Teledyne GC-Pro-FID User Manual
INSTRUCTION, OPERATING AND
MAINTENANCE MANUAL FOR
GC-PRO FID
P/N M82956
DATE 3/28/13
Toxic and/or flammable gases or liquids may be present in this monitoring system.
Personal protective equipment may be required when servicing this instrument.
Hazardous voltages exist on certain components internally which may persist for
a time even after the power is turned off and disconnected.
Only authorized personnel should conduct maintenance and/or servicing. Before
conducting any maintenance or servicing, consult with authorized
supervisor/manager.
Teledyne Analytical Instruments
DANGER
GC-Pro FID
Copyright © 2013 Teledyne Analytical Instruments
All Rights Reserved. No part of this manual may be reproduced, transmitted, transcribed,
stored in a retrieval system, or translated into any other language or computer language in
whole or in part, in any form or by any means, whether it be electronic, mechanical,
magnetic, optical, manual, or otherwise, without the prior written consent of Teledyne
Analytical Instruments, 16830 Chestnut Street, City of Industry, CA 91748.
Warranty
This equipment is sold subject to the mutual agreement that it is warranted by us free from
defects of material and of construction, and that our liability shall be limited to replacing or
repairing at our factory (without charge, except for transportation), or at customer plant at
our option, any material or construction in which defects become apparent within one year
from the date of shipment, except in cases where quotations or acknowledgements provide
for a shorter period. Components manufactured by others bear the warranty of their
manufacturer. This warranty does not cover defects caused by wear, accident, misuse,
neglect or repairs other than those performed by Teledyne or an authorized service center.
We assume no liability for direct or indirect damages of any kind and the purchaser by the
acceptance of the equipment will assume all liability for any damage which may result from
its use or misuse.
We reserve the right to employ any suitable material in the manufacture of our apparatus,
and to make any alterations in the dimensions, shape or weight of any parts, in so far as
such alterations do not adversely affect our warranty.
Important Notice
This instrument provides measurement readings to its user, and serves as a tool by which
valuable data can be gathered. The information provided by the instrument may assist the user
in eliminating potential hazards caused by his process; however, it is essential that all
personnel involved in the use of the instrument or its interface be properly trained in the
process being measured, as well as all instrumentation related to it.
The safety of personnel is ultimately the responsibility of those who control process
conditions. While this instrument may be able to provide early warning of imminent
danger, it has no control over process conditions, and it can be misused. In particular, any
alarm or control systems installed must be tested and understood, both as to how they
operate and as to how they can be defeated. Any safeguards required such as locks, labels,
or redundancy, must be provided by the user or specifically requested of Teledyne at the
time the order is placed.
Therefore, the purchaser must be aware of the hazardous process conditions. The purchaser
is responsible for the training of personnel, for providing hazard warning methods and
instrumentation per the appropriate standards, and for ensuring that hazard warning devices
and instrumentation are maintained and operated properly.
Teledyne Analytical Instruments, the manufacturer of this instrument, cannot accept
responsibility for conditions beyond its knowledge and control. No statement expressed or
implied by this document or any information disseminated by the manufacturer or its
agents, is to be construed as a warranty of adequate safety control under the user’s process
conditions.
Teledyne Analytical Instruments ii
GC-Pro FID
Safety Messages
Your safety and the safety of others are very important. We have
provided many important safety messages in this manual. Please read
these messages carefully.
A safety message alerts you to potential hazards that could hurt you
or others. Each safety message is associated with a safety alert symbol.
These symbols are found in the manual and inside the instrument. The
definition of these symbols is described below:
GENERAL WARNING/CAUTION: Refer to the
instructions for details on the specific danger. These
cautions warn of specific procedures which if not
followed could cause bodily Injury and/or damage the
instrument.
No
Symbol
CAUTION: HOT SURFACE WARNING: This warning is
specific to heated components within the instrument.
Failure to heed the warning could result in serious burns
to skin and underlying tissue.
WARNING: ELECTRICAL SHOCK HAZARD: Dangerous
voltages appear within this instrument. This warning is
specific to an electrical hazard existing at or nearby the
component or procedure under discussion. Failure to heed
this warning could result in injury and/or death from
electrocution.
Technician Symbol: All operations marked with this
symbol are to be performed by qualified maintenance
personnel only.
NOTE: Additional information and comments regarding
a specific component or procedure are highlighted in the
form of a note.
STAND-BY: This symbol indicates that the instrument is
on Stand-by but circuits are active.
Teledyne Analytical Instruments iii
GC-Pro FID
CAUTION: THE ANALYZER SHOULD ONLY BE USED FOR THE
PURPOSE AND IN THE MANNER DESCRIBED IN
THIS MANUAL.
IF YOU USE THE ANALYZER IN A MANNER OTHER
THAN THAT FOR WHICH IT WAS INTENDED,
UNPREDICTABLE BEHAVIOR COULD RESULT
POSSIBLY ACCOMPANIED WITH HAZARDOUS
CONSEQUENCES.
This manual provides information designed to guide you through the
installation, calibration and operation of your new analyzer. Please read
this manual and keep it available.
Occasionally, some instruments are customized for a particular
application or features and/or options added per customer requests.
Please check the front of this manual for any additional information in
the form of an Addendum which discusses specific information,
procedures, cautions and warnings that may be specific to your
instrument.
Manuals do get misplaced. Additional manuals can be obtained from
Teledyne at the address given in the Appendix. Some of our manuals are
available in electronic form via the internet. Please visit our website at:
www.teledyne-ai.com.
Teledyne Analytical Instruments iv
GC-Pro FID
Additional Safety Information
DANGER
COMBUSTIBLE GAS USAGE
This is a general purpose instrument designed for use in a
non-hazardous area. It is the customer's responsibility to
ensure safety especially when combustible gases are being
analyzed since the potential of gas leaks always exist.
WARNING
The customer should ensure that the principles of operating
of this equipment are well understood by the user. Misuse of
this product in any manner, tampering with its components,
or unauthorized substitution of any component may
adversely affect the safety of this instrument.
Since the use of this instrument is beyond the control of
Teledyne, no responsibility by Teledyne, its affiliates, and
agents for damage or injury from misuse or neglect of this
equipment is implied or assumed.
WARNING: HYDROGEN GAS IS USED IN THIS INSTRUMENT AS
A FUEL. HYDROGEN IS EXTREMELY FLAMMABLE.
EXTREME CARE MUST BE USED WHEN WORKING
AROUND GAS MIXTURES CONTAINING
FLAMMABLE GASES.
A successful leak check was performed at TAI on the
sample system of this instrument prior to calibration,
testing and shipping. Ensure that there are no leaks
in the fuel supply lines before applying power to the
system.
Teledyne Analytical Instruments v
GC-Pro FID
Always purge the entire system before performing
any maintenance and always leak check the system
after removing any tubing or fittings on the sample
system. See the procedures for purging and leak
checking this instrument on the following pages.
If toxic gases or other hazardous materials are
introduced into the sample system, the same
precautions regarding leak checking and purging
apply to the sample lines and sample supply or
delivery lines.
WARNING: ELECTRICAL SHOCK HAZARD.
WITH THE EXCEPTION OF OPENING THE DOOR
AND ADJUSTING THE PRESSURE REGULATORS,
FLOW CONTROLLER, OR OBSERVING THE
PRESSURE GAUGES AND THE FLOWMETER, ONLY
AUTHORIZED AND SUITABLY TRAINED
PERSONNEL SHOULD PERFORM WORK INSIDE OF
THE INSTRUMENT. COMPONENTS WITHIN THE
COVER ON THE INSIDE OF THE DOOR, INSIDE THE
ISOTHERMAL CHAMBER (SAMPLE SYSTEM), AND
ON THE ELECTROMETER-AMPLIFIER PC BOARD
CONTAIN DANGEROUSLY HIGH VOLTAGE
SUFFICIENT TO CAUSE SERIOUS INJURY OR
DEATH.
There are the following three types of inaccessible
shock hazards within the Analyzer:
1. Line voltages and line related voltages such as
115 VAC which exists within the 230 VAC
versions as well. These voltages stop when the
Analyzer is turned off and the mains (line) cord is
removed from the instrument.
2. The sensor anode supply voltage (approximately
250 VDC). This voltage exists on the Flame
Guard, anode power supply, PCB, the
motherboard, and the anode/igniter terminals on
the sensor. THIS VOLTAGE WILL REMAIN
HAZARDOUS FOR MANY MINUTES AFTER THE
ANALYZER HAS BEEN TURNED OFF!
Teledyne Analytical Instruments vi
GC-Pro FID
3. External hazardous voltages which may be
connected to the Analyzer alarm relay
connections.
Procedure for Removal of Internal Inaccessible
Shock Hazards
CAUTION: SERVICING OR MAINTENANCE OF THE ANALYZER
SHOULD ONLY BE DONE BY SUITABLE TRAINED
PERSONNEL. TO AVOID THESE INACCESSIBLE
1. Switch off the power to the Analyzer and remove the main (line)
power cord from the Analyzer.
HAZARDOUS VOLTAGES WHEN SERVICING THE
GC-PRO FID, PERFORM EACH OF THE FOLLOWING
STEPS, IN THE ORDER GIVEN, BEFORE SERVICING
BEGINS:
2. Remove all external voltages from the connections to the alarm
contacts.
3. Wait one minute.
4. Discharge the anode supply voltage.
a. Connect one end of an insulated (to 1000 VDC or more)
clip lead to Analyzer chassis ground (the standoff for the
upper right corner of the mother PCB).
b. Put one end of a 500V rated 1000 ohm resistor in the
other end of the clip lead.
c. Check the voltage between chassis ground (the standoff
for the upper right corner of the mother PCB) and the top
side of R2 at PCB number B74671. It should be between
-5VDC and +5VDC. If is in that range, the inaccessible
hazardous voltage removal procedure is completed, if not
repeat steps 4.a and 4.b.
If it is absolutely necessary to work inside the instrument with power
on, use the ONE HAND RULE:
Work with one hand only.
Keep the other hand free without contacting any other object. This
reduces the possibility of a ground path through the body in case of
accidental contact with hazardous voltages.
Teledyne Analytical Instruments vii
GC-Pro FID
WARNING: THIS INSTRUMENT IS DESIGNED TO BE OPERATED
IN A NONHAZARDOUS AREA. THE ANALYZER USES
HYDROGEN GAS AND/OR OTHER COMBUSTIBLE
GASES IN ITS OPERATION. THIS EQUIPMENT, IF
NOT USED AND MAINTAINED PROPERLY CAN BE
AN EXPLOSION HAZARD. THE ANALYZER,
DEPENDING ON THE APPLICATION, MAY ALSO USE
TOXIC GASES. IT IS THEREFORE, THE
CUSTOMER'S RESPONSIBILITY TO ENSURE THAT
PROPER TRAINING AND UNDERSTANDING OF THE
PRINCIPLES OF OPERATION OF THIS EQUIPMENT
ARE UNDERSTOOD BY THE USER. SINCE THE USE
OF THIS INSTRUMENT IS BEYOND THE CONTROL
OF TELEDYNE, NO RESPONSIBILITY BY TELEDYNE,
ITS AFFILIATES AND AGENTS FOR DAMAGE OR
INJURY RESULTING FROM MISUSE OR NEGLECT
OF THIS INSTRUMENT IS IMPLIED OR ASSUMED.
MISUSE OF THIS PRODUCT IN ANY MANNER,
TAMPERING WITH ITS COMPONENTS OR
UNAUTHORIZED SUBSTITUTION OF ANY
COMPONENT MAY ADVERSELY AFFECT THE
SAFETY OF THIS INSTRUMENT.
CAUTION: WHEN OPERATING THIS INSTRUMENT, THE DOORS
MUST BE CLOSED AND ALL COVERS SECURELY
FASTENED. THE GAUGES MUST BE IN PROPER
WORKING ORDER. DO NOT OVERPRESSURIZE THE
SYSTEM.
READ THIS MANUAL BEFORE OPERATING THE
INSTRUMENT AND ADHERE TO ALL WARNINGS
INCLUDED IN THIS MANUAL.
Teledyne Analytical Instruments viii
GC-Pro FID
Table of Contents
Safety Messages .......................................................................... iii
Additional Safety Information ...................................................... v
List of Figures ............................................................................. xiii
List of Tables .............................................................................. xiv
Introduction ................................................................................... 1
1.1 Main Features of the Analyzer 1
1.2 Principle of Operation 2
1.3 Analyzer Description 3
1.4 Applications 6
Operational Theory ....................................................................... 7
2.1 Introduction 7
2.2 Modes of Operation 8
2.3 Analyzer Subsystems 8
2.3.1 Sample System 9
2.3.2 Gas Flow Control System 9
2.3.3 Fuel and Blanket Air Systems 10
2.3.4 Flame Ionization Detection Cell 10
2.4 Detection Cell 12
2.4.1 Electrometer-Amplifier 13
2.4.2 Anode Power Supply 14
2.4.3 Flame Guard Circuit 14
2.4.4 Flame Ignition Circuit 14
Installation ................................................................................... 15
3.1 Unpacking the Analyzer 15
3.2 Mounting the Analyzer 15
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GC-Pro FID
3.3 User Connections 16
3.3.1 Electrical Power Connections 16
3.3.2 Electronic Connections 16
3.3.2.1 Primary Input Power 17
3.3.2.2 Fuse Installation 18
3.3.2.3 50-Pin Equipment Interface Connector 18
3.3.2.4 Analog Output 18
3.3.2.5 Alarm Relays 20
3.3.2.6 Digital Remote Cal Inputs 22
3.3.2.7 ‘Measure Once’ (or one shot measurement)
contacts 23
3.3.2.9 Pin Out Table 23
3.3.2.10 RS-232 Port 26
3.3.3 Gas Connections 27
3.3.3.1 Effluent 29
3.3.3.2 Sample Bypass Vent 29
3.3.3.3 Fuel and Air Connections 30
3.3.3.4 Sample and Span Gas Connections 30
3.4 Placing the System in Operation 30
Operation ..................................................................................... 31
4.1 Equipment 32
4.2 Preliminary Power-Off Check List 33
4.3 Powering Up the Unit 33
4.4 Activating the Support Gases 35
4.4.1 Air 35
4.4.2 Carrier Gas 36
4.4.3 Span Gas 36
4.4.4 Fuel 36
4.5 Sample Pump 36
4.6 Flame Ignition 36
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GC-Pro FID
4.6.1 Verification of the Flame Guard Circuit 39
4.6.2 Ignition and/or Flame Guard Circuit Failure 40
4.7 Analyzer Operation 40
4.7.1 Default Parameters 41
4.7.2 The HOME Screen 41
4.7.3 The MENU Screen 43
4.7.4 Standby 44
4.7.5 Overlay Chromatogram 45
4.7.6 Timing 47
4.7.7 Temperature 51
4.7.7.1 Thermocouple 52
4.7.7.2 Settings 53
4.7.7.3 PID Settings 53
4.7.7.4 Status 55
4.7.8 Group Setup 55
4.7.9 Analog Adjust 59
4.7.10 Calibration 60
4.7.10.1 Span 61
4.7.10.2 Alt Span 63
4.7.10.3 Auto cal 66
4.7.11 Self Test 67
4.7.12 Settings 69
4.7.12.1 Alarms 70
4.7.12.2 Range 73
4.7.12.3 Change Stream 74
4.7.12.4 Time 75
4.7.12.5 Password 76
4.7.12.6 Communication 77
4.7.13 Analysis Mode 79
4.7.13.1 T-Time 80
Teledyne Analytical Instruments xi
GC-Pro FID
4.7.13.2 T_Cycle 81
4.7.13.3 Chromatogram 82
4.7.13.4 VS Count 83
4.7.13.5 Cold Boot 83
Maintenance & Troubleshooting ................................................ 87
5.1 Measuring Circuit Electrical Checks 88
5.1.1 Anode Voltage Check 88
5.1.2 Electronic Stability 89
5.1.3 Printed Circuit Board Replacement 89
5.1.4 Collector Cable 90
5.2 Temperature Control Electronic Check 90
5.3 Ignition and/or Flame Guard Circuit Checks 91
5.4 Sampling System 92
5.5 Printed Circuit Board Descriptions 93
5.5.1 Flame Guard and Anode Power Supply PCB 93
5.5.2 Proportional Temperature Controller PCB 94
5.5.3 Electrometer-Amplifier PCB 95
Appendix ...................................................................................... 97
A.1 Specifications and Initial Settings: 97
A.2 Recommended Spare Parts List 98
A.3 Drawing List 99
Appendix B ................................................................................ 101
B1. VNC for GC-Pro FID 101
Appendix C ................................................................................ 107
C1 Addendum and Testing Results 107
Teledyne Analytical Instruments xii
GC-Pro FID
List of Figures
Figure 1-1: GP-Pro Front Panel ....................................................... 3
Figure 1-2: GC-Pro FID Rear Panel ................................................ 4
Figure 1-3: Internal PCB Arrangement ............................................ 5
Figure 1-4: GC-Pro FID Internal View ............................................. 6
Figure 2-1: Internal Temperature Controller Screens ...................... 9
Figure 2-2: Typical Piping Diagram for the GC-Pro FID Analyzer . 11
Figure 2-4: Onscreen Re-Ignition Button ....................................... 14
Figure 3-1: GC-Pro FID Electronic Connections ............................ 17
Figure 3-2: Equipment Interface Connector Pin Arrangement ....... 18
Teledyne Analytical Instruments xiii
GC-Pro FID
List of Tables
Table 3-1: Analog Output Connections — Middle Connector ........ 19
Table 3-2: Analog Concentration Output—Example ..................... 20
Table 3-4: Alarm Relay Contact Pins — Top Connector ............... 21
Table 3-5: Remote Calibration Connections — Bottom Connector 22
Table 3-6: ‘Measure Once’ Relay Connections ............................. 23
Table 3-7: Pin out of Alarm Relay O/P (Top) 50 pin D-Sub
Connector .................................................................... 24
Table 3-8: Pin out of Analog Signal (Middle) 50 pin D-Sub
Connector .................................................................... 24
Table 3-9: Pin out of Standard (Bottom) 50 pin D-Sub Connectors25
Table 3-10: Commands via RS-232 Input ..................................... 26
Table 3-11: Required RS-232 Options .......................................... 26
Teledyne Analytical Instruments xiv
GC-Pro FID Introduction
Introduction
The GC-Pro FID Analyzer is a microprocessor controlled digital
instrument incorporating a Flame Ionization Detector (FID) coupled
with a gas separation column and switching valve designed to measure
the quantity of aromatic hydrocarbons present in a positive pressure
sample gas. Up to 8 channels of output are present for measuring
specific analytes in a sample stream. Unlike other benzene or
hydrocarbon analyzers, the GC-Pro FID Analyzer expands its diagnostic
capabilities to look for other aromatics, like toluene, ethyl benzene,
xylenes and other separable species. The GC-Pro FID Analyzer has
multiple channels for measurement with enhanced versatility and
capabilities. Due to its flexibility, it is vitally important that you refer to
Appendix C for the specific factory setup for your application.
The GC-Pro FID features a modern user interface with a touch
screen front panel facilitating operation, calibration, data collection and
display. With the Ethernet connectivity feature, this new interface allows
the instrument to be operated remotely with a VNC software application
from another digital device whereby the analyzer can be accessed,
controlled, data displayed etc. as if the analyzer were physically present.
Although the analyzer arrives already setup for your specific
application, a gas chromatograph mode allows the user to program the
instrument for measuring different species present in the sample.
1.1 Main Features of the Analyzer
The GC-Pro FID Analyzer is sophisticated yet simple to use. A
touch screen display on the front panel provides access all phases of
setup, calibration, operation, and troubleshooting on the GC-Pro FID.
The main features of the analyzer include:
Data acquisition and control functions supporting:
Pressure measurements, 5-Channels
Flow (MFC) measurements, 3-Channels
Oxygen measurements, 6-Channels
Teledyne Analytical Instruments 1
Introduction GC-Pro FID
Temperature measurements and control, 4-Channels
6-Channel Dew point Hygrometer measurements, 6-
Channel
Relay, (10) and solenoid outputs, (4)
Alarm, (3) and over range indication outputs, (4)
4-20mA current loop outputs, 10 channels
HMI through Maple touch sensitive display
The system operates at single phase AC, 110 or 220V 50/60
Hz.
High resolution, accurate readings of concentration.
Versatile analysis with three user-definable analysis ranges.
Microprocessor based electronics: 8-bit CMOS
microprocessor with 32 kB RAM and 128 kB ROM.
Auto ranging allows analyzer to automatically select the
proper preset range for a given measurement. Manual
override allows the user to lock onto a specific range of
interest.
Two adjustable concentration alarms and a system failure
alarm.
Extensive self-diagnostic testing at startup and on demand
with continuous power supply monitoring.
RS-232 serial digital port for use with a computer or other
digital communication device.
8-Analog outputs for concentration and range identification
(0-1 VDC standard and isolated 4-20 mA dc).
Superior Accuracy
1.2 Principle of Operation
The analyzer uses a gas separation column to separate the
component of interest, for instance, benzene, from the other
hydrocarbons in the sample gas. Using a carrier gas and a
microprocessor actuated switching valve, the eluted gas is analyzed in
Teledyne Analytical Instruments 2
GC-Pro FID Introduction
Flame Ionization Detector (FID) and the column is back flushed to
accept the fresh sample for the next cycle. More information is provided
in Section 2.1 Introduction, under Operational Theory. The electrical
output of the electrometer-amplifier is directly proportional to the
concentrations of the ionizable hydrocarbons present over the ranges of
interest.
1.3 Analyzer Description
The standard analyzer is a rack mountable instrument designed to fit
into a standard 19” instrument rack. The front interface screen is
mounted on the left side of the panel. The right side of the panel
includes the gas controls, pressure gauges and flowmeter. The front
panel is shown in Figure 1-1.
Figure 1-1: GP-Pro Front Panel
Gas pressure gauges and controls are mounted on the front panel
adjacent to the touch screen (human/machine interface abbreviated as
HMI) display as shown in Figure 1-1.
At the rear of the instrument are ports for the introduction of air,
fuel, zero, span, and sample gas as well as vent port connections. Three
50-pin user-interface cable connectors route input/output and alarm
signals to external devices. RS232 and a network port are also available
Teledyne Analytical Instruments 3
Introduction GC-Pro FID
at the rear panel for connection to a remote computer or other digital
communication device. Internally, there are two USB user connections
which are used for updating firmware to the PCBs. Figure 1-2 shows the
rear panel including the user connections for the standard instrument
without the auto calibration manifold.
The analyzer is set up for either 120 VAC 60 Hz or 230 50/60 Hz
operation depending on the customer’s requirements. The appropriate
power cord for your unit is included with the analyzer.
Figure 1-2: GC-Pro FID Rear Panel
Internally, there are three isothermal chambers each separately
controlled for precise control and separation of analyzed species. In the
electronics section, internal PC boards are stacked in an assembly in an
order based on inter connectivity needs between the PCBs as well as
their association with other sub assemblies distributed within the system.
See Figure 1-3.
Following is the card stack-up from top to bottom planned inside the
system
Heater card
9261 controller card
Teledyne Analytical Instruments 4
GC-Pro FID Introduction
Analog data acquisition card
Analog signal conditioning card
89C5131 controller card
Figure 1-3: Internal PCB Arrangement
Teledyne Analytical Instruments 5
Introduction GC-Pro FID
Figure 1-4: GC-Pro FID Internal View
1.4 Applications
Monitoring the benzene concentration of carbon dioxide gas
for use in the beverage industry.
Monitoring aromatic contamination in air liquefaction and
other gas production processes.
Gas purity certification.
Detecting trace benzene in ambient air.
Detecting atmospheric pollutants.
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GC-Pro FID Operational Theory
Operational Theory
2.1 Introduction
The GC-Pro FID Analyzer uses a Flame Ionization Detector (FID)
and a Gas Chromatograph (GC) Column to separate and analyze
different factions of a volatile hydrocarbon sample. Using a carrier gas
and a microprocessor actuated switching valve, a fixed volume of
sample is pushed into the Column maintained at a constant temperature.
The eluted gas is analyzed for benzene or other specific analyate
configured for your specific application in a FID detector and the
column is back flushed to accept the fresh sample for the next cycle.
Actual separating and detecting sequence may vary depending on
compounds of interest in the application for which the analyzer is
configured.
The Flame Ionization Detector was selected for use in the GC-Pro
FID Analyzer based on the positive performance and extensive
experience in the use of this detector in other Teledyne analyzers. The
FID has proven itself to be a rugged, stable, long life sensor giving years
of trouble free operation in various applications. Also considering the
fact that the required sensitivity of 100 ppb full scale was achieved, FID
was considered a better choice over the limited life and less reliable
Photo Ionization Detector.
A stainless steel packed column containing Chromosorb Diatomite is
used at a constant temperature of 70°C. Using nitrogen as a carrier gas
and a 5 ml sample loop, benzene elutes from the column within a few
minutes. Additionally, a clear separation is observed from other
aromatic hydrocarbons, namely toluene, ethyl benzene, and xylenes. The
actual temperature setpoint and compound separation for your
instrument may be different depending on the application. It is listed in
the Addendum and Testing Results section of Appendix C.
Teledyne Analytical Instruments 7
Operational Theory GC-Pro FID
2.2 Modes of Operation
The analyzer has 2 modes of operation depending on the position of
the GC Sampling Valve (See Piping Diagram in Figure 2-2). They are:
Sample Mode (position A) and Analysis Mode (position B).
1. Valve Position A—Sampling Mode
In this mode the analyzer configures the operational valve to
back flush the column and charge the sample loop. The Sample
Mode is programmed to continue for a 7 minute period by
factory default; however, it is usually modified to match the
needs of a particular process. The specific timing interval for
your system is listed in the Addendum and Testing Results
section of Appendix C. It is possible to set the Sample Mode
duration up to 25 minutes.
2. Valve Position B—Analysis Mode
In this mode the analyzer configures the sampling valve to feed
the gas in the sample loop through the column and to the
detector. The eluted sample from the column is fed to the FID
for the analysis of the compound of interest in the hydrocarbon
stream. If configured to do so, the analyzer may read the detector
for a programmed 5 second period at some point within this
mode cycle to obtain a baseline reading for further calculation.
This mode is usually programmed to continue until the
compound of interest is fully eluted from the column. It is
possible to set it up to 25 minutes.
During the Analysis Mode, a ‘Peak Detect’ period is programmed at
which time the analyzer reads the detector output. The analyzer
integrates the peak area during this time in conjunction with the baseline
settings to calculate the concentration of the compound of interest. The
calculation is performed at the end of the ‘Peak Detector’ period and the
result is displayed at the end of Analysis Mode.
2.3 Analyzer Subsystems
The Model Analyzer is composed of three subsystems:
1. Sample System
2. Detector Cell
3. Electronic Signal Processing, Display and Control
Teledyne Analytical Instruments 8
GC-Pro FID Operational Theory
2.3.1 Sample System
All components used to control the sample and supporting gases, as
well as the combustion portion of the detector cell, are located inside the
analyzer chassis. They are accessible by opening the front door of the
analyzer.
Adjustments are made using the appropriate control on the front
panel.
The analyzer contains three separate isothermal chambers
‘SAMPLE’, ‘FID’, and ‘COLUMN’ that are controlled by internal
temperature control PCBs. The temperature can be monitored and
controlled using the touch screen main menu item ‘Temperature’. See
Figure 2-1 and Section 4.7.7.
Figure 2-1: Internal Temperature Controller Screens
The sample chamber contains the 10-port GC switching valve and 2
sample loops. The ‘FID’ chamber contains the flame, pressure
regulators, pressure gauges and flow restrictors used by the FID
detector. The ‘COLUMN’ is housed in a separate ‘COLUMN’ enclosure
and maintained at a temperature of 70° C by its PID temperature
controller. The actual temperature setpoint for your instrument may be
different depending on the application. It is listed in the Addendum and
Testing Results section of Appendix C.
2.3.2 Gas Flow Control System
The analyzer is equipped with ports for the introduction of air, fuel,
carrier gas, span, and sample gas. It is imperative that these gases are
supplied at constant pressures using two stage stainless steel diaphragm
gas regulators. The recommended pressure range is 30 to 80 psig;
however, the span gas should be supplied at a pressure of 20 psig to the
restrictor fitting either on the optional auto calibration module or the
span inlet on the rear panel.
Teledyne Analytical Instruments 9
Operational Theory GC-Pro FID
The Piping Diagram for the standard instrument is shown in Figure
2-2. A 10-port 2-position GC sampling valve is used to control and
direct gas flows including sampling, back flush, and carrier gas. The
fixed volume sample loop ensures the same volume of sample injection
in the column every cycle.
If your instrument is fitted with the optional auto calibration module,
a separate compartment containing of a pair of solenoid valves is
installed for controlling the introduction of sample or span gas to the
detector. Calibration can be performed automatically on a programmed
schedule or manually using the front panel interface.
2.3.3 Fuel and Blanket Air Systems
Stable flow is achieved by maintaining a constant pressure across
restrictors upstream from the cell. Each system incorporates an adjustable
pressure regulator, pressure gauge, and restrictor. A flame out light is
included to indicate when the flame fails. A fuel shut-off solenoid valve,
mounted on the line that supplies fuel, stops the fuel flow in case of flame
failure. This valve is located in line with the fuel port.
2.3.4 Flame Ionization Detection Cell
The carrier gas containing sample and fuel are combined within a tee
fitting located in the isothermal chamber. The mixed gas is emitted from
a burner within the sensor assembly. Blanket air is introduced into the
sensor (or cell) by means of a separate fitting that is located in the base
section of the assembly. The upper half of the assembly houses the
anode-igniter, collector, and flame guard thermistor.
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GC-Pro FID Operational Theory
Figure 2-2: Typical Piping Diagram for the GC-Pro FID Analyzer
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Operational Theory GC-Pro FID
2.4 Detection Cell
The upper section of the stainless steel flame ionization cell houses
the cylindrical collector electrode, the high voltage (+260 VDC) anodeigniter coil, and the sensing thermistor of the flame guard circuit (see
cell cross-section in Figure 2-3).
WARNING: DANGEROUS HIGH VOLTAGE EXISTS AT THE
ANODE IGNITER COIL (+260 VDC). DO NOT
ATTEMPT TO DISCONNECT THE IGNITER COIL
CABLE OR DISASSEMBLE ANY OF THE FLAME
IONIZATION CELL COMPONENTS WITHOUT
TURNING OFF THE POWER AND DISCONNECTING
THE POWER CORD.
The collector is interconnected with the electrometer-amplifier PC
board by a coaxial cable. Although the cable and fittings are intended for
coaxial service, the cable is actually being used as a shielded singleconductor connection.
The anode-igniter, as its name implies, serves two functions. When
relay K2 at PCB part number B74671 is energized, the coil becomes an
electrical heating element that glows red-hot and ignites the hydrogen
fuel. When relay K2 at B74671 is de-energized, the coil is connected to
the +260 volt DC terminal of the anode-flame guard power supply PC
board. In this configuration, the necessary potential difference is
established between the coil (anode) and collector to promote ionization
of the burned hydrocarbons. The coil functions as the high voltage anode
in all three-range positions of the selector switch.
The thermistor acts as the sensor in the flame guard circuit. Its
ambient temperature resistance is in the 100 K ohms region. When the
flame is ignited, its resistance is reduced by a factor of 100. The
thermistor is coupled to a semiconductor control circuit on the anodeflame guard power supply PC board, which will be described in a
following section.
The cell electrodes of both the anode-igniter and flame guard
thermistor are connected to the electronics chassis by means of a plug-in
cable.
The electrode section of the cell may be removed for inspection by
turning off the power, disconnecting the electrode lead plug, and
removing the screws, which retain the electrode assembly in the sensor
body.
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GC-Pro FID Operational Theory
2.4.1 Electrometer-Amplifier
The collector cable is coupled directly to a coaxial fitting located on
the electrometer-amplifier PC board. The PC board is located on the side
panel next to but outside of the isothermal chamber. It consists of an
electrometer amplifier and an operational amplifier. This circuit is a very
high-gain, current-to-voltage converter circuit, having an input
impedance measuring in the billions of ohms. It is static sensitive and
highly susceptible to contamination. Special care must be taken in
handling this PC board.
Refer to Section 5.5.3: Electrometer-Amplifier PC Board for more
information concerning the electrometer-amplifier and the other printed
circuits that follow.
Figure 2-3: Flame Ionization Cell
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Operational Theory GC-Pro FID
2.4.2 Anode Power Supply
The high voltage anode power supply components are mounted on
the anode power supply printed circuit board. High voltage regulation is
achieved through the use of series-connected zener diodes. The
simplicity of this circuit’s design can be attributed to the extremely low
current demand of the anode circuit. The positive output voltage is
nominally 125 volts. Output tolerance is ±10 volts from the specified
125 volts.
2.4.3 Flame Guard Circuit
A thermistor-controlled, transistorized switching circuit is employed
to operate a relay in the event of a flame-out condition. A panel indicator
light and fuel shut-off solenoid valve are operated by the relay to alarm
personnel that a flame-out condition has occurred. The fuel shut-off
solenoid valve stops the hydrogen flow.
2.4.4 Flame Ignition Circuit
The flame ignition circuit includes the anode-igniter electrode (in the
detector cell), a transformer, and processor controlled relay. The circuit
is automatically energized when the FID cools due to lack of flame.
If automatic ignition fails five times, there will be a message that
reports this, and the flame can be re-ignited by pressing the re-ignite
icon from the touch screen. See Figure 2-4 and Section 4.6.
Figure 2-4: Onscreen Re-Ignition Button
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GC-Pro FID Installation
Installation
Installation of the GC-Pro FID Analyzer includes:
1. Unpacking
2. Mounting
3. Gas connections
4. Electrical connections
5. Testing the system.
3.1 Unpacking the Analyzer
Although the analyzer is shipped with all the materials you need to
install and prepare the system for operation. Carefully unpack the
Analyzer and inspect it for damage. Immediately report any damage or
shortages to the shipping agent.
3.2 Mounting the Analyzer
The GC-Pro FID is a general-purpose analyzer and is designed with
(non-sealed) enclosures. It must be installed in an area where the
ambient temperature is not permitted to drop below 32ºF or rise above
100ºF. In areas outside these temperatures, auxiliary heating/cooling
must be supplied. The GC-Pro FID enclosure is oil and dust resistant
and although it is designed to resist moisture, it should NOT be
considered completely watertight. Mounting to walls or racks must be
made securely. Avoid locations that are subject to extreme vibration and
sway.
Sufficient space must be provided around and above the analyzer to
accommodate the necessary electrical conduit and plumbing connections
and top cover removal. The top cover must be allowed to be lifted off for
possible service access to all components within the enclosure. Refer to
the system/analyzer outline drawings for dimensions.
Regardless of configuration, the analyzer/system must be installed
on a level surface with sufficient space allocated on either side for
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Installation GC-Pro FID
personnel and test equipment access. Subject to the foregoing, the
Analyzer/system should be placed as close to the sample point as is
possible.
All pertinent dimensions, connecting points, and piping details can
be found in the drawings section as part of the outline, input-output, and
piping diagrams. These drawings are specific to the instrument or
system to which the manual applies.
3.3 User Connections
All user connections are made on the rear panel. Consult the inputoutput and outline diagrams in the drawing section of the manual. Not
all the features displayed may be present in your system. Refer to any
Addenda for additional information that may apply to your instrument.
3.3.1 Electrical Power Connections
The standard analyzer requires a supply of 100-125VAC, singlephase power. Power connections are made at the rear panel of the unit.
Refer to the input-output diagram for more information. The electrical
power service must include a high-quality ground wire. A high-quality
ground wire is a wire that has zero potential difference when measured
to the power line neutral. If you have the 220 VAC option, you will
require 220 or 240 VAC, 50/60 Hz power. Check the analyzer inputoutput diagram, power schematic, outline, and wiring diagrams for
incoming power specifications and connecting points.
CAUTION: PRIMARY POWER TO THE SYSTEM SHOULD NOT
BE SUPPLIED UNTIL ALL CUSTOMERS WIRING IS
INSPECTED PROPERLY BY START-UP PERSONNEL.
3.3.2 Electronic Connections
Figure 3-1 shows the GC-Pro FID rear panel. There are connections
for power, digital communications, and both digital and analog
concentration output.
For safe connections, no uninsulated wiring should be able to come
in contact with fingers, tools or clothing during normal operation.
CAUTION: USE SHIELDED CABLES. ALSO, USE PLUGS THAT
PROVIDE EXCELLENT EMI/RFI PROTECTION. THE
PLUG CASE MUST BE CONNECTED TO THE CABLE
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