EVALUATION REPORT E 2720 K 01

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Published by WIB, November 2001

Index classification 4.2

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TESTA FID 123 analyser

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Germany
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INTERNATIONAL INSTRUMENT USERS' ASSOCIATIONS

SIREP-WIB-EXERA

Members of the international Instrumentation Evaluation Agreement Group of

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the European Organisation for Testing and Certification (EOTC) Registration No 0003
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 CIRCULATION

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the report must not be divulged to persons not employed by SIREP, WIB and EXERA member companies
without the express consent of the issuing organisation.

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ABOUT SIREP-WIB-EXERA

SIREP-WIB-EXERA are international instrument users' associations who collaborate in the sponsoring,
planning and organisation of instrument evaluation programmes. They have the long term objective of

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encouraging improvements in the design, construction, performance and reliability of instrumentation and
related equipment.

SIREP-WIB-EXERA are formally recognised by the European Organisation for Testing and Certification
(EOTC) as the Agreement Group for International Instrumentation Evaluation, Registration No 0003.

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The evaluation of the selected instruments is undertaken by approved, independent laboratories with
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standards.

Each evaluation report describes the assessment of the instrument concerned and the result of the testing.
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No approval or certification is intended or given. It is left to the reader to determine whether the instrument
is suitable for its intended application. All reports are circulated throughout the entire membership of
SIREP-WIB-EXERA.
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INERIS
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KEMA Nederland BV
Utrechtseweg 310, 6812 AR Arnhem

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P.O. Box 9035, 6800 ET Arnhem
The Netherlands
Telephone +31 26 3 56 91 11
Telefax +31 26 3 51 56 06

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KEMA
is an independent company whose goal is to provide international professional
services and know-how, on a commercial basis, in the field of (electrical) energy
systems and the environment, as well as in the area of quality related issues such as

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testing and certification.

Core activities of KEMA are:

* Research and Development

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* Engineering and Consultancy * Testing and Certification
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Subject EVALUATION OF THE TESTA FID 123 ANALYSER

Manufacturer TESTA GmbH

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Report No E 2720 K 01

Index Classification 4.2

Sponsors International Instrument Users' Association WIB and the manufacturer

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Author P.H.J. Gamelkoorn

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EVALUATION UNDERTAKEN AND REPORT PREPARED BY KEMA NEDERLAND B.V.

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Author P.H.J. Gamelkoorn

KEMA Approval J.H.M. Overbeek

 CONTENTS

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Section Page

1 INTRODUCTION 1

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2 MAJOR FINDINGS AND COMMENTS 2
2.1 Instrument performance 2
2.2 Comments on construction and use 7
2.3 Comments on documentation 7

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2.4 Cost of ownership 7
2.5 Manufacturer's comments 7

3 TEST RESULTS 8
3.1 Results' summary 8

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4 MANUFACTURER'S DATA 18

5 OPERATING PRINCIPLE AND CONSTRUCTION 20

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5.1 Operating principle 20
5.2 Mechanical construction 20

6 TEST METHODS AND REFERENCES 21

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6.1 Test methods 21

6.2 References 25
6.3 Definitions 25

APPENDIX I EMC
APPENDIX II Manufacturer's QA procedures and instrument status
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APPENDIX III Information on the product evaluated by WIB

FIGURES

Fig 1 External view of instrument 6

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Fig 2 Measured error, C2H4 12

Fig 3 Conformity, C2H4 12
Fig 4 Dead band, C2H4 13
Fig 5 Ambient temperature variations 13
Fig 6 Long term drift, C2H4 14
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Fig 7 Sample pressure variation, C2H4 14

Fig 8 Sample temperature variation, C2H4 15
Fig 9 Sample flow variation 15
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Fig 10 Start-up drift zero C2H4 16

Fig 11 Start-up drift span C2H4 16
Fig 12 Basic test arrangement 23
Fig 13 Axes of vibration 23
 Fig 1 EXTERNAL VIEW OF INSTRUMENT

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FID 123

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The High Temperature Flame Ionisation Detector (FID) measures Total Hydro-
Carbons in catalytic and thermal after-burner plants, waste gas industries, room and
environmental air, solvent recovery plants and vehicle exhaust gases.

Special Benefits:
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Max. sample temperature 300C (572F)

Warm-up from room temperature to 300C (572F) in 20 minutes.
Quick response time
Combustion air from room or compressed air.
Ready for operation quickly.
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Low maintenance costs.

Little service.
Pressure and flow independent over the range of 1,0 bar (14psi) overpressure and
0,3 bar (4psi) vacuum
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FID - 123:
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Corrosion resistant materials

Sample transport by air-injector with 58 psi (input pressure).
 Technical Specifications

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Flame-Ionisation-Detector FID 123

Mains connection: 220V/50Hz (110V/60Hz on request)

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Power input: 400W (approx.), without sample line
Ambient temperature: Max. + 45C (110F)
Reproducibility: Range 1 + 3% all other ranges + 1%
Ranges: 5 measuring ranges

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10/100/1000/10.000/100.000ppm
(other ranges on customer request)
Recorder output: 0-10V / 0-20mA or 2-10V / 4-20mA
Lowest range: 0-10ppm relative to propane (calibration
gas=C3H8)

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Zero & Span gas consumption: 3-4 litres/min.
Zero drift: + 1% in 24 hours
Combustion gas: Either afterpurified Hydrogen or a
Helium/Hydrogen mixture (60/40%)
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Combustion gas consumption: H2 30-49ml/min; H2/He 80-100ml/min
Supply for heated sample line: Regulated and controlled by thermocouple
Max. sample temperature: 300C (572F) in continous operation
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Warm-up time: From room temperature to 300C (572F)

in approx. 20 min
Response time: 1-2 sec. from rear panel of unit
Size: H=220mm; B=440mm; D=350mm for both
desktop and 19" rack version
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Weight: 15kg (approx.)

Combustion air consumption: 0,4 litres/min
Flame control: With thermocouple, indicated by lamp

Optional Extras:
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Automatic Zero & Span

without intervention: Cycle intervall 30 min.;
adjustable between 30 min. and 49,5h
Span/Zero gas from 0,5 min. to 4,5min
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Alarm contacts: Between 0-10V continously adjustable,

potentialfree contacts (24V/1A)
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Automatic flame ignition

and H2 cut off: By mains failure or "flame-out"
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TESTA FID 123 PROCESS ANALYSER

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Author: P.H.J. Gamelkoorn

Reported by KEMA Nederland B.V. on behalf of International Instrument Users' Association WIB and the
manufacturer

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SIREP-WIB-EXERA Report E 2720 K 01
Index classification 4.2

The full report comprises 26 pages: the abridged report comprises the first 7 pages of the full report

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November 2001

1 INTRODUCTION
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This report describes the evaluation of a model Testa FID (Flame Ionisation Detector) Analyser
manufactured by Testa GmbH. The instrument was a standard production model manufactured in
Germany.
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The instrument was evaluated to a test programme drawn up by WIB and KEMA Nederland B.V. and
agreed with WIB and the manufacturer. The test programme was based on IEC 770 : Part 1 : 1984
Methods of evaluating the performance of transmitters for use in industrial-process control systems.

The evaluation report was based on the discussions with WIB members, the TNO memorandum
(assessment of TV-Reports: HEC-MEMO-950031) and two reports performed by TV (references:
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Report no. 1529455 (according to the specifications in 13. BlmSchV) from August 1992 and the
additional Report no. 24014741 (according to the specifications in 17. BlmSchV) from February 1996).

The tested analyser is designed for continuous on line measurement of hydrocarbon in gaseous process
streams.
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The tests were performed in the following concentration range:

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C2H4 range 0 - 100 ppm(v) (about 0 - 100 mgC/m ).

All manufacturer's specifications are given as percentages of full scale, unless otherwise stated
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(dimensions given by the manufacturer):

linearity error : less than 1%
zero drift : 1% in 24 hours
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ambient temperature : max +45 C

voltage : 220 V
frequency : 50 Hz
power : approx. 600 W without specimen line

Page 1 of 26 E 2720 K 01
 sample flow : 3-4 l/min
sample temperature : max 200 C

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smallest measuring range : 0-10 ppm(v) C3H8
warming-up time : from 20 C to 200 C approx. 15 min.
outputs : 0-10 V/0-20 mA or 2-10 V/4-20 mA
weight : approx. 15 kg.

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The sample chamber and detector were thermostatted at 180 C.

The instrument was delivered on 25 January 2001. The instrument was evaluated over a period of 6
months from January to July 2001. The draft report was issued in August 2001.

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2 MAJOR FINDINGS AND COMMENTS

These findings are summarised for ready reference and to give an overview of the evaluation. For a

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complete assessment of the instrument the report must be read and considered as a whole.

2.1 Instrument performance

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All errors and changes are expressed as percentage output span unless otherwise stated. Concen-
trations are expressed as parts per million by volume (ppm(v)). Flow rates are expressed as l/h under
normal conditions (0 C and 1013.3 mbar (abs)).
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All errors and changes are indicated as falling within arbitrary bands and compared with the
manufacturer's specification as folllows:

within the manufacturer's specification

x outside the manufacturer's specification
i no manufacturer's specification
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Test Results expressed as error % span Other results Manufacturers
< 0.1 < 0.5 < 1.0 < 5.0 specification

ACCURACY
Measured error i

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Conformity i

Maximum hysteresis i

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Repeatability <1%

Dead band
at zero i
at 25% span i
at 40% span i

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Detection limit (3s) i

ENVIRONMENTAL TESTS
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Mounting position
zero shift i
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span change i

Vibration
10 to 60 Hz at 0.2g amplitude
(axes are given in Fig 13)
zero shift i
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span change i

Shock
zero shift i
span change i
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Ambient temperature variations

temperature range of +5C to +45C max. + 45 C
zero shift (as %/C) i
span change (as %/C) i
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 Test Results expressed as error % span Other results Manufacturers

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< 0.1 < 0.5 < 1.0 < 5.0 specification

ERRORS

Drift
start up power on zero drift 1%/24hours

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zero shift at 5% span after 15 min
(ignition)
5 min i
1h i
4h i

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span change at 45% span
5 min i
1h i
4h i

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long-term (limits over 33 days)
zero shift i
span change i
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Over-range
zero shift i
span change i
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OUTPUT SIGNAL INTERFERENCES

Electromagnetic Compatibility Appendix I

Isolation resistance > 100 M:

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DYNAMIC BEHAVIOUR

Step response
lag time (T10) x (6 s) 1-2 sec.
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response time (T90)

x (10 s)

FUNCTIONAL TESTS
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Sample pressure variation

(range 80 to 120 kPa)
zero shift (as %/mbar)
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i
span change (as %/mbar) i

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 Test Results expressed as error % span Other results Manufacturers

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< 0.1 < 0.5 < 1.0 < 5.0 specification

Sample temperature variation

(range 25 to 250C)
zero shift (as %/C) i
span change (as %/C) i

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Sample flow variation
(range 666 ml/min to 1232 ml/min)
zero shift (as %/100 ml/min) i

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span change (as %/100 ml/min) i

INTERFERENCE TESTS

Cross sensitivity
50.0 ppm(v) C2H4 in N2 reference

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49.9 ppm(v) C2H4 in air
zero shift i
span change i
31.2 ppm(v) C4H10 in air
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zero shift i
span change + 10.1%
49.9 ppm(v) C2H4/101 ppm(v) NO2 in air
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zero shift i
span change i
49.9 ppm(v) C2H4/101 ppm(v) NO2/
98.7 ppm(v) CO in air
zero shift i
span shift i
51.7 ppm(v) C2H4/10.2 vol% CO2 in air
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zero shift i
span change i
49.9 ppm(v) C2H4/2.9 vol% H2O in air
zero shift i
span change i
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span concentration 15 mgC/m
15 vol% CO2 in N2
zero shift i
span change i
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272 mg/m NO in N2
zero shift i
span change
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i
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45 mg/m NO2 in N2
zero shift i
span change i

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 Test Results expressed as error % span Other results Manufacturers

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< 0.1 < 0.5 < 1.0 < 5.0 specification
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1216 mg/m SO2 in N2
zero shift i
span change i
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229 mg/m NH3 in N2

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zero shift i
span change i
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80 mg/m HCl in N2
zero shift i

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span change i
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47 g/m H2O in N2
zero shift i
span change i
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133 g/m H2O in N2
zero shift i

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span change i
20.8 vol% O2 in N2
zero shift i
span change i
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10.4 vol% O2 in N2
zero shift i
span change i
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 2.2 Comments on construction and use

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Construction

The analyser is housed in a metal casing. The analyser is robust and well constructed. The quality of
materials and standard of finish appears to be good.

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Installation and Commissioning

Installation, connection and use of the analyser were straightforward procedures.

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2.3 Comments on documentation

The user manual (available in the English language as well as the German version) supplied with the
instrument gives comprehensive information on:
introduction

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installation
commissioning
calibration diagram
flow diagram
spare parts list
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technical specification
circuit diagram.
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Only simplified circuit diagrams are included in the manual.

The readableness of the manual was good.

2.4 Cost of ownership

After installation of the analyser, the cost of ownership is based on the following items:
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x frequency of regular maintenance of the analyzer

x the costs and use of materials

the costs and use of spare parts

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The manufacturer doesnt specify the maintenance interval and frequency of changing filters etc.

2.5 Manufacturer's comments

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Dynamic behaviour: Lag time and response time can be adjusted via bypass flow. If we increase the
bypass stream we can get a response time up to 10 ms.
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The presentation of the results as an error or deviation as percentage output-span is very confusing
form of presentation. We ask herewith to present this in a better way. For example in absolute figures.

Page 7 of 26 E 2720 K 01
 3 TEST RESULTS

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Unless otherwise stated, the tests were performed at 20 2 C, relative humidity 45 to 60 %, supply
voltage 230 2 V, frequency 50.0 0.5 Hz at the concentration range for C2H4 0-100 ppm(v).

The analogue output 4-20 mA was recorded by means of a datalogger.

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Unless otherwise stated, all errors are expressed as percent output span.
Unless otherwise stated, the analyser was tested at 0% and 50% span.

The estimated uncertainties (of the test results) for the different tests were:

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measured error : 0.2 %
conformity : 0.2 %
repeatability : 0.6 %
dead band : 6%

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drift : 11 %
step response : 14 %
sample pressure variation : 11 %
sample flow variation : 11 %
sample temperature variation :
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11 %
cross sensitivity : 11 %

The basic test gas concentration was about 50 ppm(v) C2H4 in N2.
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The uncertainty of the concentration of the gas used was 1 %.

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 3.1 Results' summary

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Test Test results Manufacturer's specification/
Report ref

ACCURACY

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Measured error IEC 770; 6.1.2, (Fig 2)
limits of average error -0.07 to +0.04%
average zero error < -0.01%
average span error < -0.01%

Conformity IEC 770; 6.1.3, (Fig 3)

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limits of average error -0.07 to +0.04% < 1%

Maximum hysteresis +0.05% IEC 770; 6.1.4

Repeatability 0.06% IEC 770; 6.1.5

< 1%

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Dead band IEC 770; 6.1.6, (Fig 4)
at zero < 0.1%
at 25% span < 0.1%
at 40% span < 0.1%
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Detection limit (3s) < 0.1%

ENVIRONMENTAL TESTS
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Mounting position zero shift span change IEC 770; 6.2.12

10 right < 0.1% < 0.1%
10 left < 0.1% +0.22%
10 back < 0.1% +0.44%
10 front < 0.1 - 0.20%

Vibration
10 to 60 Hz at 0.2g (axes are given in Fig zero shift span change IEC 770; 6.2.14
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11) < 0.1% +1.0% After vibrating, the analogue output lines
inside the analyser were vibrated loose from
the connector.

Shock zero shift span change

< 0.1% -0.2%
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Ambient temperatures TV-Report No. 24014741; 5.2.2, 5.2.3 and

temperature range of +5C to +45C 5.2.4 and TUV-Report No. 1529455; 5.2.2,
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range analyser 15 mgC/m 5.2.3 and 5.2.4 (Fig. 5)
maximum zero shift coefficient +0.06%/C
(from initial 25 C) Max. ambient temperature + 45C
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maximum span change coefficient +0.2%/C

(from initial 25 C)
maximum zero shift 0.6% (at +35C and at +45C)
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maximum span change +2.3% (at +15C)

final zero shift < 0.1%
final span change -1.8%

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Test Test results Manufacturer's specification/
Report ref

ERRORS

Drift

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start-up IEC 770; 6.3.1 (Fig 10 and 11)

output after (relative to that after 4 h):

after 15 min. warming-up time after
switching power on, analyser could be zero shift span change
ignited at 5% span at 45% span

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- +5 min < 0.1% +1.0%
- +1 h < 0.1% < 0.1%
- +4 h < 0.1% < 0.1% reference

long-term zero shift span change IEC 770; 6.3.2, (Fig 6)

limits over 32 days +0.05% +4.3%

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Over-range IEC 770; 6.2.15
zero shift +0.05% (performed at 2000% span)
span change +0.02%

OUTPUT SIGNAL INTERFERENCES

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Electromagnetic Compatibility Appendix 1

Germanischer Lloyd; Test Specification

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Isolation resistance
each test > 100M Nr.1; chapter 7
(500 V applied between supply, output and
input terminals)

DYNAMIC BEHAVIOUR

Step response
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- lag time (T10) 6s TV-Bericht Nr. 24014741

- response time (T90) 10 s 1-2 seconds
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Test Test results Manufacturer's
specification/
Report ref

FUNCTIONAL TESTS

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Sample pressure variation WIB test set-up, (Fig 7)
(range 800 to 1200 mbar (abs.))
zero shift +0.00002 %/mbar
span change +0.0006 %/mbar
regression formula

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y=ax+b
y=change, %
x=pressure, mbar (abs.)
factors at 0% span a=+0.00002 b=+0.017
factors at 50% span a=+0.0006 b=-0.64

Sample temperature variation WIB test set-up, (Fig 8)

(range 25 to 250 C)

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zero shift +0.0007%/ C
span change -0.0004%/ C
regression formula
y=ax+b
y=change, %
m
x=temperature, C
factors at 0% span a=+0.0007 b=-0.026
factors at 50% span a=-0.0004 b=+0.051
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Sample flow variation WIB test set-up, (Fig 9)

(range 666 ml/min to 1232 ml/min)
zero shift < 0.1%/ ml/min
span change < 0.1%/ ml/min
regression formula
y=ax+b
y=change, %
x=sample flow ml/min
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factors at 0% span a=0 b=0

factors at 50% span a=-0.00004 b=+0.035
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Test Test results Manufacturer's
specification/
Report ref

INTERFERENCE TESTS

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Cross sensitivity zero shift span change WIB test set-up
50.0 ppm(v) C2H4 in N2 reference reference
49.9 ppm(v) C2H4 in air + 0.3% - 3.2%
31.2 ppm(v) C4H10 in air + 0.3% + 10.1%
49.9 ppm(v) C2H4/101 ppm(v) NO2 in air + 0.7% - 2.3%

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49.9 ppm(v) C2H4/101 ppm(v) NO2/
98.7 ppm(v) CO in air + 1.0% - 3.3%
51.7 ppm(v) C2H4/10.2 vol% CO2 in air - 0.1% - 4.6%
49.9 ppm(v) C2H4/2.9 vol% H2O in air + 0.2% - 3.9%

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span concentration 15 mgC/m TV-Bericht Nr. 24014741
15 vol% CO2 in N2 < 0.5% < 0.5%

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3
272 mg/m NO in N2 < 0.5% < 0.5%
3
45 mg/m NO2 in N2 < 0.5% < 0.5%
3
1216 mg/m SO2 in N2 < 0.5% < 0.5%
3
229 mg/m NH3 in N2 < 0.5% < 0.5%
3
80 mg/m HCl in N2 < 0.5% < 0.5%
3
47 g/m H2O in N2 + 0.5%
m+ 0.9%
3
133 g/m H2O in N2 + 0.6% + 1.3%
20,8 vol% O2 in N2 + 1.6% + 1.1%
10,4 vol% O2 in N2 + 0.6% < 0.5%
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0,08

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Average output error (%span)

0,06

0,04

0,02 upscale

0,00 downscale

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average
-0,02
terminal-based straight line
-0,04

-0,06

-0,08

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0 10 20 30 40 50 60
Input (% span)
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Fig 2 Measured error, C2H4
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0,08

0,06
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Average output error (% span)

0,04

0,02
upscale
0,00 downscale
average
-0,02
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-0,04

-0,06

-0,08
0 20 40 60
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Input (% span)
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Fig 3 Conformity, C2H4

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1
0,8

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0,6
Delta output (ppm(v))

0,4
0,2 at 0% span
0 at 25% span
-0,2 at 40% span

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-0,4
-0,6
-0,8
-1
-1 -0,8 -0,6 -0,4 -0,2 0 0,2 0,4 0,6 0,8 1

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Delta input (ppm(v))

Fig 4 Dead band, C2H4

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2,5

1,5
Output error (% span)

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0,5

-0,5 at 0% span
at 15% span
-1,5
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-2,5
25 35 45 35 25 15 5 15 25
Temperature (C)
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Fig 5 Ambient temperature

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5,00

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Average error (% span)

3,00
at 0% span
at 50% span

1,00

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-1,00
0 5 10 15 20 25 30 35

Time (days)

Fig 6 Long term drift, C2H4

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0,20
Deviation from 1013 mbar (% span)

0,15
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0,10

0,05
at 0% span
0,00
at 50% span
-0,05

-0,10
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-0,15

-0,20
750 850 950 1050 1150 1250
Sample pressure (mbar)
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Fig 7 Sample pressure variation, C2H4

Page 15 of 26 E 2720 K 01
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0,25
0,20
Deviation from 25 C (% span)

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0,15
0,10
0,05
at 0% span
0,00
at 50% span
-0,05

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-0,10
-0,15
-0,20
-0,25
0 50 100 150 200 250 300
Sample temperature (C)

Fig 8 Sample temperature variation, C2H4

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0,04
Deviation from 1,2 l/min (%span)

0,03

0,02

0,01
at 0% span
0,00
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at 50% span
-0,01

-0,02

-0,03

-0,04
600 700 800 900 1000 1100 1200 1300
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Sample flow (ml/min)

Fig 9 Flow variation, C2H4

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6,00
5,80

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5,60
5,40
Output (ppm(v))

5,20
5,00 at 5% span
4,80

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4,60
4,40
4,20
4,00
0 50 100 150 200 250

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Time (min)

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Fig 10 Start-up drift C2H4 at 0% span
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42,50

42,00
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41,50
Output (ppm(v))

41,00
at 45% span
40,50
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40,00

39,50
0 50 100 150 200 250
Time (min)
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Fig 11 Start-up drift C2H4 at 50% span

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 4 MANUFACTURER'S DATA

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Instrument specification and other details provided by the manufacturer

Manufacturer TESTA GmbH

Kathi-Kobus-Strasse 15

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80797 Mnchen
Germany

Tel No : (0 89) 1293005

Fax : (0 89) 1298835

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Instrument Analyser for measurement of total hydrocarbon concentration in
proces gases

Model FID 123

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Serial No 40/08/00

Consistency Range 1 less than 3% all other ranges less than 1%

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Zero drift 1% in 24 hours

Ambient temperature Max. + 45 C

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Warm-up time From room temperature to 300 C in approx. 20 min

Response time 1-2 sec. from rear panel of unit

Ranges 5 measuring ranges; 10/100/1000/10000/100000 ppm

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Lowest range 0-10 ppm relative to propane (calibration gas=C3H8)

Recorder output 0-10 V/0-20 mA or 2-10 V/4-20 mA

Voltage 220 V
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Frequency 50 Hz

Power approx. 600 W, without specimen line

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Sample flow about 12 ml/min

Combustion gas consumption H2 30-40 ml/min; H2/He 80-100 ml/min

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Flame control with thermocouple, indicated by lamp

Combustion air consumption 0,4 l/min

Page 18 of 26 E 2720 K 01
 Zero/span gas consumption 2-3 l/min

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Supply for heated sample line Regulated and controlled by thermocouple

Sample temperature 300 C in continous operation

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Dimensions (h x w x d) 220 x 440 x 350 mm

Weight 15 kg. (approx.)

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 5 OPERATING PRINCIPLE AND CONSTRUCTION

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5.1 Measuring principle

The gas concentration is converted into an electrical signal by means of a flame ionisation detector
(FID). In the FID, a hydrogen flame burns in hydrocarbon-free air, called combustion air.

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An electric field is applied between jet and cylinder electrode by means of polarisation voltage.
When the sample contains hydrocarbon molecules, they are heated in the flame and then cracked
and stripped causing CH fragments to form. These fragments are oxidized by the oxygen in the
+
combustion air and CHO ions form. The ion current can be measured and is proportional to the
quantity of carbon atoms of organic compounds.

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5.2 Mechanical construction

The flame ionization detector is proving to be an important tool for industry in the direct
measurement of hydrocarbon concentration. It permits accurate measurements of concentration

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from a few parts per million (ppm) up to 100% and meets industrial requirements with regard to the
speed with which it is ready to use, ease of installation and the low level of sophistication in its
operation.
In contrast to familiar designs, the test specimen in the TESTA-FID-1 is sucked through the
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detector. This provides the following advantages:
- All moving parts are located behind the ionization chamber in the cold zone and are thus no
longer exposed to the high temperature of the specimen gas.
- The path of the specimen from the measuring location to the burner nozzle contains no moving
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parts and is thus completely maintenance-free.

- Due the modified construction of the unit, there is perfect thermal equilibrium between the
specimen inlet and the burner nozzle. Since all parts coming into contact with the specimen are
manufactured from metal, any depositing of hydrocarbons in the specimen path are not
possible due to the high unit temperature.
- Thanks to the high specimen temperature of max. 300 C, the unit is largely insensitive to
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variations in room temperature. The proof of this is an extremely constant zero and calibration
point.
- The FID-123 is fitted with an additional, heated specimen pump to eliminate measurement
errors caused by variations in specimen pressure in the range between 1.0 bar pressure and
0.3 bar vacuum.
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 6 TEST METHODS AND REFERENCES

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6.1 Test methods

The test gases originated directly from compressed gas cylinders or were mixed from different gas
cylinders by using a gas mixer based on dilution by mass flow controllers. The accuracy of the mass flow

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controllers had been established by calibration with a Brooks volumeter with a ring of mercury.

The estimated uncertainties (of the test results) of the different tests were:
measured error : 0.2 %
conformity : 0.2 %

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repeatability : 0.6 %
dead band : 6%
drift : 11 %
sample pressure variation : 11 %
sample flow variation : 11 %

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sample temperature variation : 11 %
cross sensitivity : 11 %

The basic test gas concentration was about 50 ppm(v) C2H4 in N2.
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The uncertainty of the concentration of the gas used was 1 %.

The output data of the analyser was recorded with a megalog datalogger. In most tests, the signal
was measured with an average of 60 seconds.
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Accuracy

An eleven point calibration (10% interval) with four runs at each point for up-scale readings and four runs
at each point for down-scale readings, was carried out by diluting the basic test gas. From this test,
average errors, conformity, hysteresis and repeatability were determined. At the start of the evaluation,
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the analyser was adjusted with calibration gas at about 50% span.

Dead band

The dead band was measured at lower and higher span values span by varying the concentration of the
test gas in steps of about 0.1 ppm(v) (= about 0.1 % span).
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The change in output was measured after a settling time of at least twice the response time.

Detection limit
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The detection limit was calculated as three times the standard deviation of 30 recordings of the test gas
at 0% span.
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 Mounting position

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The effect on the output of tilting the analyser through angles of 10 in four mutually perpendicular
planes was measured at 0% and 50% span.

Shock

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The effect on the output was investigated by tilting the analyser about one bottom edge so that the
distance between the opposite edge and the test surface is 100 mm. Before and after a freely fall onto
the test surface the influence was measured at 0% and 50% span.

Vibration C2H4

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Initial resonance search
The analyser was vibrated over the frequency range of 10 to 60 Hz at 0.2g acceleration. The sweep rate
was 0.2 octave per minute. The peak to peak amplitude was 0,14 mm. Vibration was applied in three
directions (X,Y,Z). A resonance search was carried out.

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Endurance conditioning
The instrument was subjected to vibration for 45 minutes in each axis at the largest resonance
frequencies.
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Before and after the vibration tests measurements were carried out at 0% span and 50% span. Due to
safety conditions of the vibration test lab, it was not allowed to operate the analyser with H2 and
calibrationgas during vibration.
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Start-up drift

The analyser was subjected to reference conditions for at least 24 h with the power supply switched off.
The output of the analyser was recorded during the first 4 hours. The test was repeated using a test gas
with a concentration of 0% span.
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Long-term drift

During 32 days the analyser was operated continuously with a test gas of 0% span. After 0, 1, 4, 6, 8,
11, 13, 15, 18, 20, 22, 26, 28 and 32 days, the output of the analyser was recorded with test gases of
0% and 50% span. The output was corrected for barometric and temperature influence.
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Step response

The analyser was subjected to a sudden change from test gas with a concentration of 0% span to test
gases of a concentration of 70% span. The output and corresponding time of the analyser was
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recorded.

Over-range
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This test was carried out by measuring the changes in lower-range value and span which result from
over-ranging at the minimum and maximum span (1950 ppm(v) C2H4).
After the over-range has been applied for 1 minute, the input was reduced to the nominal lower
range-value. After a further 5 minutes had elapsed, the lower range-value and the span was

Page 22 of 26 E 2720 K 01
 determined.
Sample pressure variation

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The analyser was fed with test gases of 0% and 50% span at pressure levels varying between 800 to
1200 mbar (abs.) at a steady flow of 2 l/min. The pressure was measured with a calibrated pressure
transmitter. The influence of the sample pressure was calculated by linear regression.

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Sample temperature variation

The analyser was fed with test gases of 0% and 50% span at sample temperature varying between 25
to 250 C at constant pressure. The sample temperature were measured with a calibrated temperature

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transmitter.

Sample flow variation

The analyser was fed with test gases of 0% and 50% span at flow variations of 666 ml/min to 1232
ml/min. The flow was measured with a Bios DryCal flowmeter (graphite composite piston).

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Interference tests

The output of the analyser was recorded after application, at test gas concentrations of 0% and 50%
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span, of:
- 50 ppm(v) C2H4 in N2 (reference)
- 50 ppm(v) C2H4 in air
- 30 ppm(v) C4H10 in air
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- 50 ppm(v) C2H4/100 ppm(v) NO2 in air

- 50 ppm(v) C2H4/100 ppm(v) NO2/100 ppm(v) CO in air
- 50 ppm(v) C2H4/10 vol% CO2 in air
- 50 ppm(v) C2H4/2 vol% H2O in air
3
furthermore at test gas concentrations of 0% and 15 mgC/m with:
- 15 vol% CO2 in N2 *
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3
- 272 mg/m NO in N2 *
3
- 45 mg/m NO2 in N2 *
3
- 1216 mg/m SO2 in N2 *
3
- 229 mg/m NH3 in N2*
3
- 80 mg/m HCl in N2 *
3
- 47 g/m H2O in N2 *
3
- 133 g/m H2O in N2 *
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- 20,8 vol% O2 in N2 *
- 10,4 vol% O2 in N2 *

* Test results from the TV reports.

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analyser personal computer

T p

x x MC

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WG MF MF MF

water test/interference gases in cylinders

MF : massflow controller
MC : mixing chamber
p : pressure transmitter

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T : temperature transmitter
WG : watervapour generator
x : disconnected if not used m
Fig 12 Basic test arrangement
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Y
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front X
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Fig 13 Axes of vibration

Page 24 of 26 E 2720 K 01
 6.2 References

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IEC 770: 1984. Methods of evaluating the perfomance of transmitters for use in industrial-process
control systems

TV-Bericht 1529455, Bericht ber die Eignungsprfung einer Gesammtkohlenstoff-Messeinrichtung,

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August 1992

TV-Bericht 24014741, Bericht ber die Ergnzungsprfung einer Gesammtkohlenstoff-

Messeinrichtung, Februar 1996

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Memorandum HEC-MEMO-950031, TNO Centre for Evaluation of Instrumentation and Security
Techniques (EIB), April 1995

6.3 Definitions

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Reference operating conditions (IEC 902): The range of operating conditions within which the
influence on the device by the changes in environmental conditions are disregarded.
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Gas analyser: An analytical instrument that provides an output signal which is a monotonic function of
the concentration, partial pressure or condensation temperature of one or more components of a gas
mixture.
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Stable test gas mixture: A mixture of gases (and/or vapour) in which the component to be measured is
known and does not react with and is not adsorbed onto the containment system (e.g. cylinder).
The concentrations of gases and their inaccuracy shall be known for the components of the gas mixture
and commensurate with the criteria to be evaluated.

Zero gas: A gas mixture used to establish the zero point of a calibration curve when used with a given
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analytical procedure within a given calibration range.

Calibration gas: A stable test gas mixture of known concentration used for periodic calibration of the
analyser and for various performance tests.

Range (IEC 770): The region between the limits within a quantity is measured; limits are given by stating
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the lower and upper range values.

Lower range value (IEC 770): The lowest value of the measured variable that a device is adjusted to
measure.
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Upper range value (IEC 770): The highest value of the measured variable that a device is adjusted to
measure.
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Span (IEC 902): The algebraic difference between the upper and lower limit values of a given range.

Error (IEC 902): The algebraic difference between the measured value and the true value of the

Page 25 of 26 E 2720 K 01
 measured variable.

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Zero shift (IEC 902): The change of the output value, due to some influences, when the input variable is
at the lower range value.

Span change (IEC 902): The change in output span due to some influences.

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Average error: The arithmic mean of the errors at each point of measurement , for rising and falling
inputs separately.

Residual error: The algebraic difference between two output measurements at reference conditions,

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one before and one after an excursion from the reference condition.

Response time (T90): The time interval from the instant a step change occurs in the value of the
property to be measured to the instant when the change in the indicated value passes (and remains
beyond) 90% of its steady state amplitude difference, that is: T90 = T10 + Tr (or Tf).

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Drift: The rate of change of error, stated over a specified time interval.
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APPENDIX I

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 APPENDIX II

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Manufacturers QA procedures and instrument status

Basic Informations to TESTA GmbH-Quality Management System

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Company/adress: Kathi-Kobus-street 15
80797 Munich, Germany

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Parent company: --

Range of products: FID + Acessoires for FID

Organizational form: GmbH

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Production premises: On 3 floors in above standing adress

Subsidiaries in Germany: --
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Work force: 15 fix, 25 flexibel

Sales volume: 5 Mio. DM p.o.

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Production and test facilities:

QM Standard: Test report for each analyser and accesoir

QM management representative: Dr. B. Ulrich

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QM-manual: Existing

Certification: No

Further audits on Testa QM system: --

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Approval by German authorities: TV, Germany

For more details please contact: Dr. B. Ulrich

Kathi-Kobus-Strasse
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80797 Munich
Germany
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 Manufacturers QA procedures and instrument status

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1 Quality Assurance

1.1 Has your company adopted a structured QA policy and if so, when was this fully
implemented?

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Yes, 1989

1.2 On which national/international standard is your QA system based? Is it registered under

any particular scheme? If so, please state which.

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DIN ISO 9001, not registered

1.3 Does it cover all aspects of design, manufacturer and installation?

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No, only manufacture and installation

1.4 If your company is part of a corporate organisation, is your QA system subject to and
controlled by a corporate QA policy?
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No

1.5 Does your QA system cover all activities and products in your manufacturing facility? If
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not, please specify where it does apply.

Yes

1.6 How many times, and by whom, has your location or company been audited by an
external organisation during the last 3 years?
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Once by Siemens

1.7 Who required the audit to be carried out?

Siemens Germany
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1.8 Are (corporate) products, if manufactured elsewhere in your organisation, also subject to
an identical QA system?

Yes
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APPENDIX III

Information on the product evaluated by WIB

2.1 Is the product evaluated being produced elsewhere in your organisation? If so, please state

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where. Are all/any parts of the product fully interchangeable regardless of origin?

No, Yes fully interchangeable.

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2.2 What is the expected lifetime of the product?

25-30 years.

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2.3 What is the guarantee period for the hardware and software if applicable, of the product
evaluated?

24 months.
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2.4 For how long after manufacture of the product ceases will you provide service/maintenance
facilities and spare parts?
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20 years guaranteed.

2.5 In what language are product documentation, manuals etc. written? Are they available in English,
French and German?

English + German, French in process (available 2002).

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