EuroFID Gas Analyzers for Measurement of the Total Hydrocarbon Content

Front page OPERATING INSTRUCTIONS EuroFID Gas Analyzers for Measurement of the Total Hydrocarbon Content Installation Operation Maintenance

Document Information Described Product Product name: EuroFID Components: Analyzer unit type wall housing Analyzer unit type 19" slide-in enclosure Analyzer unit type inline Analyzer unit type industrial housing Operating unit type 19" slide-in enclosure Operating unit type ½-19" slide-in enclosure Terminal box Terminal module 1 Terminal module 2 Shut-off fitting Mounting flange Heat insulation unit Hood for weather protection Software version: 5.x, mode Process or Emission (Version LEL : 4.12084) Document ID Title: Operating Instructions EuroFID Order No.: 8011094 Version: 2.3 Release: 2013-05 Manufacturer SICK AG Erwin-Sick-Str. 11 79183 Waldkirch Germany Tel.: +49 7641 469-0 Fax: +49 7641 469-11 49 E-mail: info.pa@sick.de Trademarks Kalrez and Viton are trademarks of DuPont Performance Elastomers. Other product names used in this document may also be trademarks and are only used for identification purposes. Glossary AC: Alternating Current ATEX (Atmosphère explosible): Abbreviation for European directives related to safety in potentially explosive atmospheres BImSchV: FICA (Regulation for implementation of the Federal Immission Control Act of the Federal Republic of Germany) CSA: Canadian Standards Association (www.csa.ca) DC: Direct Current FID: Flame ionization detector Firmware: Internal software of the device, normally in a deletable memory chip (EEPROM) IP XY: International Protection (also: Ingress Protection); protection type of a device in accordance with IEC/DIN EN 60529. The first digit designates protection against contact and foreign bodies, the second against moisture. LED: Light emitting diode (small indicator lamp) LEL: Lower explosion limit (Minimum concentration in a combustible gas or steam above which the gas mixture can be ignited) NAMUR: Abbreviation for Normen-Arbeitsgemeinschaft für Messund Regeltechnik in der chemischen Industrie, now Interessengemeinschaft Automatisierungstechnik der Prozessindustrie (www.namur.de) PC: Personal computer PTFE: Polytetrafluorethylene TA Luft: TI Air - Technical instructions for the prevention of air pollution (general administrative regulation for the Federal Immission Control Act of the Federal Republic of Germany); defines threshold values and measurement and calculation methods UV: Ultraviolet light UVRAS: Ultraviolet resonance absorption spectrometry Windows: PC operating system from Microsoft Corporation Original Documents The English edition 8011094 of this document is an original document of SICK AG. SICK AG assumes no liability for the correctness of an unauthorized translation. Please contact the manufacturer or your local representative in case of doubt. Legal information Subject to change without notice. SICK AG. All rights reserved. 2 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Warning Symbols Information Symbols Hazard (general) Information about the use in potentially explosive atmospheres Hazard by voltage Important technical information for this device Hazard in potentially explosive atmospheres Important information on electrical or electronic functions Hazard by explosive substances/mixtures Supplementary information Hazard by poisonous substances Link to information at another place Warning levels / Signal words Nice to know WARNUNG Risk or hazardous situation which could result in severe personal injury or death. CAUTION Hazard or unsafe practice which could result in less severe or minor injuries and/or property damage. NOTICE Indicates a hazard or unsafe practice which could result in property damage. EuroFID Operating Instructions 8011094 V2.3 SICK AG 3

Contents Contents 1 Important Information.............................................. 11 1.1 Product identification........................................................ 12 1.2 Main hazards............................................................... 13 1.3 Main instructions for operation............................................... 14 1.4 Intended use............................................................... 15 1.4.1 Purpose of the device..................................................... 15 1.4.2 Installation site........................................................... 15 1.4.3 Restrictions of use........................................................ 16 1.5 Responsibility of the user.................................................... 17 1.6 Additional documents....................................................... 17 2 Product Description.................................................. 19 2.1 Measuring principle......................................................... 20 2.2 Measuring method.......................................................... 20 2.3 Measuring ranges........................................................... 22 2.4 Device modules............................................................. 24 2.4.1 Analyzer units............................................................ 24 2.4.2 Operating units........................................................... 25 2.4.3 Terminal box............................................................. 25 2.5 Additional equipment........................................................ 26 2.5.1 Device options........................................................... 26 2.5.2 Accessories.............................................................. 26 3 Project Planning...................................................... 27 3.1 Scope of delivery............................................................ 28 3.2 Overview of installation work................................................. 29 3.2.1 Required resources (overview)............................................ 29 3.2.2 Mechanical installations (overview)......................................... 30 3.2.3 Mains connection (overview)............................................... 30 3.3 Supply of operational gases.................................................. 31 3.3.1 Screw connections of the gas connections.................................. 31 3.3.2 Safety instructions for gas supply.......................................... 31 3.3.3 Supply of instrument air................................................... 31 3.3.4 Supply of fuel gas......................................................... 32 3.4 Exhaust gas connections..................................................... 32 3.4.1 Exhaust gas connection................................................. 32 3.4.2 Bypass gas connection.................................................. 32 3.4.3 Exhaust gas lines......................................................... 33 3.5 Sample gas supply.......................................................... 34 3.5.1 Correct sample gas supply................................................ 34 3.5.2 Connection of the sample gas line.......................................... 35 3.6 Span gas supply ( Calibration gas connection)................................ 36 4 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Contents 4 Installation of the Analyzer Unit................................... 37 4.1 Installation of the wall housing type analyzer unit............................. 38 4.1.1 Assembly/securing........................................................ 38 4.1.2 Gas connections.......................................................... 38 4.1.3 Electrical connections..................................................... 39 4.2 Installation of the 19" slide-in enclosure type analyzer unit.................... 40 4.2.1 Installation/securing...................................................... 40 4.2.2 Gas connections.......................................................... 41 4.2.3 Electrical connections..................................................... 41 4.3 Installation of the inline type analyzer unit................................... 42 4.3.1 Safety notes on the lifting points........................................... 42 4.3.2 Assembly.................................................................43 4.3.3 Installing the hood for weather protection................................... 44 4.3.4 Gas connections.......................................................... 45 4.3.5 Electrical connections..................................................... 45 4.4 Installation of the analyzer unit industrial housing type....................... 47 4.4.1 Supplied condition........................................................ 47 4.4.2 Assembly.................................................................49 4.4.3 Installation of the industrial housing........................................ 49 4.4.4 Installing the analyzer..................................................... 50 4.4.5 Gas connections.......................................................... 51 4.4.6 Electrical connections..................................................... 51 5 Installation of the Terminal Box................................... 53 5.1 Installing the terminal box.................................................... 54 5.2 Electrical connections of the terminal box..................................... 54 6 Installation of the Operating Unit................................. 57 6.1 Installing the operating unit.................................................. 58 6.2 Mains connection of the operating unit........................................ 59 6.2.1 External mains switch..................................................... 59 6.2.2 Mains cable connection................................................... 59 6.3 Signal connections.......................................................... 60 6.3.1 Overview of signal connections............................................. 60 6.3.2 Contact assignment of the plug connector Analog and digital I/O.......... 61 6.3.3 Analog outputs........................................................... 62 6.3.4 Analog inputs............................................................. 63 6.3.5 Switching outputs (threshold value alarm, status)............................ 64 6.3.6 Control inputs............................................................ 65 6.4 Printer connection........................................................... 66 EuroFID Operating Instructions 8011094 V2.3 SICK AG 5

Contents 7 Terminal Modules (Accessory).................................... 67 7.1 Terminal module 1.......................................................... 68 7.1.1 Functions................................................................ 68 7.1.2 Installation............................................................... 69 7.1.3 Configuration options (jumper)............................................. 69 7.1.4 Terminal assignment...................................................... 70 7.2 Terminal module 2.......................................................... 72 7.2.1 Functions................................................................ 72 7.2.2 Technical design.......................................................... 72 7.2.3 Functional descriptions................................................... 73 7.2.4 Installation............................................................... 74 7.2.5 Function of the relay switching contacts.................................... 74 7.2.6 Configuration options (jumper)............................................. 74 7.2.7 Signal connections...................................................... 76 8 Start-up................................................................. 77 8.1 Safety information for start-up................................................ 78 8.2 Preparing for start-up........................................................ 78 8.3 Activation procedure........................................................ 78 9 Operation (General).................................................. 81 9.1 Controls and indicators/displays.............................................. 82 9.1.1 Display.................................................................. 82 9.1.2 LEDs (indicators)......................................................... 82 9.1.3 Keypad.................................................................. 83 9.2 Menu system............................................................... 84 9.2.1 Main menu.............................................................. 84 9.2.2 Navigation principle....................................................... 84 9.2.3 Overview of the menu system.............................................. 85 9.3 Checking the operational state (visual control)................................. 86 9.3.1 Features of a safe operational state........................................ 86 9.3.2 Indications of an unsafe operational state.................................. 86 9.4 Behavior in an emergency................................................... 87 10 Main Menu Functions............................................... 89 10.1 Measurement display........................................................ 90 10.2 Selecting the measuring range............................................... 91 10.3 Calibration (note)........................................................... 91 10.4 Flame ignition.............................................................. 92 10.5 Diagnosis.................................................................. 93 10.5.1 Purpose of the diagnosis function.......................................... 93 10.5.2 Activating the diagnosis messages......................................... 93 10.5.3 Malfunction messages in the diagnosis function............................. 93 10.5.4 Operational displays in the diagnosis function............................... 94 10.6 Maintenance (note)......................................................... 98 10.7 Language (language selection)............................................... 99 10.8 General Help............................................................... 99 6 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Contents 11 Maintenance Sub-menu Functions............................101 11.1 Accessing the Maintenance sub-menu......................................102 11.2 Calibration gas value (note).................................................103 11.3 Conversion factors..........................................................104 11.3.1 Setting the conversion factor..............................................104 11.3.2 Calculation of conversion factors..........................................105 11.4 Standby...................................................................107 11.5 Error archive...............................................................108 11.5.1 Function of the error archive..............................................108 11.5.2 Displaying the error archive...............................................109 11.5.3 Printing the error archive.................................................110 11.5.4 Deleting the error archive.................................................111 11.6 Filter change (menu).......................................................112 11.7 System Parameters (overview)...............................................113 11.8 User level (activation).......................................................114 11.9 Range select mode (Measuring range selection)...............................115 11.10 Temperature of the sensor block.............................................117 11.11 I/O Parameters.............................................................118 11.11.1 Integrated value (averaging for the measurement display)...................118 11.11.2 Display rate.............................................................119 11.11.3 Setup filter (averaging for the Measured value analog output)..............120 11.11.4 Median value time (averaging for the Reference value analog output).......121 11.11.5 Display range............................................................122 11.11.6 Output range............................................................123 11.11.7 Range select mode (note).................................................124 11.11.8 Set measuring range (note)...............................................124 11.11.9 Configuring threshold value alarms........................................124 11.11.10 Setting the measuring ranges.............................................127 11.11.11 Purging parameters (purging time).........................................128 11.12 Device status System in Service............................................129 11.13 Threshold reset............................................................130 11.14 Time and date settings......................................................131 11.14.1 Setting the date and time.................................................131 11.14.2 Changing the time zone...................................................132 11.14.3 Summer / winter time (automatic switchover)..............................133 11.15 Supplementary text for physical unit (Unit of measurement)....................134 11.16 Name of analyzer...........................................................135 11.17 Printer functions...........................................................136 11.17.1 Paper format............................................................136 11.17.2 Log settings.............................................................137 11.17.3 Printing measurement archive/average value archive.......................138 11.17.4 Print instrument log......................................................139 11.17.5 Print diagnosis...........................................................140 11.17.6 Print selftest.............................................................141 11.17.7 Print all parameters (device data).........................................142 11.18 Restart....................................................................143 EuroFID Operating Instructions 8011094 V2.3 SICK AG 7

Contents 12 Calibration............................................................ 145 12.1 Introduction to calibration of the EuroFID..................................... 146 12.2 Types of calibration........................................................ 146 12.3 Calibration gases.......................................................... 147 12.3.1 Zero gas................................................................ 147 12.3.2 Span gas............................................................... 147 12.4 Settings for calibration..................................................... 148 12.4.1 Calibration control....................................................... 148 12.4.2 Setpoint value for the span gas (calibration gas value)...................... 149 12.4.3 Calibration times for automatic calibration................................. 150 12.5 Manual calibration......................................................... 151 12.6 Checking calibration........................................................ 153 12.6.1 Zero check.............................................................. 153 12.6.2 Sensitivity test (calibration gas test)....................................... 153 13 Shutdown............................................................. 155 13.1 Preparing shutdown........................................................ 156 13.1.1 Securing the connected systems.......................................... 156 13.1.2 Protection against condensation.......................................... 156 13.2 Deactivation procedure..................................................... 156 13.3 Transport.................................................................. 157 13.4 Disposal................................................................... 157 14 Maintenance......................................................... 159 14.1 Necessary technical knowledge for maintenance work......................... 160 14.2 Safety instructions for maintenance work................................... 160 14.3 Maintenance plan.......................................................... 161 14.3.1 Maintenance by the user................................................ 161 14.3.2 Maintenance by the manufacturer's service technicians.................... 161 14.4 Servicing the sample gas filter.............................................. 162 14.4.1 Access to the sample gas filter........................................... 162 14.4.2 Replacement/cleaning of the filter element (procedure)................... 163 14.4.3 Cleaning the filter........................................................ 166 14.4.4 Spare parts for the sample gas filter....................................... 168 15 Clearing Malfunctions.............................................. 169 15.1 If the EuroFID does not work at all........................................ 170 15.2 If the measured values are obviously incorrect............................. 170 15.3 Electrical fuses............................................................ 171 15.3.1 Mains fuse of the operating unit.......................................... 171 15.3.2 Fuses in the analyzer unit type industrial housing......................... 171 15.3.3 Fuses in the terminal box................................................. 172 15.4 Overtemperature protection on the analyzer unit.............................. 173 15.4.1 Function of the overtemperature protection................................ 173 15.4.2 Resetting the temperature monitor (after tripping).......................... 173 15.4.3 Testing the overtemperature protection (note).............................. 174 15.5 Malfunction messages...................................................... 175 15.5.1 Malfunction messages on the display (general)............................. 175 15.5.2 Possible malfunction messages........................................... 176 8 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Contents 16 Technical Data.......................................................183 16.1 Dimensions................................................................184 16.1.1 Analyzer units...........................................................184 16.1.2 Operating units..........................................................189 16.1.3 Terminal box.............................................................190 16.2 Housing specifications......................................................191 16.2.1 Operating units..........................................................191 16.2.2 Analyzer units...........................................................191 16.2.3 Terminal box.............................................................191 16.2.4 Flange specification......................................................191 16.3 Ambient conditions......................................................192 16.4 Supply voltage (mains voltage)..............................................193 16.5 Gas connections...........................................................193 16.6 Auxiliary gases.............................................................194 16.6.1 Instrument air.........................................................194 16.6.2 Fuel gas................................................................195 16.7 Sample gas conditions.....................................................195 16.8 Measuring characteristics................................................196 16.9 Approvals (suitability tests).................................................196 16.10 Accessories................................................................197 16.10.1 Mounting connections....................................................197 16.10.2 Heat insulation flange....................................................197 16.10.3 Hood for weather protection..............................................198 16.10.4 Shut-off fittings..........................................................199 16.10.5 Plug connector for the operating unit......................................200 16.10.6 Terminal modules........................................................200 16.10.7 Cable...................................................................200 17 Older Device Versions..............................................205 17.1 Operating unit older version...............................................206 17.2 Terminal box older version.................................................207 EuroFID Operating Instructions 8011094 V2.3 SICK AG 9

Contents 10 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Important Information EuroFID 1 Important Information Main hazards Main instructions for operation Intended use Own responsibility EuroFID Operating Instructions 8011094 V2.3 SICK AG 11

Important Information 1.1 Product identification Device modules A EuroFID gas analyzer contains three main device modules: a) Analyzer unit: Contains the physical measuring system and basic electronics b) Operating unit: Contains the electronic control unit, display and controls. c) Terminal box: Connects the analyzer unit and operating unit Description of the device modules P. 24, 2.4 Product versions The EuroFID gas analyzers make up a product family featuring various modules ( P. 23, Fig. 2) which are combined to device versions for various applications. The analyzer unit version is decisive for its function: The range includes analyzer units for direct measurement in the process ( inline and industrial housing types) and for extractive gas analysis ( wall housing type, 19" slide-in enclosure type). Depending on the housing version, the analyzer unit is designed either for indoor operation or outdoor installations ( P. 15, 1.4.2). The industrial housing type analyzer unit is also available as an Ex1 industrial housing version for potentially explosive atmospheres. The Ex1 industrial housing analyzer unit is not described in these Operating Instructions. If the EuroFID is equipped with the Ex1 industrial housing analyzer unit: In addition to these Operating Instructions also observe the information in the document Operating Instructions (Annex) EuroFID Ex1 industrial housing analyzer unit. Identification of the product version The version of a device module can be recognized by its exterior ( P. 23, Fig. 2). The mains voltage is stated on the type plate of the operating unit. 12 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Important Information 1.2 Main hazards Main safety notes in abbreviated form Always observe the fully safety information (see cross-references). Health risks CAUTION: Risk of hydrogen explosion The EuroFID requires hydrogen H 2 (pure hydrogen or a hydrogen-helium mixture) for operation. Always observe the notes on explosion prevention. P. 32, 3.3.4 CAUTION: Health risk caused by exhaust gas If there is the risk of formation of hazardous substances resulting from the combustion of the sample gas: Eliminate the exhaust gases in a safe manner. P. 32, 3.4 WARNING: Danger to life/health risk due to leaks in the gas path If the device measures toxic gases: Ensure suitable safety measures. Accuracy of the measured values CAUTION: Risks resulting from incorrect or incomplete calibration If the EuroFID is not correctly calibrated, the measured values are either incorrect or inaccurate. This can have dangerous consequences if the measured values are used directly for the control of production processes or for providing warnings for dangerous gas concentrations. Calibrate the device after each start-up ( P. 151, 12.5). Check that the setpoint value is correct ( P. 149, 12.4.2). Calibrate the device regularly during operation. EuroFID Operating Instructions 8011094 V2.3 SICK AG 13

Important Information 1.3 Main instructions for operation Start-up Ensure gas tightness; check the filters, valves etc. Ensure correct supply of operation gases (specifications P. 194, 16.6). After start-up wait until the warm-up period has elapsed (approx. 2 hours). Then calibrate the device ( P. 145, 12). Operational state Observe the LED displays: Alarm (red) = measured value is/was outside the threshold values Fault (yellow) = malfunction in the measuring system; the measured values are not valid Service (yellow) = action by user required (service requirement) OK (green) = EuroFID measuring system is ready for operation; meas. value is valid Observe the messages at the bottom of the display. If Alarm is displayed Check the current measured value. Assess the situation. Take appropriate action to deal with this situation during operation. If the alarm message is self-locking: Cancel the alarm message ( Reset P. 130, 11.13) as soon as the measured value is inside the threshold value. In hazardous situations Switch off the emergency off switch/main switch of the higher-level system. The mains switch of the EuroFID is on the rear of the operating unit ( P. 59, Fig. 18). Maintenance Calibrate the device regularly ( P. 145, 12). Clean the integrated sample gas filter regularly (every 2 months P. 162, 14.4). If the EuroFID is used as a gas detector: Check the function of the alarms regularly. NOTICE: Only open the sample gas filter when the Filter change status is activated (procedure P. 163, 14.4.2). Otherwise dust-laden ambient air can enter the measuring system. Soiling which occurs as a result can render the measuring system useless. Shutdown Secure/deactivate connected systems ( P. 156, 13.1.1). Prevent condensation in the measuring system. To this purpose purge the sample gas path with dry gas. The simplest solution: Use the Zero point test function ( P. 153, 12.6.1). Let the analyzer unit cool before starting work on the interior of the device (risk of burns). Fragile sampling probe Only valid for inline and industrial housing type analyzer units. Observe the permissible lifting points ( P. 42, 4.3.1). Do not use the sampling probe as a lifting point. Do not subject the sampling probe to mechanical loads. This could cause breakage of the glass vacuum tube. 14 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Important Information 1.4 Intended use 1.4.1 Purpose of the device The gas analyzer EuroFID is used to measure the total carbon content of hydrocarbon compounds in air. The possible measured concentration ranges from 0.015 ppm to 100 % LEL. The EuroFID can analyze corrosive and condensing gases at gas temperatures up to 350 C (660 F). The EuroFID is tested for suitability for continuous monitoring of the emissions of organically bound carbon according to 13. FICA and TI Air 17. FICA 1.4.2 Installation site The operating unit and analyzer unit ( P. 23, Fig. 2) are generally designed for indoor operation. These devices should not be exposed to direct atmospheric influences (wind, rain, sun). Such influences can damage the devices and negatively affect the measuring accuracy. The inline type analyzer unit can also be used outdoors if it is provided with a hood for weather protection (accessory). The industrial housing type analyzer units can be used outdoors. The terminal box can be used outdoors. The EuroFID is not suitable for operation in potentially explosive atmospheres. The maximum permissible distance between the terminal box and the analyzer unit is 500 m. The standard cable length is 6 m. EuroFID Operating Instructions 8011094 V2.3 SICK AG 15

Important Information 1.4.3 Restrictions of use Explosion protection The EuroFID is not suitable for operation in potentially explosive atmospheres. Operation in potentially explosive atmospheres requires additional safety equipment. Properties of the sample gas The EuroFID should never be used For measuring operationally explosive gas compounds For sample gas compounds which form an explosive mixture with air. If the EuroFID is used for measuring combustible gases or for sample gases which can form a combustible gas mixture with air, there is a potential risk of explosion in the event of a defect in the internal gas paths (leakage). The gas could ignite when it comes into contact with hot surfaces or the FID flame. For such applications: Check which regulations and laws apply at the installation site in such cases. Check whether additional safety equipment has to be installed (e.g. housing enclosure and purging). The sample gas should not contain substances which could chemically corrode the components in contact with the sample gas (materials P. 195, 16.7). Such substances should also not be formed during combustion of the sample gas (in the FID flame). The sample gas should not contain any gas components which could condense in the measuring system (temperature in the measuring system P. 117, 11.10). No solids should be formed during gas combustion.solids in the gas path could obstruct the measuring system. If the inline type analyzer unit is installed: Do not exceed the following temperature limits: Sample gas temperature at the gas inlet of the sensor tube: 350 C (660 F) max. Dewpoint temperature of the sample gas: 200 C (390 F) max. Influence of oxygen (O 2 ) and sulphur dioxide (SO 2 ) in the sample gas If the O 2 concentration in the sample gas fluctuates, the measured values can be corrupted. The EuroFID is set at the works so that the measurement error is not greater than 4 % of the measuring range end value. If the following conditions apply at the same time in the sample gas: SO 2 concentration > 50 mg/m3 O 2 concentration < 15 percent by volume then the measurement error in the measuring range tested for suitability (15 mg/m3 C) is higher than 4 % if H 2 is used as fuel gas. In such cases an H 2 -He mixture must be used as a fuel gas for measurement in the validity range of the suitability test (specification P. 195, 16.6.2). The EuroFID is configured and adjusted accordingly for such applications at the manufacturer's works. For all other applications, H 2 is preferable as a fuel gas. 16 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Important Information 1.5 Responsibility of the user Designated users The gas analyzer EuroFID may only be installed and operated by skilled technicians who, based on their technical training and knowledge as well as knowledge of the relevant regulations, can assess the tasks given and recognize the hazards involved. Correct use Use the device only as described in these Operating Instructions. The manufacturer bears no responsibility for any other use. Perform the prescribed maintenance work. No components may be removed from, added to or changed on the device unless this is described and specified in the official manufacturer information. Otherwise: The device could become dangerous Any warranty by the manufacturer becomes void. The approvals according to the suitability test for the device are rendered invalid. Special local conditions In addition to these Operating Instructions, follow all local laws, technical rules and company-internal operating directives applicable at the respective installation site of the equipment. Responsibility for hazardous substances WARNING: Danger to life/health risk caused by leaks in the gas path If the device measures toxic gases: A leak in the gas path can constitute a serious risk for personnel. Take suitable safety measures. Ensure that the safety measures are complied with. Examples for safety measures: Marking of the device with warning signs Marking of the installation site with warning signs Safety-related instruction of personnel who could be in the vicinity of the installation site. Safeguarding of documents Keep these Operating Instructions ready for reference at all times. They must be passed on to new owners. 1.6 Additional documents Each EuroFID is supplied with a test log containing the most important operating parameters (e.g. measuring range, fuel gas, mains voltage). For device versions with the analyzer unit type Ex1 industrial housing (not described in these Operating Instructions) the separate Additional Operating Instructions for the EuroFID analyzer unit type Ex1 industrial housing also apply. EuroFID Operating Instructions 8011094 V2.3 SICK AG 17

Important Information 18 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Product Description EuroFID 2 Product Description Product identification Functional principle Characteristics Versions EuroFID Operating Instructions 8011094 V2.3 SICK AG 19

Product Description 2.1 Measuring principle Fig. 1 Measuring principle Combustion air (instrument air) U= Sample gas Fuel gas The EuroFID uses a flame ionization detector (FID) for measuring the hydrocarbons. A hydrogen flame supplied by fuel gas and combustion air burns in the FID. The sample gas is routed into this flame. The hydrocarbons contained in the sample gas are split; the produced hydrocarbon fragments are ionized. A stream of ions forms in the electric field and this electrical stream is measured. The measuring signal is proportional to the number of the listed, non-oxidized hydrocarbon atoms. Hydrocarbon atoms which are already oxidized are only partially detected.co and CO 2 are ineffective. The quantitative correlations between the measurement signal and the hydrocarbon concentration in the sample gas is determined by performing reference measurements with calibration gases which do not contain any hydrocarbons (zero gas) or of which the hydrocarbon concentration is known exactly (calibration gas e.g. 80 ppm propane in air). 2.2 Measuring method Instrument air The EuroFID requires hydrocarbon-free instrument air for operation. The instrument air is used in the EuroFID for the following purposes: As induction air for the ejector pump As combustion air for the FID As control air for regulation of the sample gas flow to the FID As zero gas for calibration Heated sensor block To prevent condensation in the sample gas path, the parts in contact with the sample gas (sample gas filter, ejector, sample gas capillaries, bypass orifice plate, sensor) are accommodated in a heated, thermostatically controlled sensor block. The constant temperature is the pre-requisite for a constant sample gas flow to the FID. The temperature in the sensor block depends on the individual measurement application (90 200 C). 20 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Product Description Ejector pump For transporting the sample gas the EuroFID uses a patented jet pump, referred to in these instructions as an ejector pump. The ejector pump does not have any mechanical, moving parts and uses a part of the instrument air as induction air. The sample gas is diluted with the instrument air in the ejector pump. The dilution ratio is variable and depends on three pressure parameters of the ejector pump. These pressure parameters are constantly measured and used for a correction calculation which compensates for the variability of the dilution ratio. The pressure parameters are also used to automatically monitor the function of the measuring system (sample gas volume flow, condition of the sample gas filter, plausibility of the measured values). The induction air is pre-heated in the sensor block. This prevents condensation of elements of the sample gas in the ejector pump. The sample gas is diluted before it is supplied to the FID as the ejector pump is installed upstream from the FID. This reduces the effect of damaging sample gas elements. Sample gas volume flow (to the detector) The internal sample gas system comprises a sample gas capillary, a bypass gas capillary and a pressure controller. The pressure upstream from the sample gas capillary is kept constant to ensure that the volume flow through the sample gas capillary is constant. To this purpose control air is added to the bypass flow downstream from the ejector pump with the aid of a pressure regulator. To this purpose the pressure upstream from the bypass capillary is kept constant. FID The permanent FID flame is supplied with combustion air and fuel gas. Part of the instrument air serves as combustion air. H 2 or an H 2 /He mixture is used as fuel gas ( P. 32, 3.3.4). The volume flow of the fuel gas is kept constant by a system comprising a pressure regulator and a flow controller. If a malfunction occurs during operation which makes operation impossible, the EuroFID switches the fuel gas off internally. The instrument air remains switched on for several minutes to flush the sample gas out of the measuring system. The internal volume flows of each analyzer unit are optimized individually at the manufacturer's works. Supply of calibration gases An internal solenoid value is provided for the supply of both zero gas and span gas during calibration. The respective calibration gas is routed into the installed sample gas filter; pressure and volume flow are dimensioned so that the calibration gas completely displaces the sample gas. The excess calibration gas is discharged through the sample gas inlet. The ejector pump draws the calibration gas out of the sample gas filter. EuroFID Operating Instructions 8011094 V2.3 SICK AG 21

Product Description 2.3 Measuring ranges Measuring ranges The EuroFID has 6 measuring ranges. Each measuring range starts at 0. The measuring range end values vary by the factor 10. The physical unit can be selected ( P. 127, 11.11.10). The measuring ranges can be modified by changing the end value of the largest measuring range ( P. 127, 11.11.10). The smaller measuring ranges are automatically derived from the largest measuring range and are therefore not variable. Table 1 Alternative scaling The EuroFID is calibrated at the works with propane, i.e. the hydrocarbon measurement is modified for propane. Measuring ranges (example) Measuring range 1 Measuring range 2 Measuring range 3 Measuring range 4 Measuring range 5 Measuring range 6 0 2 ppm 0 20 ppm 0 200 ppm Propane 0 2000 ppm 0 20000 ppm 0 200000 ppm It is possible to reference the measuring ranges to another physical unit (e.g. mg/m3) or another substance (e.g. butane). To this purpose corresponding conversion factors can be set ( P. 104, 11.3). 22 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Product Description Fig. 2 EuroFID device modules (overview) Operating unit type 19" slide-in enclosure with integrated terminal box Operating unit type 19" slide-in enclosure Operating unit type ½-19" slide-in enclosure Terminal box Analyzer unit type industrial housing Analyzer unit type inline Analyzer unit type wall housing Analyzer unit type 19" slide-in enclosure EuroFID Operating Instructions 8011094 V2.3 SICK AG 23

Product Description 2.4 Device modules 2.4.1 Analyzer units Fig. 3 Types Analyzer unit type wall housing : This analyzer unit is designed for installation in an outer housing which protects it against general environmental influences (e.g. measuring cabinet). The measuring system is mounted on a base plate under a protective hood. The sample gas must be supplied through a heated sample gas line. Analyzer unit type 19" slide-in enclosure : In this version the measuring system is installed in a 19" rack. The sample gas must be routed in the same manner as for the analyzer unit type wall housing. Analyzer unit type inline : A flange, a sampling probe and the measuring system form one unit. The sample gas is taken directly from the process. The analyzer unit is mounted with the flange directly on the process. The outer housing protects the measuring system, can be quickly removed and can also be equipped with a fan (option). A hood for weather protection is available as an accessory. Analyzer unit type industrial housing : This is a special version of the inline type in which the measuring system is accommodated in an enclosed housing. It is equipped with a flange with a sampling probe in the same way as the inline type and is directly mounted on the process. The industrial housing is either equipped with housing ventilation or an air conditioner and features a frost-protection heater. Design of the analyzer Analyzer unit: Design of the analyzer A B C D E Electronic components (with voltage converters) Sensor block heated (to prevent condensation in the measuring system) Ejector pump Sample gas filter Pneumatic components (pressure regulator, flow controller, solenoid valves) The individual operating parameters are the analyzer unit are programmed in the electronic section (e.g. characteristic curve of the ejector pump, calibration of the pressure sensors, data of basic calibration). When the system is started, the operating unit takes these operating parameters from the analyzer unit. Integrated sample gas filter The integrated sample gas filter filters particles from the sample gas before the sample gas enters the measuring system. Filter soiling is automatically monitored by the EuroFID. If the filter requires cleaning, the malfunction message Service requir. is activated. 24 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Product Description 2.4.2 Operating units Types 19" slide-in enclosure for installation in 19" frame (3 HU) ½-19" module for installation in 19" racks (4 HU) Diagrams with dimensions P. 189, 16.1.2 Contents Microcomputer system Operating elements Display for measurement display and user interaction Keypad LEDs (signal lamps) Signal connections Digital interface Option: Electronic card for the flow barrier option Option: Fitted terminal box (only for 19" slide-in enclosure type). An operating unit can only control and evaluate one operating unit. The operation concept complies with the recommendations of the standards committee of the German chemical industry (NAMUR). 2.4.3 Terminal box Versions Terminal box in its own housing ( P. 190, Fig. 39) Terminal box integrated into the operating unit 19" slide-in enclosure type Terminal box integrated into the analyzer unit industrial housing type Functions Cable connections for the analyzer unit Voltage converters for the analyzer unit Voltage supply for the fan of the inline outer housing Control of the solenoid valve of the flow barrier option EuroFID Operating Instructions 8011094 V2.3 SICK AG 25

Product Description 2.5 Additional equipment 2.5.1 Device options Option for Flow barrier 1 Analyzer unit type inline Analyzer unit type industrial housing Housing fan Analyzer unit type inline Air conditioner Analyzer unit type industrial housing 1 prevents process gas (sample gas) flowing from the opened filter when maintenance work is being performed on the sample gas filter 2.5.2 Accessories Accessory components Information for Hood for weather protection P. 44, 4.3.3 Analyzer unit type inline Mounting connections P. 197, Fig. 40 Analyzer unit type inline Analyzer unit type industrial housing Heat insulation flange for mounting connections P. 197, Fig. 41 Analyzer unit type inline Shut-off fitting P. 199, Fig. 43 Analyzer units Terminal modules P. 67, 7 Counterparts of the plug connectors large connector set1 Operating units P. 57, 6 Counterparts of the plug connectors small connector set2 1 All D-SUB plug connectors + Power mains connection 2 D-SUB plug connectors Analyzer assembly, Data line Power mains connection 26 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Project Planning EuroFID 3 Project Planning Scope of delivery Overview of the installation Operating materials Gas supply Exhaust gas venting EuroFID Operating Instructions 8011094 V2.3 SICK AG 27

Project Planning 3.1 Scope of delivery Standard scope of delivery 1 analyzer unit with 3 m connection cable to the terminal box (if not integrated into the industrial housing) 1 operating unit 1 terminal box (if not integrated into the operating unit or the industrial housing) with 6 m connection cable to the operating unit 1 mains cable, 3 m long with plug connector for connection to the terminal box 4 screws for flange + 1 flange seal (only with the analyzer unit inline type) 1 individual test log 1 Operating Instructions NOTICE: for analyzer unit types inline and industrial housing The surrounding tube of the sampling probe contains a glass vacuum tube. Incorrect use can damage the sampling probe. Observe the safety note on the lifting points ( P. 42, 4.3.1). NOTICE: Soiling in the gas paths can damage the analyzer. Only remove protective caps from the gas connections when the gas lines are connected. Possible accessories (options) Mounting connection for the inline type analyzer unit Hood for weather protection for gas analyzer type inline Shut-off fitting (for gas supply) Solenoid valve (for the flow barrier option) Terminal module 28 EuroFID Operating Instructions 8011094 V2.3 SICK AG

Project Planning 3.2 Overview of installation work 3.2.1 Required resources (overview) Required resource Notes, requirements Note Instrument air Constant supply of the analyzer unit with P. 31, 3.3.3 technical compressed air CH-free; purity depending on the P. 194, 16.6.1 application and measuring range Fuel gas Continuous supply of the analyzer unit P. 32, 3.3.4 Normally from compressed air cylinders H 2 or H 2 /He mixture, depending on the P. 195, 16.6.2 device version Leakage monitoring For warning of explosion risk in the event of P. 32, 3.3.4 device1 H 2 leakage Pressure reducer For instrument air P. 31, 3.3.3 Pressure monitor 1 Shut-off valves 1 Heated sample gas For fuel gas Or other condensation-free supply of the P. 32, 3.3.4 P. 35, 3.5.2 line2 sample gas to the analyzer unit Span gas Only during calibration; hydrocarbon P. 147, 12.3 concentration depending on the measuring range Exhaust gas lines Exhaust P. 32, 3.4 Bypass2 Power supply Mains connection on the operating unit P. 59, 6.2 Ventilation/air conditioning If the ambient temperature exceeds 40 C during operation 3 1 Recommendation 2 Only for the analyzer unit types wall housing and 19" slide-in enclosure 3 Take the lost heat of the analyzer unit into account (heated sensor block) EuroFID Operating Instructions 8011094 V2.3 SICK AG 29

Project Planning 3.2.2 Mechanical installations (overview) The following system components must be installed: Component Installation site, requirements Detailed notes Supply line or Suitable pressure reducer P. 31, 3.3.3 compressed air Gas line to the analyzer unit cylinders for instrument air Oil-free installation Compressed gas cylinder(s) for fuel gas 3.2.3 Mains connection (overview) At a suitable location which meets the safety requirements Suitable pressure reducer Gas line to the analyzer unit Leakage monitoring device 1 P. 32, 3.3.4 Analyzer unit Wall housing type: In an enclosed P. 38, 4.1 interior (e.g. system cabinet) 19" slide-in enclosure type: In 19" P. 40, 4.2 frame Inline type: On a mounting connection P. 42, 4.3 Industrial housing type: On a mounting P. 47, 4.4 connection Shut-off valves Near the analyzer unit 2 Refer to Analyzer Solenoid valve 3 Near the analyzer unit unit Terminal box 4 Near the analyzer unit 5 P. 53, 5 Operating unit Near the 6 external terminal box 4 or the P. 57, 6 analyzer unit Electrical Analyzer unit ( terminal box)4 P. 37, 4 connections Analyzer unit Signal connections as required P. 60, 6.3 1 (recommendation) 2 Pre-assembled shut-off fitting available as accessory 3 Only for devices with the flow barrier option 4 Not for device versions with an integrated terminal box 5 Standard length of the connection cable: 3 m 6 Standard length of the connection cable: 6 m The mains voltage for all device modules is supplied through the operating unit ( P. 59, 6.2). An additional, separate mains switch must normally be installed ( P. 59, 6.2.1). The terminal box receives the mains voltage from the operating unit and in turn supplies the analyzer unit with operating voltage. 30 EuroFID Operating Instructions 8011094 V2.3 SICK AG