SICK FID3006 Operating instructions

OPERATING INSTRUCTIONS

Title Page

Start-up

Operation

FID 3006

2 FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG

Document Information

Product

Product name: FID 3006

Document ID

Title: Operating Instructions FID 3006

Part No.: 8011272

Version: 4-0

Release: 2014-03

Manufacturer

SICK AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

Phone: +49 7641 469-0

Fax: +49 7641 469-1149

E-Mail: [email protected]

Original documents

The English version 8011272 of this document is an original

document from SICK AG.

SICK AG assumes no liability for the correctness of an

unauthorized translation.

In case of doubt, please contact SICK AG or your local

representative.

Legal information

Subject to change without notice.

FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG 3

Warning Symbols

Warning Levels / Signal Words

DANGER

Risk or hazardous situation which will result in severe personal

injury or death.

WARNING

Risk or hazardous situation which could result in severe personal

injury or death.

CAUTION

Hazard or unsafe practice which could result in personal injury or

property damage.

NOTICE

Hazard which could result in property damage.

Information Symbols

Hazard (general)

When there is a warning on the device:

Observe the corresponding information in the

Operating Instructions.

Hazard by voltage

Hazard by explosive substances/mixtures

Hazard by high temperature or hot surface

Important technical information for this product

Important information on electric or electronic

functions

Nice to know

Supplementary information

Link to information at another place

Contents

4 FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG

1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1.1 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1.2 Purpose of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1.3 Application limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.1.4 Dimensions and tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.2 Responsibility of user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Product Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.1 Configuration overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

2.2 Fields of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.3 Functional principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1 Preparations for initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.1.2 Demands on the auxiliary gases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.2 Preparations for start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.3 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.3.1 Switching on the main power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.3.2 Heating up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.3.3 Igniting the flame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3.4 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.1 Shutting down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.1.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5.1.1 Instructions on cleaning the enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

5.2 Replacing the dust filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.3 Replacing the activated charcoal filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.4 Removing the sample gas filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6 Clearing Malfunctions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.1 Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Contents

FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG 5

7 Calculation of Calibration Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7.1 Short description of the evaluation of the measured value display. . . . . . . . . . . . . . . . 44

7.1.1 Unknown sample gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.1.2 Known sample gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2 Definitions and symbols used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2.1 C

V

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2.2 C

VPa

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2.3 C

m

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2.4 C

C

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2.5 n

c

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2.6 KA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2.7 MA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2.8 C

VPO

, C

CPO

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2.9 KF

V

, KF

C

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2.10 r, r

K

, r

P

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.2.11 M. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.3 Formula relationships . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

7.4 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

8 Additional Subassemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

8.1 Probe with reducing union. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.1.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.1.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

8.1.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.2 Adaptor tube for the prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8.2.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8.2.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

8.2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8.3 Prefilter, 2-stage, with connection for the probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

8.3.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

8.3.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

8.3.3 Spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.3.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.4 Filter heating for the prefilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.4.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

8.4.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.5 Heated lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

8.5.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.5.2 Conditions of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.5.3 Transport of the heated line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.5.4 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

8.5.5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.5.5.1 Option: Exchangeable PTFE core - exchange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.5.6 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Contents

6 FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG

9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

9.1 Compliances and approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

9.1.1 Electrical protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

9.2 Suitability test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

9.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9.4 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Important Information

FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG 7

Subject to change without notice

FID 3006

1 Important Information

Main safety information

Main operating information

Intended use

Responsibility of user

8 FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG

Important Information

Subject to change without notice

1.1 Intended use

1.1.1 Product identification

1.1.2 Purpose of the device

By using a flame ionisation detector, the FID 3006 can measure total hydrocarbons in cold

as well as hot aggressive gases, and all the physical variables which can be derived from

this, such as the concentrations of the substances concerned, or the risk of explosion.

1.1.3 Application limitations

The range of application is limited by the physical regularities, which are in detail as

follows:

● The sample gas must not contain any aggressive constituents which could act upon the

materials of parts in contact with the sample gas.

● Materials in general:

– Stainless steel 1.4305, 1.4301, graphite, quartz, platinum

– Elastomers used in the sample gas pump: TEFLON, KALREZ, VITON

● The parts of the unit in contact with the sample gas can be heated up to 200 °C.

None of the constituents of the sample gas should condense above the selected

temperature.

● The sample gas in the analyzer should not react in a way that the formation of solids is

caused in the unit.

● A hydrogen flame burns in the detector of the unit which is fed with the gases to be

measured. No matter should be formed by thermal oxidation which could act upon the

materials mentioned above. No solid matter, which could settle on any of the detector

parts, should be formed by oxidation.

● If the unit is used outdoors, please remember that the unit is not protected against

dripping water and rain.

1.1.4 Dimensions and tolerances

Wherever possible, the dimensions were used in compliance with German standard

DIN 1301...1304. For simplification reasons no tolerances have been mentioned for the

values given. Please note that all values have tolerances. The values mentioned in this

publication are the standard values without tolerances.

Product name: FID 3006

Manufacturer:

SICK AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

WARNING: Risk of explosion

▸

Gases oder gas mixtures whch are at or above the LEL (Lower Explosion

Limit) may not be measured.

WARNING: Health risk through toxic sample gas

▸

The operating company is responsible for the composition of sample gas

and the relevant safety measures.

▸

Pay attention to the leak tightness of the gas connections on the device

and the gas lines outside the device.

Important Information

FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG 9

Subject to change without notice

1.2 Responsibility of user

▸

Put the FID 3006 into operation only when you have read the Operating Instructions.

▸

Observe all safety notices.

▸

If there is something you do not understand: Please contact SICK Customer Service.

Intended users

The FID 3006 may only be operated by persons properly instructed on the tasks assigned,

possible risks and protective measures.

Correct use

▸

Use the FID 3006 only as described in these Operating Instructions. The manufacturer

bears no responsibility for any other use.

▸

Carry out the specified maintenance work.

▸

Do not remove, add or change any components in or on the FID 3006 unless such

changes are officially allowed and specified by the manufacturer.

Otherwise:

– The manufacturer’s guarantee becomes void

– The FID 3006 could become dangerous

Retention of documents

These Operating Instructions:

▸

Must be available for reference.

▸

Must be conveyed to new owners.

10 FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG

Important Information

Subject to change without notice

Product Description

FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG 11

Subject to change without notice

FID 3006

2 Product Description

Product identification

Functional principle

Characteristics

Variants

12 FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG

Product Description

Subject to change without notice

2.1 Configuration overview

Basic unit

● Total hydrocarbon analyzer FID3006, 115 V / 230 V

Fig. 1 View of FID3006

Options

● LED display instead of analog display

● Combustion gas supply H

2

/He

● Special measuring range 0 - 1 vpm

● Special scale mgC

Alternative option

● Analog output 0 - 20 mA

● Analog output 4 - 20 mA

Option

● Electrical isolation of measured value output

Product Description

FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG 13

Subject to change without notice

Accessories

● Power cable for FID 3006

Alternative accessories

● Measured value cable for FID 3006 (standard)

● Measured value cable for FID 3006 (full version)

Alternative accessories

● Heated line 3 m PTFE, 230 V for FID 3006

● Heated line 5 m PTFE, 230 V, for FID 3006

● Heated line 3 m PTFE, core exchangeable, for FID 3006

● Heated line 5 m PTFE, core exchangeable, for FID 3006

● Heated line 3 m stainless steel, 230 V, for FID 3006

● Heated line 5 m stainless steel, 230 V, for FID 3006

Accessories

● Adapter for heated line (3005)

2.2 Fields of application

By using a flame ionisation detector, the device can measure total hydrocarbons in cold as

well as hot aggressive gases, and all the physical variables which can be derived from this,

such as the concentrations of the substances concerned, or the risk of explosion.

In spite of the robustness of the measurement device for its use in the field, the FID 3006

is easy to carry. Inspections can be carried out, or continuous measurements performed

for as long as required, at sites which are difficult to reach.

The broad measurement range of 0.05 ppm up to 10% by volume makes possible not only

emission measurements or control of the air at the place of work, but also emission

measurements and process inspections in industry.

In order to carry out measurements on aggressive or condensing gas mixtures without

problems, the device has a complete heating system for the gas lines and filter. This can

heat up to 200 °C.

14 FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG

Product Description

Subject to change without notice

2.3 Functional principle

The analyzer operates according to the principle of comparison. The unknown sample gas

concentration is compared with the known concentration of the calibration gas. The

physically measured quantity is converted into an electric signal by means of a flame

ionisation detector (FID). Here an electric field is connected to a pure hydrogen flame which

burns while being supplied with hydrocarbon-free air. If organic compounds are fed to this

flame through the sample gas, a measurable ionisation current is produced. The signal is

proportional to the number of carbon atoms which are fed to the flame and are not pre-

oxidized. Pre-oxidized carbon atoms are only partially registered. Carbon monoxide and

carbon dioxide are not registered.

Fig. 2 FID functional principle

The instrument has a linear characteristic, the slope of which can be defined by means of

two points. In practice, this is done in such a way that first of all a test gas with a concentra-

tion value of zero (zero gas) is passed through the instrument, and the zero point is

electrically set to zero subsequently. In a second stage, a certain concentration of organic

compounds (span gas, e.g. 1% by volume propane in air) is fed to the instrument, and the

sensitivity of the instrument is then electrically set to this value. After this calibration

process, the concentration of the gas to be measured (sample gas) can be determined.

Test gases are only consumed during the calibration process. The exact concentration of

the test gases is determined by the supplier of the gases. Each delivery of a test gas bottle

includes an analysis certificate rendering information on the content and its tolerances.

During operation of the analyzer, hydrogen is constantly consumed as combustion gas. In

case of considerably varying oxygen concentrations in the sample gas of 0 to 21%, the

instrument can be operated with an H

2

He mixture as a combustion gas to improve the

measuring properties. However, alternate use is not possible, and therefore the instrument

has to be readjusted in the factory or at a service station of SICK.

Polarisation voltage

Electrodes

Amplifier and readout

Jet

Sample gas

Combustion gas

Flame

Combustion air

Ions

Product Description

FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG 15

Subject to change without notice

Fig. 3 Flow chart with functional principle FID 3006

The sample gas pump M1 sucks the gas to be analyzed through the sample gas filter F1.

The gas is divided into two streams on the pressure side. A few ml/min flow through the

capillary K1 to the FID. The main stream, approx. 1.5 l/min, leaves the device through the

bypass capillary K2.

All the construction parts listed in this paragraph are located in the thermostatted

controlled analysis chamber. The amount of gas passing through the capillary K1 depends

on the temperature of the analysis chamber and on the difference in pressure between the

capillary inlet and outlet. The more gas is led through the capillary K1 to the FID, the more

hydrocarbon can be detected by the detector. In order to achieve reproducible measure-

ment results, the amount of through-flow through the capillary K1 must be stabilized. The

outlet at the capillary K1 is at atmospheric pressure. The pressure head at the front of the

capillary is dependent on the performance of the particular pump in question, as well as

on the state of the sample gas filter. The less the sample gas pump pumps, the lower is the

pressure head. The greater the extent of contamination in the sample gas filters, the more

the sample gas pump is choked, and the pressure head also thus reduced.

For the stabilization, a so-called control air system is built in. The system consists of an

ambient air pump M2 and the sample gas pressure regulator D2. The bypass capillary K2

is dimensioned so that if the pump performance is set to 1.5 l/min and a control air

amount of about 0.8 l/min set by the sample gas pressure regulator D2, a pressure head

of about 200 mbar results. When the amount of gas pumped sinks, the sample gas

pressure regulator D2 automatically adjusts the sample gas pump up to a minimum

volume stream of about 0.8 l/min. In this way, the pressure head remains constant. Even if

the amount pumped by the sample gas pump drops still further, the sample gas pump

regulator attempts to readjust. For this, however, larger and larger through-flow amounts

have to be made available by means of the ambient air pump M2. The increased through-

Bypass

Calibration gas inlet

Ambient air inlet

Sample gas inlet

Synthetic air inlet Combustion gas inlet

Heated analysis chamber

Detector upper part

separately heated

Outlet

FID lower

part

FID upper

part

16 FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG

Product Description

Subject to change without notice

flow amount means that the minimum input pressure of the sample gas pressure regulator

cannot be maintained and the secondary pressure, i.e. the pressure head, falls. This

pressure drop is displayed on the manometer “sample gas pressure”.

The calibration of the measurement system results by locking on to two comparison gases,

the zero gas and the span gas. The lock on is performed by steering the magnetic valve Y3

for the span gas or Y2 for the zero gas. The minimum inlet pressure at the sample gas pres-

sure regulator D2 for this process must not be undercut. For this reason, the pump

performance is designed for this operational state. During the measurement, the excess

amount of through-flow flows through the ambient air magnetic valve Y5 and the fresh air

needle valve R3 to reach the ambient air pump M2 once again. A longer lifetime for the

dust filter F3 is achieved by means of this construction. The zero gas and the combustion

air are purified of organic compounds by absorption processes in the activated charcoal

filter F2. Both these gases have to be free from hydrocarbons or the measurement preci-

sion would be reduced. The amount of through-flow made available from the capillary K3

and the ambient air pump M2 for calibration purposes is larger than the amount of sample

gas sucked in by the sample gas pump. For this reason, during the calibration procedure,

the excess gas flows out of the sample gas inlet, and an exact calibration is ensured. In

order to be able to use an external air processing system, the pressure on the pressure

side of the magnetic valve for synthetic air Y4 has to be greater than 1 bar; the pressure

switch is then closed and the magnetic valve is opened.

The amount of combustion air is set by means of the needle valve R4.

The amount of combustion air is set by means of the pressure regulator D1 and the flow

controller R1.

Valve Y6 switches the combustion gas supply off when an error occurs and when the

device has been switched off.

During the ignition procedure, the amount of combustion gas is increased by opening the

ignition gas magnetic valve. The extra flow of combustion gas is determined by the setting

of the ignition gas needle valve R2.

The device characteristics such as linearity and cross-sensitivity depend on the through-

flow of combustion gas and combustion air. The amounts of through-flow are therefore

individually determined and set for every device after production.

The activated charcoal filter internal to the device has an efficiency of about 95% up to an

ambient air loading of 160 mgC/m

3

. The residual value can be easily compensated for in

the calibration. However, possible fluctuations in the ambient air concentration which

affect the measurement results, although reduced by the activated charcoal filter, cannot

be taken into consideration. In order to eliminate this effect, external synthetic air can be

connected for trace measurements. The inlet pressure for synthetic air is monitored with

the pressure switch P. If at least 1 bar is present at the synthetic air inlet, the magnetic

valve Y4 is switched over and combustion air and zero gas are supplied externally. If the

external supply falls under 1 bar, the switch over to internal supply occurs automatically.

The capillary K4 serves to equilibrate the pressure difference between the internal and

external supplies.

Start-up

Subject to change without notice

FID 3006

3 Start-up

Preparations for start-up

Start-up

Subject to change without notice

3.1 Preparations for initial start-up

The description contains instructions for the preparation of the standard version. Special

sheets are obtainable for the preparation of other models.

The preparation consists of the assembly of the total hydrocarbon analyzer and the

connection with pneumatic and electrical lines.

Fig. 4 View of FID3006

3.1.1

Unpacking

The consignment must be checked for visible defects and completeness.

The analyzer is as shown above.

Connecting the supply gases

Fig. 5 Partial view (front)

Start-up

Subject to change without notice

All pneumatic connections on the front plate are designed as quick-fitting couplings.

The connection is carried out in a simple manner in that the appropriate piece is plugged

onto the corresponding gas connection. Combustion gas and calibration gas are always

required. Synthetic air is only necessary for trace measurements.

Use synthetic air when the expected measurement results lie in the concentration region of

the surrounding air. The gas connections are quick-fitting couplings.

● Coupling socket for zero gas and calibration gas: Part No. 5312808

● Coupling socket for combustion gas: Part No. 2035070

On connecting, the object to be coupled is held steady and pushed onto the appropriate

quick-coupling plug.

On releasing, the knurled release ring is held steady and the quick-coupling pulled off. The

coupling parts must be kept free of impurities.

3.1.2 Demands on the auxiliary gases

Span gas

Depending on the task in question, approx. 80% of the hydrocarbon concentration of the

measurement range used with respect to the propane-equivalent in synthetic air from

pressurized containers with an inlet pressure of 3 bar.

Combustion gas

According to the device settings, pure hydrogen H

2

5.0 or hydrogen helium mixture (40%

H

2

; 60% He) “combustion gas for FID”. The residual hydrocarbon content must be less than

0.5 ppm with respect to C1; from pressurized containers, inlet pressure: 3 bar.

Synthetic air

Used when combustion air is not provided internally by the activated charcoal filter, accord-

ing to the measurement task in question, air from pressurized containers is used. The

remaining HC content must be less than 0.5 ppm. Inlet pressure: Constant 3 bar.

Residual HC

The residual HC content of the gases is to be adhered to for measurement of low concen-

trations; for higher concentrations larger values of up to 4 ppm may be allowed.

NOTICE: Avoid contamination of tubes

It is important to note that contaminated sample lines will cause considerable

interferences. This will lead to incorrect measurements and, in most cases, a

breakdown of the measurement system can be expected.

▸

Only the sample lines delivered with the device should be used.

The gas lines and control elements internal to the device cannot be cleaned!

These have to be replaced. The repair costs are many times higher than the

cost of a clean sample line.

Start-up

Subject to change without notice

Consumption

All auxiliary gases have to have a minimum inlet pressure of 3 bar during operation. The

maximum inlet pressure is 3.2 bar.

In case the inlet pressure of the external synthetic air should fall under 1 bar, the pure air

conditioning is then automatically carried out internally. This can lead to incorrect results

when measuring lower hydrocarbon concentrations.

Gas When? Consumption

External span gas: Only during calibration Approx.2 l/min

Combustion air, external:

Synthetic air

Continually Approx. 12 l/h

Zero gas, external: Synthetic air Only during calibration Approx.2 l/min

Combustion gas Continually Approx.1.2 l/h H

2

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SICK FID3006 Operating instructions

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