SICK FID3006 Operating instructions

Category
Measuring, testing & control
Type
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
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.
© SICK AG. All rights reserved.
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
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
FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG 17
Subject to change without notice
FID 3006
3 Start-up
Preparations for start-up
Start-up
18 FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG
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
FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG 19
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.
20 FID 3006 · Operating Instructions · 8011272 V4-0 · © SICK AG
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
1 / 1

SICK FID3006 Operating instructions

Category
Measuring, testing & control
Type
Operating instructions

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