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MessKonzept FTC300, Operating Manual

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Page 5 of 58

Chapter 1

Operator Safety

This chapter 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.

File name:

FTC300 Manual 1.09KD140704CWI1V05.pdf

Summary of Contents for FTC300

Page 1: ...FTC300 Gas analysis using thermal conductivity measurement Operating Manual ...

Page 2: ... and drawings may not be in scale For the latest revisions to this manual contact Messkonzept or visit www messkonzept de Messkonzept welcomes comments and suggestions relating to the product and this manual Please Note The design of this instrument is subject to continuous development and improvement Consequently this instrument may incorporate minor changes in detail from information contained i...

Page 3: ... warnings saftey instructions and intended use Chapter 3 Assembly of the Instrument Mounting pneumatic and electric connection Also see Chapter 12 Appendix Dimensional Drawing Chapter 6 Calibration Recommended calibration intervals the calibration process and rec ommended test of functionallity after bringing into service File name FTC300 Manual 1 09KD140704CWI1V05 pdf ...

Page 4: ...rical Connectors 17 3 4 2 Ground 17 3 4 3 Data exchange via serial interface RS 232 17 4 The Front Panel 19 4 1 Display 19 4 2 LED Indicators 19 4 3 Keys 20 5 Switching on the device 21 5 1 Warm up Screen 21 5 2 Operation Screen 22 5 3 Top Level Main Menu 22 6 Calibration 23 6 1 General Information on Calibration 23 6 1 1 Calibration gas purities and flooding time 23 6 2 Set Offset Gas Concentrati...

Page 5: ...nt Loop modes and adjustment of the measuring range 39 8 4 2 Analog Output 1 41 8 4 3 Analog Output 2 42 8 4 4 Current loop calibration 42 8 5 Expert Setup 43 8 5 1 Parameter 43 8 5 2 Access Modes 44 8 5 3 Reset Functions 44 8 5 4 Test of Relays Analog Outputs and Connections 45 9 Appendix System Errors 47 10 Appendix Specifications 50 10 1 Specification of Thermal Conductivity Measurement 50 10 2...

Page 6: ...s 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 File name FTC300 Manual 1 09KD140704CWI1V05 pdf ...

Page 7: ...ices 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 FTC300 especially because of the loose glass balls When the ...

Page 8: ...rom the process This applies for apparent damages of the device such as physical damages but also in the case of unclarified malfunctions in the operation Separate the device from the process pneumatically both gas inlet and gas outlet and remove the power supply from the device Make sure that the electric installation protection against accidental contact agree to the ap plicable safety regulatio...

Page 9: ...c insulation as well as mechanical protection for operation FTC series gas analyzers do not have a metrology marking in the sense of EU directive 2014 32 EU They may therefore not be used for example in analyzes in medical and pharmaceutical laboratories or in the manufacture of pharmaceuticals in pharmacies based on a doctor s prescription The specifications of the device and its manual have to b...

Page 10: ...atly For TC measurement based analysis one of the following conditions must be met The mixture contains only two different gases binary mixture e g CO2 in N2 or H2 in N2 The thermal conductivity of two or more components is similar e g measuring H2 or He in a mixture of O2 and N2 quasi binary mixture The mixture contains more than two gases but all but two components or component groups volumetric...

Page 11: ... temperature A micro mechanically manufactured membrane with a thin film resistor serves as heat source A control loop stabilizes the membrane temperature at 135 C for most applications Above and below the membrane two small cavities are etched into the silicon These cavites are filled with measuring gas by diffusion The surfaces opposite to the membrane are thermally connected with the heat sink ...

Page 12: ... N2 0 100 0 15 85 100 Yes O2 Ar 0 100 0 2 97 100 Yes N2 Ar 0 100 0 3 97 100 Yes N2 CO2 0 100 0 4 96 100 On request NH3 H2 0 100 0 5 95 100 On request CO2 H2 0 100 0 2 99 100 On request SF6 N2 air 0 100 0 2 96 100 On request Table 2 1 Measuring ranges of typical gas compositions for analysis with the FTC300 The FTC300 must not be used with explosive gases Flammable gases such as H2 and CH4 may only...

Page 13: ...t ranges at the end beginning and the end of the range can be estimated by linear Interpolation Measuring ranges can be set up in the Current Loop menu see Section 8 4 1 The Multi Gas Mode MGM is a configuration that allows for the consecutive measurement of different gas pairs The gas pair can be switched through the control panel or via the RS232 interface Gas pairs labeled Yes in Table 2 1 are ...

Page 14: ...oid electrical interference on the measuring output the high performance analog adap tion circuit is directly mounted on top of the stainless steel block The piggyback mounted processor board digitizes the signal in a 24bit A D converter The micro controller performs all calculations as linearization calibrations and cross sensitivity compensation directly on the detector unit Figure 3 1 FTC300 De...

Page 15: ...as quantities is possible 3 3 Gas Ports On the bottom of the FTC300 housing two tubes with 6mm outer diameter for gas connection are located 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 connector For permanent gas and pressure tightness compression fittings are recommended e g by Swagelok After connec...

Page 16: ...00 has three three plug connectors as shown in Figure 3 3 Further information on the function of each contact is given in Table 3 1 The cables 712 IP67 with molded connector plug and a length of two meters five meters available on request are part of the purchased parts pack age The cables have open ends The cross section of the conductors in cable A and C is 0 14mm2 for cable B 0 25mm2 Cable A is...

Page 17: ... Ohm burden 16 bit resolution 2 brown Current Loop 3 black Serial Interface RS232 GND for pin 4 5 4 blue Serial Interface RS232 TxD transmit data 5 grey Serial Interface RS232 RxD receive data Connector C 8 pins 1 white Relay 1 isolated contact max 30V 0 5A 2 brown Power supply GND 3 green Relay 1 isolated contact max 30V 0 5A 4 yellow Power supply 24V 18V to 30V max 700mA 5 grey Relay 2 isolated ...

Page 18: ...ying with EN 60204 1 24V GND A B C GAS OUT GAS IN Figure 3 4 Grounding the FTC300 To comply with EN 60204 1 and to ensure your device s function the device has to be installed such that the power supply PELV is connected to protective earth PE with its ground conductor see Figure 3 4 The shielding of cables A B and C should be connected to functional ground Dependent on the circumstances gas inlet...

Page 19: ...2 see Section 10 1 Only a few PCs are still delivered with a so called COM port serial RS 232 interface In order to be able to operate and program devices that have an RS 232 interface with computers without this use of converters from RS232 to USB is advised The converters often have a 9 pin D Sub connector as input but there are also converters with screw terminal connections The serial interfac...

Page 20: ...Key ENTER Terminate Key Gas Selection in MGM Mode Figure 4 1 Front view schematic of the FTC300 front panel 4 1 Display 4 2 LED Indicators System Alarm Indicator red The flashing red LED indicates a system error System error indication depends on the configuration of the Alarm matrix Please see Section 8 3 7 Common Relay to configure alarm triggers for your application Standardly internal errors s...

Page 21: ...ields with the RIGHT key and confirm with ENTER In submenus requiring numerical inputs the UP key changes the selected digit ENTER Termination Key The ENTER key calls the item that is marked as selected selection is indicated through black background highlighted text 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 Optiona...

Page 22: ...the device operated in normal mode 5 1 Warm up Screen Warm Up 58 3 Set 63 0 C Figure 5 1 warm up screen of the FTC300 The warm up screen shows the current block temperature during warm up in the center of the screen see 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 in the bottom line of the screen The current ...

Page 23: ...ion may be shown Alarms are indicated by A1 and A2 sys tem errors are indicated by Er see Section 8 3 Relay Setup and Chapter 9 Appendix System Errors for more information If the top display line is empty there are no active alarm indications From the operational screen the main menu can be opened using the UP key 5 3 Top Level Main Menu Operation Calibration Diagnosis Setup Figure 5 3 main menu o...

Page 24: ...n is that the measured concentration is in agreement with the given test gas concentration To obtain this two calibration parameters that correspond to the offset zero and the gain span of a linear equation are available A two point calibration requires two test gases Both calibration parameters offset and gain are adjusted The concentration of the test gases does not have to meet the beginning an...

Page 25: ...Set Offset Gas Concentration A1 A2 Er 0 30 H2 N2 Operation Calibration Diagnosis Setup Offset Gas set 0 00000 new 0 00000 ESC OK H2 in N2 Calibrate Offset Gas Gain Gas Figure 6 1 offset gas setup menu Before performing a calibration the concentrations of the used test gases have to be set In the sub menu Offset Gas the used concentration of the offset gas has to be entered Select the submenu Offse...

Page 26: ...bserve some signal noise around a constant value To start the calibration sam pling select OK and press ENTER The sampling phase of 10s is started Based on the average measured concentration the new offset is determined such that the currently measured and cali brated value accords with the given test gas concentration within the specifications of the device Repeat the calibration in case the meas...

Page 27: ... concentration as set up in the Gain Gas menu see Section 6 3 Again please remember to wait for a sufficient running in time to evacuate possible disturbance gases The gain calibration can be canceled in any sub menu by selecting ESC If gain calibration is canceled the previous slope of your calibration line remains unchanged 6 5 1 Use of Substitute Gases Instead of using toxic or explosive gases ...

Page 28: ...advanced diagnosis The configuration of the FTC300 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 mal functions caused by wrong settings The parameter menu allows you to scroll through the entire parameter list Contact Messkonzept for detailed information on the listed parameters The first dis ...

Page 29: ...cess to the list of current errors No Errors indicates that no error is pending for pending errors the name of the error is given Pressing ENTER proceeds to the next pending error and UP to the previous error To leave the error menu press RIGHT once or twice to select NO or YES and the ENTER key to confirm your selection An error reset will affect maintenance warnings only all other errors and war...

Page 30: ...Figure 8 1 FTC300 setup menu The Setup menu contains four submenus Instrument Setup select the measured gas pair the units and the T90 response time of the exponential filter Relay Setup define the conditions to trigger the relays Output Setup properties of the external signal channels for analog output Expert Setup grants write access to parameters reset functions access modes codes and test sign...

Page 31: ...e will always be in ppm with 1ppm resolution 8 2 2 Measuring Gas Setup A1 A2 Er 0 30 H2 N2 Instr Set Relay Set Output Set Expert Set Operation Calibration Diagnosis Setup Unit Vol H2 in N2 T90 Response List for MGM Unit Vol O2 in N2 T90 Response List for MGM Unit Vol User Poly T90 Response List for MGM Figure 8 3 measuring gas setup The second line of the instrument setup menu indicates the curren...

Page 32: ...value by navigating through the digit position using the RIGHT key and changing it using the UP key Confirm by pressing the UP key until OK is selected The changed value can be discarded by selecting ESC instead Setting T90 Response to 0 0 turns the exponential filter off The true response time is influenced by the gas exchange time which depends on the pneumatic installation and the flow rate of ...

Page 33: ...een further called List for MGM can be edited Binary gas mixtures can be added to or removed from the List for MGM gas mixtures labelled with Is in list are included in the short list Toggle through the available binary gas mixtures using the ENTER or the UP key The RIGHT key changes to the third display line where the ENTER key is used to switch between Is in list and Not in List Press RIGHT to s...

Page 34: ... or not failsafe The threshold relays are indicated by A1 respectively A2 in the first display line of the operation screen The common relay is indicated by Er in the first display line of the operation screen and also by the flashing red LED on the front panel 8 3 1 Relay 1 Mode A1 A2 Er 0 30 H2 N2 Operation Calibration Diagnosis Setup Instr Set Relay Set Output Set Expert Set Relay 1 Relay 2 Com...

Page 35: ...Relay 2 Common Relay R1 Mode Failsafe Cal active ESC OK R1 Mode L H R1 Threshold R1 Hyst ESC OK R1 Threshold set 100 000 new 100 000 ppm ESC OK Figure 8 8 Relay 1 threshold configuration In the R1 Threshold menu the threshold value is set The value is set in the currently used measur ing unit ppm in this case The threshold is independent of the measuring range You can navigate to the digit positio...

Page 36: ...y Set Output Set Expert Set Relay 1 Relay 2 Common Relay Alarm matrix Not failsafe Cal active ESC OK Alarm matrix Failsafe Cal active ESC OK Figure 8 10 Toggling between relay Failsafe and Not failsafe mode The threshold alarms can be configured as Failsafe or Not Failsafe Failsafe means that the relay is live with no error pending Hence the alarm is indicated if the threshold is reached or if the...

Page 37: ...nfigured as Calibration active or Calibration frozen With Calibration frozen the relay does not respond to any changes of the measured concentration during the calibration procedure and stays in the state it was in when the calibration began With Calibration active the relay acts according to its current settings during calibration Press ENTER to switch between Calibration frozen and Calibration a...

Page 38: ...e option of Relay 2 Relay 2 provides all functionalities of Relay 1 see description above In addition Relay 2 permits the external signaling of the Maintenance alarm or monitoring an external auxiliary signal with the menu Aux The Maintenance Alarm is always indicated by the yellow flashing LED on the front panel The FTC300 is still functioning but should be put into maintenance in the near future...

Page 39: ...Errors for a detailed description The menu Alarm matrix offers a list of errors that can be included in the common relay Scroll forward through the list with ENTER and backwards with UP The third display line indicates whether this error is included C Alarm YES or not included C Alarm NO in the common relay Press RIGHT to proceed to the third display line and press ENTER to switch between C Alarm ...

Page 40: ...alibration Diagnosis Setup Instr Set Relay Set Output Set Expert Set Current Loop Analog Out 1 Analog Out 2 Adjust Loop I O Mode Cal frozen ESC OK I O Mode Cal active ESC OK 4 20mA C IOutMin C IOutMax ESC OK I O Mode Cal active ESC OK 4 20mA Err C IOutMin C IOutMax ESC OK 0 20mA C IOutMin C IOutMax ESC OK 0 20mA Err C IOutMin C IOutMax ESC OK 0 20mA Corr C IOutMin C IOutMax ESC OK Const I Out I Ou...

Page 41: ...n C IoutMax I O Mode 0 20mA Err This mode works analogously to I O Mode 4 20mA Err but in a 0 20mA current range Please note that the default error current is set to 3 mA lying inside the typical output value range The error current can be changed manually see I O Mode 4 20mA Err I O Mode 0 20mA Corr The current output of this mode creates a voltage drop from 0V to 10V over a 510 Ohm resistor Corr...

Page 42: ...0 ESC OK Figure 8 16 Setup of Analog Output 1 Analog Out 1 is a non DC isolated 0 to 10V output The maximum load is 1kOhm Several parameters can be routed to the analog output In the AOut Parameter menu you can select the signal you wish to route to the analog output by entering the value number If you wish to route the linearized measuring signal select 1 00000 Please contact Messkonzept for a li...

Page 43: ... as for Analog Out 1 described before 8 4 4 Current loop calibration A1 A2 Er 0 30 H2 N2 Operation Calibration Diagnosis Setup Current Loop Analog Out 1 Analog Out 2 Adjust Loop Reading set 19 5000 new 19 5000 mA ESC OK Instr Set Relay Set Output Set Expert Set Figure 8 18 Calibration of the current loop In the menu Adjust Loop the current loop can be calibrated Opening the menu Adjust Loop sets t...

Page 44: ...code is 222 000 8 5 1 Parameter Parameter Access Modes Reset Funct I O Test LCD Contrast set 25 0000 Change P009 OK LCD Contrast set 25 0000 Change P009 OK LCD Contrast set 25 0000 new 25 0000 ESC OK Compound ppm set 2105 13 P009 OK Figure 8 20 Parameter change in expert mode The configuration of the FTC300 is represented by an internal list of parameters These param eters govern all settings and ...

Page 45: ... the passcodes for the Operator Mode and the Expert Mode can be changed Further the device s mode can be switched between Safety Mode and Operation Mode For the Operation Mode set 1 00000 in the menu Mode Set for the safe mode enter 3 00000 In the safe mode every change of settings requires manual input of the Operator Code 8 5 3 Reset Functions Parameter Access Modes Reset Funct I O Test Restart ...

Page 46: ...ontact Messkonzept have to be written to the device again see Section 8 5 1 or the manual of SetApp which you can find on www messkonzept de 8 5 4 Test of Relays Analog Outputs and Connections Parameter Access Modes Reset Funct I O Test Relays Current Loop Analog Out Rel 1 open Rel 2 open Rel 3 open DIN low Relays Current Loop Analog Out I Out Const set 10 0000 new 10 0000 mA ESC OK Relays Current...

Page 47: ...The output Current Loop can be set to currents between 0 and 22mA The analog outputs 1 and 2 can be set to supply a voltage between 0V and 10V Note All test signals are permanently on until leaving the I O Test menu It is the responsibility of the expert to assure that the I O test does not interfere with the subsequent connected systems and processes in an unintended way File name FTC300 Manual 1...

Page 48: ... attention to these points when sending the device Close gas ports to keep gas duct clean Preferably use black rubber caps that came with delivery Put the device in a suitable shockproof packing material Preferably use the foam box that came with delivery Please attach a short note with a description of the problem or refer to prior mail correspondece on this subject with Messkonzept Never open th...

Page 49: ... of error CAL OFFS ER Calibration offset exceeding max allowed range 100 mV See CAL GAIN ER CAL DEV ER Calibration deviation exceeding max allowed range 50000 ppm See CAL GAIN ER CAL VAR ER Calibration variation exceeding max allowed range 1000ppm Repeat procedure Check if the measurement is stable before data sampling Are there sudden fluctioations in relevant process parameters for example press...

Page 50: ...sts send the device to Messkonzept with description of error BT MAX ER Block temperature above specified range SetTemp 0 6K See BT MIN ER BU MIN ER Bridge voltage below specified range 1V Send the device to Messkonzept with description of error BU MAX ER Bridge voltage above specified range 11V Send the device to Messkonzept with description of error TC MIN ER TC signal below specified range 500mV...

Page 51: ...higher 60 l h or dependant on user selected T 90 filter time Noise 0 5 of smallest range Drift at zero point 2 of smallest range per week Repeatability 1 of range Error due to change of ambient temper ature 1 of smallest range per 10 K temperature change Error due to change of flow at 80 l h 1 of smallest range per 10 l h Error due to change of pressure 800 hPa p 1200 hPa 1 of smallest range per 1...

Page 52: ...g Output 1 2 Voltage range 0 to 10 V Reference potential ground Load resistance min 10 kΩ Resolution 16 bit Relay 1 2 3 Maximum Voltage 30 V Switching current 0 5 A max Switching capacity 10 W max Reference potential fully floating max 500 V to ground Power Supply Voltage range 24 6 V DC Max current 1 A Typical current draw 500 mA Safeguard PELV Protective Extra Low Voltage Digital Interface Type ...

Page 53: ... falling below dew point in the measuring path small quantities tolerable with protective filter against condensate and dust Table 10 3 Environmental conditions 10 4 Environmental conditions Operating temperature 20 C to 50 C 4 F to 122 F or if casing filled with glass balls 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...

Page 54: ... called with the ENTER key In submenus requiring numerical inputs the RIGHT key scrolls to the next digit and to ESC OK at the end UP Selection Key In menus or submenus the UP key quits the recent menu and bring 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 In submenus requiring nu...

Page 55: ...Page 54 of 58 This page is intentionally left blank File name FTC300 Manual 1 09KD140704CWI1V05 pdf ...

Page 56: ...ESC OK H2 in N2 Calibrate Offset Gas Gain Gas Gain Gas set 100 0000 new 100 0000 ESC OK Stability Targ 100 00 Actu 99 98 ESC OK Operation Calibration Diagnosis Setup Parameter Errors Compound Raw set 3000 00 P001 OK Sampling 10s for Gain Calibration Please Wait A1 A2 Er 0 30 H2 N2 Operation Calibration Diagnosis Setup A1 A2 Er 0 30 H2 N2 Apply Process Gas Actu 0 00 ESC OK R1 R2 Er 0 30 H2 N2 Opera...

Page 57: ...r Access Modes Reset Funct I O Test LCD Contrast set 25 0000 Change P009 OK Compound ppm set 2105 13 P009 OK Current Loop Analog Out 1 Analog Out 2 Adjust Loop Reading set 19 5000 new 19 5000 mA ESC OK AOut1 Param AOut1 Offset AOut1 Gain AOut1 Gain set 0 00000 new 0 00000 ESC OK Current Loop Analog Out 1 Analog Out 2 Adjust Loop AOut1 Param AOut1 Offset AOut1 Gain AOut1 Offset set 0 00000 new 0 00...

Page 58: ...Page 57 of 58 Chapter 12 Appendix Dimensional Drawing File name FTC300 Manual 1 09KD140704CWI1V05 pdf ...

Page 59: ...mm flexibel cabel R min 80mm Steckverbindung plug and socket connection A 7 polig 7 pins B 5 polig 5 pins C 8 polig 8 pins Minimaler Freiraum 95mm bei fixierten Kabeln 122mm bei losen Kabeln minimal clearance 95mm with cables fixed 122mm with cables movable D E F C 1 2 3 4 B A 3 2 1 5 C D 4 6 7 8 A B 003 002 01 Zust Änderungsnr 21 11 18 15 01 16 28 04 15 Datum Name VA VA VA Datum 28 04 2015 Ashmor...

Page 60: ...hnology Niedwiesenstr 33 60431 Frankfurt Germany Telefon 49 69 53056444 Fax 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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