 66 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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